Test Bed Engineer

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About the role

Job Summary
The Quality Engineer is responsible for applying practical knowledge to ensure that manufacturing processes and outputs meet quality standards. This includes auditing, monitoring, and troubleshooting deviations in production.
This job profile is intended for experienced professionals who apply practical knowledge of a job area and work independently with general supervision.

JOB TITLE: Test Bed Engineer (x3 Positions)

REPORTING TO: Service Centre Manager

GRADE: 4

LOCATION: Sulzer Zambia Service Centre, Chingola

ROLE PURPOSE: The incumbent is responsible for the safe, accurate, and efficient operation of the Pump Performance Test Bed at the Sulzer Zambia Service Centre in Chingola. This role is critical to ensuring that all pumps assembled, refurbished, or serviced by Sulzer Zambia undergo rigorous performance testing and validation in accordance with Sulzer Flow "Excellence" standards, contractual obligations, and OEM specifications before delivery to customers. The Test Bed Engineer will support the execution of the KCM contract, contribute to securing the long-term follow-on agreement, and enable the facility to serve as a regional hub for pump performance testing across the Central African market, including major customers such as Mopani Copper Mines and other mining and industrial operations with significant Sulzer HPH/HPL multi-stage pump installed bases.

SPECIFIC RESPONSIBILITIES (NOT LIMITED TO):

- Test Preparation & Execution: Prepare pumps for testing, including rigging, alignment, coupling to drive systems, and installation of all required instrumentation (flow meters, pressure transducers, temperature sensors, vibration probes, etc.). Conduct pump performance tests in strict accordance with Sulzer Flow testing procedures, ISO 9906 standards, and customer-specific contractual requirements. Operate the test bed control systems and data acquisition software to capture accurate, repeatable test data.
- Data Analysis & Reporting: Analyze test results, generate performance curves (flow, head, efficiency, power consumption, NPSH), and identify any deviations from OEM specifications or customer acceptance criteria. Prepare and issue certified test reports and performance certificates for customer submission and internal quality records. Maintain comprehensive, traceable records of all test activities, results, and certifications in line with Sulzer Flow "Excellence" documentation standards.
- Quality, HSE & Compliance: Ensure all testing activities are conducted in full compliance with Sulzer's Health, Safety, Environment, and Quality (HSEQ) policies, 5'S standards, and Disciplinary Code of Conduct. Perform routine calibration and verification of all test bed instrumentation to maintain measurement accuracy and traceability. Identify and report any non-conformances, equipment defects, or safety hazards, and participate in root cause analysis and corrective actions.
- Collaboration & Communication: Work closely with the Service Centre workshop team to coordinate pump handover, testing schedules, and feedback on performance issues requiring rectification. Maintain effective communication with the Service Centre Manager on test progress, resource requirements, and any operational challenges. Collaborate with regional Sulzer technical teams when required for complex testing scenarios or troubleshooting.
- Facility Maintenance & Continuous Improvement: Perform routine maintenance and housekeeping of the test bed facility, equipment, and ancillary systems to ensure operational readiness. Contribute to continuous improvement initiatives aimed at enhancing testing efficiency, accuracy, safety, and overall operational "Excellence." Assist in the development and updating of standard operating procedures (SOPs) for the test bed.
- Flexible Operations: Participate in shift rotations as required to support extended operating hours and peak demand periods. Provide on-site testing and commissioning support at customer locations when necessary.

KEY PERFORMANCE AREAS (KPIs):

- Achieve testing throughput targets in accordance with agreed production schedules and contractual delivery commitments.
- Maintain zero lost-time injuries (LTI) and full compliance with HSEQ standards during all testing operations.
- Deliver 100% of certified test reports accurately and on time, meeting both internal quality standards and customer requirements.
- Ensure test bed instrumentation remains within calibration at all times, with zero unplanned downtime due to calibration lapses.
- Demonstrate effective collaboration with the Service Centre workshop team and adherence to Sulzer Flow "Excellence" principles in all activities.

SKILLS AND ATTRIBUTES REQUIRED:

Skills (must be able to):

- Apply sound technical knowledge of pump performance testing, rotating equipment, and hydraulic principles.
- Demonstrate working knowledge and application of pump testing standards (ISO 9906 or equivalent).
- Operate and interpret data from instrumentation, data acquisition systems, and test bed control software.
- Read and interpret engineering drawings, P&IDs, and pump performance curves.
- Apply sound troubleshooting and analytical skills to diagnose performance deviations.
- Maintain meticulous attention to detail in data recording and reporting.

Attributes (be able to):

- Deadline and target driven, with the ability to work under pressure during peak testing periods.
- Strong commitment to safety, quality, and operational discipline.
- Self-motivated and capable of working independently as well as collaboratively within a team.
- Excellent communication skills, both verbal and written.
- Flexible and adaptable to shift work and changing operational demands.

EXPERIENCE REQUIRED:

- National Diploma or Degree in Mechanical or Electrical Engineering.
- 3 – 5 years of hands-on experience in pump testing, rotating equipment commissioning, or a related technical field within an industrial, mining, or service centre environment.
- Proven experience with multi-stage pumps (HPH/HPL) and slurry pumps will be a significant advantage.
- Experience with instrumentation calibration, data acquisition systems, and test report generation is essential.
- Familiarity with ERP systems (e.g., SAP) and maintenance management systems will be beneficial.
- Computer literate (Word, Excel, PowerPoint, data analysis tools).

WORK ENVIRONMENT:

- Work is primarily based at the Sulzer Zambia Service Centre test bed facility in Chingola.
- The role involves hands-on work in an industrial workshop and test bed environment, with exposure to rotating equipment, pressurized systems, and electrical hazards (all mitigated by strict HSE controls).
- Shift work and extended hours may be required to meet operational demands.
- Occasional travel to customer sites for on-site testing and commissioning support may be required.
- Interaction is with workshop technicians, Service Centre management, quality personnel, and occasionally customers during witness testing.

QUALIFICATIONS AND SPECIAL REQUIREMENTS:

- National Diploma or Degree in Mechanical or Electrical Engineering (minimum).
- Grade 12 Certificate.
- Valid driver's Licence (unendorsed).
- Certification in pump testing standards (ISO 9906) or vibration analysis (ISO 18436) will be an added advantage.
- Proficiency in English (both written and verbal) is essential. Working knowledge of French or local languages will be beneficial for customer interactions.

POLICIES AND PROCEDURES: The incumbent must conform to the company's Disciplinary Code of Conduct, 5'S, Health and Safety, and all other relevant Policies and Procedures.

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