This newly created role requires an experienced and confident engineer to the Reliability section of the Technical Division of this Fertilizer/Petrochemical group
This position is responsible for guiding efforts to ensure reliability and maintainability of equipment, processes, utilities, facilities, controls and safety/security systems. Identify and manage asset reliability risks that could adversely affect plant or business operations. This broad primary role includes loss elimination, risk management and life cycle asset management.
3. Key Duties and Responsibilities
? Works with project engineering to ensure the reliability and maintainability of new and modified installations. The Reliability Engineer is responsible for adhering to the Life Cycle Asset Management (LCAM) process throughout the entire life cycle of new assets.
? Participates in the development of design and installation specifications along with commissioning plans.
? Participates in the development of criteria for and evaluation of equipment and technical MRO suppliers and technical maintenance service providers. Develops acceptance tests and inspection criteria.
? Participates in the final check-out of new installations. This includes factory and site acceptance testing that will assure adherence to functional specifications.
? Professionally and systematically defines, designs, develops, monitors and refines an asset maintenance plan that includes:
1) Value-added preventive maintenance tasks.
2) Effective utilization of predictive and other non-destructive testing methodologies designed to identify and isolate inherent reliability problems
? Provides input to a risk management plan that will anticipate reliability-related and non-reliability-related risks that could adversely impact plant operations.
? Develops engineering solutions to repetitive failures and all other problems that adversely affect plant operations. These problems include capacity, quality, cost or regulatory compliance issues. To fulfil this responsibility, the reliability engineer applies:
1) Data analysis techniques that can include:
2) Statistical process control
3) Reliability modeling and prediction
4) Fault tree analysis
5) Weibull analysis
6) Root cause analysis (RCA) and root cause failure analysis (RCFA)
7) Failure reporting, analysis and corrective action system (FRACAS)
? Works with Production to perform analyses of assets including:
1) Asset utilization
2) Equipment effectiveness
3) Remaining useful life
4) Other parameters that define operating condition, reliability, reliability and costs of assets.
? Provides technical support to production maintenance and technical personnel
? Applies value analysis to repair/replace, repair/design and make/buy decisions
Quality Assurance / Quality Controls (QA/QC)
? Participates in the development of Reliability Engineering Group KPI’s to ensure responsiveness to customer needs and to promote continuous improvement
? Assist with root cause analysis of repeated or major failures to ensure continuous improvement.
? Troubleshoots Reliability Engineering problems in the plant and proposes solutions.
? Assist in ensuring all relevant engineering standards and procedures are followed during project phase, plant operations, repairs and alterations by in-house and contract resources.
? Supports the development and implementation of the maintenance reliability program.
? Assist in conducting the technical audit of Reliability Engineering function to ensure that project consultants and contractors implement effective project standards and fulfilling the contract requirements.
Policies, Processes & Procedures
? Assist in the development and implementation of policies, processes, procedures and controls covering all areas of Reliability Engineering design, system upgrades and maintenance.
Maintenance for Shutdown and Turnaround
? Assists with the planning, execution and cost control of shutdowns and turnarounds to meet Reliability Engineering design and maintenance.
? Ensure the spare parts; manpower and equipment are available for the efficient and timely completion of shutdown and turnaround activities.
? Identify and manage critical Reliability Engineering spare parts and all maintenance tools including specialized tools needed for shutdown or turnaround maintenance.
? Ensures spare parts and consumables are stocked in the warehouse and that adequate specifications and Suppliers have been developed to enable ordering/reordering.
Budgets and Plans
? Assists in the Preparation statistical cost estimates for budgetary purposes including outlining modifications and change impact on the Capex to project and equipment.
? Evaluates and advises on bids/proposals received from consultants’ tenders/vendors including reviewing comparative estimate statements, recommending modifications and determining the validity and reliability of technical content according to approved standards and contractual terms and conditions.
Effective Relationship
? Develops and maintains positive relationships with wide-range of superiors and subordinates personnel, both internally and externally.
? ? Minimum Education:
BS Degree in Mechanical Engineering
Experience and Qualifications:
10 or more years of direct experience in the field of Reliability Engineering operation & maintenance, condition monitoring, performance analysis within a Fortune 200 company, such as: Petroleum, Chemical, Fertilizer/Mining or other Industrial Manufacturing organizations.
Skills
Management skills, budgeting, planning, forecasting and staff development
? Thorough knowledge of CBM techniques, predictive and proactive maintenance techniques, maintenance management strategies.
? Knowledge of modern vibration analysis, data collection/analysis and the formulation of reports.
? Experience of Laser alignment, dynamic balancing and ultra sound.
? Excellent analytical, impact assessment and problem solving skills.
? Good working knowledge of rotating and associated equipment.
? Knowledgeable in standard Non-Destructive Examination (NDE) methods.
? Knowledgeable in visual welding inspection
? Proven track record of managing time limited projects.
? Excellent relationship building skills (internal and external)
? Excellent written, verbal and presentation skills in English required,
? Extensive computer skills in using Microsoft software (Word, Excel, PowerPoint, etc.) plus other software pertinent to the work performed would be advantageous.
? Ability to work with diverse populations, and foster a cooperative team environment.
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