Job Summary:
We are seeking a Lead Mechanical Integrity & Reliability Engineer to oversee the implementation, management, and optimization of predictive maintenance programs and mechanical integrity systems. This role will be critical in ensuring the long-term reliability and performance of our rotating equipment, tanks, piping, and heat exchangers across multiple sites. The plant is located in Louisville, KY. (Please note, if required, an above-market corporate relocation package will be available).
Key Responsibilities:
- Predictive Maintenance Program:
- Lead and manage the Predictive Maintenance program, utilizing tools such as vibration analysis, infrared thermography, ultrasonic testing, and oil analysis to monitor equipment health and predict potential failures.
- Mechanical Integrity Program:
- Oversee and maintain the Mechanical Integrity program, ensuring full compliance across all sites. Collaborate with site maintenance leaders to assess and address MI reports, fitness-for-service evaluations, and necessary repairs.
- Risk Insurance Program:
- Administer the corporate risk insurance program and coordinate audits to ensure proper risk management practices are in place at all sites.
- Asset Management & Budgeting:
- Maintain a long-term equipment asset replacement plan and ensure that major equipment is included in the MI program budget.
- Rotating Equipment Monitoring:
- Review and assess the condition of rotating equipment using various PdM data (vibration, oil analysis, IR, ultrasound), as well as critical process data to evaluate equipment health.
- Data Management:
- Manage and maintain the ZCLP PdM and MI databases to ensure accurate, up-to-date records for analysis and reporting.
- Cost Analysis & Strategy Development:
- Analyze equipment history, maintenance costs, and failure patterns to refine asset management strategies, focusing on cost avoidance, cost savings, and increased equipment uptime.
- Bad Actor Program:
- Lead and monitor the Site Bad Actor Program to identify and address recurring equipment failures. Track key performance indicators (KPIs) related to PdM and MI efforts in the Reliance database.
- Root Cause Analysis:
- Provide PdM data (vibration, oil analysis, etc.) to support root cause analysis (RCA) and Failure Modes, Effects, and Criticality Analysis (FMECA) processes.
- Third-Party Contractor Management:
- Oversee and manage third-party MI inspection services and contractors.
- Reliability and Maintainability in New Projects:
- Support the Design for Reliability, Maintainability, and Inspectability (DFR/M/I) in new equipment projects. Ensure that all technical documentation, OEM manuals, and support materials are available during equipment commissioning.
- SAP Integration:
- Ensure new or redesigned equipment is accurately set up in SAP with proper asset criticality prioritization and asset strategies for all critical assets.
- Spare Parts Strategy:
- Lead the spare parts strategy, focusing on equipment criticality, lead times, and cost-benefit analysis to minimize downtime and risk.
- Reliability Analytics:
- Integrate reliability analytics and modeling tools to analyze equipment trends, build failure prediction models, and enhance mechanical availability.
Qualifications:
- Education:
- Bachelor’s Degree in Mechanical Engineering or a related field.
- Experience:
- At least 5 years of experience in predictive maintenance of rotating equipment within a chemical or petrochemical facility.
- Minimum of 5 years evaluating tank, piping, and heat exchanger conditions according to ASME, API, or STI standards.
- Certifications (Preferred):
- Certifications in vibration analysis, oil analysis, thermography, and ultrasound analysis (or a minimum of 5 years of relevant experience in these areas).
- Technical Skills:
- Proficient in Microsoft Office Suite (Outlook, Excel, PowerPoint).
- Experience with SAP CMMS is highly preferred.
- PSM experience is highly preferred
