JOB TITLE: Mechanical Integrity and Reliability Engineer
DEPARTMENT: Maintenance
LOCATION: Kankakee, IL
SUPERVISOR: Director of Engineering
JOB SUMMARY
The Mechanical Integrity and Reliability Engineer has a long-term and strategic focus. This position will coordinate and lead the plant's mechanical integrity program as it relates to stationary equipment, piping, and pressure relief devices and the plant's reliability program for rotating equipment and utilities. Ensure compliance with corporate, federal, state, and local inspection and testing requirements. Lead Root Cause Failure Analyses and monitor equipment KPIs for the early identification and resolution of reliability issues. The position supports capital and expense projects by reviewing fabrication drawings and coordinating Quality Control and Vendor Surveillance inspections as requested. Direct reports for this position include API Inspectors and Reliability Technicians.
PRIMARY RESPONSIBILITIES
Mechanical Integrity
Ensure new installations and repairs comply with corporate, federal, state, and local codes and requirements such as: BC032.018, N-P-MC-105, N-G-MC-105, OSHA CFR 1910.119, API 510, API 570, API 653, API 579, ANSI B31.1, ANSI 31.3, ANSI 31.5, ASME B31G, NBIC NB23 and other regulatory requirements.
Direct and coordinate the activities of contract examiners and inspectors to execute routine, shutdown, and turnaround inspections and tests on stationary equipment and piping.
Plan and schedule inspection work based upon the MI schedule.
Provide technical knowledge and expertise, including coaching and mentoring of contractors, to ensure inspections, tests and reporting are in accordance with corporate, federal, state, and local inspection and testing requirements.
Provide technical knowledge and expertise and ensure compliance with inspection and repair codes/procedures including API 510, API 570, and API 653.
Review and authenticate inspection reports to ensure accuracy. Analyze Inspection results and findings. Make recommendations based upon results of as-found condition, including repair recommendations, the need for additional NDT testing, and re-inspection intervals. Issue reports in accordance with internal procedures.
Maintain the Inspection Reporting database including set up of new inspections, results of inspections, re-inspection frequencies, schedules, due/overdue, etc.
Coordinate offsite inspections of process equipment such as heat exchangers, vessels, tanks, and other fabricated equipment. Coordinate or document vendor surveillance inspections for new equipment, including compliance to engineering specifications, dimensions, nozzle orientation, lining integrity, etc.
Participate in failure investigations and analysis, problem solving activities associated with stationary equipment and piping.
•Reliability:
Apply appropriate reliability tools to drive improvements, optimize costs, and improve AE (i.e., Bad Actor Program, FMEA, RBI, RBM, RCM, Reliability Roadmap, etc.)
Ensures development and sustenance of Critical Equipment list.
Ensure the development of equipment strategies to optimize site availability (including PM, PDM, spare parts, etc.)
Monitor Key Performance Indicators (KPIs) and metrics for proactive identification and resolution of reliability issues.
Lead Root Cause Failure Analysis (RCFAs) and corrective actions for complex and/or repetitive problems.
Lead the Bad Actor Program and create action plans for improving reliability.
Identify and implement best practices across companys 5 sites.
Ensure the effective management of the PDM programs which include Vibration Analysis, Oil Analysis, Steam Trap, and Thermography.
Evaluate new technologies.
Evaluate alternatives for equipment repair seeking cost and time advantages.
Support capital projects by supplying engineering expertise in the specification, design, and construction of capital projects in accordance with plant design requirements as well as regulatory and corporate standards.
Scope development
Spare parts recommendations
Support with technical Bid analysis and bonus/malus reviews.
Support commissioning and startup activities.
Supervisory Responsibilities
Manage merit and PIC process for Reliability technicians and API inspectors.
Manage discipline issues and conflict resolution.
Owner for Team development / Build and maintain an engaged work force.
Ensure direct reports maintain required API certifications.
Talent development / career management for direct reports.
Performance Management inc: job assignments for development. Consistent and ongoing dialogs.
Consistent enforcement of rules and policies.
Effective change management.
Effective and clear communication.
On-boarding of new employees and transfers to the department.
EDUCATION
Required: Bachelor's degree in engineering or 5+ experience in plant engineering.
EXPERIENCE:
5-10 Years of Experience; preferably within chemical or related industry.
Experience in the design, construction, repair, inspection, or operation of pressure vessels, of which one year must be in supervision of inspection activities or performance of inspection activities as described in the API codes.
ESSENTIAL FUNCTIONS:
High sense of urgency.
Deal effectively with the unknown and unexpected and possess the ability to handle non-routine and emergency activities, such as plant shutdowns, start-up, commissioning, etc.
Be able to lift 60 lbs., walk, sit, squat, bend, push/pull with arms/legs, body, reach overhead, stoop.
Available for occasional after hours support of Maintenance activities such as planned turn arounds and unplanned shutdowns.
The process problems include dealing with the technical difficulties of corrosive and hazardous chemicals and operating temperatures up to 2400°F.
This is a site-based position located within Kankakee, IL (Onsite/Hybrid work schedule).