Senior Engineer, Reliability (Condition Monitoring)

JOB PURPOSE

The jobholder is responsible to develop and implement a Condition Monitoring program for the assigned plants to ensure rotating equipment healthiness and initiates timely recommendations.

This role includes utilizing on-line & off-line hardware/software systems and techniques to minimize failures and reduce maintenance costs, prevent production losses, and improve equipment reliability & availability.

Advising and supporting plant Discipline Engineers in performing complex troubleshooting, root-cause failure analysis and reviews design Condition Monitoring parameters to suggest changes as required.

KEY ACCOUNTABILITIES

Condition Monitoring

1. Develop and implement condition monitoring program to ensure rotating equipment health monitoring and assessment, enhancing operational efficiency.
2. Use on-line/off-line MCM systems for vibration analysis and other techniques to perform troubleshooting, ensuring equipment reliability.
3. Implement new monitoring technologies to improve diagnostic skills, staying ahead of potential issues.
4. Initiate timely Condition Monitoring recommendations to avoid unexpected failures, minimizing maintenance costs and production losses.
5. Support plant Reliability Engineers in root-cause failure analysis to identify corrective actions, preventing repeated failures.
6. Actively participate in Reliability improvement programs to optimize machinery protection parameters, enhancing plant performance.

Reliability

1. Follow-up and provide advice during field maintenance jobs to solve major failures, enhancing equipment reliability.
2. Analyze strengths and weaknesses of Condition Monitoring strategies to develop new solutions, improving reliability standards.
3. Identify statutory requirements and make procedures to comply, ensuring adherence to regulations.
4. Participate in internal/external audits and prepare plans to close audit points, maintaining compliance.
5. Provide inputs for budget preparation and monitor variance to control costs, aligning with financial goals.
6. Keep abreast of updates in Health, Safety, Environment, and Risk Registers, ensuring safe operations.

HSE Excellence

1. Promote and lead by example all safety-related communications and standards, fostering a safe work environment.
2. Contribute to providing timely feedback and recommendations to ensure a risk-free environment, achieving safety goals.
3. Conduct regular data collection to monitor equipment health and predict failures, preventing unexpected downtimes.
4. Utilize advanced monitoring tools to gather accurate data, supporting reliable analysis.
5. Implement data acquisition systems to streamline monitoring processes, enhancing efficiency.
6. Ensure data integrity to provide a solid basis for decision-making, supporting informed actions.

Analysis & Diagnosis

1. Perform detailed analysis of collected data to identify potential issues, ensuring proactive maintenance.
2. Use diagnostic tools to pinpoint root causes of equipment problems, facilitating effective solutions.
3. Develop predictive models to forecast equipment failures, optimizing maintenance schedules.
4. Collaborate with engineering teams to validate analysis results, ensuring accuracy.
5. Provide actionable insights to improve equipment reliability, enhancing operational performance.
6. Document analysis findings to support maintenance planning, ensuring informed decision-making.

Maintenance Planning

1. Develop maintenance schedules based on condition monitoring data, ensuring timely interventions.
2. Coordinate with maintenance teams to implement preventive strategies, reducing downtime.
3. Prioritize maintenance activities to address critical issues first, optimizing resource allocation.
4. Ensure maintenance plans align with operational goals and safety standards, maintaining compliance.
5. Monitor the effectiveness of maintenance activities to identify improvement areas, enhancing efficiency.
6. Communicate maintenance plans to relevant stakeholders, ensuring alignment and transparency.

Technical Support

1. Provide technical support to maintenance and operations teams, minimizing equipment downtime.
2. Assist in troubleshooting equipment issues, ensuring quick resolution.
3. Develop and implement solutions to address recurring problems, enhancing reliability.
4. Train team members in monitoring tools and techniques, building team capabilities.
5. Stay updated on the latest monitoring technologies, ensuring best practices.
6. Share technical knowledge to enhance team performance, fostering continuous improvement.

Reporting & Documentation

1. Prepare detailed reports on condition monitoring activities, ensuring comprehensive documentation.
2. Communicate monitoring results to management and stakeholders, supporting strategic decisions.
3. Maintain accurate records of monitoring activities, ensuring compliance with policies.
4. Use reports to support strategic planning, aligning with business objectives.
5. Provide regular updates on the status of monitoring programs, ensuring transparency.
6. Identify opportunities to improve monitoring processes, driving continuous improvement.

QUALIFICATIONS, EXPERIENCE, KNOWLEDGE & SKILLS

1. University degree in Mechanical Engineering or related discipline
2. Fluency in English Language; written and oral
3. Minimum 5 years of relevant experience in oil/gas or petrochemical industry / Condition Monitoring company
4. Working experience of latest PC based On-Line & Periodic Condition Monitoring systems (Instruments & Software) from Bently Nevada / CSI / SKF
5. Expert in condition monitoring of high-speed rotating equipment and maintenance strategies, repairs, diagnostics, and fault analysis.
6. Working knowledge on HSE policies applicable in chemical & petrochemical industry.
7. Hands on Reliability Centred Maintenance (RCM)
8. Hands on Trouble shooting techniques and Root Cause Analysis (RCA)
9. Specialized Mechanical with training in vibration analysis and other Condition Monitoring
10. Knowledge in multistage steam turbines, pumps, motors, gearboxes, turbo compressors, screw compressors, Extruders, Reciprocating Compressors, etc.
11. Knowledge of international standards for mechanical equipment/systems and CMMS.
12. Certification in vibration analysis / machinery diagnostics will be an added advantage.