Operational Excellence Manager

Arabian Consulting Engineering Center; Saudi Arabia; On-site; SAR 150,000 - 200,000; Full time

Job summary

An established industry player is seeking a dedicated Assets Integrity & Reliability Management Systems Specialist to enhance the integrity and reliability of critical refinery assets. This role involves developing and implementing robust asset management programs, focusing on preventive maintenance strategies, and ensuring compliance with industry standards. The ideal candidate will have extensive experience in asset integrity and reliability engineering, along with strong technical and soft skills to thrive in a high-pressure environment. Join a forward-thinking organization where your expertise will contribute to operational excellence and safety in the oil and gas sector.

Qualifications

• 10-15 years of experience in asset integrity and reliability engineering.
• Bachelor's or Master's degree in relevant engineering fields.

Responsibilities

• Develop and maintain Asset Integrity Management programs for refinery equipment.
• Implement Reliability-Centered Maintenance and Condition-Based Monitoring programs.

Skills

Asset Integrity Management

Reliability-Centered Maintenance

Risk-Based Inspection

Failure Analysis

Predictive Maintenance

Problem-Solving

Communication Skills

Education

Bachelor's degree in Mechanical Engineering

Master's degree in Mechanical Engineering

Tools

CMMS (SAP PM, Maximo, Meridium)

Vibration Monitoring Tools

Thermography Equipment

Ultrasonic Testing Tools

Job description

The Assets Integrity & Reliability Management Systems Specialist is responsible for ensuring the integrity, reliability, and availability of critical refinery assets through the development, implementation, and continuous improvement of asset integrity and reliability programs. This role focuses on preventive and predictive maintenance strategies, risk-based inspection (RBI), reliability-centered maintenance (RCM), and compliance with industry standards to minimize equipment failures, improve plant safety, and enhance operational efficiency.

Key Responsibilities:

1. Asset Integrity Management (AIM):
   Develop, implement, and maintain Asset Integrity Management (AIM) programs to ensure equipment operates safely and efficiently.
   Conduct risk-based inspections (RBI) and fitness-for-service (FFS) assessments for critical refinery equipment, including pressure vessels, piping, heat exchangers, storage tanks, and rotating machinery.
   Ensure compliance with API, ASME, OSHA, and company integrity standards for static and rotating equipment.
   Perform failure analysis and root cause investigations (RCFA) to prevent recurring issues.
   Develop and oversee corrosion monitoring and mitigation programs, including material selection and chemical treatment strategies.
   Collaborate with inspection, operations, and maintenance teams to ensure integrity threats are identified and addressed proactively.
2. Reliability Management Systems:
   Implement and improve Reliability-Centered Maintenance (RCM) and Condition-Based Monitoring (CBM) programs.
   Develop preventive and predictive maintenance (PdM) strategies using vibration analysis, thermography, oil analysis, and ultrasonic testing.
   Utilize Failure Modes and Effects Analysis (FMEA) to improve reliability performance and reduce downtime.
   Optimize spare parts strategies and work with procurement to ensure critical equipment availability.
   Identify and recommend technological upgrades to enhance equipment reliability and reduce lifecycle costs.
3. Compliance & Continuous Improvement:
   Ensure adherence to regulatory requirements, including OSHA, API (510, 570, 653), ASME, and ISO 55000 (Asset Management Standards).
   Lead and participate in refinery-wide asset integrity audits, inspections, and gap assessments.
   Develop and track key performance indicators (KPIs) for asset integrity and reliability, such as Mean Time Between Failures (MTBF) and Overall Equipment Effectiveness (OEE).
   Foster a culture of continuous improvement by implementing best practices from the oil & gas industry.
   Support digitalization initiatives, such as predictive analytics, AI-based monitoring, and Industrial Internet of Things (IIoT) solutions for asset health monitoring.
4. Technical Support & Training:
   Provide technical support for major turnarounds, shutdowns, and capital projects to ensure asset integrity and reliability goals are met.
   Work with multidisciplinary teams (engineering, maintenance, operations) to troubleshoot and resolve complex reliability issues.
   Develop and deliver training programs for refinery personnel on asset integrity, risk management, and reliability best practices.

Qualifications & Skills:

1. Education & Experience:
   Bachelor's or Master's degree in Mechanical Engineering, Materials Engineering, Reliability Engineering, or a related field.
   10-15 years of experience in asset integrity, reliability, or maintenance engineering within an oil refinery, petrochemical plant, or heavy industry.
   Strong understanding of refinery processes, equipment degradation mechanisms, and integrity risk management.
   Certifications (Preferred):
   API 510, API 570, API 653 (Pressure Vessels, Piping, and Storage Tanks Inspections).
   Certified Reliability Engineer (CRE) or Maintenance & Reliability Professional (CMRP).
   ISO 55000 (Asset Management) Certification.
   Vibration Analysis (CAT I-IV), Thermography, or NDT Certifications.
2. Technical Skills:
   Expertise in Risk-Based Inspection (RBI), Failure Analysis (RCFA), and Fitness-for-Service (FFS) Assessments.
   Knowledge of Predictive Maintenance (PdM) tools like vibration monitoring, infrared thermography, and ultrasonic testing.
   Familiarity with CMMS (SAP PM, Maximo, Meridium, or similar) for asset tracking and maintenance planning.
   Experience with Finite Element Analysis (FEA), corrosion modeling, and structural integrity assessments.
3. Soft Skills:
   Strong problem-solving and analytical skills to diagnose and resolve reliability challenges.
   Excellent communication and teamwork skills to collaborate with cross-functional teams.
   Ability to work in a high-pressure refinery environment with strict safety and operational requirements.

Work Environment:

Based at an oil refinery, with fieldwork, site inspections, and audits required. Exposure to high-temperature, high-pressure equipment, rotating machinery, and hazardous chemicals. May involve on-call responsibilities and occasional travel for audits, training, or technical reviews. Requires use of personal protective equipment (PPE) when in operational areas.