INEOS Olefins & Polymers USA
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Training and Reliability
Chocolate Bayou Works
Tuesday, August 10, 2021
Organizational context and job purpose
The Chocolate Bayou Works site is located in Southeastern Texas about 40 miles south of Houston and consists of two Olefin units that produce approximately 3bn pounds/year of ethylene, 2 Polypropylene units that produce approximately 800m pounds/ year of polypropylene, storage and transfer facilities at Stratton Ridge. The site also provides knowledge sharing support and functional guidance through relationships with the PE / PP facilities at Battleground and the Hobbs gas processing facility in New Mexico, with the headquarters located in League City, TX.
How the Role Fits In:
The INEOS Chocolate Bayou Mechanical Maintenance Trainer will be part of the Reliability group and will be responsible for training coordination for Mechanical Techs, Reliability Techs, Inspection Techs and Mechanical Engineers across the site.
This position reports directly to the Mechanical Integrity & Reliability Superintendent at CBW.
Responsibilities AND Accountabilities
Accountability 1: SHE Stewardship
- The position is accountable for understanding and putting into practice the INEOS 20 Principles. Additionally, this position has a special responsibility to cascade the understanding of these principles throughout the craft teams that execute maintenance activities in the field.
- Remains in compliance with CBW SHE policies and procedures.
- Ensures that job plans comply with and reflect all requirements established in CBW SHE policies and procedures.
- Promotes and demonstrates safe behaviors through personal participation in SHE activities including incident investigations, HAZOP's, audits, observations, housekeeping and in reviewing other groups’ safety incidents and near misses.
- Ensure SHE delivery, compliance and self-verification processes for departmental maintenance activities.
Accountability 2: Training
- Consults with Maintenance, Reliability, Inspection and Operations management to define training opportunities within the Mechanical Groups.
- Gathers feedback from technicians, team leaders and others on training effectiveness.
- Works with the Learning and Development organization to enhance presentation and instructional methods.
- Leads the development and facilitation of mechanical maintenance training programs.
- Communicates with plant mechanical groups as needed to identify potential training needs.
- Gathers training materials and data to ensure the most appropriate material is being utilized.
- Conduct quarterly training meetings with pertinent plant personnel to assess future training needs of technicians.
- Develops a continuous improvement plan for the upskilling of technicians.
- Coordinates annual Pride training for Super Users.
- Ensures quarterly Pride meetings with Operations management.
- Supports Reliability Superintendent in development of annual budget for craft training to pursue grant-training funds from Texas Workforce Commission.
- Assists in delivery of maintenance training program to Chocolate Bayou personnel and participates as an instructor as needed.
- Arranges for vendor delivery of training instruction; works with team leaders to schedule their technicians.
- Jointly responsible with working team leaders to:
- Assure compliance with all maintenance-related OSHA 1910 requirements.
- Initial training of the mechanical craft personnel.
- Supports maintenance new hire/bid selection process.
- Supports superintendents in succession planning for technicians based on service, skills, and needs.
- Manage the Mechanical Maintenance Apprentice Program and Apprentice development.
- Work with Apprentices in the units to ensure training program success.
- Coordinate with local colleges to ensure pipeline of talent from these sources.
- Participate in Apprentice interviews, evaluations, and unit assignment work.
- Maintains an up-to-date database with training records for all mechanical maintenance personnel.
- Assists with maintenance training reviews and audits.
- Responsible for reviews and evaluations of maintenance training hardware and training programs.
- Reviews computer video based training including computer.
- Manage plant Job Rep training program and document qualified job reps for both company employees and site contractors.
- Manage contractor Job Rep training through Texas City Safety Council.
- Keep procedures training modules up-to-date.
Accountability 3: Reliability Activities
- Update, correct and maintain equipment files. Ensure new equipment file has information needed for maintenance and makes recommendations on stores stock parts.
- Works with the Procurement department to procure and expedite materials and services as needed.
- Act as a field representative and point of contact for outside vendors working in the plant. This includes performing field safety orientations, permit and regular field visits during the course of the work being performed.
- Serve as field Job Rep for third party contractors performing millwright type work on the premises on an as needed basis and during major outages.
- Represent plant at vendor shops during repairs and tests of plant equipment. Witness tears down and re-assembly of rotating equipment, balance checks, and run tests. Provide Plant personnel a detailed report of all shop witnessed activities.
- Serve as field Job Rep for third party contractors performing millwright type work on the premises on an as needed basis and during major Outages.
- Coordinate work on vibration systems with site Reliability Group and also other specialty contractors performing items such as field balancing, piping/structural vibration analysis, etc.
Accountability 4: Troubleshooting and Technical Support of Mechanical Equipment
- Prior to Turn Around (TAR) or Outage, candidate must review all the equipment historical data available to provide a precise recommendation for rotating equipment repair or upgrade
- Provide a clear scope of work for all rotating equipment that will be worked on during TAR along with a cost estimate and submitted to the TAR group in a timely manner
- Provide clear communication and direction to any shop or vendor worked with to support the TAR or outages
- During the TAR or Outage, high involvement should be seen and progress should be communicated to the proper personnel on a regular basis to prevent missing any opportunity and to avoid a miscommunication, which could lead to a delay in TAR
- After TAR or outage, confirm all documentation of progress has been captured and entered into Sharepoint to aid in future TAR’s.
- Ensure all capital spares for rotating equipment in area of responsibility are up to date
- Generate a list of all the existing rotating equipment procedures within the assigned area; review updates and submit them for approval in a timely manner
- Develop procedures for any rotating equipment in need of one
- For Root Cause Analyses (RCA) that have been assigned for the purpose of improving reliability, ensure they have been completed in a timely manner, that management approval has been received, and the action items have been documented into Traction with the date of completion
- Upon RCA completion, a Learning From Incident (LFI) needs to be generated and communicated to the appropriate personnel
- Provide the technical support needed for project and commissioning to start up the unit successfully
- Technical expertise in maintenance repair techniques. Works with outside services to find innovative/new technology available in the maintenance field.
- Analyze, troubleshoot and solve rotating equipment problems with air compressors, API pumps, centrifugal pumps and compressors, pump and motor installations, polymers finishing equipment, gearboxes, and solids handling equipment.
- Provide estimates to the area budgeting team for small capital jobs and serve as SPA on small project and expense jobs.
- Participate as a member of certain large capital and new technology groups as part of the optimization of the operations.
- Project activities include scoping and prioritization, preliminary and detailed mechanical equipment designs, start-up support, post audit evaluations and completion of proper documentation.
- Serve as the mechanical lead during unit turnarounds.
- Specify repair/replacement methods and materials per INEOS specifications, approves job plans and estimates.
Skills & Knowledge Required
- High School Diploma or G.E.D. required
- Minimum five (5) years of chemical, refining, or manufacturing industry
- Strong background in mechanical maintenance especially in rotating equipment.
- Excellent written and oral communication skills
- Proficiency in Microsoft products
- Excellent organizational, analytical, and technical abilities
- Ability to influence others to be motivated and work toward company objectives
- Works well with others; coordinates tasks efficiently; gathers information from others and cascades appropriately
- Follows INEOS’s core values and mission statement; follows direction adhering to the company-wide goals
- Quick learner; can learn from experience on the job and correct mistakes from lessons learned
Our culture is one of honesty and integrity with an emphasis on safety, health and environmental performance.On our team, people are acknowledged for embracing new practices that help create real value for customers.