Asset Reliability and Project Engineer

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Compensation Grade

The PZ Reliability & Project Engineer will combine expertise in reliability engineering, manufacturing, and project management to ensure that systems, equipment, and processes operate consistently and predictably over time.

Accountability 1: Meet all SHE objectives and comply with all governmental laws and policies for a manufacturing site.

• Ensures compliance with HSSE (Health, Safety, Security, and Environment) standards and expectations set through the INEOS Life Saving Rules and 20 Safety Principles.
• Promoting safety culture through visible leadership in the field, including safety observation conversations, audits, and near miss reporting.
• Drive compliance with legislative requirements, engineering standards, procedures and practices.
• Complete all assigned safety, compliance and reliability action items in a timely manner and maintain status tracking.
• Serve as Management of Change (MOC) initiator when appropriate, working with SME’s around the site as needed to complete associated safety and technical reviews.
• Develop and execute safety strategies for assigned projects.
• Lead Root Cause Analysis (RCA) and 5 Why investigations to drive improvement in safety and reliability performance.
• Develop, optimize and maintain Asset Care strategies for asset equipment on an evergreen or continuous improvement basis.

Accountability 2:  Support project development and execution for the asset to support SHE, productivity, growth and sustainability improvements.

• Responsibility for specific capital and expense budget projects as applicable, include developing project scope, design, bid specifications and budget estimates.

• Define and implement plans for needed changes and improvement projects in the areas of safety, quality, reliability and cost
• Involvement with awarding the bid and assisting with the field execution of the project.
• Coordination of safety kick-off meetings, Job Safety Analysis (JSA) reviews, schedule development and coordination of the project with other site resources.
• Assist the development of expense and capital project priorities for the asset and associated cost estimates for annual budget process and execution cost forecasting.
• Interact daily with asset Operations personnel, Process and Development Engineers, and Asset Support teams.
• Support Capital projects by providing input into initial scope reviews, project package IFA reviews and assisting with field execution. This includes working knowledge of applicable industry standards and codes relating to fixed and rotating equipment including API, NFPA, ANSI, etc.
• Supporting preparation of project plans and schedules for TAR events.
• Work with Site Development and Asset Support to ensure the reliability and maintainability of new and modified installations including design solutions and commissioning plans.

Accountability 3: Achieve asset production and reliability objectives through process and equipment health monitoring, root cause analysis (RCA) leadership and championing of preventative and predictive maintenance tasks.

• Works with Asset Process and Development Engineer and SME’s to perform analysis of equipment reliability including asset utilization, overall equipment effectiveness (OEE), remaining useful life, reliability and costs of asset maintenance throughout the entire life cycle of assets.
• Identify equipment bad actors and develop plans to remediate via FMEA, RCFA, PMs and other reliability tools to improve lifecycle, reduce cost and increase MTBF of all asset equipment.
• Complete and publish monthly reliability reports and summaries.
• Develops and maintain KPIs focused on equipment reliability.
• Develop and maintain equipment health modelling tools.
• Lead RCA and 5 Why investigations into equipment failures and asset downtime, working with supporting organizations around the site as needed.
• Champions completion of RCA, 5 Why and other investigation action items in a timely manner.
• Develops acceptance tests and inspection criteria.
• Observes and/or conducts tests at suppliers or repair facilities to evaluate reliability factors, such as causes of equipment failures and to provide oversight of critical repairs as needed.
• Provides input on process plans as needed to complete specific optimization and/or operations tasks.
• Supports maintaining the asset protective systems integrity and equipment mechanical integrity program.
• Applies value analysis to repair/replace, repair/redesign, and make/buy decisions
• Guides efforts to ensure reliability and maintainability of equipment.
• Professionally and systematically defines, designs, develops, monitors and refines an asset maintenance plan that includes:
  • Value-added preventive maintenance tasks
  • Effective utilization of predictive and other non-destructive testing methodologies designed to identify and isolate inherent reliability problems
• Provides input to a risk management plan that could adversely impact site operation.
• Develops engineering solutions to repetitive failures and all other problems that adversely affect operations based on capacity, quality, cost or regulatory compliance issues through utilization of data analysis techniques (reliability modelling and prediction, FTA, statistical process control, RCA, FMEA, etc.)
• Participates in the development of design and installation specifications along with commissioning plans.
• Participates in the development of criteria for and evaluation of equipment and technical MRO suppliers and technical maintenance service providers.
• Support for spare parts management through SAP for reliability improvement.
• Develops maintenance strategies to optimize asset performance.
• Evaluates risks related to reliability, safety, and environmental impact.
• Contributes to reliability-related scope development for Asset Outages and turnarounds.

Level of Education & Knowledge:

• Bachelor’s degree in Chemical or Mechanical Engineering
• Experience with execution of capital projects and expense projects
• Experience working with multiple engineering disciplines, as well as contractors supporting delivery of projects
• 2+ years of experience in refinery or chemical plant preferred

Experience & Technical Skills:

• Experience in refinery or chemical manufacturing environment
• Knowledgeable in the use and integration of predictive and preventive maintenance tools
• Knowledgeable in reliability and failure analysis methodologies such as FMEA, RCFA, and MTBF
• Must understand Computerized Maintenance Management System (SAP)
• Familiarity with the LDAR program and the regulations that accompany the annual completion of the assigned routes and ensure we meet regulatory compliances set in place by the government.
• A demonstrated ability to apply fundamental concepts of science and engineering to solve problems in a manufacturing plant.
• Knowledgeable of manufacturing industry best practices (design, control, safety, etc.)
• Basic knowledge of the PHA process, pressure relief systems, and safety instrumented systems.

Competencies & Behavioral Skills

• Relentlessly pursue and leverage market insights to guide strategies and make superior choices
• Make courageous decisions to innovate and accelerate value creation
• Optimistically focus on continual growth - pursuing superior outcomes for business & customer success
• Have a bias for action, prioritizing issues and making sound decisions - appropriately accounting for uncertainty and risk
• Adapt to changing market and customer opportunities quickly to deliver results in the most effective way
• Proven track record in problem solving and decision making and exceeding objectives and delivering results
• Works and interacts effectively as a team member and acts as mentor to others.
• Ability to lead and positively influence others/promote philosophy, win concessions without damaging relationships
• Strong demonstrated ability to manage, progress and deliver multiple and competing priorities
• Proven commitment and delivery of SHE compliance
• Ability to positively influence others/promote philosophy
• Defines personal success in terms of the whole team   
• Makes timely and effective decisions, includes use of good judgment and consideration of proper balance between benefits/risks
• Creates strong morale and spirit, feeling of belonging in team, broadly shares both routine and important tasks