I&E Reliability Engineer

Company:

Interested in joining a winning team? A team whose employees share in the ownership of the business and are empowered to make a difference?

Organizational Context and Job Purpose

INEOS Organization:

INEOS is a global manufacturer of petrochemicals, specialty chemicals and oil products. It comprises 15 businesses each with a major chemical company heritage. Its production network spans 65 manufacturing facilities in 16 countries throughout the world. INEOS products make a significant contribution to saving life, improving health and enhancing standards of living for people around the world. Its businesses produce the raw materials that are essential in the manufacture of a wide variety of goods: from paints to plastics, textiles to technology, and medicines to mobile phones - chemicals manufactured by INEOS enhance almost every aspect of modern life.

BUSINESS CONTEXT:

Ethylene oxide (EO) is an important building block for the preparation of a wide variety of EO derivatives (EODs), including various surfactants, as well as a host of other chemical intermediates including Glycol Ethers, Polyethlene Glycols, Ethanolamines, and Alkyl Alkanolamines. 

INEOS Oxide is one of the world’s leading producers of Ethylene Oxide (EO) and Ethylene Oxide Derivatives (EODs).  We currently have a total EO and EOD capacity of 920 kta spread across five different production units throughout Europe and the US. These units have leading cost economics, due to economies of scale, state-of-the-art technology, strategic locations, etc. Our EO project in the US is targeting the fast-growing merchant EO market, building on our experience and leadership position in Europe.

Purpose of the Job:

This role is part of the Bayport Reliability Group supporting plant operation and reliability improvement efforts. Working in a team environment, it carries responsibility for implementing reliability best practices, developing and optimizing preventive maintenance tasks, and supporting maintenance activities. The position interacts with other technical groups on site (process engineering, maintenance, and capital project groups), corporate technical networks and peers, and vendors/suppliers as needed to resolve problems and improve plant reliability and performance.

The candidate is responsible for safe and efficient operation of assigned production unit using established operating discipline and procedures. The I&E reliability Engineer is responsible for maintaining the plant assets and protective systems integrity and to deliver established production targets set by the business. 

Responsibilities and Accountabilities

SHE

• Maintain the safe and efficient operation of the production unit using established operating disciplines and procedures.  Ensure safety and environmental compliance is achieved.
• Responsible for maintaining the plant assets and protective systems integrity.
• Assist in defining and maintaining the correct operating envelopes for the organization.  Investigate when deviations outside of the operating envelopes occur.
• Participate in the development of operating procedures and training materials.
• Support PSM and Environmental efforts including Process Hazard Analyses (PHAs), Management of Change process, Risk Assessments and incident investigations.
  • Input, evaluate and approve MOCs
  • Conduct PSSRs for MOCs
  • Participate in PHAs as the instrumentation and reliability engineering representative
• Understand and lead by example for all safety and environmental programs.
• Report and address SHE near misses.
• Complete all assigned action items from PHAs, incidents, audits, etc in a timely manner and keep status and plans for action items updated.
• Maintain safety as the highest priority of the plant
• Maintain the 20 Principles of Safety
• Conduct routine AsCare tours and participate in audits.
• Adhere to and uphold all safety policies and standards

ROLES & RESPONSIBILITIES

• Apply data analysis techniques to develop engineering solutions to repetitive failures and other problems that adversely affect plant operations including capacity, quality, cost, and regulatory compliance issues
• Consult with peers at the site and across the company
• Serve as a resource and conduit to share best practices and leverage operating improvement opportunities across the site and company
• Provide technical support/expertise within your discipline in the design and installation stages of projects for new assets and modification of existing assets to minimize life cycle cost and maximize asset availability
• Participate in the development of design and installation specifications and commissioning plans.
• Participate in the development of criteria for and evaluation of equipment and technical MRO suppliers and technical maintenance service providers. Develop acceptance tests and inspection criteria
• Maintain awareness of emerging technology, assessing applicability to improve reliability and performance, or to reduce maintenance cost
• Lead or participate in incident investigations and root cause analysis
• Provide input to a risk management plan that will anticipate reliability-related and non-reliability- related risks that could adversely impact plant operations
• Systematically define, design, develop, monitor, and refine 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
• Apply value analysis to repair/replace, repair/redesign, and make/buy decisions
• Provide technical support to production, maintenance, project, and process engineering groups
• Implement Safety Instrumented Systems that meet availability requirements by translating Process Hazard Analysis requirements into technical design specifications and preventive/predictive maintenance plans.
• Provide backfill coverage for I/E engineers during absences or peak workloads.  
• Develop both short-term and long-term I&E reliability strategies, benchmarks, and continuous improvement plans.
• Lead reliability improvement initiatives and identify reliability opportunities.
• Perform root cause failure analysis (RCFA) and develop corrective action plans.
• Support hazard and risk assessments, PHAs, MOC/LOPA, PSSR and other Process Safety Management programs
• Ensure compliance with applicable industry codes and standards (ISA, IEC 61511, NFPA, NEC, API, etc.) in design, maintenance, and reliability practices.
• Oversee I&E calibration programs, optimize spare parts inventory, and refine PdM/PM tasks based on reliability data.
• Serve as a technical resource to operations, technicians, contractors, vendors, etc.
• Develop and monitor asset management plans and reliability metrics (e.g., failure frequency, MTBF), and report findings to stakeholders.

Skills/Competencies

Level of Education & Experience in General

• BS degree in Electrical Engineering with a minimum of 5-10 years relevant experience in the refining, petrochemical, chemical process, or power generation industries.
• Strong interpersonal leadership skills are critical due to the requirement for effective communication of complex issues across the organization as well as for mentoring and consensus building.
• The successful candidate must exhibit an understanding of business drivers, management of change requirements, reliability processes, and maintenance workflow.
• The individual must have or develop basic proficiency in the following areas with the ability to develop into a subject matter expert in particular areas:

Technical skills

• Basic understanding of industry codes and standards (i.e. IEEE, ISA, NFPA, NEC)
• Instrumentation and measurement technology
• Medium and low voltage power distribution, equipment, and controls
• Safety Instrumented System specification, design, calculations, and implementation
• Analysers and sample systems
• Component failure analysis
• Project Management
• Basic Flow Calculations
• Reliability Engineering concepts
• Reliability data analysis techniques
• Familiarity with Electrical Area Classification
• Root Cause Failure analysis and Incident investigations
• Basic knowledge in DCS Control systems and PLCs
• Basic knowledge in SAP system
• Predictive and Preventive Maintenance concepts
• Ability to apply computer software tools (SAP, Microsoft Office, ExSILentia, Conval)
• Strong understanding of Plant Instrumentation

Behavioral Skills

• Exceptional communication skills, both oral and written
• Strong mechanical aptitude
• Safety role model
• Problem solving skills with data analysis ability
• Ability to work cross functionally

ADA Physical requirements, visual acuity requirements and environmental conditions

Outside

Light Work:  Exerting up to 20 pounds of force occasionally, and/or up to 10 pounds of force frequently, and/or a negligible amount of force constantly to move objects

• The worker is subject to inside environmental conditions:  Protection from weather conditions, but not necessarily from temperature changes.
• The worker is subject to outside environmental conditions:  No effective protection from the weather.
• The worker is subject to both environmental conditions:  Activities occur inside and outside.
• The worker is subject to extreme cold:  Temperatures below 32 degrees F for periods of more than one hour.
• The worker is subject to extreme heat:  Temperatures above 100 degrees F for periods of more than one hour.
• The worker is subject to noise:  There is sufficient noise to cause the worker to shout to be heard above the ambient noise level.
• The worker is subject to hazards:  Includes a variety of physical conditions, such as proximity to moving mechanical parts, electrical current, working on scaffolding and high places, exposure to high heat or exposure to chemicals.
• The worker is subject to atmospheric conditions:  One or more of the following conditions that affect the respiratory system or the skin:  fumes, Odors, dusts, mists, gases, or poor ventilation.

Inside:

Sedentary Work:  Exerting up to 10 pounds of force occasionally and/or a negligible amount of force frequently or constantly to lift, carry, push, pull or otherwise move objects, including the human body.  Sedentary work involves sitting most of the time.

• Subject to inside environmental conditions:  Protection from weather conditions, but not necessarily from temperature changes.
• The employee must have the ability to see written documents, computer screens, and to adjust focus.
• Hearing: Perceiving the nature of sounds at normal speaking levels with or without correction.   Ability to receive detailed information through oral communication and make discriminations in sound.

PERFORMANCE INDICATORS

• Achieve SHE metric targets for safety and environmental incidents
• Meet or exceed plant production goals
• Meet or exceed production supply reliability
• AsCare, 20P, MOC/PSM compliance achieved
• Meet or exceed efficiency targets
• Completion of assigned action items
• Achieve plant department and personal metrics as defined in annual performance assessment

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.