Company:
INEOS OligomersInstrument & Electrical Reliability Supervisor
Location
Chocolate Bayou, Alvin, TX - USA
Organizational context and job purpose
With LAO manufacturing facilities in Canada and Belgium, INEOS Oligomers is one of the large merchant suppliers of Linear Alpha Olefins (LAO).
LAO is used in a variety of industries, with main markets being comonomers for polyethylene, feedstock for production of lubricants, surfactants, lubricant additives, and paper sizing chemicals, and base stock for drilling fluids. PAO is a synthetic lubricant.
As part of its growth strategy, INEOS Oligomers invested $500 million in a new world scale LAO & PAO production facility located in Chocolate Bayou, Alvin, Texas.
As a Responsible Care company we encourage our employees to embrace the principles of Responsible Care® by actively practicing them, promoting awareness of Responsible Care® and encouraging others to commit to these principles. Responsible Care® is the chemistry industry's commitment to sustainability - the betterment of society, the environment and the economy. Its ethic and principles compel us to innovate for safer and more environmentally friendly products and processes, and to work cooperatively to identify and eliminate harm throughout the entire life cycle of their products.
This position has accountability, in keeping with the INEOS Responsible Care principles and ethics, for all aspects of the operation of the Plant, including safety/environment, people management, cost control, quality, production planning, project and process follow-up.
This position will embrace and promote the INEOS 20 safety principles. Additionally, as a manager, this position has a special responsibility to cascade the understanding of these principles through their team.
In support of this new Plant following commissioning and start-up, INEOS Oligomers is establishing the Instrumentation & Electrical Reliability Supervisor role to help establish a long-term focus and the site’s reliability programs and ensure the unit operates at a high reliability percentage. In addition, this role will support the construction and commissioning phase of a PAO unit currently in construction at the site.
Purpose of the job:
The main goals of the I&E Reliability Supervisor is to safely maximize unit availability and minimize fixed costs associated with repairs to instrumentation and electrical equipment. This is achieved by a combination of problem prevention and resolution techniques. Problem prevention techniques would include development and implementation of reliability plans for the instrumentation and electrical infrastructure components at the site including transformers, MCC’s, main substation, PLCs, valves, analyzers etc. Problem resolution techniques would include identification and resolution of repeat failures, development of repair scopes and quality assurance verifications of equipment repairs and installations.
This role will report to the Oligomers Maintenance and Reliability Manager and will have one direct report: The I&E Reliability Specialist.
The Instrument & Electrical Reliability Supervisor will act to:
support LAO/PAO Operations and Maintenance in their day-to-day activities,
facilitate implementation of a preventive maintenance culture; create SIS/SIL/Environmental/Compliance PM procedures and establish in SAP
continuously improve maintenance and reliability organization capabilities to achieve best in class reliability,
maintain consistency and integrity of the E&I Components and Systems, particularly in supporting plant modifications and minor betterment projects, and support the implementation of a plant wide comprehensive technical and behavioral safety culture.
Serve on and lead RCFA investigation teams
Help define required spare parts for equipment
Provide troubleshooting and assistance for unusual or persistent problems
Lead I&E reliability programs and systems.
Internal Factors –
Safety Performance (SHE) , specifically project implementation, and shop and field construction safety performance
Plant Reliability & Availability
Maintenance/Reliability organizational capabilities, knowledge base and know-how of maintenance E&I supervisors, technicians and planners.
External Factors –
SHE compliance
Vendor support and know-how
Responsibilities AND Accountabilities
The Instrument & Electrical Reliability Supervisor will have the accountabilities as outlined below for all Instrumentation and Electrical facilities of the Plant, including all analyzers, and the hardware of the Distributed Control System and the Programmable Logic Controllers (collectively “E&I Components and Systems”):
Accountability 1: SHE Stewardship
Meet all SHE objectives and comply with all governmental laws and policies for a manufacturing site.
Supporting activities:
Accountable for understanding and putting into practice the INEOS 20 Principles. Additionally, the I/E Reliability team leader has a responsibility to cascade the understanding of these principles through their team.
Ensure process hazards are systematically identified, risk assessed, reviewed and managed.
Always place the safe operation or shutdown of the asset ahead of production.
When in doubt ensure the asset is always taken to its safest state.
Ensure assets operating envelopes and protective systems are in place to deliver safe operation and maintain asset integrity.
Identify and establish operating, maintenance, and CAPEX strategies to drive asset integrity and environmental compliance.
Promote, ensure and sustain commitment to operate assets with no harm to people and to the environment by visibly demonstrating Safety Leadership.
Ensure that a comprehensive SHE management process delivers and improves safety performance through incident reporting, behavioral awareness, compliance to policies, audits, and corrective action tracking/resolution and incident investigation.
Ensure safety and environmentally critical PMs are completed accurately and on time.
Accountability 2:
The Instrument & Electrical Reliability Supervisor will have one direct report – the I&E Reliability Specialist The Instrument & Electrical Reliability Supervisor will specifically be accountable for:
Ensure that the I&E Reliability team is trained and has the tools necessary to perform their roles safely and efficiently
Mentors, coaches, motivates and evaluates the team to deliver exceptional business performance by providing opportunities for development and enhancement of skills and competencies
Conduct periodical performance review, workload prioritization and team meetings to maintain continuous delivery while enhancing team productivity.
Seek to consolidate and share best practices across Oligomers sites as well as with INEOS O&P at CBW with their team. This may involve having a Reliability Team member participate in INEOS electrical & instrument network meetings.
Ensuring safe and efficient I&E maintenance work execution
Technical Roles
Accountability 3: Ensure maintainability and integrity of the design and facilities from an E&I perspective:
Most important activities:
Review selection of analyzer, process control, instrumentation and signal/data transmission technologies, and review proposed field implementation to ensure E&I Component, loop and System robustness,
Verify and approve all applicable detailed engineering deliverables (analyzer, instrument and electrical equipment specifications and data sheets, DCS and PLC specifications and data sheets, instrument list, I/O list, motor list, MCC and I/O room specification and lay out….),
Guide discipline engineering on a daily basis, resolve all open and emerging questions, ensure adherence to general industry and project specific E&I standards, and assist in approval of exceptions,
Work with the Maintenance and Reliability organizations of the existing LAO units to integrate their E&I inspection, maintenance and reliability know how,
Analyze the Plant lay-out and unit sectional drawings, in particular the MCC, I/O room, and analyzer shelter lay outs, and advise on modifications required to allow safe and efficient maintenance,
Oversee field construction and verify proper installation of the E&I Components and Systems, and the oversight of final commissioning of instrumentation and electrical equipment associated with maintenance or capital projects.
Accountability 4: Develop knowledge base and environment to facilitate preventive maintenance and best in class reliability performance:
Most important activities:
Establish a thorough technical understanding of all E&I Components and Systems,
Assemble, assimilate and classify all relevant vendor information pertaining to these E&I Components and Systems,
Develop E&I Maintenance technician training,
Define the spare parts, tools and facilities, and develop the inspection, repair and reconditioning procedures required to allow proper maintenance,
Prepare all E&I aspects of the Plant pre-conditioning, commissioning and operating procedures to ensure correct and reliable functioning of all E&I Components and Systems,
Advise on the development of all applicable third-party maintenance service contracts,
Set up the E&I maintenance part of the plant SAP system.
Accountability 5: Act as E&I Component and Systems Technical Subject Matter Expert in support of Maintenance and Operations
Serve as the OCB SIS/SIL Engineering Authority and Subject Matter Expert
Be on call to provide technical support when needed,
Perform root cause failure analysis (RCFA) on E&I Component and System failures, develop and recommend corrective action proposals.
Advise and assist on-site electricians, instrument technicians, planners and maintenance supervisors on E&I Component and System re-conditionings and repairs. Advise on modifications and improvements of maintenance re-conditioning and repair procedures and practices.
Accountability 6: Maintain Consistency and Integrity of all E&I Components and Systems
Take ownership of all E&I related Specifications and Standards,
Ensure Specifications and Standards are followed for plant modifications and minor betterment projects,
Evaluate adequacy of plant inspection and testing programs to ensure integrity and availability of E&I Components and Systems.
Accountability 7: Induce preventive maintenance, maintain and expand E&I knowledge base, and drive continuous improvement of organizational capabilities to achieve best in class Reliability
Keep all relevant re-conditioning and repair procedures, vendor information, specifications and standards up to date, adapt to evolutions in available technology & lessons learned from corrective maintenance where appropriate,
Develop a risk-based inspection program proposal,
Monitor critical equipment and assist in the development and implementation of Preventive Maintenance programs,
Gather and classify all data and information pertaining to E&I Component and System failures and failure frequencies,
Perform all necessary analysis, conduct all necessary investigations involving vendors and subject matter specialists as needed to identify failure modes, and classify all findings,
Develop and implement action plans to eliminate identified failure modes, including but not limited to modifications and changes to:
- E&I Component and System specifications and standards,
- Inspection, reconditioning and repair procedures, and
- E&I technician training documents and programs,
Develop and deliver refreshment training for E&I technicians.
Accountability 8: Support plant modifications and minor betterment projects.
Participate as a technical adviser on maintenance turnarounds and minor betterment projects,
Review and approve all E&I aspects of specifications of new equipment, and develop specifications for all new E&I Components and Systems as introduced by such minor betterment projects,
Participate in pre-start-up safety reviews, and assist in punch listing, pre-commissioning and commissioning of all plant modifications and minor betterment projects.
Skills Required
Level of education & Experience in general
a minimum a BS degree in Electrical Engineering and at least 10 years of experience as Maintenance or Reliability Engineer responsible for electrical infrastructure and equipment, process instrumentation and controls in chemical plants.
Prior Supervision experience is a plus.
Technical skills
Strong engineering skills with a thorough knowledge of process analyzers, instrumentation and controls engineering, including distributed control systems and programmable logic controllers,
Basic knowledge of, and experience with high and medium voltage power supply systems and electro motors,
Experience with PLCs and DCS programming, including safety interlock, emergency shut-down, and permissive start-up systems is a plus,
Detailed knowledge of instrumentation standards as applied in petrochemical industry and knowledge of various electrical Codes (e.g. NEC and ANSI / IEEE),
Complete understanding of the engineering documents associated with process instrumentation and controls such as: P&IDs, instrument specification sheets, loop diagrams, logic diagrams, installation detail drawings etc,
Good understanding of the engineering documents associated electrical power supply and distribution such as: Electrical component specification sheets, one-line diagrams etc,
Demonstrated technical capability to assess vendor quotes against project objectives,
Experience with project cost and schedule control practices is a plus,
Experience and knowledge of SKM model, short circuit, relay coordination, arc flash, load flow, and voltage drop studies
Knowledgeable and skilled in troubleshooting I&E issues and performing RCFA reviews
Behavioral skills
Safety minded, demonstrated strong safety and environmental performance,
Good people management skills (leadership, delegation and particularly networking and influencing skills),
Strong verbal as well as written communication skills (upward, lateral, and downward),
Strong ability to work with others, team builder,
Strong bias for action to identify potential problems and co-ordinate their resolution before they become an issue,
Ability to manage work priorities to deliver performance improvements and reliability in a demanding work environment,
Good analytical and organizational skills,
Stress resistant and methodical,
Problem solver and change agent,
Inspiring and motivating,
Self-motivated, self-starter; able to work with minimal supervision.
Must be able to acquire a TWIC card
ADA Physical requirements, visual acuity requirements and environmental conditions
While performing the duties of this job, the employee is regularly required to sit and perform tasks requiring repetitive use of hands. The employee must occasionally walk, stand, and travel by car, airplane or other means. Exert 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.
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 to make discriminations in sound.
Work Environment: This job is performed mainly in a temperature-controlled office environment.
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.