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Risk Based Inspector

Company:

INEOS Oxide

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:

The risk-based inspector (RBI) will manage the RBI software accurately in compliance with inspection requirements, practices, guidelines and policies for continuous improvement in stationary equipment. 

They are the primary focal point for the Risk Based Inspection Process, managing the RBI database and RBI Inspections in the inspection database.  They work with other site inspectors to identify required RBI inspections, updating the database with accurate data and modifying the frequency of inspections where applicable.

The Inspector utilizes inspection management systems, methodology, tools and programs to ensure ongoing reliability, cost effective maintenance, safe operations and continuous improvement in the stationary equipment.

Responsibilities AND Accountabilities

Accountability 1: 

SHE

  • Maintain the 20 Principles of Safety
  • Report unexpected corrosion discovery.
  • Understand and lead by example for all safety and environmental programs.
  • Investigate SHE incidents as directed
  • Report and address SHE near misses.
  • Maintain safety as the highest priority of the plant
  • Conduct routine AsCare tours and participate in audits.
  • Adhere to and uphold all safety policies and standards

Accountability 2: 

Inspection & Inspection KPI’s

  • Primary inspection focal point for the Risk Based Inspection Process
  • Document inspections performed
  • Report number of recommendations that are new, open, and closed
  • Manage RBI database and RBI Inspections in Inspection Database
  • Interface with Inspection Supervisor regarding RBI software and RBI inspection requirements.
  • Work with other site inspectors to identify required RBI inspections
  • Update Inspection database with accurate inspection data and modify frequency of inspections per RBI assessment, where applicable
  • Knowledgeable of ASME design codes and champions inspection code compliance.
  • Reviews the requirements for fixed equipment and Operational Excellence, corporate inspection and maintenance standards, and site specific procedures.
  • Prepares the required inspection procedures and manages any required corrective actions.
  • Audit the inspection database, ensuring data is accurate.
  • Execute Turnarounds as directed by inspection supervisor.
  • Ensures RBI assessments and inspection plans meet corporate and site RBI requirements
  • Ensure inspection work is identified per the turnaround timelines
  • Maintains the pipe circuit P&IDs to account for field modifications stemming from the “management of change” process.  Determine new TML points.
  • Performs risk-based analysis (e.g. RBI, RAT, RVIFT), develops inspection plans, evaluates inspection results, develops run/repair/replace recommendations and keeps RBI evergreen.
  • Continuously optimizes inspection plans to reduce inspection and maintenance cost. Manage unit inspectors in optimizing their inspection plans and implementing best practices.
  • Develops and optimizes stationary equipment inspection and repair scope for the turnaround. Plans NDE resources for the turnaround and leads the execution of inspection scope during the turnaround.
  • Leads incident investigations and Root Cause Failure Analyses.
  • Work in SAP “cockpit” to approve jobs which require quotes for all inspection companies performing inspection activities.
  • Supports, mentors and develops less experienced inspectors and engineers.
  • Utilize inspection software as needed to predict the performance of the various process equipment.

Skills/Competencies

Level of Education & Experience in general

  • High school diploma required
  • A minimum of 10 total years as an inspector in the petrochemical, chemical or refining industries required.  With a minimum of 5 years with RBI inspection experience.

Technical Skills

  • Training Skills
  • Keen computer skills with knowledge of all MS Office applications (Outlook, word, Excel, PowerPoint, Teams).
  • Technical skills in inspection database (Currently Meridium, switching to PCMS), RBI E2G Plant Manager (will role-up into PCMS), SAP, Turnaround database if not using SAP, RAT (Re-tube analysis Tool), RvIFT (for RV inspections/schedules this will be moving to PCMS), determining T-min thickness, remaining life calcs, corrosion rates.
  • Creating recommendations for code and procedure non-conformances found during inspection activities.
  • API 510, 570, 653, 580 certifications preferred.
  • Working knowledge of cathodic protection systems and mechanisms leading to equipment failure required.
  • Supplemental APIs such as API 580, 571, 579, AWS-CWI, as well as certifications in Level II NDE Technician skills to perform UT, MT, PT, VT preferred.
  • Creation and execution of work scope during maintenance, outages and turnarounds.

Behavioral Skills

  • Safety role model
  • Decision Quality – Makes good decisions based upon a mixture of analysis, experience, and judgement; sought out by others for advice and solutions.
  • Managerial Courage – Doesn’t hold back anything that needs to be said; provides current, direct, complete and “actionable” positive and corrective feedback to others.
  • Drive for results – Can be counted on to exceed goals successfully.
  • Integrity and trust – Is widely trusted; is seen as a direct, truthful individual; admits mistakes.
  • Customer focus – Is dedicated to meeting the expectations and requirements of internal and external customers. Good people skills.
  • Functional skills / technical skills – Has the functional and technical knowledge and skills to do the job at a high level of accomplishment.
  • Problem solving skills with data analysis ability

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. Ability to climb ladders and stairs.

  • 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 in order 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.
  • The worker is subject to oils:  There is air and/or skin exposure to oils and other cutting fluids.
  • The worker is required to wear a respirator.
  • The worker is required to don a gas mask.

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

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.

PERFORMANCE INDICATORS

  • Achieve SHE metric targets for inspection, zero overdue inspections
  • Lead inspection software conversion and promote and maintain accuracy.
  • Meet or exceed plant production goals
  • 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.