What are the responsibilities and job description for the Senior Consultant – Mechanical Integrity position at IFO Group?
NO RECRUITERS!
This is a contract position and may transition to a full time salaried role. Rates are negotiable based on experience.
The Senior Consultant – Mechanical Integrity is tasked with ensuring that IFO Group’s domestic and international clients are provided with expert mechanical integrity consultancy services.
Key responsibilities :
Development and refinement of Mechanical Integrity programs, strategies and philosophies to include the following elements :
- Equipment Selection and Prioritization for MI Program
o Equipment selection based on the overall program goals : Operating parameters, jurisdiction, company management, damage mechanisms, product quality, etc.
o Equipment normally including in the MI program : Piping and piping components to include valves, in line filters (historically piping failure resulted in 80% of all loss of the pressure envelope), pressure vessels, storage tanks, pressure relieve devices, structural components, rotating equipment, instrumentation, emergency shutdown systems. Consider cooling water system, steam system, refrigeration and power systems based on the hazard of loss.
o Define rational for prioritization.
o Develop Equipment List prioritization and frequency of inspection
o ITPM Program development involves two phases, ITPM task planning and ITPM task execution. Recommendation is to include transition steps to a more risk based, proactive maintenance program.
o Identify the RAGAGEP’s to be considered; API 510,570, 653, RP 571 etc.
o Identification of proper recordkeeping requirements for equipment inspection, maintenance and history essential to a successful program.
o Identify the RAGAGEP’s to be considered regarding certification of inspectors, employees and contractors
o Documentation of training and certification
o Define QA activities for equipment and materials : Design / Engineering, procurement, fabrication, receiving, storage and retrieval, construction and installation, in service repair, alterations and rerating, temporary installations and temporary repairs, decommissioning / reuse, used equipment, spare parts and contractor supplied materials.
o Develop a formal Positive Material Identification program. The PMI program ensures that the correct materials are being utilized in accordance with code and specification.
o A deficiency is noted when an observed condition is outside the established limits (acceptance criteria) that defines equipment integrity.
o Deficiency resolution should include the following : Risk assessment, authority for temporary mitigation and corrective actions, tracking and closing of temporary mitigation measures, communication of hazard, training for affected parties on temporary mitigation, equipment specific documentation.
o Management of Change (MOC) and pre-start up safety review (PSSR) systems can be used to document the stages and activities.
o Fitness for Service (FFS) evaluations using RP 579 may be utilized for evaluation of metallic pressure vessels, piping and storage tanks.
o This refers to primarily the specific standard, code or recommended practice that will be followed when addressing various types of equipment. More importantly it points to the need to address mechanical integrity for the following systems : fixed equipment, relief and vent systems, instrumentation and controls, rotating equipment, fired equipment, electrical equipment, fire protection protective systems, safety critical utilities.
o Assist with identification and implementation of Computerized Maintenance Management System (CMMS).
o Assist with identification and implementation of an Inspection Data Management System. The IDMS is essential tool for the MI program with tasks including the storage of inspection results, calculation of corrosion rates of equipment, and scheduling of inspections.
o Assist with development of written procedures to ensure that MI program activities and tasks are performed adequately, safely, and consistently.
o New Construction QA / QC
o Fabrication shop Inspection
o Pressure Relief Valve testing program
o Review of NDE contractor QA / QC procedures, manual and qualifications
o Development of approved vendors program
o Vendor surveillance
o Inspection Data Management System (IDMS)
o Preventive maintenance for fixed equipment
o Process Piping Inspection
o Fixed Equipment Inspection
o Selection of Corrosion Monitoring Locations on Piping and Pressure Vessels
o Documentation of inspection results
o Corrosion under Insulation (CUI)
o Dead leg survey
o Valve and Flange Joint Inspection
o Identifying damage mechanisms
o Structural Inspection
o Piping Injection points / mixing points
o Small bore piping inspection
o Non-destructive testing requirements
o Cathodic Protection
o Receiving and in service - Positive Material Identification (PMI)
o Audit of Mechanical Integrity program
Reporting To :
Principal Consultant (direct reporting line)
Profile of Ideal Candidate :
Education : Science or Engineering Degree or equivalent strongly preferred; with current professional engineering or Health, Safety, and Environment certification(s), specifically one of more of the following : PE, CSP, or equivalent. Prior completion of PSM and mechanical integrity training with corresponding certification and experience is a strong advantage for candidates. Candidates not meeting these requirements, but with otherwise strong experience may be considered on a case by case basis.
Assignment Location : Preferred location for candidate is Houston or DFW metro area but other locations may be considered for outstanding applicants. All candidates must be U.S. citizens or hold current legal residency status. The project location is south of the DFW metro area. Most of the work can likely be performed remotely with frequent site visits as the construction at the site progresses and commissioning begins.
Languages : Fluency in English is required; knowledge of other languages is a plus.
Professional Skills and Qualifications
15 years of relevant track record with significant achievements in the process safety and technical safety engineering fields. Candidates must have demonstrable mechanical integrity experience with process facilities (i.e. refining or chemical plants or related)
Comprehensive knowledge of applicable PSM and RMP regulations, concepts and trends and ability to understand and interpret complex mandatory regulations and their impact on client operations.
Ability to dig into site specific details and develop solutions to complex PSM issues.
Superior technical writing skills and the ability to convey ideas in written form through clear, simple and concise communication.
Meet business financial targets, overall project budget and schedule, client expectations, and contract requirements.
Personal Characteristics
Personality that conveys poise, seniority and credibility with high levels of convincing and influencing skills to gain the trust and respect of clients and colleagues.
Able to work autonomously with regular communication to the Principal Consultant.
Shows strong initiative, working effectively without close supervision.
Acts quickly and decisively, willing to demonstrate courage and address difficult issues in a tactful and diplomatic manner.
Excellent communication, interpersonal and leadership skills with the ability to interact with different groups of diverse needs and requirements in a motivational manner.
Team player with the ability to drive results and to motivate / manage the performance of others.
Demonstrates determination and persistence, high levels of resilience and the ability to cope with pressure, refusing to give up when faced with difficulty and continues steadily and firmly to achieve the business objective.
A hands on person that likes being close to the client’s business.
Solutions oriented personality with analytical thinking.
Applies good judgment and can act according to our high standards of ethics and integrity.
Genuine, open, honest and straight forward personality that appreciates direct personal communication.
Compensation and Benefits
This is a contract position and may transition to a full time salaried role. Rates are negotiable based on experience.
For professionals able to attract new clients and expand our service offerings with existing clients, we offer additional compensation as a reward for showing initiative and delivering outstanding results.