Lead Mechanical Integrity & Reliability Engineer

Job Summary :

We are seeking a Lead Mechanical Integrity & Reliability Engineer to oversee the implementation, management, and optimization of predictive maintenance programs and mechanical integrity systems. This role will be critical in ensuring the long-term reliability and performance of our rotating equipment, tanks, piping, and heat exchangers across multiple sites. The plant is located in Louisville, KY. (Please note, if required, an above-market corporate relocation package will be available).

Key Responsibilities :

• Predictive Maintenance Program :
• Lead and manage the Predictive Maintenance program, utilizing tools such as vibration analysis, infrared thermography, ultrasonic testing, and oil analysis to monitor equipment health and predict potential failures.
• Mechanical Integrity Program :
• Oversee and maintain the Mechanical Integrity program, ensuring full compliance across all sites. Collaborate with site maintenance leaders to assess and address MI reports, fitness-for-service evaluations, and necessary repairs.
• Risk Insurance Program :
• Administer the corporate risk insurance program and coordinate audits to ensure proper risk management practices are in place at all sites.
• Asset Management & Budgeting :
• Maintain a long-term equipment asset replacement plan and ensure that major equipment is included in the MI program budget.
• Rotating Equipment Monitoring :
• Review and assess the condition of rotating equipment using various PdM data (vibration, oil analysis, IR, ultrasound), as well as critical process data to evaluate equipment health.
• Data Management :
• Manage and maintain the ZCLP PdM and MI databases to ensure accurate, up-to-date records for analysis and reporting.
• Cost Analysis & Strategy Development :
• Analyze equipment history, maintenance costs, and failure patterns to refine asset management strategies, focusing on cost avoidance, cost savings, and increased equipment uptime.
• Bad Actor Program :
• Lead and monitor the Site Bad Actor Program to identify and address recurring equipment failures. Track key performance indicators (KPIs) related to PdM and MI efforts in the Reliance database.
• Root Cause Analysis :
• Provide PdM data (vibration, oil analysis, etc.) to support root cause analysis (RCA) and Failure Modes, Effects, and Criticality Analysis (FMECA) processes.
• Third-Party Contractor Management :
• Oversee and manage third-party MI inspection services and contractors.
• Reliability and Maintainability in New Projects :
• Support the Design for Reliability, Maintainability, and Inspectability (DFR / M / I) in new equipment projects. Ensure that all technical documentation, OEM manuals, and support materials are available during equipment commissioning.
• SAP Integration :
• Ensure new or redesigned equipment is accurately set up in SAP with proper asset criticality prioritization and asset strategies for all critical assets.
• Spare Parts Strategy :
• Lead the spare parts strategy, focusing on equipment criticality, lead times, and cost-benefit analysis to minimize downtime and risk.
• Reliability Analytics :
• Integrate reliability analytics and modeling tools to analyze equipment trends, build failure prediction models, and enhance mechanical availability.
Qualifications :
• Education :
• Bachelor’s Degree in Mechanical Engineering or a related field.
• Experience :
• At least 5 years of experience in predictive maintenance of rotating equipment within a chemical or petrochemical facility.
• Minimum of 5 years evaluating tank, piping, and heat exchanger conditions according to ASME, API, or STI standards.
• Certifications (Preferred) :
• Certifications in vibration analysis, oil analysis, thermography, and ultrasound analysis (or a minimum of 5 years of relevant experience in these areas).
• Technical Skills :
• Proficient in Microsoft Office Suite (Outlook, Excel, PowerPoint).
• Experience with SAP CMMS is highly preferred.
• PSM experience is highly preferred