Senior Engineer, Reliability

Job Purpose

Analyse and assess different reliability factors with regards to different systems and equipment functionality in all Depots & Plants and all Fuel Service Stations to ensure effective Reliability Management systems. Conduct root cause analysis and suggest the remedial actions if necessary to maintain the assets’ reliability.

Ensure the dependability and efficiency of production systems within the organization, analyse data to identify patterns and potential issues, design and implement maintenance and monitoring procedures, collaborate with other departments to integrate reliability into all aspects of the company.

Focus on avoiding equipment failures, enhancing system performance, and ensuring the safety and reliability of all mechanical components and processes involved, develop comprehensive training programs for employees, enabling them to maintain high standards of equipment performance and reliability.

Key Accountabilities

Root Cause Analysis and Problem Prevention

• Conduct thorough root cause analysis to determine the underlying causes of equipment and system problems and recommend the necessary remedial actions. This involves investigating incident reports, performing detailed studies, and utilizing advanced analytical tools.
• Develop and implement new maintenance procedures aimed at preventing recurrences of identified issues. These procedures should be based on the latest industry standards and tailored to the specific needs of the organization.
• Design and implement procedures for monitoring and testing equipment to ensure optimal performance. This includes developing testing protocols and using diagnostic tools to anticipate and mitigate potential failures.
• Identify and integrate new technologies and processes that can enhance equipment performance and reliability. This involves researching advancements in the field and conducting pilot tests to evaluate their feasibility and effectiveness.
• Collaborate with other departments to ensure reliability is a key consideration in all organizational processes. This requires clear communication and coordination to align reliability goals with broader company objectives.
• Implement effectively the Reliability Management System to ensure a structured, consistent, and multi-discipline approach to reliability improvement during the operational phase.
• Perform equipment criticality assessment as required. Conduct analysis and studies related to risk based maintenance strategy such as Reliability Centred Maintenance (RCM) and Review of Existing Maintenance (REM) to ensure optimal function during the equipment life cycle.
• Participate in the reliability, availability and maintainability (RAM) studies to identify bottleneck and improve the plant performance.
• Analyse different Reliability Factors using Reliability Analytics intended to maintain and predict the equipment and system reliability measures.
• Provide support in risk strategies like risk based inspection (RBI) and safety integrity level (SIL) to contribute in maintaining the equipment level at a high integrity.
  
  

Data Analysis and Solution Implementation

• Analyze data to identify patterns and potential areas for improvement within systems and equipment. Utilize statistical analysis software and machine learning algorithms to uncover hidden trends and make data-driven decisions.
• Develop and implement solutions to prevent problems and improve system reliability. This includes designing corrective actions, process optimizations, and continuous improvement initiatives tailored to the organization's unique challenges.
• Develop a reliability, availability and improvement plan in conjunction with the Maintenance and Operations Departments based on different facilities’ requirements to improve and sustain the systems and equipment reliability and performance. Conduct preliminary hazards analysis to identify potential dangers or failures in production processes. Use risk assessment tools to prioritize hazards and develop mitigation strategies.
• Perform failure modes and effects analysis to list possible failures and their consequences. This involves detailed documentation and scenario planning to prepare for and prevent critical failures.
• Undertake criticality analysis to assess the seriousness of potential failures and their impact on production. Use this analysis to guide maintenance priorities and resource allocation.
  
  

Job Accountabilities

Maintenance and Monitoring Procedures

• Create and maintain detailed maintenance schedules to prevent equipment failures. These schedules should be dynamic, incorporating feedback from equipment performance data and predictive maintenance techniques.
• Analyze statistical data to predict failures and implement preventative measures. Leverage historical data and predictive analytics to forecast potential issues and plan maintenance activities accordingly.
• Develop inspection criteria and functionality tests to monitor equipment health. Ensure these criteria are comprehensive and regularly updated to reflect the latest operational insights and technological advancements.
• Ensure maintainability information is up-to-date and details efficient repair processes. This includes creating detailed repair manuals and training maintenance personnel on best practices.
• Implement new procedures for continuous equipment monitoring and performance testing. Use sensors, automation, and real-time data analysis to maintain optimal equipment conditions.
• Prepare, review, and update the reliability procedures to maintain robust processes.
• Develop and establish appropriate multi discipline condition monitoring programs to ensure the rotating equipment and system reliable functionality.
• Perform periodical assessment of condition monitoring strategies and review data collection frequencies in order to optimize the current processes, if required, based on the results derived from failure mode, mean time between failure (MTBF), and bad actors.
• Develop a system to track the equipment performance and issue the necessary reports to the Maintenance Department for timely correction/repairing.
• Maintain site bad actors and threat register to facilitate Root Cause Analysis.
  
  

Training and Employee Development

• Develop and implement comprehensive training programs for employees on equipment reliability and maintenance. These programs should be interactive, incorporating hands-on training and real-world scenarios.
• Provide ongoing training to ensure employees are equipped with the latest knowledge and skills. This includes regular refresher courses and access to industry-leading resources and certifications.
• Promote a culture of continuous improvement and reliability within the organization. Encourage employees to contribute ideas and participate in initiatives aimed at enhancing reliability and performance.
• Ensure all employees are aware of and adhere to reliability standards and practices. Conduct regular audits and assessments to measure adherence and identify areas for improvement.
• Collaborate with HR and other departments to identify training needs and opportunities. Work together to create development plans that align with organizational goals and individual career aspirations. Safety and Risk Management.
• Assess safety risks associated with equipment failures and implement mitigation strategies. Use comprehensive risk management frameworks to identify hazards and develop effective control measures.
  
  

QUALIFICATIONS, EXPERIENCE, KNOWLEDGE & SKILLS:

• Bachelor’s Degree in Science or in Engineering Mechanical/Electrical etc.
• Minimum 12 years of experience in reliability engineering within the Oil and Gas industry
• HSSE MS and Risk Management
• Terminal Operations
• Budget Planning and monitoring
• Compliance/ Assurance, Project Management & Performance Monitoring and Reporting
• Background in rotating equipment maintenance, electrical equipment maintenance, vibration analysis, ultrasound, lube oil analysis, thermography, and the relevant electrical condition monitoring techniques and troubleshooting.
• Strong understanding of maintenance and reliability programs related to industrial facilities to maximize equipment up-time, optimizing plants’ turnarounds/shutdowns.
• Awareness about analysis programs such as reliability centered maintenance (RCM), risk based inspection (RBI), and instrument protected function (IPF).
• Experience in root cause analysis techniques.
• Technical ability in understanding the relevant codes, standards, and inspection methods.
• Knowledge of HSE procedures and practices.
• Strong automation/instrumentation, electrical, and mechanical static equipment background.
• Strong knowledge of Microsoft packages.
• Strong verbal and writing skills.
• Excellent presentation skills.
• Planning and organizing, scheduling and coordinating, checking, examining, and recording.
  
  

27252