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