Job description:
1. JOB PURPOSE:
To carry out scheduled and unscheduled equipment condition checks, gather relevant data, and analyse and monitor vibrations, trends, and patterns to identify the rate of failure and variances in equipment performance, efficiency levels or mechanical behaviour in order to provide recommendations on proactive maintenance actions that support in maximising equipment uptime, preventing unforeseen failure and extending equipment life.
2. KEY ACCOUNTABILITIES: Policies, Processes & Procedures
- Implements functional policies, systems, processes, procedures and controls related to condition monitoring within the Reliability Engineering function so that all relevant procedural/legislative requirements are fulfilled while delivering a quality, cost-effective service in a consistent manner
Day-to-Day Operations
- Carries out day-to-day operations related to condition monitoring within the Reliability Engineering function to ensure that work processes are implemented as designed and comply with established work methods, policies, procedures, applicable codes, standards and specifications.
Equipment Checks and Monitoring
- Conducts routine scheduled and unscheduled equipment checks in the plant, and gathers data using hand-held and permanent instrumentations mounted on equipment and available at Central Control Room panels in order to collect accurate and reliable data necessary for conducting analyses and making proactive maintenance recommendations.
- Conducts all condition monitoring related activities including overhauling rotating equipment, dismantling clearances measurements, conducting damage assessment of critical components and subsequently measuring bearing clearances, axial float, and shaft alignment during the equipment assembling phase, etc., in order to check the health of equipment, and to highlight any anomalies.
- Conducts physical inspection on spare parts including newly procured and repairable spares before and after refurbishment in order to ensure the parts are in proper condition and compliant with all established standards and requirements.
Data Analysis and Reports
- Feeds all data gathered from equipment condition check including vibration readings into the computer either manually or via suitable computer interfaces in order to ensure ease of accessibility when required, and to enable conducting accurate trends analysis.
- Analyses the gathered data from the equipment and monitors lead indicators such as vibrations, trends, patterns and observations, in order to identify the rate of failure and any variances in equipment performance, efficiency levels and mechanical behaviour in order to inform the Senior Engineer Condition Monitoring/ NDT on necessary proactive maintenance and corrective actions to be taken.
- Develops daily reports on condition monitoring highlighting the equipment checked, analyses conducted and suggested action plans to support Engineers and Area supervisors in root-cause and reliability analyses.
Planning Support
- Provides support to the Planners by providing input relevant to shutdown maintenance planning and preventive maintenance planning in order to ensure that the faulty equipment or necessary improvements/ enhancements are carried out in a timely manner with minimal impact on production.
Issue Resolution
- Performs routine calibration, and operation of equipment used in the NDT in order to ensure that field tests are carried out effectively, and in compliance with applicable standards.
Safety, Quality & Environment
- Implements all relevant safety, quality and environmental management policies, procedures and controls in order to ensure employee safety, legislative compliance and a responsible environmental attitude.
Related Assignments
- Performs other related duties or assignments as directed.
3. QUALIFICATIONS & SKILLS: Minimum Qualifications:
High School Diploma (completion of technical secondary education) with a relevant trade certification (mechanical). Preferably a certification or training in condition monitoring such as vibration analysis, NDT, termalvision, etc.
Minimum Experience:
3 to 5 years of experience in condition monitoring / NDT in a production plant maintenance such as alumina refinery, oil or petrochemical.
For mechanical condition monitoring technician, the position holder should have experience in conducting trend analyses such as vibration spectrum, thickness, ultra sound, oil analysis, visual inspection, wear and dimensional measurement, etc.
For electrical condition monitoring technician the position holder should have experience in conducting trend analyses such as thermography inspection, shock pulse, electrical insulation, megger test, surge comparison, eddy current, motor phase and balance test, etc.
Skills:
- Strong knowledge of on-line and off-line (e.g. vibration data collectors) technologies and equipment condition monitoring systems
- Strong understanding of condition monitoring and NDT techniques and processes
- Knowledge/ experience of lean principles and tools
- Knowledge of pressure vessel, pipe and weld maintenance and inspection practices
- Effective communication and interpersonal skills.
- Good troubleshooting ability and problem solving skills
- Ability to diagnose and repair rotating industrial equipment
- Ability to work with specialised software such as maintenance predictive software
- Willingness to learn and grow
- Ability to read and understand equipment technical data books
- Ability to use the applicable computerised maintenance management system as well as windows and MS Office
