Reliability Engineer

Nexus Circular is seeking a highly analytical and experienced Contract Reliability Engineer to lead the development and optimization of our maintenance strategies and mechanical integrity programs. The primary objective of this contract is twofold:

• Design, write, and implement robust Preventive Maintenance (PM) and Predictive Maintenance (PdM) procedures from the ground up, utilizing Reliability Centered Maintenance (RCM) methodologies to address both known and unknown failure modes.
• Develop and structure the facility’s Mechanical Integrity (MI) program for fixed equipment, specifically focusing on Pipe Circuitization and establishing inspection plans in compliance with API and PSM standards.

You will act as the technical authority on asset care, translating complex failure data, FMEA (Failure Modes and Effects Analysis), and piping/vessel design data into actionable, step-by-step maintenance and inspection procedures., Reliability Centered Maintenance (RCM) & FMEA

• Lead and facilitate RCM and FMEA workshops with cross-functional teams (Maintenance, Operations, Engineering) to evaluate critical plant rotating and fixed assets.
• Analyze historical CMMS data, downtime reports, and operator feedback to identify and document known failure modes.
• Utilize engineering principles, OEM documentation, and industry reliability databases to postulate and document unknown or potential failure modes before they occur.
• Determine the operational, safety, and environmental consequences of identified failure modes to prioritize maintenance strategies.

Mechanical Integrity (MI) & Pipe Circuitization

• Lead the circuitization of process piping systems in accordance with API 570 guidelines. Group piping by corrosion systems, process fluids, operating conditions, and materials of construction.
• Identify and document primary Corrosion Monitoring Locations (CMLs) and Condition Monitoring Locations (TMLs) on piping isometric drawings.
• Establish and document initial inspection intervals within eMaint CMMS.

PM & PdM Procedure Development

• Develop comprehensive, step-by-step Preventive Maintenance (PM) and Mechanical Integrity inspection procedures designed to specifically mitigate identified failure modes and damage mechanisms.
• Determine the technical feasibility and ROI of Predictive Maintenance (PdM) tasks versus time-based PM tasks.
• Develop PdM procedures specifying appropriate condition-monitoring technologies (e.g., Vibration Analysis, Infrared Thermography, Oil Analysis, Ultrasonic testing, NDT/NDE techniques).
• Define clear pass/fail criteria, acceptable operating tolerances, and corrective action triggers for all PM, PdM, and MI procedures.
• Ensure all procedures are written clearly for execution by technicians and inspectors, including required tools, parts, safety precautions (LOTO), and estimated execution times.

Strategy Optimization & Implementation

• Review and rationalize existing PMs to eliminate non-value-added tasks (PM optimization).
• Establish correct maintenance frequencies based on the P-F curve (Potential-to-Functional failure interval).
• Collaborate with the CMMS Administrator to properly structure, upload, and schedule the newly developed PM/PdM/MI tasks in the eMaint CMMS., * Delivery of a comprehensive FMEA database mapping known and unknown failure modes to specific assets.
• Completion of Process Piping Circuitization, including marked-up P&IDs/Isometrics and documented CMLs.
• Delivery of fully documented, peer-reviewed PM, PdM, and MI inspection procedures ready for CMMS integration.
• Establishment of a compliant, structured Mechanical Integrity inspection schedule based on actual damage mechanisms and remaining life.

• Education: Bachelor’s degree in Mechanical, Materials, Industrial Engineering, or a related technical field (or equivalent extensive industry experience).
• Experience: 7+ years of dedicated Reliability Engineering, Maintenance Engineering, or MI/Inspection experience in a petrochemical or chemical processing environment.
• RCM Expertise: Proven, hands-on experience successfully applying Reliability Centered Maintenance (RCM) principles and facilitating FMEA sessions.
• Mechanical Integrity Expertise: Deep understanding of OSHA PSM Mechanical Integrity requirements and API inspection codes (API 510, 570, 653). Proven experience performing pipe circuitization and establishing CMLs/TMLs.
• Technical Writing: Exceptional ability to write clear, concise, and highly detailed technical maintenance and inspection procedures.
• PdM/NDT Knowledge: Strong working knowledge of condition-monitoring technologies (rotating equipment) and Non-Destructive Testing (NDT) methods (fixed equipment).
• Software: Proficiency with modern CMMS platforms, AutoCAD/Bluebeam (for marking up P&IDs and Isometrics), and data analysis tools., * Certifications: Certified Maintenance & Reliability Professional (CMRP), Certified Reliability Engineer (CRE), or RCM Facilitator Certification.
• API Certifications: Current or previous API 510, API 570, or API 580 certifications are highly desirable.
• PdM Certifications: Level I or II certifications in Vibration Analysis, Thermography, or Machinery Lubrication (ICML).