Senior Engineer, Mechanical - South Africa

Senior Engineer, Mechanical (Rotating Machinery) will be responsible for the overall management of the lifecycle mechanical integrity of the assets across the cluster through the regular review of OEM’s requirements, operating regime/strategy, maintenance programs, remaining life. Put in place programs in order to optimize the long-term safety, reliability and efficiency of the asset with an added focus on Rotating machinery. The role will be that of technical Subject Matter Expert on Rotating Machinery, proficient in components like gas and steam turbines, motors, compressors, fans, and pumps, along with associated systems.

Design, development and installation related

• Lead activities from O&M side related to the implementation of any modification, including the activities related to the design, development, manufacturing and installation of any new or modified Rotating Machinery and Mechanical Systems.
• Develop necessary specifications for Rotating Machinery and Mechanical Systems.
• Contribute in the bid/evaluation processes including preparation of bid documents, completion of technical evaluations for proposals and providing recommendations for selection.
• Support the design review of new projects within the company and specific areas of expertise.
• Ensures proposed plant design meets OTS, O&M contract obligations, and PPA (off taker) specification adhering to applicable international technical regulations and standards and recommend required design modifications to meet standards and specifications.
• Ensure that the proposed design and specification of the equipment in design are capable to meet the desired life of the project, in case of any concerns new solutions for life enhance or necessary mitigations are to be proposed.
• Review HAZOP & HAZID analysis from EPC contractor and perform the same, if necessary.
• Ensure that all plant documentation for design and as built information / drawings are managed through a proper document management system tool.
• Review and manage to implementation, the related items of the Reliability of Supply (ROS) program to ensure full compliance within the agreed timelines.
• Review risk registers routinely and ensure participation in developing risks and mitigation plans.

Maintenance Management

• Monitor and update the Rotating Machinery and Mechanical Systems preventive and corrective maintenance and overhauling work activities to ensure safe and efficient application of procedures and implementation of optimal Mechanical maintenance.
• Develop and coordinate CBM strategy for all assets within the cluster, through procedures and processes and by equipping the site teams with the necessary tools, support and knowledge.
• Continuous improvement of Rotating Machinery and Mechanical Systems Maintenance Procedures/ programs to ensure high level of reliability and resource efficiency within the business, identification of new actions as outcome of RCAs or fleet experience.
• Lead the management and analysis of Vibration, Oil and Lubrication analysis, Ultrasound, Ultrasonic testing, Radiographic, Boroscopy, and Thermographic data, as well as other condition monitoring parameters, for Rotating Machinery as well as associated systems, and provide diagnosis using the appropriate diagnostic software tools
• Ensure that all documentation is completed in SAP correctly such as the Log, outlining the fault, method of repair and the time, labor and materials used in order to support timely availability of information.
• Monitor and support on the response to all emergency breakdowns to ensure plant availability, thereby minimizing downtime and possibility of liquidity damages.
• Develop and promote a condition based preventive maintenance culture on day to day basis by conducting troubleshooting and root cause analyses, finding solutions to reduce reactive maintenance.
• Generate Rotating Machinery condition reports on routine basis and recommend proactive actions wherever required with time
• Track warranty expiration on all the relevant equipment and ensure that warranties are upheld through operation and maintenance of the said equipment and systems.
• Lead and management with the site teams, the LTSA on the various Rotating Machinery.
• Support in activities related to budgeting, forecasting, accounting, work order management.

Plant Performance and KPIs

• Join the multi-disciplinary team to drive the continuous improvement of process control strategies to optimize the efficiency and output of power plant systems.
• Ensure desired availability and reliability metrics are achieved on Mechanical related critical systems and process.

Troubleshooting and Technical Guidance

• Offering day-to-day support for Rotating Machinery and Mechanical systems to the Maintenance & Operations teams, guaranteeing uninterrupted availability of plant equipment.
• Troubleshoot critical problems/breakdowns of Mechanical machinery and investigate, diagnose faults to determine best proper action/repairs while ensuring they comply with NOMAC’s quality and HSE standards. Leads and performs Root Cause Analysis of Failures in coordination with site teams and central engineering function. Prepare lessons learnt documentation for fleet betterment.
• Lead performance monitoring of Rotating Machinery and associated systems. Review and analyze maintenance data and conduct site engineering studies to determine the feasibility of introducing modifications to increase reliability and efficiency of plant, thereby ensuring continuous improvement and operational excellence.
• Steering Root Cause Failure Analysis (RCA) efforts, including the ability to compile summaries with causes and recommendations and present them to relevant parties.
• Lead the change management (MOC) process through the identification and preparation of feasibility studies for new installations, replacements or repair of existing Rotating Machinery including technical evaluation, specifications and materials for modifications in addition to process diagrams and cost estimates and ensure proper follow up reports and evaluation on completed modifications.
• Provides field engineering oversight and direction for activities such as support, testing, installation, inspections, commissioning, etc.
• Review the risk registers with site management teams and update were necessary on a regular basis.

Outage Management

• Participate in the effective forecasting of manpower, budget and material requirements to ensure timely availability of resources and spares for effective execution of Mechanical outage maintenance plans.
• Provide necessary alignment, balancing support during emergency and scheduled outages of the plant.
• Track key areas prone to be inspected for outages and proactively manage the execution of testing, overhauls, inspections etc.
• Support in the planning and execution of the shutdown maintenance of critical Mechanical machinery, as per the recommendation of the OEM, and provide technical support to ensure the EHS, scope, cost, and timeline objectives are met.

Documentation

• Ensure availability of engineering documentation.
• Keep proper records of documentation generated related to Mechanical engineering activities (i.e. root cause analysis, troubleshooting support, performance analysis, integrity inspections, etc.).
• Ensure that all maintenance documentation for the Mechanical activities are completed correctly including the Maintenance Log, outlining the fault, method of repair and the time, labor and materials used to support timely availability of information.
• Creation, Ownership and Management of the Asset Engineering Risk Register for the Cluster in coordination with central engineering function and ROS.
• Prepare and contribute to management reports as required.

Who will fit:

• 7-10 years relevant engineering experience on Rotating Machinery is compulsory, with supplementary experience on static machinery and general mechanical engineering.
• Bachelors of Technology / Engineering Degree in Mechanical
• This is a site-based role