Position: Power Plant (POW) Mechanical Reliability Superintendent
Department: Operations & Maintenance (OM)
Location: Several Locations, Western Region, Ghana (West Africa)
Report Directly to: Plant Manager
Subordinate: Mechanical Reliability Engineer (1)
Designation Level: Functional Head
Salary: USD each month and start at $4,429.79 a month up to $5,443.79 a month - DOE. With Bonus $1,000 per qtr. (untaxed) for travel back home
OBJECTIVE: The Mechanical Reliability Superintendent will be responsible for identifying and managing asset reliability risks that could adversely affect the plant and operations. The Mechanical Reliability Superintendent will ensure the availability of assets and the overall reliability of the plant (equipment, processes, utilities, facilities, and safety/security systems) through good practices of monitoring and maintenance.
KEY RESPONSIBILITIES
• Operational Leadership: Provide strong leadership to the reliability team to ensure the plant is maintained efficiently and safely. Assist the Plant Manager to develop planned maintenance with the use of CMMS.
• Safety & Compliance: Establish and enforce safety protocols, maintenance procedures, and environmental regulations to maintain a safe and compliant facility.
• Process Optimization: Continuously identify opportunities for process improvement, energy efficiency, and cost reduction.
• Budget Management: Support the Plant Manager to develop and manage the plant's operational budget, including cost control and expenditure forecasting.
• Emergency Response: Develop and maintain emergency response plans and ensure all staff are trained for effective response to incidents.
• Reporting: Support the Plant Manager to prepare regular reports for senior management and the client, detailing plant performance, safety, and compliance metrics.
ENGINEERING, PROCUREMENT & CONSTRUCTION (EPC)
• Assist the EPC Project Team during the Construction, Installation and Commissioning Phase.
o Review Authorized For Construction drawings (AFCs), P&IDs, and commissioning checklists.
o Review all Red Lines and As Built Drawings.
o Make recommendations to the HSE team to develop strategies to improve health, safety, and environmental standards at all production systems.
o Ensure that warranty and punch list issues are effectively managed after commissioning of the plant.
o Ensure adherence of quality assurance and quality control (QAQC).
OPERATIONS & MAINTENANCE (OM)
• Ensure the reliability and maintainability of installations. Responsible for adhering to the life cycle asset management (LCAM) process throughout the entire life cycle of assets:
o Gas turbine generators.
o Pumps, air compressors, and other rotating equipment.
o Electrical motors.
o Pipe systems, tubbing systems, valves and pipe fittings.
o Tanks, vessels, pressure vessels, and heat exchangers.
o Boilers, chillers, and heaters.
• Responsible for designing, developing, monitoring, and refining an asset maintenance plan that includes:
o Value-added predictive, proactive, preventive, and corrective maintenance tasks.
o Effective utilization of predictive and other non-destructive testing methodologies designed to identify and isolate inherent reliability problems.
o Ensure the optimum utilization of the CCMS.
• Provide input to a risk management plan that will anticipate reliability-related and non-reliability-related risks that could adversely impact the plant operations.
• Develop engineering solutions to repetitive failures and all other problems that adversely affect the plant operations (capacity, quality, cost, or regulatory compliance issues):
o Statistical process control.
o Reliability modeling and prediction.
o Fault tree analysis.
o Weibull analysis.
o Six Sigma (6σ) methodology.
o Root cause analysis (RCA) and root cause failure analysis (RCFA).
o Failure reporting, analysis, and corrective action system (FRACAS).
• Work with the operations team to perform analysis of assets including:
o Asset utilization.
o Overall equipment effectiveness.
o Remaining useful life.
o Other parameters that define operating condition, reliability, and costs of assets.
• Provide technical support to the operations team and Plant Manager.
• Apply value analysis to repair/replace, repair/redesign and make/buy decisions.
• Execute predictive and preventive maintenance to eliminate catastrophic failures and unplanned maintenance.
• Act as Plant Manager during his absence.
• Maintain required regulatory documentation.
PROCUREMENT AND LOGISTICS
• Actively contribute to all Purchase and Service Order Agreements relating to the maintenance of plant.
• Actively work with the Plant Manager to manage all Procurement & Logistic agreements for consumable and spare parts.
• Ensure materials are available for planned maintenance, overhauls, and mandatory inspections.
FINANCE & COMPLIANCE
• Understand, monitor, and optimize operating costs within authorized budget.
• Assist in developing plant budget needs.
ORGANIZATIONAL DEVELOPMENT
• Supervise the Reliability Team. Support the Plant Manager to develop and staff the Plant team.
• Implement training and development program for staff in line with technical and business needs.
• Develop and implement necessary measures to ensure flexible work practices and team building.
• Carry out performance appraisals and development plans with subordinate staff.
QUALIFICATIONS
• BSc in Mechanical or Electromechanical Engineering.
• Master in Engineering, Business, or Management, is a plus.
KNOWLEDGE & EXPERIENCE
• A minimum of 10+ years of experience in oil & gas industry, specifically at power plants.
• A minimum of 7+ years of post-qualification experience and competence in power plant management and reliability processes.
• Familiarity with regulatory requirements for operating plants, including Process Safety Management, OSHA regulations, EPA regulations, EEOC guidelines, and other federal and local requirements.
COMPETENCIES
• Strategic Vision: Drive projects towards improving efficiencies based on processes and procedures.
• Strong Leadership: Ability to deal with technical, financial, and HR issues in a continually changing business environment.
• Flexibility: Ability to operate flexible work practices to achieve optimum results.
• Good Communications: Consistently communicate. Be a good listener and negotiator.
• Ability to engage with different communities, contractors, clients, suppliers, and senior management.
• Work Diligently: Manage multiple projects and deliver in a timely manner.
• Training and Development: Accountable for self-development, training, and development of subordinates.
• Optimization: Navigate complexities and uncertainties, and drive efficiency by use of technology.
• Organizational Skills: Excellent planning, organizational and time management skills, and coordinating activities across a wide range of disciplines.