Chemical Plant Reliability Manager
TOTVS Leste · United Arab Emirates
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Our teams collaborate across engineering, operations, maintenance, process safety, asset integrity, production, quality, procurement, and technology to build dependable and high-performing chemical plants.The RoleWe are seeking an experienced Chemical Plant Reliability Manager to lead reliability strategy, asset performance, predictive maintenance, failure prevention, and continuous improvement across chemical manufacturing facilities.The ideal candidate will develop reliability programs for rotating equipment, static equipment, electrical systems, instrumentation, utilities, process systems, and critical production assets while reducing unplanned downtime, improving equipment availability, and optimizing maintenance and lifecycle costs.Key ResponsibilitiesDevelop and implement a comprehensive reliability strategy aligned with production, safety, quality, and business objectives.Establish reliability standards, procedures, governance frameworks, methodologies, and performance targets.Conduct asset criticality assessments and prioritize reliability initiatives according to operational and business risk.Develop reliability strategies for critical plant equipment and production systems.Analyze equipment failure history, downtime, operating conditions, maintenance records, and production losses.Identify recurring failure modes, reliability gaps, bottlenecks, and improvement opportunities.Lead root-cause analysis for major equipment failures, production interruptions, and recurring reliability issues.Develop corrective and preventive actions and verify their effectiveness.Implement reliability-centered maintenance, risk-based maintenance, and condition-based maintenance programs.Review preventive maintenance strategies and optimize maintenance intervals based on equipment performance and failure history.Develop predictive maintenance programs using vibration analysis, thermography, oil analysis, ultrasonic inspection, motor testing, and other condition-monitoring technologies.Monitor equipment condition and identify early indicators of degradation or failure.Manage reliability programs for pumps, compressors, motors, gearboxes, agitators, fans, blowers, heat exchangers, reactors, columns, vessels, tanks, piping, valves, and other process equipment.Coordinate reliability activities for electrical systems, transformers, switchgear, motors, generators, and emergency power systems.Support instrumentation and control-system reliability covering sensors, analyzers, control valves, PLCs, DCS, SIS, and associated equipment.Work closely with asset integrity teams to address corrosion, erosion, fatigue, chemical attack, material degradation, and mechanical integrity risks.Evaluate process conditions that may contribute to equipment degradation, fouling, corrosion, vibration, thermal stress, or premature failure.Establish appropriate equipment operating limits and reliability monitoring requirements.Monitor equipment health using vibration, temperature, pressure, flow, lubrication, electrical, process, and other condition data.Develop reliability dashboards and performance reports using plant, maintenance, process, and condition-monitoring data.Use statistical analysis, reliability modeling, and predictive analytics to identify failure patterns and improve equipment performance.Establish bad-actor equipment programs targeting assets with excessive failures, downtime, maintenance costs, or production impact.Lead reliability improvement projects focused on recurring equipment and process failures.Support maintenance planning by providing reliability-based recommendations for work prioritization and resource allocation.Review maintenance backlogs and identify high-risk reliability work requiring immediate attention.Participate in plant shutdowns, turnarounds, and major maintenance campaigns to ensure reliability requirements are addressed.Develop reliability requirements for new chemical processes, plant expansions, modifications, and equipment upgrades.Review equipment specifications, maintainability requirements, vendor documentation, and lifecycle-cost considerations during project development.Participate in design reviews, hazard studies, commissioning, start-up, and operational readiness activities.Ensure new equipment is properly tested, documented, commissioned, and incorporated into reliability-management systems.Evaluate repair, replacement, refurbishment, redundancy, and modernization options based on lifecycle economics and risk.Develop business cases for reliability investments, equipment upgrades, condition-monitoring systems, and technology deployment.Quantify the financial impact of equipment failures, production losses, maintenance costs, and reliability improvements.Manage reliability consultants, OEMs, specialist contractors, technology providers, and technical service companies.Define technical scopes, performance requirements, service levels, deliverables, and acceptance criteria for reliability services.Monitor contractor and supplier performance, technical quality, response times, safety, and cost effectiveness.Work with procurement and engineering teams to improve equipment specifications, supplier quality, warranties, and reliability requirements.Establish critical spare-parts strategies based on equipment criticality, failure probability, lead times, and production consequences.Review equipment warranty claims and supplier failure data to identify corrective opportunities.Develop contingency and recovery strategies for critical equipment failures and extended plant outages.Support emergency response during major equipment failures, process disruptions, and unplanned production interruptions.Ensure reliability activities comply with applicable engineering, process safety, environmental, regulatory, and company requirements.Integrate reliability objectives with process safety, asset integrity, maintenance, and operational risk-management programs.Promote reliability ownership across operations, maintenance, engineering, production, and technical teams.Train and coach reliability engineers, maintenance personnel, operators, and technical specialists in reliability methodologies.Establish lessons-learned processes and incorporate findings from failures, incidents, inspections, and maintenance activities into future practices.Evaluate emerging technologies including AI-based predictive maintenance, digital twins, advanced sensors, machine learning, remote monitoring, and automated diagnostics.Lead continuous-improvement initiatives using RCM, FMEA, RCA, Lean, Six Sigma, and other reliability methodologies.Provide senior management with regular reports covering reliability performance, equipment risks, downtime, failure trends, costs, and improvement initiatives.Key Performance IndicatorsPlant equipment availabilityOverall equipment effectivenessPlant reliabilityUnplanned downtimeProduction losses caused by equipment failureEquipment failure frequencyMean time between failuresMean time to repairForced outage frequencyRepeat failure rateCritical equipment reliabilityRotating equipment reliabilityStatic equipment reliabilityElectrical equipment reliabilityInstrumentation availabilityControl-system reliabilityPreventive maintenance effectivenessPredictive maintenance effectivenessCondition-monitoring coverageBad-actor equipment reductionMaintenance backlogCritical reliability backlogRoot-cause analysis completionCorrective-action closureReliability improvement savingsMaintenance cost reductionMaintenance cost per unit of productionCost of unplanned downtimeAsset lifecycle costIdeal CandidateThe successful candidate should have strong experience in chemical plant reliability, reliability engineering, maintenance engineering, asset performance, mechanical engineering, or industrial asset management, preferably within chemical manufacturing, petrochemicals, refining, pharmaceuticals, specialty chemicals, polymers, or other complex process industries.The candidate should demonstrate:Proven experience managing reliability programs in chemical or process manufacturing plants.Strong understanding of reliability engineering principles and asset-management practices.Experience with rotating and static equipment reliability.Strong knowledge of pumps, compressors, reactors, agitators, mixers, heat exchangers, columns, vessels, tanks, motors, gearboxes, piping, and valves.Understanding of chemical-process conditions and their impact on equipment reliability.Knowledge of corrosion, erosion, fouling, chemical degradation, thermal stress, vibration, and other equipment failure mechanisms.Experience with electrical and instrumentation reliability.Strong knowledge of RCM, FMEA, RCA, failure analysis, bad-actor management, and reliability optimization.Experience implementing preventive, predictive, and condition-based maintenance programs.Strong knowledge of vibration analysis, thermography, lubrication analysis, ultrasonic inspection, motor testing, and other condition-monitoring techniques.Experience analyzing equipment performance, process data, maintenance records, and failure trends.Familiarity with CMMS, EAM, condition-monitoring platforms, reliability software, and industrial analytics.Strong understanding of process safety, mechanical integrity, and operational risk management.