Reliability Engineer
The role will report to the Electrical Manager and has the primary responsibilities to:
Review opportunities (including organizing external expertise and resources) to improve compliance to statutory requirements using OSH, SANS, OEM, RCM, 5Why and RCA processes to improve equipment reliability and availability. Review the maintenance strategies on the CMMS software (SAP system) and improve, update and/or add strategies to improve equipment reliability and availability. Initiate improvements of critical equipment and/or critical processes to improve equipment reliability and availability. Identify and implement Electrical training and technical coaching as needed.
Develop, Design the preventative maintenance strategies following the Reliability Centered Maintenance (RCM) approach in collaboration with the Reliability Engineering personnel. Plan and execute improvements of the Electrical grading on the electrical network including and power quality monitoring as per the best engineering practice standards including the interfacing between the electrical and instrumentation installations. Plan and execute improvements of the electrical protection including the review of the correct technology to allow for Supervisory Control and Data Acquisition (i.e., SCADA). Develop the Electrical standards and procedures in line with the OSH and relevant standards (i.e. SANS, IEC, etc.) with more focus on the requirements of the SANS 10142 Part 1 and Part 2.
Lead the Management of Change to stabilize and the correct the electrical network through ensuring grading, electrical protection, power factor correction, quality monitoring complies the engineering best practice standards. Lead the improvement and implementation of the latest technology to improve equipment reliability and availability. Lead the replacement of inferior and/or obsolete electrical equipment with equipment that are fit-for-purpose with special attention on the transformer replacement program to ensure compliance to the environmental regulations. Lead the energy management program to ensure that the energy footprint at company is continually improved/reduced.
Manage Electrical projects (i.e., maintenance/small projects) including the CAPEX processes related to the project(s). Initiate, support initiative, and implement energy efficiency and renewable energy solutions throughout the company site. Manage the spares inventory and ensure adequate spares including quality, quantity and spare that are fit-for-purpose are available to ensure an acceptable plant availability is maintain.
Measure, identify and improve deviations from Operations Within Agreed Parameters concerning electrical installation and equipment. Compile and review the KPIs (i.e., MTBF, MTTR) on equipment to initiate solutions to enforce preventative and predictable maintenance of assets. Enforce continuous improvement equipment reliability, equipment availability, and compliance to statutory and company standards and procedures.
This position profile acts as a guide to the role only, and additional work outcomes may be required to be performed by the incumbent.
The abovementioned activities shall be conducted in compliance with the Occupational Health and Safety Act, No. 85 of 1993 and all relevant company policies and procedures.
Key performance area:
Review opportunities (including organizing external expertise and resources) to improve and/or execute work in compliance to statutory requirements using OEM, RCM, 5Why and RCA processes to improve equipment reliability and availability.
Review the operational parameters against the design and/or agreed operating parameters and determine improvement opportunities.
Review historical failure, lead Electrical Root Cause Analysis to determine repeat failures and determine the criticality of equipment.
Initiate improvements of critical equipment and/or critical processes to improve equipment reliability and availability.
Improve measurements, system architect, inspection schedules and Process Control System to achieve more than 85% Plant Availability.
Identify and implement Electrical training (on-job and outsourced training) and technical coaching as needed.
Review/Assess and identify opportunities to improve the electrical grading, protection, power quality and metering of the electrical network.
Develop, Design, Lead.
Develop the preventative maintenance strategies following the Reliability Centered Maintenance (RCM) approach in collaboration with the Reliability Engineering personnel.
Implement and improve stability of the electrical network as per the best engineering practice standards including the interfacing between the electrical and instrumentation installations.
Develop the Electrical standards and procedures in line with the OSH and relevant standards (i.e. SANS, IEC, etc.) with more focus on the requirements of the SANS 10142 Part 1 and Part 2.
Lead the improvement and implementation of the latest technology to improve equipment reliability and availability. Lead the replacement of inferior and/or obsolete electrical equipment with devices that are fit-for-purpose.
Lead the replacement program for the transformers with transformer that utilizes non-PCB insulation medium.
Lead the management of change in the removal of risk of plant un-availability due to the electrical network (including installation of alternate supply to the Effluent Farm). Lead the assessment of the medium voltage equipment (i.e., switchgear, transformers and cables) and lead the corrective program to ensure electrical network availability.
Develop Service Level Agreements with contractors to support the Reliability Centered Maintenance (RCM) in the plants.
Manage Electrical projects (i.e., maintenance/small projects) including the CAPEX processes related to the project(s).
Participate in 5S continuously, implement standards and enforce 5S standards.
Enforce good practices concerning housekeeping
Enforce execution of Risk Assessments and audit plants to ensure zero injuries of personnel (including contractors in your control)
Initiate, support initiative, and implement energy efficiency and renewable energy solutions
throughout the company site.
Manage the process change from the reactive maintenance to preventative and predictive maintenance.
Manage the spares inventory and ensure adequate spares including quality, quantity and spare that are fit-for-purpose are available to ensure an acceptable plant availability is maintain.
Identify and improve deviations from Operations Within Agreed Parameters concerning electrical installations and equipment. Compile and review the KPIs (i.e., MTBF, MTTR) on equipment to initiate solutions to enforce preventative and predictable maintenance of assets.
Enforce continuous improvement equipment reliability, equipment availability, and compliance to statutory and company standards and procedures.
Identify and improve condition-based monitoring system and implement maintenance strategies to improve the operations to achieve an average production of 65kA
Assess the effectiveness of the maintenance strategies on the CMMS software (SAP system) and improve, update and/or add strategies to improve equipment reliability and availability.
Continually assess the spare management process, initiate improvements and/or acquiring of critical spare equipment to improve equipment reliability and availability.
Related SHERQ responsibilities
Knowledge/Skills/Competencies
Technical knowledge demonstrated and learnt in the electrical installations in the chemical processing plants.
Extensive knowledge of ISO 14001, 45001, 9001
Knowledge of the Occupational Health and Safety and Area Classification Standards
SHERQ Training course
Safety Work Permit training
Knowledge of mechanical and process operations (i.e., rectifier system)
Computer Literacy in MS Office (Word, Excel, Outlook, and Power Point)
Ariscu
Experience in Programming of Protection relays, Billing Meters and VSD
Knowledge of Computerized Maintenance Management Systems (I.e. SAP)
Value driven
Attention to details
Be able to do basic problem solving and decision making and analysis
Ability to work under pressure
Experience
5 to 10 years’ experience with 3 years handling maintenance projects.
Computer literacy in MS Office (Word, Excel, Outlook)
Knowledge of the Area Classification.
Experience in Programming of Protection relays, Billing Meters and VSD.
Qualifications:
Grade 12
BTech or BSc in Electrical Engineering.
GCC for Factories (Advantage).
Reporting structure:
This position reports to the Engineering Manager: E&I.
