IE&A - Maintenance Lead
18 days ago
Pasadena
Job Description Instrumentation, Electrical, and Analyzer (IE&A) Maintenance Team Lead / Foreman 1. Role Purpose The IE&A Maintenance Team Lead is responsible for the safe, efficient, and compliant execution of maintenance activities for all instrumentation, low- and medium-voltage electrical systems, and process analyzer at our clients plant in Pasadena, Texas. This role ensures asset integrity and reliability of environmental-critical, safety-critical, and production-critical systems through hands-on leadership, work prioritization, and continuous improvement, using Fluke eMaint CMMS for all maintenance planning and documentation. 2. Technical Scope: Critical Equipment Covered * Reactor Systems: Acid settlers, reactor effluent coolers, acid circulation pumps, static mixers, acid strength control instrumentation. * Feed Preparation and Compression: Refrigeration compressors, reciprocating and centrifugal compressors, knock-out drums, separators, lube systems. * Fractionation & Product Handling: Deisobutanizer, debutanizer, stabilizer and reboilers, reflux systems, composition analyzers. * Electrical Systems: MCCs, power distribution panels, backup generators, UPS and battery systems, arc flash mitigation systems. * Instrumentation & Control: Pressure, temperature, flow, level transmitters, SIS, smart transmitters, PLCs, DCS I/O cabinets. * Analyzer Systems: Acid strength analyzers, gas chromatographs, pH/conductivity analyzers, toxic gas detection systems. * Safety and Utility Systems: Gas/flame detection, analyzer shelters, ESD systems, smart valve positioners. 3. Responsibilities A. Safety, Regulatory, and Environmental Compliance * Ensure all maintenance work complies with OSHA, NFPA 70E, NEC, PSM, and site-specific safety procedures. * Conduct and lead daily toolbox talks, safety stand-downs, and audits specific to electrical arc flash, acid exposure, and analyzer shelter access. * Verify that all safety-critical instruments and shutdown systems (e.g., SIS, ESD) are properly maintained and tested on schedule. * Lead incident investigations and root cause analyses for any I&E-related safety or environmental incidents. * Ensure proper use and documentation of Lockout/Tagout (LOTO), hot work permits, confined space entry, and acid area PPE protocols. B. CMMS Oversight – Fluke eMaint * Lead the planning, scheduling, and closure of all corrective and preventive maintenance tasks in Fluke eMaint. * Ensure asset records in eMaint are accurate, including instrumentation ranges, calibration intervals, and electrical breaker IDs. * Review and improve maintenance job plans and procedures for critical equipment (e.g., GC calibration, VFD troubleshooting). * Monitor trends from CMMS failure codes and initiate RCAs for repetitive or critical failures. * Train I&E technicians on proper documentation and time entry into eMaint. C. Maintenance Execution and Leadership * Coordinate and assign daily work orders ensuring alignment with production priorities and asset criticality. * Verify job readiness: tools, permits, drawings, safety precautions, and materials. * Observe jobs in progress and provide technical oversight to ensure quality and procedural compliance. * Ensure adherence to wiring standards, loop calibration procedures, torque specifications, and safety lockout practices. * Evaluate technician performance and provide feedback to foster skill development and accountability. D. Turnarounds, Unit Shutdowns, and Project Support * Lead I&E scope development and prioritization for planned outages and turnarounds. * Validate job packages for shutdowns: scope freeze, resource allocation, material staging, and contingency planning. * Supervise field execution during outages and ensure documentation of all redlines, loop checks, and calibrations. * Collaborate with engineering on instrument cut-ins, DCS logic changes, and analyzer relocations during projects. * Support successful startup by verifying interlock readiness, tag completion, and accurate CMMS closeouts. E. Troubleshooting and Reliability Focus * Lead root cause troubleshooting for instrumentation faults, DCS communication issues, VFD trips, and analyzer drift. * Interpret trends, alarms, and failure patterns using DCS historian, loop diagnostics, and analyzer logs. * Provide guidance on control loop tuning, logic overrides, and bypass conditions during troubleshooting. * Participate in bad actor reviews and reliability improvement teams focused on high-impact equipment. * Recommend changes to PM frequency, spare parts strategy, or technology upgrades based on reliability findings. F. Training and Competency Management * Assess technician competency using a structured skills matrix and individual development plans. * Deliver on-the-job training on topics such as hazardous area electrical work, analyzer validation, and loop diagnostics. * Ensure new hires and contractors receive orientation on site-specific safety, eMaint, and instrumentation standards. * Promote multiskilling by cross-training team members on electrical and analyzer systems. * Maintain training records and certification statuses for ISA, arc flash, HF handling, and LOTO. G. Interface with Operations and Engineering * Participate in daily production and maintenance coordination meetings, ensuring alignment on priorities. * Work with Controls Engineers to evaluate alarm rationalization, loop tuning, and SIS function testing. * Support engineering with MOC execution, installation reviews, and FAT/SAT for new instruments and analyzers. * Provide input into capital project design to ensure maintainability and compliance with site standards. 4. Qualifications and Experience Required: * 10+ years of experience in refining or chemical manufacturing. Preferred experience includes HF or sulfuric acid alkylation units. * Expert-level familiarity with instrumentation, motor controls, loop calibration, and analyzer maintenance. * Experience managing maintenance workflows in eMaint CMMS or similar systems (SAP, Maximo). Preferred: * Associate degree in Instrumentation, Electrical Technology, or Process Automation or equivalent experience. * ISA CCST, Fluke Vibration/IR Level I/II, or Texas Electrician License. * Knowledge of DCS platforms (Honeywell, Emerson DeltaV, Yokogawa). * Experience with analyzer shelters, HVAC panel wiring, and sample conditioning systems. 5. Performance Indicators * Safety Performance: No recordables, 100% LOTO compliance, near-miss participation. * PM Compliance: ≥98% on-time PM and analyzer calibrations (tracked via eMaint). * Uptime: Analyzer availability > 97%, control loop deviation trends reduced. * Work Quality: <2% rework, documented field QA checks, accurate CMMS closure. * Continuous Improvement: Number of RCAs completed, PMs updated, and bad actors eliminated.