Maintenance Rotating Equipment Superintendent

Role Overview

Maintenance Rotating Equipment Superintendent at Air Products, responsible for safe, reliable, efficient and sustainable operations of rotating equipment across multiple facility technologies and sites.

Company Overview

Founded in 1940, Air Products is a world-leading industrial gases company with a proud history of innovation, operational excellence, and unwavering commitment to safety and environmental stewardship. The company works across multiple technologies including Air Separation Units (ASU), Steam Methane Reformers (HYCO), and CO2 production, along with ancillary equipment.

Role Purpose

To ensure the safe, reliable, efficient and sustainable operations of rotating equipment across BHIG, JIGH, SATORP and SASREF sites. Manage rotating maintenance activities in coordination with the Planner, Operations, and Engineering teams to execute PM overhauls and preventative and corrective maintenance activities, reducing maintenance costs while improving plant reliability and availability.

Key Responsibilities

Safety & Compliance

• Provide and maintain a safe work environment for all maintenance personnel.
• Demonstrate leadership with company and industry safe work practices to prevent injuries.
• Ensure proper implementation and documentation of all safety-related activities.
• Complete comprehensive and value-added risk assessments or Job Safety Analyses depending on risk factor, nature and complexity of the task.
• Conduct Authorized Pre-Task (APT) briefings and lead safety investigations and improvements regarding rotating equipment.
• Ensure compliance from the Maintenance team regarding safe execution and promote a safe work culture.
• Ensure the safety of all maintenance personnel by utilizing the BHIG Basic Safety Practice program, which includes Safety Work Permits, LOTO, Confined Space, and related protocols.
• Understand Environmental Regulatory requirements and contain all oil spillages, disposing correctly.
• Ensure Air Products and BHIG standards, and best practices for EH&S, productivity, reliability, quality, and overall customer service are met.
• Knowledge and understanding of local environmental and health and safety requirements.

Technical Execution & Maintenance

• Execute hands-on maintenance activities for troubleshooting, maintenance, repair, and test activities on reciprocating, centrifugal, screw, lobe and diaphragm compressors.
• Provide maintenance and technical support during the commissioning of rotating equipment.
• Maintain accurate document control and monitor quality assurance initiatives to maintain equipment history.
• Read and interpret vibration spectrums and analyze condition monitoring data.
• Ensure that all vibration, temperature and rod drop probes are set correctly and functional.
• Analyze process parameters from DCS trends with the intent of predicting future failures and rotating equipment performance.
• Troubleshoot the root cause of failures based on operating conditions and apply the correct maintenance required.
• Apply and demonstrate knowledge in both laser and Dial Test Indicator (DTI) alignment techniques.
• Ensure that alignment temperature compensating factors are applied for hot applications.
• Ensure that bolt tensioning is applied to piping systems for hot applications.
• Apply and demonstrate knowledge in measuring and coaching the team to conduct piston bumping clearance, crankshaft deflection, crankcase deflection, piston run-out corrections, crosshead guide alignment, journal and main bearing to crankshaft clearance measurements.
• Initiate an inspection program focusing on critical equipment vibration, temperature and pressure monitoring by completing daily/weekly inspection sheets.
• Note deviations and create work requests in SAP.
• Be able to overhaul cryogenic services oxygen pumps and maintain a clean room for oxygen service as a primary responsibility.
• Be able to handle, assemble and install mechanical seals and identify failure modes.
• Handle and coordinate the removal, installation and repairs to dry gas seals.
• Be familiar with different mechanical seal plans and their required maintenance to ensure effective function.
• Ensure tools, nitrogen and gauge manifolds are available to measure bladder nitrogen pressure for pulsation dampeners.
• Verify and conduct piping strain corrections and confirm that vibration dampeners, supports and grouting are in good condition.
• Develop a toolbox for each critical equipment ensuring all special tools and consumables are available to conduct maintenance.
• Ensure toolboxes are repacked and restored with all tools and consumables before placing in storage after each overhaul.

Preventative & Predictive Maintenance Program

• Assist in the development and execute the preventative and predictive maintenance program to ensure scheduled maintenance activities are completed and remain in compliance.
• Initiate a condition monitoring program by completing daily and weekly inspection sheets for critical equipment.
• Ensure compliance with the condition monitoring program by following up with Engineering on trends analysis and corrective actions.
• Achieve the best MTBF (Mean Time Between Failures), MTTR (Mean Time To Repair) and reliability metrics related to rotating equipment.
• Apply asset management techniques to monitor the integrity of critical equipment on-line run time by applying condition monitoring techniques for vibration, temperature and packing leakage rates.
• Log and analyze condition monitoring information to implement corrective actions before catastrophic failures with the objective of increasing the life cycle of equipment.

Planning & Coordination

• Provide maintenance input for scheduled outages to ensure effective planning and execution.
• Provide input into the execution plan for major PM overhauls during shutdowns and Turnarounds (TAR).
• Lead and coordinate activities with service providers and ensure that all protocols, Quality Control Plans (QCPs) and standards are conducted and achieved.
• Supervise and coordinate rotating service providers with all site-related activities, ensuring focus is on quality and reliability.
• Coordinate with Operations and Engineering teams to rectify rotating equipment issues and implement cost-effective solutions.
• Lead rotating activities during turnarounds, including preparation of job packages, spares and materials, contractors, tools and safety management during execution.
• Support on-call activities when required and provide rotating recommendations outside of normal working hours when consulted.

Leadership & Team Development

• Manage a team of Technicians to achieve high maintenance standards by providing day-to-day support, safe and effective execution and support for reliable and efficient operation of rotating equipment.
• Manage the team's development ensuring that proper Individual Development Plans (IDPs) are in place, implemented and monitored to improve the team's rotating equipment knowledge and competence.
• Coach and mentor junior Technicians on rotating equipment maintenance practices with hands-on execution.
• Coach and mentor the team by leading equipment overhauls and ensuring effective knowledge transfer.
• Performance manage the team to encourage and ensure a high-performance culture.

Reliability & Optimization

• Act as a subject matter expert (SME) for rotating equipment root cause analysis and maintenance strategy development and optimization.
• Execute preventative and corrective maintenance activities for all sites with the intention of improving MTBF, MTTR and reliability of rotating equipment.
• In cooperation with Engineering, execute a reliability program to achieve operational excellence by sustaining equipment operation and driving productivity to increase efficiency.
• Maximize the availability and safety of critical compression assets while minimizing unplanned downtime in production environments.
• Achieve and maintain operations excellence and customer satisfaction through maintenance productivity, reliability, quality and cost reduction efforts.

Documentation & Reporting

• Complete technical reports of all major repairs and PM overhauls for critical rotating equipment.
• Develop a shared folder with all rotating equipment specifications, spares, special tools, repairs and major overhauls including Root Cause Analyses (RCAs) and Management of Change (MOC) documentation.
• Maintain equipment maintenance document integrity through accurate technical reports.
• Ensure protocols and QCPs are completed for all rotating equipment overhauls.
• Develop work instructions for ease of reference and execution for the maintenance team.
• Provide technical report writing and the ability to clearly and articulately explain findings to Senior Management.

Inventory & Procurement

• Ensure critical spares have sufficient quantity, are refurbished to the correct standard, preserved correctly, and are as specified on delivery.
• Provide input for the critical spares inventory and follow-up on delivery and lead times.

Incident Investigation

• Participate in incident investigations and root cause analysis.
• Identify and implement sustainable corrective actions.
• Provide maintenance support and participate in incident investigations.

Qualifications & Experience

• Bachelor's degree or equivalent in mechanical engineering or maintenance management in rotating equipment is desirable.
• Minimum 15 years demonstrated competency in oil and gas industry on rotating equipment, which includes reciprocating, centrifugal, screw, lobe and diaphragm compressors.
• Demonstrated knowledge and experience in oil and gas industry of leading reciprocating, centrifugal and screw compressor overhauls.
• Hands-on experience working with reciprocating compressors and pump overhauls.
• Knowledge and ability to overhaul cryogenic pumps especially in oxygen service, centrifugal pumps, positive displacement pumps, high-speed integral pumps (for example, Sundyne LMV models), screw