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Maintenance Engineer

Longview, TX
$120,000 +
April 11, 2016

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**** * ******** **

Longview TX 75604



Versatile & results-oriented leader offering broad-based experience & hands-on skills in Industrial Reliability / Maintenance Management & organizational administration. Successful track record in driving and leading a cross functional Reliability / Maintenance team with-in the area of responsibility comprised of direct reports and plant based maintenance resources. Solid background in execution of Safety, Reliability of maintenance activities, Minor Maintenance, Major Turnarounds and implementation of solutions to maintain problem areas and failure analysis for Refineries, Chemical and Air Separation Units including compressors, pumps, mixers, gear box, pressure relief devices, heat exchangers, drums and cryogenic distillation columns. Models exemplary safety behavior, leads by personal example to achieve “Zero Accidents” by insuring that all employees have the required training and skills to perform their assigned functions safely, reliable, efficient and in compliance with company and local, state or federal regulatory requirements. EXPERIENCE

Flint Hills Resources (Longview Texas Plant) Oct. 2013 – Nov 2015 Mechanical Reliability Engineer (Oct. 2013 – Nov. 2015) Initiated continuous improvement and reliability program on rotating equipment ie: centrifugal / reciprocating compressors, pumps, gearboxes, extruders, mixers, fans, etc through the development and application of effective reliability strategies, identified risks & bad actors, root cause and team based problem solving, spare parts material upgrade and implementing industry best practices and standards.

Achieved 95% plant availability compared to 60% availability from previous years. This converts to $3.5MM additional income.

Reviewed and optimized PM / PdM program including job plans and created operators daily round sheets and mechanic toolbox procedure’s or guide on equipment maintenance and repair to monitor and improve equipment KPI’s and Mean Time Between Failure (MTBF) This initiative saves the company $650M on spare parts cost per year and $1.2MM on loss profit opportunity.

Supported the Engineering, Maintenance, Operations, Inspection, Process and Project personnel on design, evaluation, installation, operation, and maintenance of mechanical equipment, systems, and processes to meet operational requirements, applying knowledge of engineering principles.

Air Liquide US LI Onsite Kennesaw GA Sept. 2005 – Sept. 2013 Maintenance (Reliability) Manager (May 2008 – Sept.-2013) Managed the maintenance and reliability functions to ensure plant operations efforts are supported with properly operating equipment and maintained in a cost effective manner, with high standard of safety and quality.

Implement a sustainable Reliability and Maintenance Continuous Improvement process that produces effective value added short-term and long-term deliverables consistently across the business unit.

Lead the Team that initiates and rollout Enhanced Maintenance and Reliability Leadership Team:

• Job Plan Development:

- Standardized Job Plan Creation

- Developed KPI’s to measure Job Plan Improvement

- Created Master Job Plans that improved maintenance works

• Detailed Metrics for PdM Problem Resolutions

- PdM Work Orders

- PdM Work Order Complete

- PdM Work Order Past Due

- PM Optimization

• Critical Equipment Identification

- Critical Spare Parts Identification

- Spare Parts Quality Assurance Incident Tracking

- Equipment parts Preservation

Developed and prepared annual maintenance plan and budget including major Turnarounds

(TAR) and ensure that plans are followed and deferrals are forwarded to the next years plan. Identify and implement opportunities’ to reduce cost including control of overtime. Develop and implement maintenance strategy, plans, objectives and goals for the zone. Was able to reduced Maintenance spending from $5.5MM per year to $3.5MM Reliability Engineer (Sept. 2005 – May 2008)

Ensure that Preventive Maintenance (PM) and Predictive Maintenance Program (PdM) are done on time and in compliance to ensure plant reliability to improve plant availability. Conduct Failure Mode and Effect Analysis (FMEA) / Root Cause Failure Analysis (RCFA) / Mean Time Between Failure (MTBF) to analyze major breakdowns and collect data to report on cause failure and follow up actions to reduce or eliminate reoccurrence or unplanned maintenance. Identified critical initiatives required to meet business team reliability and maintenance cost goals. Support for maintenance cost goals includes identifying top initiatives for each discipline to reduce failure rates and cost and includes identifying equipment bad actors. Conduct Root Cause Failure Analysis (RCFA) and initiate corrective actions for complex and repetitive problems.

Keeps maintenance documentations current, including equipment files using MAXIMO (CMMS program) and ensures PM and PdM programs are optimized. Participate and conduct Vulnerability Assessment and Risk Management Study as related to plants within the zone.

Air Products & Chemicals Inc Sept. 1999- Oct 2004

Maintenance Manager

Developed, implement, and contribute plant wide maintenance programs including normal routine maintenance work, predictive and preventive maintenance, spare parts inventory, plant lubrication, mechanical integrity, and infrastructure maintenance. Ensures that maintenance work is executed safely and efficiently, following Internal Policies & Procedures, federal state and Local regulations, Engineering standards, Codes, Health and Environmental regulations. Budgets, monitors and controls plant maintenance costs, both for routine upkeep of equipment and planned major turnarounds (TAR).

Caltex (Phils) Inc Refinery Oct. 1981 – June 1999

Maintenance / Reliability Supervisor – (May 1988- June 1999) Lead the Integrated Machinery Inspection (IMI) group that conducts Predictive Maintenance Program (PdM) to ensure that assets condition are well monitored to prevent unplanned production downtime, costly machinery replacements, as well as safety problems, environmental concerns and regulatory violations. Responsibilities include developing and implementing machinery surveillance plans, providing coverage for unplanned/emergency machinery situations, and developing machinery reliability recommendations. Provides guidance on preventive and predictive machinery maintenance, determines causes of machinery failures, and develops solutions to prevent recurrence.

Supports the safe commissioning of systems by ensuring that new or repaired equipment installations meet safety standards and all Management of Change (MOC) documents are in order. Provides technical support to ensure that key mechanical equipment is adequately protected by reliable protection systems. Provides routine vibration surveillance and diagnostics of both minor and major machinery in addition to increased vibration monitoring as dictated by machine condition. Performs visual surveillance of operating equipment and breakdown inspection of failed equipment.

Maintenance Shutdown Planner (Jan. 1985 – Apr. 1988) Works with maintenance supervision, staff, corporate engineering, contractors and OEMs to insure effective maintenance is planned, performed and documented. The Maintenance Planner makes a direct contribution to important plant goals of increasing labor productivity, reducing maintenance costs and improving equipment reliability. This is accomplished by preparing detailed job plans, coordinating key scheduling activities with other departments, maintains preventive maintenance schedule, ensuring work order data integrity, and ordering and managing spare parts inventories.

Maintenance Metal Craft Mechanic (Oct. 1981 – Dec. 1985) Works includes repair and maintenance of all stationary equipment ie pressure vessels / columns’ & drums / heat exchangers / tanks / pressure safety valves (PSV) / piping fabrications / fire fighting equipment / etc.

Assist / perform mechanical integrity inspections plant vessels and piping. Coordinate and apply various nondestructive technologies used in evaluating the condition of all critical production equipment to effectively support plant operations. Job duties include performing Ultrasonic and Visual integrity inspections on vessels and piping. Assist / conduct Penetrant and Mag Particle testing, bore scope inspections, helium leak testing and reading x-rays of plant equipment.

Local Water Utilities (Phils) June 1979 – Oct. 1981 City Engineer (JUNE 1979 – OCT. 1981)

Responsible for the enforcement of building permits for all permanent structures / new construction and building remodeling including residential houses. Responsibilities also includes providing potable water for the residence of the city. Conduct deep well water pump testing to check aquifer capacity and monitors water drawdown. Education

Bachelor of Science in Mechanical Engineering---June 1979 Adamson University Manila, Philippines

Master in Business Administration (MBA) ---Undergraduate Professional Training & Certifications

• Passed the Mechanical Engineering Board Licensures for Philippines Professional Regulation Commission

• Clark-Dresser Rand Reciprocating Compressor Hands On Training

• Centrifugal Pumps / Gearbox / Motor –Dis-assembly Training

• Vibration Analysis / Welding & X-Ray Analysis Training / SKF Bearing Training

• NFPA 70E ARC Flash Electrical Safety Training


Brent McCauley

Maintenance Manager

Flint Hills Resources

Tel # 903-***-****

Terry Colleran

Air Liquide US LI

Tel # 678-***-****

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