Failure Analysis / RCA Engineer – Turbines

We are seeking a highly analytical and hands-on Mid-Level Failure Analysis / RCA Engineer to lead and support investigations into mechanical failures and performance issues associated with steam and gas turbines, including key rotating equipment. The role focuses on applying root cause methodologies, supporting metallurgical assessments, and recommending preventive and corrective measures that improve operational reliability and reduce downtime.

Key Responsibilities:

🔍 Turbine Failure Investigation

• Investigate mechanical and performance-related failures in critical turbine components: blades, vanes, rotors, diaphragms, seals, couplings, casings, and fasteners.

• Analyze data related to vibration, temperature, pressure, and operational parameters to detect anomalies leading to failure.

• Supervise or assist with teardown inspections, photo documentation, material sampling, and field evidence collection.

🧩 Root Cause Analysis (RCA)

• Lead or participate in multidisciplinary RCA teams using tools such as:

  • 5 Whys, Fishbone Diagrams, FMEA, Fault Tree Analysis, or Apollo RCA

• Identify technical root causes, contributing factors, and latent system issues (design, maintenance, human error, process deviation).

• Ensure traceability between failure observations and root cause hypotheses.

📑 Technical Reporting

• Prepare high-quality RCA and investigation reports with photos, diagrams, and evidence-supported conclusions.

• Propose corrective and preventive actions (CAPA) aligned with reliability improvement goals.

• Track action implementation and assess effectiveness post-closure.

🏭 Asset Reliability & Design Feedback

• Collaborate with operations, inspection, and maintenance teams to eliminate reoccurrence of failures.

• Provide input to maintenance strategies, inspection intervals, and risk-based equipment evaluations.

• Support design reviews or redesign recommendations in collaboration with OEMs or internal design engineers.

🧪 Testing & Metallurgical Analysis

• Coordinate or support laboratory testing (NDT, SEM, metallography, hardness testing, replica metallography).

• Interpret lab results and incorporate findings into RCA documentation.

🤝 Cross-Functional Collaboration

• Engage with OEMs, repair shops, labs, and field service teams for data gathering and RCA validation.

• Participate in technical review meetings, audits, and incident investigation boards.

• Serve as a liaison between field operations and engineering during breakdowns or high-priority events.

Qualifications:

🎓 Education:

• Bachelor’s degree in Mechanical Engineering, Materials Engineering, Metallurgy, or equivalent technical field.

• Additional certifications in Reliability Engineering, RCA, or FMEA are advantageous.

🧰 Experience:

• 3–7 years of hands-on experience with rotating equipment failure analysis, particularly gas and steam turbines.

• Experience in power generation, oil & gas, or industrial heavy equipment environments.

Technical Competencies:

• Strong understanding of failure modes: fatigue, creep, thermal distortion, corrosion, erosion, FOD, HCF/LCF.

• Familiarity with relevant standards:

  • API 687, API 579, ASME, ASTM, OEM repair manuals

• Experience with CMMS and reliability tools (e.g., SAP PM, Maximo, ReliaSoft, RCPro, TapRooT).

• Proficient with technical drawing review, report writing, and data interpretation.

Soft Skills:

• Critical thinking and diagnostic skills

• Excellent communication and presentation ability

• High attention to detail and documentation quality

• Ability to lead or support investigations independently

• Team-oriented with strong stakeholder engagement skills