The Mechanical Maintenance Manager – Valve Systems is responsible for the lifecycle maintenance, reliability, and integrity of all valve systems within the plant or operating unit. This role leads the planning, execution, and optimization of preventive, predictive, and corrective maintenance activities. The manager is a technical authority and maintenance strategist, ensuring that all valves function safely, efficiently, and in compliance with regulatory standards.
Develop and oversee maintenance plans for critical and non-critical valves (gate, globe, ball, butterfly, relief, safety, and control valves)
Ensure timely execution of maintenance and inspection work orders, including pre-shutdown and turnaround schedules
Supervise valve disassembly, reconditioning, calibration, lapping, seat repairs, and testing procedures
Lead mechanical maintenance scope for valves during scheduled outages
Collaborate with planning and execution teams to ensure spares, tools, and personnel readiness
Maintain strict turnaround timelines and safety compliance
Implement Condition-Based Monitoring (CBM) and Risk-Based Inspection (RBI) for valve performance
Analyze valve failure modes, develop FMEA reports, and recommend design or process changes
Establish valve reliability KPIs (leak rates, rework rates, MTBF, valve downtime)
Maintain accurate valve records, datasheets, inspection reports, and certification files
Enforce compliance with ASME, API, OSHA, and in-house mechanical integrity standards
Review vendor repair procedures, technical datasheets, and design changes for consistency and safety
Evaluate and supervise external valve servicing contractors and OEMs
Ensure proper torqueing, seat testing, hydrostatic and pneumatic test protocols during refurbishment
Conduct incoming inspection audits and shop visits for rebuilt valves
Lead and mentor valve technicians, fitters, inspectors, and mechanical planners
Identify training needs and build technical capabilities within the team
Create a high-performance maintenance culture focused on safety and quality
✅ Valve lifecycle management and criticality classification
✅ Preventive and predictive maintenance execution
✅ Shutdown and outage valve scope planning
✅ Valve testing, calibration, and failure analysis
✅ Documentation, compliance, and traceability
✅ Safety relief and pressure control valve systems
CMMS Systems: SAP PM, Maximo, Infor EAM, or Oracle
Testing Tools: Hydrostatic test benches, lapping machines, portable calibration tools
Software: Valve sizing tools (e.g., Fisher DVC, Emerson AMS), maintenance analytics dashboards
Standards: API 598, 600, 602, 608, 621, ASME B16.34, B31.3, ISO 5208
% adherence to valve PM/CM schedules
Valve rework or leak rate post-maintenance
MTBF for control and isolation valves
% reduction in valve-related process disruptions
Safety valve recertification compliance rate
Contractor/vendor performance and quality audits
Strong planning and execution capabilities
Attention to detail and safety consciousness
Ability to lead diverse field and workshop teams
Communication skills to interface with operations, HSE, inspection, procurement, and OEMs
Decision-making under pressure during critical outages or emergencies
Reports To: Director of Maintenance, Engineering Manager, or Plant Manager
Supervises: Valve maintenance technicians, planners, QC inspectors, and contractors
Collaborates With: Reliability Engineering, Inspection/NDT, Operations, Procurement, QA/QC, and Turnaround Teams