Reliability Manager (Steam Systems)

The Reliability Manager – Steam Systems is responsible for ensuring the reliable, safe, and cost-effective operation of steam systems including boilers, steam distribution networks, condensate recovery, and associated control systems. This role focuses on failure prevention, condition monitoring, root cause analysis, and continuous improvement to increase uptime, reduce unplanned outages, and extend equipment lifecycle.

📌 Key Responsibilities:

1. Steam System Reliability Strategy

• Develop and implement asset reliability programs for boilers, steam lines, PRVs, steam traps, condensers, and heat exchangers.

• Define KPIs such as MTBF, MTTR, equipment availability, and steam losses.

2. Preventive & Predictive Maintenance

• Oversee preventive and condition-based maintenance programs using vibration analysis, infrared thermography, ultrasonic testing, and steam trap surveys.

• Ensure critical asset health monitoring systems (IoT sensors, BMS/DCS data) are used for early fault detection.

3. Failure Analysis & Troubleshooting

• Lead root cause failure analyses (RCFA) for boiler tube leaks, steam trap failures, corrosion, water hammer incidents, and control valve malfunctions.

• Collaborate with maintenance, operations, and engineering teams to resolve chronic reliability issues.

4. Asset Lifecycle Management

• Support capital planning and replacement schedules for aging steam infrastructure.

• Manage risk-based inspection (RBI) plans and lifecycle cost analysis for pressure systems.

5. Standards & Compliance

• Ensure compliance with ASME Boiler & Pressure Vessel Code, API 579/580, NBIC, and local steam regulations.

• Maintain documentation for audits, insurance inspections, and regulatory reporting.

6. Performance Improvement

• Benchmark steam system performance and identify loss points (e.g., steam leaks, inefficient condensate return).

• Implement reliability-centered maintenance (RCM) and total productive maintenance (TPM) initiatives.

7. Team Leadership & Training

• Guide a multidisciplinary team of reliability engineers, planners, and technicians.

• Conduct reliability awareness training and promote a culture of proactive maintenance.

🔍 Key Focus Areas:

• Boiler and steam system availability and reliability

• Steam leak reduction and condensate recovery

• Predictive maintenance and asset health monitoring

• Compliance with pressure system codes and standards

• RCA/RCM implementation and continuous improvement

🎓 Qualifications:

• Education:
  B.E./B.Tech in Mechanical Engineering, Power Engineering, or a related field
  (Postgraduate qualifications in Reliability Engineering or Maintenance Management are a plus)

• Experience:

  • 10–15 years in industrial utilities or mechanical systems maintenance

  • 5+ years specializing in steam systems, pressure equipment, or boiler reliability

  • Experience in refineries, chemical plants, or heavy industry preferred

• Certifications:

  • Certified Maintenance & Reliability Professional (CMRP) or equivalent

  • Knowledge of ASME, API 579/580, NBIC, and steam/boiler codes

  • RBI or FMEA/RCFA training is desirable

• Skills:

  • Strong analytical skills with a focus on failure mode analysis

  • Proficient in using CMMS (SAP, Maximo), RCA tools, and reliability software

  • Effective communicator with cross-functional leadership abilities

  • High safety and regulatory awareness, especially around high-pressure systems