Engineer - Inspection & Condition Monitoring مهندس - الفحص ومراقبة الحالة

Brief Posting Description
The Engineer – Inspection & Condition Monitoring is supporting in developing, implementing, and continuously improving the condition monitoring, predictive maintenance, asset inspection, and integrity management programs across mining, processing, utilities, and infrastructure assets. The role ensures that equipment health is effectively monitored using predictive technologies and inspection methodologies to identify potential failures, optimize maintenance strategies, improve equipment reliability, and maximize asset availability.
The position provides support to technical leadership in vibration analysis, thermography, lubrication analysis, ultrasound testing, nondestructive testing (NDT), asset integrity management, reliability improvement initiatives, and risk-based inspection programs. The role supports maintenance, reliability, operations, and project teams through data-driven decision-making, equipment condition assessment, failure prevention, and continuous improvement programs to achieve world-class asset performance and operational excellence.
Detailed Description
CONDITION MONITORING PROGRAM MANAGEMENT
Support in developing, implementing, and continuously improving the site-wide condition monitoring program.
Support in establishing predictive maintenance strategies for critical plant and mobile equipment.
Support in developing equipment monitoring routes, inspection plans, and asset health assessment methodologies.
Ensure effective utilization of condition monitoring technologies to detect early-stage equipment deterioration.
Review asset condition data and provide recommendations to prevent equipment failures.
Establish inspection frequencies, alarm limits, and monitoring standards.
Ensure condition monitoring activities are aligned with reliability and asset management objectives.
Support digitalization initiatives relating to equipment health monitoring and predictive analytics.
VIBRATION ANALYSIS & MACHINERY DIAGNOTICS
Perform vibration monitoring and analysis activities for rotating equipment.
Conduct advanced vibration diagnostics and fault identification.
Identify bearing defects, misalignment, imbalance, looseness, resonance, gear defects, and mechanical degradation.
Establish vibration baselines and equipment health indices.
Develop corrective action recommendations based on vibration analysis findings.
Provide technical guidance to maintenance teams regarding equipment condition and required interventions.
Monitor effectiveness of corrective actions and maintenance outcomes.
THERMOGRAPHY AND INFRARED INSPECTION
Execute and manage infrared thermography inspection programs.
Conduct thermal condition assessments of electrical, mechanical, and process equipment.
Identify abnormal temperature conditions and potential equipment failures.
Verify corrective actions through follow-up thermal inspections.
Maintain thermal imaging databases and inspection records.
Develop thermography inspection standards and reporting requirements.
LUBRICATION AND OIL ANALYSIS MANAGEMENT
Execute lubrication excellence and oil analysis programs.
Monitor lubricant condition, contamination levels, wear metals, and fluid degradation.
Establish oil sampling schedules and testing requirements.
Analyze laboratory reports and recommend corrective maintenance actions.
Optimize lubrication practices and lubricant selection strategies.
Support contamination control and machine health improvement initiatives.
ULTRASOUND AND ADVANCED PREDICTIVE TECHNOLOGIES
Manage ultrasound inspection activities for mechanical, electrical, and process systems.
Conduct inspections for compressed air leaks, steam leaks, bearing defects, and electrical discharge.
Evaluate and implement advanced predictive maintenance technologies where applicable.
Support development of asset health monitoring systems and online condition monitoring solutions.
Identify opportunities to improve predictive maintenance effectiveness.
INSPECTION & ASSET INTEGRITY MANAGEMENT
Support in developing inspection strategies and risk-based inspection programs for fixed and rotating assets.
Ensure inspection activities comply with applicable engineering standards, statutory requirements, and company procedures.
Coordinate internal and external inspection activities.
Develop statutory inspection programs for pressure vessels, tanks, pipelines, lifting equipment, and critical structures.
Coordinate thickness monitoring and corrosion management programs.
Manage inspection intervals and equipment integrity risk assessments.
Ensure compliance with API, ASME, ISO, and applicable regulatory inspection requirements.
Support Fitness-for-Service (FFS) assessments and equipment life extension studies
Review inspection findings and assess equipment fitness for service.
Monitor asset degradation mechanisms and recommend mitigation actions.
Support asset integrity assessments and life extension studies.
Maintain inspection records, reports, and regulatory compliance documentation.
NON-DESTRUCTIVE TESTING (NDT) MANAGEMENT
Coordinate NDT activities including:
Ultrasonic Testing (UT)
Magnetic Particle Testing (MT)
Dye Penetrant Testing (PT)
Radiographic Testing (RT)
Eddy Current Testing (ECT)
Visual Inspection (VT)
Review NDT results and evaluate equipment condition.
Ensure inspection activities are performed by qualified personnel.
Verify compliance with applicable codes and standards.
RELIABILITY IMPROVEMENT & FAILURE ANALYSIS
Support reliability improvement programs and maintenance optimization initiatives.
Conduct Root Cause Failure Analysis (RCFA) investigations for significant equipment failures.
Identify recurring failure trends and implement corrective actions.
Support Reliability Centered Maintenance (RCM) studies.
Participate in asset criticality assessments and maintenance strategy development.
Develop recommendations for improving equipment reliability and performance.
Monitor benefits realization from reliability improvement initiatives.
SHUTDOWN & MAJOR MAINTENANCE SUPPORT
Support shutdown planning through equipment condition assessments and inspection findings.
Identify equipment requiring maintenance intervention during shutdowns.
Develop inspection scopes and condition monitoring requirements for shutdown execution.
Support equipment recommissioning and post-shutdown inspections.
Participate in shutdown reviews and lessons learned activities.
CONTRACTOR & SERVICE PROVIDER MANAGEMENT
Manage specialist inspection, condition monitoring, and laboratory service providers.
Review technical proposals, inspection methodologies, and service reports.
Monitor contractor performance and quality compliance.
Ensure contractors meet site safety and technical requirements.
Verify completion and acceptance of contractor deliverables.
PERFORMANCE MONITORING & REPORTING
Develop and maintain KPIs for condition monitoring and inspection programs.
Monitor and report:
Asset Health Index
Condition Monitoring Compliance
Predictive Maintenance Effectiveness
Equipment Failure Reduction
Inspection Compliance
Asset Integrity Performance
Mean Time Between Failures (MTBF)
Mean Time to Repair (MTTR)
Condition-Based Maintenance Success Rate
Maintenance Cost Avoidance
Prepare technical reports, dashboards, and management presentations.
Utilize SAP, Power BI, and reliability systems for performance analysis and reporting.
HEALTH, SAFETY, ENVIRONMENT & QUALITY
Promote and maintain a strong safety culture within inspection and condition monitoring activities.
Ensure compliance with all HSE policies, procedures, and regulatory requirements.
Participate in risk assessments, HAZID, HAZOP, and safety reviews.
Ensure safe execution of inspection and monitoring activities.
Support incident investigations and implementation of corrective actions.
Ensure quality and technical integrity of all inspection and condition monitoring outputs.
PEOPLE LEADERSHIP & DEVELOPMENT
Provide technical leadership, coaching, and mentoring to inspectors, condition monitoring technicians, and reliability personnel.
Develop competency improvement and succession plans.
Promote knowledge sharing and continuous learning.
Support workforce development in predictive maintenance and asset integrity disciplines.
Foster teamwork, accountability, and continuous improvement.
COST CONTROL & BUDGET MANAGEMENT
Develop and manage annual budgets for condition monitoring, inspection, NDT, and asset integrity activities.
Monitor expenditure against approved budgets.
Identify opportunities to reduce maintenance costs through predictive maintenance initiatives.
Support business cases for new inspection technologies and monitoring systems.
Optimize utilization of inspection resources and external service providers.
Ensure effective financial management and reporting.

Job Requirements
Education:
• Bachelor’s degree in mechanical engineering, Electrical Engineering, Reliability Engineering, Asset Management, Industrial Engineering, or equivalent discipline.
Experience:
• Bachelor’s Degree with 5+ years or Higher Diploma with 10+ years of experience in condition monitoring, inspection, reliability engineering, asset integrity, and predictive maintenance within mining, minerals processing, oil & gas, petrochemical, power generation, or heavy industrial operations.
Certifications: Mandatory: Vibration Analysis Certification (ISO CAT II minimum).
Added Advantage:
• ISO CAT III or IV Vibration Analyst,
• ISO 18436 Condition Monitoring Certifications,
• Infrared Thermography Certification Level I/II,
• Ultrasound Certification Level I/II,
• ASNT NDT Level II/III,
Technical Skills:
• Condition Monitoring Program Development and Management.
• Vibration analysis, diagnostics, and rotating equipment health assessment.
• Infrared Thermography and Thermal Imaging Technologies.
• Lubrication Excellence, Oil Analysis, and Tribology.
• Ultrasound Inspection and Acoustic Monitoring Technologies.
• Predictive, Preventive, and Condition-Based Maintenance Methodologies.
• Reliability Centered Maintenance (RCM).
• Root Cause Failure Analysis (RCFA).
• Failure Modes and Effects Analysis (FMEA).
• Asset Integrity and Fitness-for-Service Assessments.
• Risk-Based Inspection (RBI) Programs.
• Non-Destructive Testing (NDT) Methods and Standards.
• Asset Criticality Assessment and Lifecycle Management.
• Mining and Mineral Processing Equipment Reliability.
• Crushers, Conveyors, Mills, Pumps, Motors, Gearboxes, and Rotating Equipment Diagnostics.
• Electrical Equipment Condition Monitoring.
• Inspection Planning and Regulatory Compliance.
• Reliability Engineering Principles and Statistical Analysis.
• Maintenance Strategy Development and Optimization.
• SAP PM, IBM Maximo, Pronto, Oracle, or equivalent CMMS/ERP systems.
• Power BI Reporting, Data Analytics, and Reliability Dashboards.
• International Standards including ISO 55000, ISO 17359, ISO 18436, API, ASME, and IEC.
• HAZOP, HAZID, Risk Assessment, and Asset Risk Management.
• Technical Report Writing and Engineering Documentation.
• Microsoft Office Suite (Advanced Excel, Power BI, Word, and PowerPoint).
• Digital Transformation and Online Condition Monitoring Systems.
Soft Skills:
• Excellent verbal, written, and interpersonal communication skills in English are essential.
• Excellent analytical and problem-solving skills.
• Strong diagnostic and investigative mindset.
• Effective communication and technical reporting skills.
• Strong stakeholder engagement and relationship management.
• Excellent planning, prioritization, and organizational skills.
• Strong attention to detail and commitment to technical accuracy.
• Effective contractor and vendor management skills.
• Strong safety leadership and risk awareness.
• Ability to work under pressure and manage competing priorities.
• High level of accountability, integrity, and professional ethics.
• Continuous improvement mindset focused on reliability and operational excellence.
• Strong collaboration skills across multidisciplinary teams.
• Adaptability and resilience in changing operational environments.
• Strong presentation and facilitation skills.
• Results-oriented approach with focus on safety, reliability, availability, and cost optimization.