Failure Analysis Engineer – Valve Failures (RCA Expert)

We are looking for a detail-oriented Junior Failure Analysis Engineer with a strong interest in valve failure investigation and root cause analysis (RCA). The ideal candidate will assist in evaluating failed valve components from the field, conducting structured analyses, supporting corrective action development, and documenting failure trends. This position offers growth into a specialized role in reliability and forensic engineering.

Key Responsibilities:

1. Failure Analysis & Investigation

• Assist in the disassembly and inspection of failed or degraded control valves, isolation valves, relief valves, and actuators.

• Support root cause analysis (RCA) efforts using methodologies such as 5 Whys, Fishbone Diagrams, Fault Tree Analysis (FTA), and Apollo RCA.

• Collect and interpret evidence from valve failure cases including:

  • Visual damage patterns

  • Seal and gasket degradation

  • Erosion, corrosion, galling, cracking, or cavitation

  • Valve trim wear and actuator failure

2. Testing & Lab Coordination

• Coordinate with test labs for:

  • Non-Destructive Testing (NDT): dye penetrant, radiography, ultrasonic, magnetic particle testing

  • Metallurgical analysis: hardness testing, microstructure analysis, SEM/EDS examination

  • Material verification: PMI (Positive Material Identification), chemical composition analysis

• Record and document findings in a structured format, including photos, sketches, and test reports.

3. Reporting & Documentation

• Prepare clear, well-structured failure investigation reports summarizing findings, probable causes, and recommendations.

• Maintain failure tracking databases and support development of Corrective and Preventive Actions (CAPA).

• Document valve failure trends to identify systemic or recurring issues and support reliability initiatives.

4. Cross-Functional Collaboration

• Work closely with maintenance, reliability, quality, operations, and OEM vendors to gather data and context on failed valves.

• Participate in field inspections and post-failure interviews with maintenance technicians or operators.

• Support design and engineering teams by sharing field failure data for valve improvement projects.

Required Qualifications:

• Bachelor’s Degree in Mechanical Engineering, Materials Science, Metallurgy, or related discipline.

• 0–3 years of experience in industrial equipment failure analysis, preferably with exposure to valves or rotating equipment.

• Knowledge of mechanical design principles, valve types (globe, gate, ball, check), and materials used in valve construction.

• Familiar with basic RCA techniques, root cause documentation, and structured problem-solving.

• Exposure to engineering documentation such as P&IDs, valve datasheets, and maintenance logs.

Preferred Qualifications:

• Internship or project experience in a power plant, oil refinery, process plant, or valve manufacturing company.

• Basic understanding of API, ASME, ASTM, NACE, or MSS valve-related standards.

• Exposure to reliability engineering tools or platforms (e.g., SAP PM, Maximo, Meridium, Reliasoft).

• Hands-on experience with valve teardown, workshop inspections, or forensic evaluation (even in an academic or training setting).

Key Competencies:

• Strong analytical skills and attention to detail.

• Ability to interpret failure patterns and mechanical anomalies.

• Technical writing and communication skills for reporting and cross-functional collaboration.

• Eagerness to learn and grow in reliability engineering and forensic failure investigation.

Work Environment:

• Combination of office, workshop, and field work.

• Occasional travel to plants, refineries, or vendor locations for onsite inspections.

• Must be comfortable working around heavy equipment and industrial environments.