We are hiring a Senior Failure Analysis Engineer with deep expertise in valve failure diagnostics and root cause analysis (RCA). This role is responsible for investigating complex valve failures, identifying systemic reliability issues, and driving corrective and preventive actions across high-criticality systems (e.g., steam, feedwater, chemical service, cryogenic, corrosive fluids). The ideal candidate brings extensive experience in both technical failure investigations and reliability improvement programs.
Lead complex failure investigations of industrial valves (control, relief, isolation, check, and actuated valves).
Diagnose failure mechanisms including:
Corrosion (pitting, stress cracking, H2S-induced), erosion, cavitation, seal wear
Thermal fatigue, galling, foreign body damage, misalignment
Control logic or actuator performance failures
Facilitate structured RCA workshops using FMEA, FTA, 5 Whys, TapRooT, or Apollo RCA methods.
Validate field hypotheses with metallurgical, chemical, and mechanical analysis results.
Oversee lab coordination for destructive and non-destructive testing (NDT, PMI, SEM/EDS, microstructure, hardness).
Interpret diagnostic data and issue high-accuracy failure reports with actionable recommendations.
Maintain a repository of lessons learned and case histories to guide future designs and decisions.
Provide expert support to operations, maintenance, QA/QC, and design teams during plant upsets, shutdowns, and turnarounds.
Recommend valve material upgrades, design modifications, or process condition changes to enhance reliability.
Guide bad actor elimination programs and long-term asset improvement planning.
Align findings with international codes and best practices (API 598/6D/621, ASME B16.34, NACE MR0175, ISO, ASTM).
Contribute to corporate reliability and mechanical integrity strategies.
Mentor junior engineers and promote a culture of proactive failure prevention.
Bachelor's degree in Mechanical Engineering, Materials Science, or Metallurgy (Master’s preferred).
8–15+ years of experience in failure analysis or mechanical reliability engineering.
In-depth knowledge of valve construction, materials, and operating behavior in harsh or critical environments.
Strong familiarity with forensic failure investigation techniques and RCA methodologies.
Experience leading field investigations and collaborating with cross-disciplinary teams.
Industry certifications (CRE, API 579/580, Certified RCA Practitioner).
Experience in oil & gas, power, petrochemical, or chemical processing sectors.
Familiarity with reliability systems like SAP PM, Meridium, or XFRACAS.
Competence with smart valve diagnostics (e.g., Fisher ValveLink, ND9000).
High technical acuity and forensic engineering mindset
Strong leadership in cross-functional problem-solving
Advanced technical writing and communication skills
Analytical thinking with hands-on mechanical intuition
Proactive, structured, and detail-oriented work approach
Office and lab-based with regular field inspections at industrial plants or vendor locations.
May involve travel for shutdown investigations, factory failure audits, or RCA facilitation.