Condition Monitoring Jobs in Illinois (NOW HIRING)

The Reliability Engineer – Mechanical Integrity Focus is responsible for developing and improving maintenance and inspection strategies for fixed equipment and other critical assets in a Process Safety Management (PSM) regulated facility. This role partners closely with the Asset Integrity Coordinator/API Inspector to transform inspection results, asset condition data, and failure history into effective reliability strategies. The position defines preventive and predictive maintenance programs, inspection technologies, and long-term asset integrity plans to ensure safe, reliable, and cost-effective operation of plant equipment. The Reliability Engineer supports continuous improvement of the Mechanical Integrity program by applying reliability engineering tools such as Root Cause Problem Solving (RCPS), Failure Modes and Effects Analysis (FMEA), and risk-based analysis.

Develop and maintain reliability strategies for fixed equipment including pressure vessels, tanks, piping systems, relief devices, and other critical assets.

Translate inspection findings and asset condition data into optimized maintenance strategies and inspection plans.

Define preventive and predictive maintenance programs to improve equipment reliability and integrity.

Partner with the Asset Integrity Coordinator/API Inspector to support the site Mechanical Integrity program.

Ensure inspection and maintenance strategies align with applicable codes, regulatory requirements, and industry best practices.

Support development and improvement of inspection technologies and condition monitoring methods.

Create and optimize Preventive Maintenance (PM) procedures and job plans for integrity-critical equipment.

Identify opportunities to improve inspection methods, monitoring techniques, and maintenance practices.

Support implementation of reliability-centered maintenance approaches.

Manage and optimize the pressure relief device inspection and calibration program.

Ensure compliance with applicable codes, internal standards, and regulatory requirements.

Track calibration intervals, maintenance history, and performance trends.

Analyze equipment performance, inspection data, and failure trends to identify reliability risks.

Lead or support Root Cause Problem Solving (RCPS) investigations for critical failures.

Perform Failure Modes and Effects Analysis (FMEA) and risk-based evaluations to prioritize improvement opportunities.

Develop and maintain the CAPEX roadmap for mechanical integrity and reliability improvements.

Identify equipment upgrades, replacements, and inspection technology improvements that enhance safety and reliability.

Support justification and prioritization of capital projects related to asset integrity.

Provide technical support during field inspections, troubleshooting activities, and maintenance work.

Participate in turnarounds and major maintenance activities related to integrity-critical equipment.

Work closely with maintenance, operations, and engineering teams to improve equipment performance.

Identify opportunities to improve reliability while reducing lifecycle maintenance costs.

Support risk-based decision making to balance cost, safety, and equipment reliability.

• Bachelor’s degree in Mechanical Engineering, Chemical Engineering, or related engineering discipline.
• 5+ years of experience in reliability engineering, maintenance engineering, or mechanical integrity programs in chemical, refinery, or similar industrial environments.
• Strong knowledge of fixed equipment reliability, inspection programs, and maintenance strategies.
• Experience in applying reliability tools such as RCPS, FMEA, and risk-based analysis.
• Familiarity with OSHA Process Safety Management (PSM) Mechanical Integrity requirements.
• Experience in PSM-regulated chemical manufacturing facilities.
• Knowledge of API inspection standards (API 510, API 570, API 653).
• Familiarity with Risk-Based Inspection (RBI) methodologies.
• Experience with asset management or CMMS systems.
• Certification or training in reliability engineering methodologies.

Salary range: $88,000.00 to $125,600.00, with potential progression up to $163,300.00 based on qualification, experience, and certification.

Annual bonus eligibility.

Medical, dental, vision, and basic life insurance. 401(k) plan participation.

Paid time off and company holidays throughout the calendar year.