Principal Technical Consultant – Asset Integrity & Asset Management

Principal Technical Consultant – Asset Integrity & Asset Management

KBR is seeking a Principal Consultant with asset integrity, life extension, and asset management consulting experience to join our international consulting organisation. The successful candidate will be a senior technical leader, providing high‑value advisory and practical engineering input across the full asset lifecycle, helping clients manage asset integrity and risk, improve reliability, and optimise performance.

Key Responsibilities

Act as a technical authority on asset integrity management and structural/mechanical life extension, including facilities, infrastructure and equipment in operating/brownfield environments.

• Structured asset life extension evaluations, including HSE and business risk‑based approaches.
• Debottlenecking studies including identification of existing constraints in a logical, sequenced manner against client production objectives, ranging from least costly, easiest implementation to more involved and costly solutions.
• Mechanical integrity and inspection program assessments / gap closure, including management systems, procedures, execution, documentation and training, and a multi‑year continuous improvement model.
• Integrity Operating Window (IOW) / Damage mechanism reviews / Corrosion Control Document (CCD) program development or validation and equipment reliability reviews to control and monitor damage mechanisms; or determine end of life.
• Risk Based Inspection (RBI) program implementations.
• Fitness‑for‑Service (FFS) evaluations (Per API 579) and assessment of pressure equipment damage (including use of Finite Element Analysis (FEA) where appropriate).
• Perform fire damage assessments to evaluate inspection and repair requirements.
• Equipment asset care strategies and life cycle analysis, and operator care / on‑stream monitoring programs. Develop and review high‑quality technical deliverables including reports, presentations, models and decision support materials, applying engineering judgement to identify integrity threats, operational constraints, risk drivers, and value‑led intervention options.

Client Engagement & Advisory

• Act as a trusted technical advisor to clients, communicating effectively at both technical and executive levels, translating complex engineering topics into clear, decision‑ready business insights.
• Support client discussions and delivery across the four core asset management pillars:
• Asset Integrity Management (life extension, Mechanical Integrity (MI), inspection strategies, FFS, IOW/CCD).
• Risk Management (insurance / loss control advisory, Root Cause Failure Analysis (RCFA), HSSE / PSM programs).
• Reliability Programs (criticality, RAM, FMEA, electrical infrastructure, machinery lifecycle).
• Process Optimisation (risk registers, turnaround scope optimisation, debottlenecking, business processes).

Reliability, Risk & Operational Readiness

• Criticality analysis (rotating machinery and static equipment).
• RAM analysis, including operability assurance and sparing optimisation for new and existing units and utilities.
• Troubleshooting equipment performance leveraging discipline Subject Matter Experts and applying Root Cause Failure Analysis (RCFA) methodology where appropriate.
• Failure Mode & Effect Analysis (FMEA) and failure mode reviews.
• Electrical infrastructure support (preventive maintenance programs, power system modelling e.g., ETAP, and electrical asset life extension programs).
• Static & rotating machinery design & life cycle management (Preventative Maintenance (PM) / Predictive Maintenance (PdM) programs, lubrication/vibration/operator care strategies).

Process Optimisation & Turnaround / Outage Support

• Risk register development to evaluate business and safety risk and optimise CAPEX/maintenance spend.
• Turnaround & planned outage support, including TAR strategy / interval definition, risk‑based scope development and scope challenge processes, critical path definition / optimisation, preparedness reviews, and post‑TAR lessons learned.
• Process engineering optimisation, such as process modelling/optimisation, debottlenecking studies, Process Safety Valve (PSV) studies, and catalyst life evaluation.
• Reviewing / benchmarking asset integrity business processes, Key Performance Indicators, tools, organisational capability and competencies.
• Project services, including supplemental estimating, “cold eye” reviews, and FEL / process gate reviews.

Business Development & Market Support

• Proposal preparation, technical inputs to bids and presentations, client meetings and technical workshops.
• Identifying and shaping opportunities across upstream, refining / petrochem, midstream, power and other operator led portfolios where integrity, reliability and optimisation are priorities.
• Contributing to thought leadership, market positioning and capability development across asset management services.
• Optionally, support short, high‑impact “on‑demand” advisory engagements (retainer model), designed to rapidly address immediate issues or shape follow‑on project work, supported by periodic check‑ins.

Team & Knowledge Leadership

• Mentor and guide less‑experienced engineers and consultants.
• Develop internal methodologies, tools and best practices across integrity, risk, reliability and optimisation.
• Collaborate across KBR’s global organisation to integrate multi‑discipline expertise.
• Prepare and deliver conference papers and support the growth of the business.

Experience & Capability

• Asset Integrity Management
  • Structured asset life extension evaluation (structural and/or mechanical).
  • Mechanical Integrity programme assessments, compliance, gap closure and multi‑year Continuous Improvement (CI) models.
  • IOW/CCD programme development / validation and damage mechanism control.
  • Fitness‑for‑service / FEA‑supported evaluations and inspection/test planning.
  • Equipment asset care strategies and lifecycle analysis (incl. boilers/heaters, operator care/on‑stream monitoring).
• Risk Management
  • Root Cause Failure Analysis (lead or SME support; recommendation validation / prioritisation).
  • PSM programme support (OSHA or equivalent, compliance assessments, Process Hazard Analysis (PHA) support, action validation / prioritisation).
  • HSSE programme assessments (best‑practice benchmarking, gap closure, leadership training, sustainability check‑ins).
• Reliability Programmes
  • Criticality analysis (fixed equipment and machinery).
  • RAM analysis, sparing optimisation, utility‑focused studies.
  • FMEA.
  • Electrical infrastructure preventive maintenance and asset life extension (power system modelling e.g., ETAP).
  • Machinery lifecycle management and PM / PdM strategies.
• Process Optimisation
  • Risk registers, CAPEX / maintenance optimisation.
  • Turnaround scope reviews/optimisation and scope challenge.
  • Debottlenecking, PSV studies, catalyst life evaluation.
  • Maintenance business processes, key performance indicators, tools (including CMMS) and organisational requirements, including competencies.
  • FEL reviews, cold eye reviews, estimating support.

Essential Skills

• Relevant number of years’ experience in production operations within an operating company organisation or operations and maintenance consultancy.
• Strong experience working with and supporting development / projects groups in feasibility, concept, and front‑end consulting assignments, with practical production readiness / delivery focus.
• Prior involvement in technical due diligence or lender’s engineer roles is advantageous.
• Proven ability to work independently, manage multiple assignments and deliver high‑quality outputs to tight schedules. Willing to travel up to ~30%.
• Principal Consultants will ideally have existing client relationships in their areas of expertise.

Key Competencies

• Able to work within a “sell‑do” model; strong self‑starter and motivated to succeed.
• Excellent communication skills including concise reports and presentations for all levels (Board to Technician), good cultural awareness.
• Confidence to work at all levels of a client organisation (Board to Technician).
• Commercial awareness: can identify opportunities, shape scope, plan execution and deliver value‑driven outcomes.
• Continuous improvement mindset, identifies gaps and helps develop work processes, tools and methodologies.
• Desire to expand role and be adaptable to client’s needs.
• Contribute to preparation of proposals, execution plans and budgets.

Other Functions

• Based in our Leatherhead office.
• Good analytical and problem‑solving skills.
• Positive and flexible attitude.
• Diplomatic in meeting and working with people (internally and externally).
• Flexible and willing to work extra hours as necessary to accommodate occasional work‑load peaks.
• Fluent English, additional languages are a plus.

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