Corrosion and Materials Engineer

INEOS Olefins & Polymers USA LLC – Corrosion and Materials Engineer, Grade 37. Salary range $161,100 – $200,365 (commensurate with experience), location TBD (Hybrid).

Overview

The Corrosion & Materials Engineer serves as the enterprise technical authority for metallurgy, corrosion control, damage mechanisms, and welding practices across INEOS O&P USA. The role provides expert guidance on material selection, welding procedures, and corrosion mitigation for critical equipment worth over $15B in replacement value. It supports site engineering, inspection, turnaround, and capital projects across three manufacturing sites and the O&P pipeline business.

Responsibilities

Materials & Metallurgy Technical Support

• Provide authoritative guidance on alloy selection, welding compatibility, and material upgrades for vessels, piping, storage tanks, and critical equipment.
• Review fitness‑for‑service evaluations, repair strategies, and material substitutions for severe or complex integrity challenges.
• Support Management of Change processes for exotic materials or non‑routine material decisions.
• Lead failure analyses and root‑cause investigations involving materials or metallurgical failures.
• Maintain enterprise materials engineering standards and reference documents.

CUI Inspection & Mitigation Strategy

• Lead the enterprise CUI inspection and mitigation strategy across all sites.
• Develop and maintain the CUI inspection program, risk‑based prioritization, and coatings strategy.
• Define standards for insulation systems, protective coatings, and weatherproofing.
• Track program performance and drive continuous improvement.

Damage Mechanism Management & Corrosion Control

• Identify, document, and manage active and potential damage mechanisms (e.g., hydrogen attack, sulfidation, chloride stress corrosion cracking).
• Conduct damage mechanism reviews (DMRs) and maintain corrosion control documents (CCDs).
• Collaborate with inspection teams, process engineering, and operations to monitor damage mechanisms.
• Interpret inspection data to identify systemic threats and emerging degradation risks.

Welding Engineering & Repair Practices

• Develop and approve welding procedures and repair practices for all assets.
• Support field execution of critical welds, fabrication methods, and in‑service repairs.
• Ensure compliance with applicable codes (e.g., API, ASME SectionIX).
• Review contractor WPS/PQR documents and align them with enterprise expectations.
• Coach site teams on welding practices, repair planning, and quality expectations.
• Lead resolution of welding‑related issues during turnarounds and capital projects.

Turnaround & Capital Project Support

• Provide technical support for turnaround planning and execution from a materials, welding, and corrosion perspective.
• Support post‑turnaround reviews and feed findings into DMRs, CCDs, and welding practices.
• Support capital project teams with material selection, fabrication specifications, and quality assurance for new equipment and modifications.
• Influence the materials, welding, and corrosion‑related portion of annual maintenance and inspection spend (~$175MM+).

Program & Procedure Development

• Define and maintain technical procedures for weld repair approvals, metallurgical evaluations, and material selection guidance.
• Collaborate with inspectors and engineers to ensure programs meet risk tolerance and design expectations.
• Establish enterprise best practices for documentation, application, and review of materials, welding, and corrosion controls.
• Drive continuous improvement and standardization across O&P USA.

Discipline Coaching & Technical Capability Development

• Provide functional coaching and mentoring to site mechanical engineers, inspection professionals, and reliability personnel.
• Develop competency standards for the materials and corrosion engineering domain.
• Build a network of site‑based engineering and inspection professionals to share technical learnings.

External Codes & Industry Engagement

• Ensure alignment with API, NACE/AMPP, and ASME codes.
• Maintain visibility in external forums and represent INEOS interests.
• Stay current on emerging threats, NDE technologies, and industry incidents.
• Bring external learnings into enterprise standards and practices.

Qualifications

• Bachelor’s degree in Materials Science, Welding Engineering, Metallurgical Engineering, or Mechanical Engineering; advanced degree preferred.
• 15–20 years of experience in welding, materials, or corrosion engineering in refining, petrochemical, or heavy industrial environments.
• Certified or highly proficient with API 510, 570, 579 (FFS), 582 and ASME SectionIX.
• Experience developing or qualifying welding procedures and reviewing contractor WPS/PQR documents.
• Strong understanding of corrosion mechanisms in hydrocarbon and polymer processing (CUI, high‑temperature sulfidation, chloride stress corrosion cracking).
• Demonstrated experience with damage mechanism reviews and corrosion control document development.
• Active participation in external industry forums (e.g., API committees, NACE/AMPP) preferred.

Technical Skills

• Authority on metallurgy, materials selection, and fabrication methods for pressure equipment and piping.
• Extensive knowledge of materials and welding codes (API 510, 570, 571, 579, 580, 581, 582, 653, ASME SectionIX).
• Proficiency in developing welding procedures, evaluating weld quality, and supporting field execution of critical repairs.
• Experience in fitness‑for‑service assessments, failure analysis, and root‑cause investigations.
• Ability to interpret inspection data and translate findings into actionable strategies.
• Knowledge of coatings, insulation systems, and cathodic protection for corrosion mitigation.
• Working knowledge of OSHA (PSM) as it relates to Mechanical Integrity programs.
• Engagement with external industry networks and application of new technologies.

Behavioral Skills

• Effective communicator capable of providing field support, authoring technical documents, and coaching stakeholders.
• Build credibility through technical depth, practical problem‑solving, and consistent follow‑through.
• Develop strong, trust‑based relationships with site leaders, engineers, inspectors, and welding personnel.
• Persistent and thorough in resolving complex materials and corrosion challenges.
• Steer sites toward standard practices through coaching and influence while recognizing local constraints.
• Prioritize and organize complex workloads with competing stakeholder demands.
• Collaborate effectively across functions including inspection, maintenance, operations, process engineering, and project teams.
• Adopt a long‑term stewardship view of asset integrity and lifecycle risk.
• Identify patterns and systemic risks across sites to inform enterprise strategies.
• Demonstrate sound judgment in high‑stakes engineering decisions affecting equipment safety and reliability.
• Stay curious, maintain external awareness, and drive continuous improvement.
• Earn trust by delivering value rather than merely enforcing compliance.