Allegiance Refining (operator of The San Antonio Refinery “TSAR”) operates by its three tenets: Safety: We aim for everyone to go home safely every day and strive for an accident and incident-free workplace. Stewardship: We are stewards of the assets we operate and are committed to being safe and environmentally responsible. Service: We strive to provide first-class service to our customers. PURPOSE AND ROLE The Maintenance & Reliability Manager is a leadership position reporting to the General Manager, with full accountability for the maintenance expense budget, work execution, and mechanical integrity. The role pairs maintenance leadership — people, budget, craft execution, turnaround support with hands-on ownership of the site’s reliability data and models. The position sets the tone for safe, compliant, reliability-centered operations at TSAR. KEY ACCOUNTABILITIES Maintenance Leadership & Work Execution - Lead the maintenance organization to deliver the refinery’s process safety, personnel safety, environmental, reliability, and cost objectives.
- Own work management end to end — identification, prioritization, planning, scheduling, execution, and close-out.
- Drive schedule compliance, wrench time, backlog health, and rework reduction through measured performance and root cause resolution.
- Direct QA/QC of repairs; maintain job plans, repair procedures, and craft work standards.
- Manage spare parts strategy, critical spares inventory, and vendor/contractor performance.
Reliability Modeling & Data Ownership - Use Newton platform (a quantitative engine that calculates probability of failure at the failure-mode level and aggregates asset-level risk into a live, facility-wide system model to drive day-to-day reliability and maintenance decision-making, with direct ownership of modeling for non-fixed assets (rotating, electrical, and instrumentation equipment).
- Configure and tune models so assessments reflect actual operating conditions and observed equipment behavior.
- Validate model accuracy through structured quality checks and field verification; keep models and asset relationships current through the site MOC process.
Reliability Analysis & Decision Support - Analyze model output and maintenance history to identify bad actors, failure drivers, chronic cost centers, and data gaps; maintain a dynamic watchlist and mitigation plans for the top contributors to refinery risk and unplanned downtime.
- Optimize PM/PdM strategies, condition monitoring, and task intervals against quantified risk rather than convention; recommend maintenance intervals, repair-versus-replace decisions, upgrades, and stocking levels.
- Lead root cause analyses for mechanical and process equipment failures; drive corrective actions to closure and write findings back into the model.
- Produce Decision Support Packages for rotating equipment found deficient in design or at end of life, supporting the site capital intake and prioritization process.
- Identify operating practices that adversely affect asset life — operation outside design envelope, improper shutdown sequences, inventory workflow gaps — and partner with Operations to correct them.
- Own reliability and maintenance KPI reporting to the Refinery Leadership Team and ownership, including availability, MTBF, PM compliance, maintenance cost per barrel, and cost avoidance realized.
Mechanical Integrity & Process Safety - Accountable for the site Mechanical Integrity program under OSHA PSM (29 CFR 1910.119) and RAGAGEP, including API 510, 570, 653, 580, and 581.
- Champion continuous improvement of Risk-Based Inspection methodology and CML optimization and site Inspection.
- Maintain and annually review the PSM critical equipment list; keep Process Safety Information current and documented.
- Participate in MOC, PSSR, PHA, and incident investigation activities; resolve assigned PSM action items by due date.
Annual Budget and Field Support - Develop and manage the maintenance operating budget and associated capital plan; support other departments in building spending plans that is aligned with reliability outlook.
- Track, forecast, and adjust spend to deliver to plan; build cost justification and life-cycle cost analysis for reliability improvements.
- Provide field support during emergency and unplanned downtime events, including after hours.
People Leadership - Develop direct reports through training, coaching, mentoring, and candid performance feedback; build a competent and durable maintenance workforce.
- Lead, influence, and mentor across the organization, including personnel not under direct supervision, and contribute to facility-wide strategic direction.
REQUIREMENTS - Bachelor’s degree in Mechanical, Electrical, or Chemical Engineering or a closely related technical discipline. An equivalent combination of technical education and directly applicable refining maintenance leadership experience will be considered.
- Ten (10) or more years of progressive experience in maintenance, reliability, or engineering within refining, petrochemical, or comparable heavy process manufacturing, including three (3) or more years of direct supervisory or management responsibility.
- Working knowledge of OSHA PSM, mechanical integrity requirements, RBI methodology, and applicable API and ASME codes.
- Demonstrated experience implementing and sustaining preventive and predictive maintenance programs.
- Demonstrated fluency with CMMS/EAM systems and reliability data — able to work in the data personally, not solely through others — and proven understanding of budget management and cost control.
- Ability to respond to plant events outside normal business hours, including nights, weekends, and callouts, and to support extended turnaround schedules.
- Excellent organizational, interpersonal and communication skills (both verbal and written)
- Effectively communicate with personnel at all organizational levels, vendors, and state/federal regulators
- Ability to foster teamwork and demonstrate good, methodical decision making
PHYSICAL DEMANDS - On-site position at an operating petroleum refinery, working in both office and field environments with exposure to outdoor weather, elevated noise, hydrocarbons, and process hazards; required PPE is provided and its use is mandatory.
- Regularly required to stand; grasp, handle, or feel; reach with hands and arms; climb, balance, stoop, kneel, crouch, or crawl; and lift or move up to 50 pounds.
- Must be able to climb stairs, ladders, and elevated structures and work in confined spaces as required.
- Vision requirements include close, color and peripheral vision and depth perception.
Allegiance Refining, LLC operates (The San Antonio Refinery “TSAR”) offers equal employment opportunity and treatment to all qualified applicants regardless of race, color, religion, sex, national origin, or any other protected status.
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