Principal Technical Consultant – Asset Integrity & Asset Management

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KBR is a global provider of differentiated, professional services and technologies delivered across a wide government, defense and industrial base. Drawing from its rich 100-year history and culture of innovation and mission focus, KBR creates sustainable value by combining engineering, technical and scientific expertise with its full life cycle capabilities to help our clients meet their most pressing challenges today and into the future.

We deliver science, technology and engineering solutions to governments and companies around the world. KBR employs approximately 37,000 people worldwide with customers in more than 80 countries and operations in over 29 countries. KBR is proud to work with its customers across the globe to provide technology, value-added services, and long-term operations and maintenance services to ensure consistent delivery with predictable results. At KBR, We Deliver.

KBR Consulting 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.

KBR’s asset management services are built on decades of engineering knowledge across upstream, midstream, downstream, and petrochemical processes and equipment, with a proven track record as a business partner for operating companies and a practical owner-user perspective for right-sized solutions. This role will draw on KBR’s depth of resources, methodologies and tools across the wider business when needed.

Reporting to the KBR Consulting International leadership team, the Principal Consultant will deliver technically robust, commercially informed consulting assignments. Assignments typically include life extension evaluations, integrity and inspection programme assessments, maintenance planning, Reliability Availability & Maintainability (RAM) studies, risk, Health, Safety, Security & Environment (HSSE) / Process Safety Management (PSM) support, turnaround optimisation, and brownfield performance improvement, as well as technical due diligence and lender’s technical advisor engagements.

As a more experienced team member, the Principal Consultant performs their own work in terms of collecting information, developing deliverables, analysing trends and key findings, and preparing reports and presentations. Recognising their project management responsibilities, the Principal Consultant should have excellent organisational skills, be good at communicating and guiding others and adept at managing competing drivers often managing multiple assignments concurrently.

Additionally, the Principal Consultant will support the group’s overall sales effort through proposal/tender preparation, contract negotiation, and other client interfacing activities.

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.

Lead or provide senior technical oversight for:

• 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; and 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).

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

Provide senior consulting input to improve reliability and reduce business risk, including:

• 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 applyig 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).

Process Optimisation & Turnaround / Outage Support

Lead or contribute to performance improvement and brownfield optimisation, including:

• 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 capaility and competencies.

• Project services, including supplemental estimating, “cold eye” reviews, and FEL / process gate reviews.

Business Development & Market Support

Support KBR Consulting’s growth strategy through:

• 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, the role may also 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

The candidate should be able to demonstrate depth of experience and knowledge in several of the following services areas:

• 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/onstream monitoring).

• Risk Management

  • Root Cause Failure Analysis (lead or Subject Matter Expert (SME) support; recommendation validation / prioritisation).

  • PSM programme support (Occupational Safety & Health Administration (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).

• 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:

• a 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

The candidate must demonstrate competence in the following:

• 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.

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.

KBR COMPANY INFORMATION

When you become part of the KBR team, your opportunities are endless. Through collaboration with our customers, we’re defining tomorrow’s challenges, then providing the solutions and services to overcome those challenges, always maintaining our commitment to total safety and reliability.

At KBR, we partner with government and industry clients to provide purposeful and comprehensive solutions with an emphasis on efficiency and safety. With a full portfolio of services, proprietary technologies and expertise, our employees are ready to handle projects and missions throughout their entire lifecycle, from planning and design to sustainability and maintenance. Whether at the bottom of the ocean or in outer space, our clients trust us to deliver the impossible on a daily basis.

Working at KBR means being rewarded for your contributions. In addition to competitive benefits and professional development, our people are empowered to use all their potential, creating meaningful change for themselves and our clients. We attract the best minds in the world because our expertise thrives on creativity, resourcefulness and collaboration. That is how we supply our clients with cutting-edge solutions and services. 

As the needs of the world change, we’re ready to respond and guide the way forward with strategic, sustainable, and technological advancements grounded in more than a century of practical application and execution.

KBR Consulting, through the incorporation of KBR’s wholly owned subsidiary Granherne, draws on a heritage of over thirty five years specialising in the front end phases of oil & gas field, refinery and petrochemical development projects from pre-feasibility, through feasibility and pre-FEED, up to and including preliminary FEED phases. In addition, we undertake small FEEDs as well as providing specialist consultancy to later through to phases of projects including debottlenecking studies, brownfield modifications, production optimisation, operations an decommissioning.

Our experience covers all forms of oil and gas field developments including onshore and offshore production and gathering facilities for greenfield, brownfield and refinery rehabilitation projects. The front end nature of the work means that we are often involved in developments in areas and technologies new to the oil and gas industry. We are currently heavily involved globally in the transition from oil and gas to other sources of energy and the move towards minimal manning of offshore production facilities. Other CCUS related projects have included:

• Strategy / master plan development;

• Pre-Feasibility and Feasibility Studies;

• FEED Studies;

• Maximising asset performance; and

• Product & energy optimisation.

Cost estimation and planning are both a regular feature of our studies and they are often bespoken to specific client methodologies. In addition to cost estimating and project planning, our capability covers the spectrum of all the front end technical disciplines including risk and safety analysis and value engineering. With access to the entire KBR organisation globally we can draw on a great depth of technical capability and experience, including that of legacy companies Granherne, GVA and Energo, and also ensure that our projects take full advantage of the execution experience obtained in the later phases of projects.

Over the years, KBR has provided support for some of the largest industry capital investments in modern times. Moreover, KBR has acted as lender’s advisor on well over 200 projects for a broad range of clients and financial institutions across many sectors including upstream and downstream oil and gas, speciality chemicals, mining, biofuels, pulp and paper, power, and general infrastructure.

KBR has an increasing bias towards operations related activities both in the impact on the design of new especially unmanned production facilities as well as the optimisation of operations. We have a number of personnel with oil company / operations backgrounds and have developed several unique applications to support our operations related activities.

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