Maintenance Technician (Mechanical Bias) in Barry

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Position Overview

The Multiskilled Maintenance Technician (Mechanical Bias) is responsible for ensuring the safe, reliable, and efficient operation of plant assets within a high‑hazard chemical manufacturing environment. The role provides mechanical expertise while supporting electrical, instrumentation, and control tasks within competency limits. The technician performs preventative and corrective maintenance, troubleshoots equipment failures, and supports continuous improvement initiatives to maximise plant uptime and compliance with regulatory requirements (COMAH, PUWER, LOLER, Pressure Systems Safety Regulations, etc.).

Job Responsibilities

• Maintenance & Repair
  • Perform planned preventive maintenance (PPM) on mechanical equipment, including pumps, vessels, pipework, gearboxes, compressors, boilers, rotating equipment, and mechanical seals.
  • Diagnose and repair mechanical faults safely and efficiently, minimising downtime.
  • Support electrical and instrumentation maintenance tasks within competency (e.g., basic fault finding, isolations under supervision, low‑complexity repairs).
  • Ensure all work is completed in compliance with site safety procedures, permit‑to‑work systems, and relevant UK legislation.
• Plant Operation Support
  • Respond promptly to breakdowns and process interruptions.
  • Assist operations teams with the safe start‑up, shutdown, testing, and commissioning of plant equipment.
  • Participate in root cause analysis (RCA) for repetitive equipment failures.
• Compliance & Documentation
  • Ensure maintenance activities comply with COMAH safety requirements.
  • Complete accurate maintenance records in the site’s CMMS (SAP).
  • Support statutory inspections and audits under PSSR, LOLER, DSEAR, ATEX, and insurance requirements.
• Continuous Improvement
  • Identify and support reliability improvements for plant equipment.
  • Participate in improvement projects, shutdowns/turnarounds, and equipment upgrades.
  • Contribute to the development of maintenance procedures, SOPs, and safe systems of work.
• Teamwork & Communication
  • Work collaboratively with operations, engineering, contractors, and technical teams.
  • Provide technical mentoring to apprentices and less experienced technicians.
  • Attend toolbox talks, shift handovers, and team meetings as required.

Local Specific Requirements For The Role

• Ability to work on a COMAH upper‑tier chemical plant with hazardous substances, pressurised systems, and high‑risk energy sources.
• Participation in 7-day shift pattern and on‑call rota.
• Competent use of site permit systems: PTW, confined space, hot work, process & electrical isolations, first breaks.
• Ability to wear all required PPE including respiratory protection (subject to face‑fit).
• Knowledge of site utilities (steam, condensate, cooling water, compressed air, etc.).
• Experience working with process equipment such as batch reactors, heat exchangers, storage tanks, filtration & transfer systems, boilers, bio‑plant or effluent treatment systems (if applicable).

Functional Competencies

• Mechanical Competencies
  • Mechanical fitting, alignment, and assembly skills.
  • Pump strip‑down and rebuild (centrifugal, positive displacement).
  • Pipework installation and repair (flanged, threaded, welded—depending on qualifications).
  • Mechanical seal replacement and troubleshooting.
  • Rotating equipment maintenance.
  • Basic machining or workshop skills (drilling, grinding, tapping).
  • Pressure systems awareness.
• Electrical & Instrumentation Support (basic level)
  • Ability to read electrical drawings and P&IDs.
  • Basic fault finding on motors, sensors, switches, and control panels.
  • Understanding of isolations and lockout–tagout (LOTO).
  • Competence in instrumentation basics (pressure, flow, temperature transmitters) desirable.
• Safety & Compliance
  • Strong understanding of process safety (COMAH, DSEAR).
  • Knowledge of LOLER, PUWER, COSHH, and Permit‑to‑Work systems.
  • Hazard identification and risk assessment skills.
• Other Competencies
  • CMMS proficiency (SAP).
  • Good problem‑solving and diagnostic skills.
  • Ability to work independently or as part of a team.
  • Effective communication skills for cross‑functional working.

Essential Education & Experience

• Time‑served mechanical apprenticeship or equivalent NVQ Level 3 qualification.
• Demonstrable experience as a maintenance technician in a chemical, pharmaceutical, petrochemical, or related heavy industry environment.
• Strong mechanical skill base with some electrical/instrumentation exposure.
• Experience with hazardous area equipment or regulated environments.

Desirable

• HNC/HND or equivalent in Mechanical Engineering or similar discipline.
• COMPEX (EX01‑04) competence – advantageous.
• BOAS / steam boiler experience.
• MEWP, forklift, scaffold awareness, or rigging qualifications.
• Experience with permit writing and isolations.
• Training or mentoring experience.