Plant and equipment Inspector
Sadara Chemical Company
Total years of experience :13 years, 0 months
Plants: PMDI (Polymeric diphenylmethane diisocyanate)
ISS (Isocynate and Shared Services)
KPIs:
• Initiating and coordinating all intrusive and non-intrusive inspection/NDT activities of plant vessels, piping and tanks.
• Correspondence of Planned Preventive Maintenance (PPMs) with the maintenance teams.
• Completion of PPMs inspection within due dates and coordinating with maintenance for closing the work orders.
• Correspondence of any corrective maintenance while equipment is in-service.
• Review and analysis of previous inspection reports to summarize the integrity status of the piping systems.
• Appropriate inspection/NDT techniques selection as per the site conditions according to the codes/standards and specification.
• Preparation of inspection reports/certificates with all findings, abnormalities and recommendations
• Reviewing of NDT reports, final dossier from contractor after any corrective action.
• Cooperate and communicate with the Corrosion Engineer to investigate / resolve issues related to corrosion/erosion.
• Ensure full compliance with company safety regulations and HSE management systems.
• Preparation of final inspection reports, updating the reports of full and general inspections in meridium.
Client: TR & SAUDI ARAMCO
Project: Fadhili Gas Program Project
Project Scope: Construction of 12 No’s tanks in package 1 & 2 as per API 650 standard.
KPIs:
• Responsibility of all aspect related to Mechanical Integrity, quality control and overall implementation of approved quality procedures at site.
• Carry out material receiving inspection (material, dimensional, coating) at site as per material test certificates and release notes.
• Raising the RFI for material receiving inspection with all the documents as per approved ITP.
• Responsible for the inspection of all Mechanical activities in the project.
• Follow up the QC activities regarding construction activities.
• Witnessing the Survey for foundations and accepting as per tolerances in API 650.
• Raising the RFIs for inspections related to mechanical activities for TR and Saudi Aramco.
• Managing the RFIs and related documents for internal and Saudi Aramco Audits.
• Follow up of any site modification technical enquiry and coordination with client.
• Maintaining the Saudi Aramco quality standards during all the construction activities.
• Ensure the works being executed as per the drawings, specifications and comply with the quality norms
Client: AL WAHA & SAMAPCO (SAHARA Petrochemical Company)
Project: Mechanical Integrity (RC Corridor)
Project Scope:
On-stream inspection of corridor pipelines of AL WAHA and SAMAPCO plants, marking of CMLs for thickness monitoring, UT gauging, Development of missing isometrics.
KPIs:
• Carried out external inspection for corrosion, leaks, and previous temporary repairs, clamps, coating breakdown, insulation damage, vibration, and misalignment, pipe support deterioration specifically in touch points and to air to soil interface, pipe hanger distortion or breakage.
• Determination of CMLs points in piping isometric sketches based on the potential for general or localized corrosion and service specific damage mechanisms.
• Direct the team members of the plant inspectors and the NDT crew at work site for the planned inspection, in coordination with the Inspection Coordinator.
• Thickness monitoring/measurement of RC Corridor pipelines of Sahara Petrochemicals company
• Inspection of dead legs and corrosion under insulation of insulated pipelines
Client: Petrokemya (SABIC)
Project: Olefins III, TAM 2017
Project Scope:
Intrusive planned inspection of static equipment includes pressure Vessels, Heat Exchangers, Columns, Boiler, Heater, Tanks as per Turnaround Scope.
KPIs:
• Internal and External visual Inspection carried out on pressure vessels, columns and Tanks.
• Liaise with contractor quality control inspector regarding shutdown activities and progress regarding assigned equipment.
• Organizing and witnessing various non-destructive testing such as MPT, DPT and UTT.
• Final inspection before box up of the equipment.
• Making appropriate reporting at each step of shutdown activities and final reporting after box up.
Client: AL WAHA (SAHARA Petrochemical Company)
Project: PDH and PP, TAM 2017
Project Scope:
Intrusive planned inspection of static equipment includes pressure Vessels, Heat Exchangers, Columns, Boiler, Heater, Tanks as per Turnaround Scope.
KPIs:
• Internal and External Inspection carried out on heat exchangers, pressure vessels and columns.
• Liaise with contractor QC regarding shutdown activities and progress regarding assigned equipment.
• Witnessing Hydro tests and Pneumatic tests for heat Exchangers.
• Organizing and witnessing various non-destructive testing.
• Performing Pressure vessels internal assembly visual inspection and thickness survey.
• Visual inspection of fit up, and weld visual reviewing welding procedure specification and quality plan.
• Witnessing and reporting of pre-heating, post heating and post weld heat treatment procedures.
• Final inspection before box up of the equipment.
• Making appropriate reporting at each step of shutdown activities and final reporting after box up.
Client: SADAF (SABIC)
Project: Mechanical Integrity II
Project Scope:
Re-validation of Corrosion loops and Corrosion circuits of all the plants in SADAF facility, Guided wave UT for Pipe rack piping, Preparation of missing Corrosion Isometrics of piping and thickness measurement of piping, preparation of Injection Points circuits, Visual Inspection and Profile RT of Injection Points and Dead Legs, uploading of the inspection reports to Meridium.
KPIs:
• Field verification of all the process lines, Pipe rack piping and corridor pipelines to verify the existing and modified piping.
• Dividing whole unit piping into piping loops, circuits and sub-circuits based on process condition and potential damage mechanism.
• Evaluate possible damage mechanisms (especially regarding corrosion) to be occurred in pipe line according to service.
• Development of corrosion isometrics of pipelines based on corrosion circuits.
• Determination of CMLs points in piping isometric sketches based on the potential for general or localized corrosion and service specific damage mechanisms.
• Carry out external inspection for corrosion, leaks, and previous temporary repairs, clamps, coating breakdown, insulation damage, vibration, and misalignment, pipe support deterioration specifically in touch points and to air to soil interface, pipe hanger distortion or breakage.
• Inspection of Dead Legs, Injection Points and CUI for corrosion.
• External thickness measurement on CMLs on piping circuits including dead legs.
• Profile Radiography of small bore piping
• Uploading all the inspection and thickness monitoring reports in meridium.
Client: TASNEE (National Industrialization Company)
Project: PDH, TAM 16
Project Scope:
Intrusive planned inspection of static equipment includes pressure Vessels, Heat Exchangers, Columns, Boiler, Heater, Tanks as per Turnaround Scope.
KPIs:
• Internal and External Inspection carried out on heat exchangers, pressure vessels and columns.
• Liaise with contractor QC regarding shutdown activities and progress regarding assigned equipment.
• Witnessing hydro tests and leak tests for heat Exchangers.
• Organizing and witnessing various non-destructive testing.
• Performing Pressure vessels internal assembly visual inspection and thickness survey.
• Visual inspection of fit up, and weld visual reviewing welding procedure specification and quality plan.
• Witnessing and reporting of pre-heating, post heating and post weld heat treatment procedures.
• Final inspection before box up of the equipment.
• Making appropriate reporting at each step of shutdown activities and final reporting after box up.
Client: SABTANK (SABIC)
Project: Mechanical Integrity
Project Scope:
On-stream Inspection of the piping under SABTANK jurisdiction of all the SABIC affiliates from Fence boundary limit until the tanks (both corridor pipeline and process piping). CMLs marking and UT thickness measurement, development of inspection isometrics.
KPIs:
• Technically direct the team members of the plant inspectors and the NDT crew at work site for the planned inspection, in coordination with the Inspection Coordinator.
• Ensures the validity of the data with the aid of the data analyst, and ensures that the inspection is carried out in line with the requirement of the relevant API code and Company requirements.
• Creating piping isometric sketches to facilitate inspection and the recording of corrosion monitoring locations (CMLs).
• Selecting appropriate NDE techniques for each piping circuit based on the circuit damage mechanism.
• Determination of CMLs points in piping isometric sketches based on the potential for general or localized corrosion and service specific damage mechanisms.
• Carry out external inspection for corrosion, leaks, and previous temporary repairs, clamps, coating breakdown, insulation damage, vibration, and misalignment, pipe support deterioration specifically in touch points and to air to soil interface, pipe hanger distortion or breakage.
• External thickness measurement on CMLs on each piping circuit
• Determination of piping circuit inspection interval based remaining life calculation and piping service class
• Internal inspection in opened flanges for deposition, corrosion, localized corrosion, erosion, etc.
• Internal inspection of clad or lined piping for disbanding, bulging and cracking
• Inspection of injection points for localized corrosion, dead legs for corrosion, Corrosion under insulation of piping in susceptible temperature range
Fine Gas Co Ltd. (FG) is an unquoted public limited Co., incorporated in 1978. FG started its production in 1978 with the setting up of an Air Separation Unit (ASU) with a capacity of 6 tons/day (TPD). The production capacity was further enhanced by 25 (TPD) in 1985. FG set up another Air Separation Unit of 100 TPD in 1998. FG is also capable of producing Nitrous Oxide with the production capacity of 30 kg/hour and Dissolved Acetylene with the capacity of 45 m3/hour.
KPIs:
• Supervision and coordination of all on-stream and shutdown inspection/NDT activities of plant equipment, piping, pipelines & tanks.
• Supervision of a team of inspectors, multi-disciplined NDT and rope access personnel to complete client inspection program.
• Identifying areas of special concern and deterioration (e.g., dead legs, injection points, buried piping, corrosion under insulation (CUI), erosion & corrosion/erosion), preparation of inspection procedures to follow-up their resolution to improve Plant integrity.
• Review and analysis of previous inspection reports to summarize the integrity status of the piping systems.
• Selection of an appropriate inspection/NDT techniques as per codes/standards and specification.
• Carrying out thorough visual inspection complemented with NDT examination on pressure vessels, heat exchangers, fin fan coolers, fired heaters, RVs, process piping systems, pipelines and above ground storage tanks as per planned frequency to assure the mechanical integrity.
• Corrosion rate calculation based on metal loss in a specific time interval, Retirement thickness calculation based on the minimum required thickness and minimum required structural thickness, remaining life calculation based on the available thickness for corrosion and the corrosion rate value
• Reviewing of NDT reports and corrosion analysis (remaining service life calculation based on corrosion rate).
• Preparation of inspection reports/certificates with all findings, abnormalities and recommendations.
• Assist and participate in RBI analysis and developing the inspection plans/frequencies for static equipment, piping and pipelines.
• Advise on repair techniques, materials selection, welding procedures, inspection & testing requirements.
• Cooperate and communicate with the Corrosion Engineer to investigate / resolve issues related to corrosion/erosion.
• Assist in preparation of yearly estimates of work required, for inclusion in the division's budget proposals.
• Assist in testing & certifying welders and welding procedures specifications as per ASME Sec IX.
• Review of WPS, PQR, NDT, PWHT procedures & qualification of NDT technician.
• Ensure full compliance with company safety regulations and HSE management systems.
• Preparation of final inspection reports. Maintain and update all inspection files as needed.
Post Graduate Diploma (PGT) in Chemical Engineering specialized in Process Engineering. Course work was completed only in Master in Sciences (M.Sc.) Chemical Engineer Thesis topic: Toxic waste analysis of discharges from metal finishing industry.
Internship: Three Week internship at PACKAGES (Pvt) Ltd in Q&EHS Department. Projects: 1- Production of 50 MW electricity by integrated gasification combined cycle (IGCC). 2-Feasibility report on IGCC for 50 MW in Pakistan.