Inspection Engineer
Engro Polymer & Chemicals Limited
Total years of experience :13 years, 3 Months
Responsible for implementing and improving the established comprehensive asset integrity management program to assure the mechanical integrity of stationary equipment and piping in a large integrated chlor - vinyl petrochemical complex. My current assigned unit is EDC / VCM.
Key responsibilities are:
- Executing external, internal, and on-stream inspections of pressure vessels, columns, KO drum, storage tanks, furnace, PSVs, and piping as per defined condition monitoring plans
- Generation and monitoring of inspection recommendations using MAXIMO to ensure their timely competition
- Optimization of inspection plans of fixed assets using RBI approach
- Providing repair procedures to maintenance section as a technical support
- Developing and reviewing WPS to ensure compliance with relevance codes
- Developing quality and inspection test plans for new equipment or equipment subjected to modification as a technical support to project section
- Liaison with 3rd party inspection parties for NDT services
- Training of inspectors as per skill enhancement program
- Development of shutdown job package and resource planning for annual turnaround or forced outages
- Stewarding temporary repairs in assigned area to ensure their timely removal as well as providing temporary repair procedure to maintenance section as technical support
- Participate in management of change program regarding mechanical changes to ensure compliance with relevant codes and standards
- Conducting root cause analysis of equipment and piping failure
- Participate in equipment reliability studies to provide technical support in terms of inspection strategy, corrosion protection, and materials improvement
- Budget preparation for inspection section including both OPEX and CAPEX
- Review and updating of inspection work procedures as per relevant API codes
- Safety audits of the area to ensure compliance with company HSE policy
Responsible for ensuring the reliability of stationary equipment to maximize their utilization and minimizing the risk of unexpected failure by using the systematic asset integrity management program in a large urea fertilizer complex.
Major projects done:
- Integrity Assessment of 2000MT Single Walled Anhydrous Ammonia Storage Tank as per API653.
- DuPont PSRM element Mechanical Integrity and Quality Assurance (MIQA) implementation.
- Inspection and repair of auxiliary fired heater 101B in TA2014.
I worked there as an Internee for 2 weeks was assigned in the production department. My job was to the document the process flow in the form of report.
Skills Acquired:
- Heat treatment (Spray quenching followed by tempering)
- Machining
- Passivation
- Electroplating
I worked there as an Internee for 6 weeks and was assigned in the maintenance department. Sub - section was Local Fabrication Cell. I worked on three projects namely:
a) Feasibility report on increasing workforce and its effect on backlog
b) Justification of installation of CNC machines (Part of CNC machines feasibility in workshop)
c) Heat treatment process selection of throat bushes of a plunger pump installed at Urea - 1 to meet required mechanical properties
Skills Acquired:
- Technical report writing and presentation
- Positive Material Identification test
- Dynamic hardness test
- Welding procedures
Majors: 1 - Ferrous and Non-Ferrous Metallurgy 2 - Materials Evaluation Techniques (Destructive and Non-destructive testing) 3 - Manufacturing Processes 4 - Foundry Engineering 5 - Polymers, Ceramics, and Composites Engineering 6 - Corrosion Engineering 7 - CAD / CAM 8 - Powder Metallurgy 9 - Operations Management 10 - Total Quality Management Honors: Awarded best final year project in the Faculty of Materials Science and Engineering