Risk Based Inspection Consultant
Maxgrip
Total years of experience :14 years, 6 Months
• Consulted Risk Based Inspection (RBI) methodologies to ensure optimization of inspection strategies and efficient asset risk mitigation, through engineering solution which incorporates integrity engineering framework and software development, resulted in the improved safety, equipment integrity and operational reliability while leveraging overall assets management system.
Project List & Accomplishment
i. Risk Based Inspection Revalidation for Pearl GTL. Client - Qatar SHELL GTL, Ras Laffan, Qatar.
• Organized revalidation works of Risk Based Inspection initiatives as per SHELL RBI (S-RBI) methodologies and web Integrity Management System (w-IMS) on 65 downstream processing units in Qatar SHELL Pearl GTL; the world’s largest gas-to-liquid production plant and one of the most challenging sites within SHELL company-wide entities in term of development of pressure equipment integrity strategy.
• Indirect value creation to date; avoided USD 8.4M per day production loss and injuries up to 1 fatality due to explosion and toxic gas release (in case of leak) and unplanned shutdown in Feed Gas Processing, Gas to Liquid and Liquid Processing Area.
• Developed new initiatives on existing inspection and corrosion management programs, standard guidelines and procedures (PETRONAS Technical Standard and Best Practice), for deployment in PETRONAS operating unit as mean of continuous improvement on sustaining asset integrity conformance and safe operation as per PETRONAS requirement.
• Delivered on time, on budget and on scope’s specialized engineering solution, within materials, corrosion and inspection engineering context, that specifically resolve assets integrity, reliability and failure due to deterioration caused by damage mechanism, which brings to direct/indirect value creation, in terms of cost avoidance, in various PETRONAS operating facilities (e.g. offshore platforms, refinery and petrochemical plant). Value creation for FY 2016/2017 is USD 28M.
Accomplishment
• Expedited materials selection programs for PETRONAS new development project through development of corrosion philosophy, material specification and compatibility review, chemical control requirement, surface preparation, fabrication and heat treatment guidelines, leading to selection of the most economical materials of construction that meets design criteria.
• Developed Integrity Operation Window (IOW), by validation of corrosion groups, and establishment of process limits and condition monitoring parameters supplemented with mitigation response for each key process variables, leading to creation of process safety management elements that focus on rigorous inspection plan to address specific damage mechanism associated with pressure equipment.
• Reduced the Loss of containment of pressurized equipment in oil & gas and petrochemical processing facilities by developing Risk Based Inspection (RBI) program as part of Plant Integrity Management that successfully enhance safety and reliability of operating facilities and increased direct/indirect value creation.
• Executed various optimization of plant inspection programs through implementation of consistent RBI methodology for assessing the best combination of inspection methods and frequencies based on equipment risk category, resulted in effective utilization of inspection resources (man-hour and cost).
• Incorporated Written Scheme of Examination, as an initiative to Plant Integrity Management, resulted in the creation of comprehensive periodic inspection scheme intended for avoidance of failure of in-service pressure systems.
• Endorsed new corrosion monitoring strategies through NDE / NDT and indirect monitoring technique to address the issue triggered due to decommissioning of ineffective corrosion monitoring equipment, saving the company expenditure over MYR 1M in terms of direct inspection cost.
• Assessed the condition of oil and gas production facilities in BARAM Field, within materials, corrosion and inspection context, as part of the JV partnership between PETRONAS and Shell Global Solutions for Enhanced Oil Recovery (EOR) technologies, resulted in development of numerous remediation action to extend service life of production facilities until 2043.
• Sustained the implementation of inspection management programs (e.g. Risk Based Inspection, Reliability Maintenance) in Clients’ refinery and petrochemical facilities through visual inspection and deployment of conventional and advanced nondestructive examination (NDE / NDT) techniques, during both in-service and turnaround / shutdown windows, as to ensure compliance with the relevant inspection and construction codes / standards.
Project List & Accomplishment
i. CA/EDC Plant Turnaround. Client ― SADAF (Saudi Petrochemical Company), Al-Jubail, Saudi Arabia.
ii. Static Equipment & Piping Reliability Project, and PDH Plant Turnaround. Client ― SAHARA Petrochemical Company, Al-Jubail, Saudi Arabia.
iii. Piping Inspection Program for Direct Reduction Plant. Client ― HADEED (Saudi Iron and Steel Company), Al-Jubail, Saudi Arabia.
iv. LDPE Plant Turnaround. Client - SIPCHEM (Saudi International Petrochemical Company), Al-Jubail, Saudi Arabia.
v. Piping Reliability Project. Client - SHARQ (Saudi Eastern Petroleum Company), Al-Jubail, Saudi Arabia.
• Executed non-intrusive, periodic and turnaround inspection of fixed / static equipment, through visual inspection and suitable NDE / NDT techniques, for getting a good judgment on equipment physical condition, the type, rate and causes of probable deterioration, resulted in higher inspection confidence, prolonged plant operation without unscheduled shutdown, estimation on future repair and replacement, development of well-planned maintenance program and improvement on operational reliability.
• Coordinated standard mechanical testing procedure such as tensile test, bend test, hardness test, and impact test, on bulk material specimen, welding qualification specimen, failure analysis specimen, to ensure quality and integrity of components are in accordance with the requirement stated in the relevant codes and standards.
• Identified chemical composition, ferrite count, and metallography structure of pressure equipment’s’ material of construction, through field Positive Material Identification technique, Ferritescope test and in-situ metallography replication technique, resulting in conformance of materials specification as per materials standard (e.g. ASME II, ASTM).
* Majoring: Material Science, Corrosion and Degradation Study, Selection of Materials, Physical