Snr. Inspection Engineer
International Inspection Centre CO
Total years of experience :17 years, 4 Months
Project Worked ( Manpower Supply for various companies)
a) Joint Operation - Kuwait - Inservice, out of service, repair & mantenace inspections of static equipments.
b) Petrochemical Industries Company (PIC) - Turnaround (TA-2021) QC & Plant Inspection - Kuwait
c) KNPC- Third Party Inspection of Pipes, fittings and valves
d) Saudi Arabia Chevron(SAC)-Kuwait - Inservice Floating roof Tank inspection as per API-653
e) KOC Feed Pipeline for New Refinery Project(NRP) -Kuwait
f) KGOC (JO)-Kuwait - Gas and Condensate Export On shore Pipeline welding - TPI Inspection
Responsibilities:-
• Inservice and out of service inspections of 1st stage crude oil storage, firewater & chemical tanks, 3-phase separator vessels, gas scrubbers, gas boots, pump skids, Gas burned Oil Heaters etc.
• Witnessing stage wise maintenance, repair & replacement inspections of Tanks, pressure vessels & Piping in oil & gas fields.
• Co-ordinate & review UT thickness survey reports & assessing mechanical integrity based on API code suitability minimum thickness, corrosion rate & remaining life evaluations & providing preventive maintenance recommendations for piping (Main oil lines (MOL) Facilities, Dead legs, service piping, sour water piping), vessel and tanks.
• Tank bottom plate MFL and UT report review and assessing the integrity.
• Stage wise QC inspections for tank bottom, roof and shell plate and vessel nozzle, vessel internal repair & replacement inspections
• PIC- Polypropylene (PP) Plant TA-2021 Inspection- Visual, thickness survey of reactor, process & utility piping, heat exchangers, tube bundles, dead ends, PSV, normal & spring supports. Final inspection of new spring support installation and Torqueing of various flanges.
• Safety valves turnaround inspection - Witnessing of Overhauling, CDTP popup, seat tightness & back pressure test.
• KNPC-Third party inspection for pipes, fittings (normal and cement lined), valves - rubber lined, Safety valves and U tube bundles for heat exchangers
• Inservice inspections of Floating & fixed roof tank as per API-653- Thickness survey, dimensional, plumbness, settlement and visual inspections of dike, bottom plate, shells, roof, staircase, ladder etc.
• Design calculations and Evaluation of suitability for service and mechanical integrity of tank shell, bottom, roof for continues service and type & cause of deterioration
• Evaluation of corrosion rate and remaining life of tank components
• Tank foundation suitability for service. Assessment of settlement and concrete ring visual evaluation
• Visual inspections of shells (external and internal), wind girder, shell appurtenance (manway, nozzles, piping, auto gauge system, sample stations, mixer), deck plates, floating roof seal system, roof appurtenance and accessways.
• Evaluation and measuring of physical dimensions of tank as per API-653 -Diameter, level of floating roof and seal annular spacing at 30ft
• Review of cathodic protection inspection report &grounding systems.
• Witnessing and coordination of Valve hydrostatic test for pipeline and launcher/receiver stations
• Material Verification & Traceability, Fit-up & weld visual Inspection as per approved ITP for piping in valve stations
• All QC inspections related to pipeline mainline and Tie in welds
• Incoming material inspections includes pipes, fittings, valves etc.
• Witnessing and Approval of PWPS, PQR and WPS
• Welder Qualification Test (WQT) for piping, Pipeline. (As per ASME-IX, API-1104).
• Inservice and turn around thorough visual inspections of 3 pass smoke tube boilers
Responsibilities:-
• In service, turnaround and emergency shutdown inspection of Power plants, oil & water storage tanks, process piping’s, water distillation plants, and pressure vessels such as steam transformer, feed water tank, de aerating vessel and steam drums of MEW-Kuwait
• Preparations of periodic and emergency boiler inspection reports with repair/replacement recommendations
• Preventive tube failure analysis based on previous failure history and providing recommendations for periodic tube replacement.
• Performing stage wise & final inspections of boiler maintenance & repair-Such as boiler internal cleaning, tube replacement, refractory & insulation repairs. Witnessing & interpretation of various NDT as per ITP, project specification & construction codes ASME-31.3, 31.1, SEC-I, VIII, API-650, 1104etc.-Inspections Includes fabrications & assembly QC activities, pneumatic, hydro, vacuum box testing, safety valve testing etc
• External & Internal inspection of Fuel oil fixed & Floating roof tanks as per API-650, 653 & 575- Bottom plate & shell internal visual inspection and witnessing & review of Magnetic Flux Leakage (MFL), Acoustic emission testing and Ultra sonic thickness survey.
• Stage wise inspections of HFO tank fixed roof plate replacement.
• Plan and carry out pre-surveys (in-service inspection) of piping, tank and equipment and where necessary identify preparation for inspection and Non-Destructive Examination (NDE) requirements.
• Make recommendations as required in inspection worksheet and follow-up with inspection worksheets for items requiring repair.
• All QA/QC in line and final inspections of new plant construction, piping’s, storage tanks & its accessories, pipelines and shop fabrication inspections.
• Review, Assessment & Approval of Fabrication& erection procedures, method statements, ITP, welding procedure specification (WPS), Procedure qualification record (PQR), NDT & Heat Treatment procedures.
• Witnessing & Approval of procedure qualification tests (PQR) & welder qualification test (WQT).
• Surveillance of welding & Heat treatment activities and review of PWHT thermal charts.
• Incoming material inspections / review of material certificates and documents as per quality plan, purchase order and specifications. Materials include -tubes, pipes, plates, valve, fittings etc.
• Inspection, calibration & approval of equipment’s& material for welding, NDT & heat treatment.
• Inspection and approval of hot taping of 42” Fuel Gas pipeline And Cold taping of 20” Gas oil pining.
• Inspection and surveillance of Blasting and coating for piping’s and tanks.
Project Worked
a. Barh Thermal Power Project - 8X660 MW Barh, Bihar-India ( Super critical boiler)
b. Sri Damodaram Sanjeevaiah Thermal power project, 8X800 MW, AP-India( Super critical boiler)
c. Prayagraj Thermal Power Project - 6X660 MW Bara, UP-India. ( Super critical boiler)
d. Yermaras Thermal Power Project - 8X800 MW, Raichur, Karnataka-India (Super critical boiler)
e. Mouda Thermal Power Project-8X660MW, MH-India (Super critical boiler)
Responsibilities:-
• Fit up and weld visual inspection of pressure piping’s, headers and tube joints of Sub & super critical power plants.
• Surveillance of shop welding processes like SMAW, GTAW, FCAW, SAW and ORBITAL, STBW welding in conformance with approved WPS.
• Preparation of WPS and PQR as per ASME and the job requirement.
• Preparation of Weld plan, Weld map and RCA for fabricated components.
• Impart Training and Qualification of Welders/Welding operators as per ASME and IBR.
• Regular training of welder’s regarding weld quality& weld defects if observed in radiography.
• Control weld repair by analyzing the root cause of defect and implementing corrective action to prevent reoccurrence. (8D analysis)
• Coordinating and interpretation of various NDT (DPT, MPT, UT and RT) of field and fabrication of joints as per ITP.
• Monitoring of welding process of materials like Grade 91, Grade 92, Grade 23 and SS Super 304H.
• Inspection and monitoring of pre-heating, PWHT activities and review of PWHT thermal chart.
• Internal auditing of QA&QC departments.
Project Worked
a. Cairn Energy India Pty Ltd (CEIL) - Rajasthan Northern Area Development Project (RNAD)- India largest on shore Crude oil processing terminal ( Oil and Gas field)
b. Barmer to Salaya Pipe Line ( BSPL).
c. Salaya to Bhagat Pipe Line ( SBPL).
Responsibilities:-
• Material Verification & Traceability, Fit-up & weld visual Inspection as per approved ITP for process piping, storage tanks & pipe line. Materials include CS, SS, LTCS, Low alloy steels etc.
• Ensuring the welding is carried out as per the approved WPS.
• Capable of preparing & producing Welding Procedure Specification (WPS) & Procedure Qualification Record (PQR), Inspection Test Plan (ITP) for Fabrication & Erection for process &power piping, pipeline &tanks.
• Welder Qualification Test (WQT) for piping, Tanks, Pipeline and structural. (As per ASME-IX, API-1104).
• Coordinating & interpretations of Non-Destructive Testing (NDT), which include RT, MPI, UT & DPT as per project specifications and codes such as ASME31.3, API-650, 1104 etc.
• Ensuring of required NDT coverage for different piping’s classes.
• Review of PWHT charts and ensuring hardness of alloy steel weld joints.
• Inspections and surveillance of 24” and 8” Pipe line activities includes stringing, mainline, tie -in welding, bending of pipes, trenching and backfilling.
• Inspection of Blasting and coating for AG, UG piping’s, tanks, casing pipes, field coating of 24” &8” pipeline weld joints.
• Issue of Non-conformance reports and action for timely closing.
• Preparation of Line history sheets and Pre hydro test punching - includes preparation of A & B item punch list and document review.
• Reinstatement - Visual inspection of tested lines, verification of B items punch list, make the line ready for final painting & pre commissioning.
• Co-ordinates with TPI for Final inspection.
• Preparation and maintaining of inspection reports, inspection checklist, welder performance and QC documents.
• Witnessing of pneumatic, hydro and vacuunm box testing .
Cochin Port Trust -
Responsibilities:-
• Co ordinations of Destructive / Non-Destructive
Testing.
• Preparation of WPS, Welding Procedure Qualification
Test (WPQT) and Welder Qualification Test (WQT).
• Weld Visual Inspections for Power plant parts.
• Material Verification & Traceability, Fit-up & Weld
visual Inspection as per approved ITP.
• Ensuring the welding is carried out as per the approved
WPS.
• Inspection of pre assembly of structures at
prefabrication shop.
• Radiographic film interpretation.
MECHANICAL ENGINEER- 4 YEAR FULL TIME B-TECH COURSE
POST GRADUATE CERTIFICATION IN WELDING ENGINEERING FROM IIT MADRAS AND WELDING RESEARCH INSTITUTE