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Job title
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Snr Engineer Material & Corrosion – Asset Integrity
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Grade
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Stream
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Commercial & Downstream – RPI
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Function
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TSD - Asset Integrity - Material & Corrosion
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Location
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Oman – Suhar
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Budget control
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*OPEX and/or CAPEX and/or Revenue amount as relevant*
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Reporting to
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TL Material & Corrosion - Asset Integrity
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Direct reports
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-
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Job purpose
Provide robust & detailed Engineering Material and Corrosion Inspection & recommendations at RPI assets, under TL Material & Corrosion scope, acting as team player for the monitoring & control to minimize equipment failures; through (1) Carryout detailed Material & Corrosion Inspection, analysis support to support to various teams, including operations, maintenance, and inspection, to ensure that they are equipped with the knowledge and skills needed to prevent and manage corrosion-related issues, (2) Developing and implementing corrosion prevention strategies to prevent corrosion in the equipment and infrastructure, (3) Developing and implementing a corrosion monitoring program to identify potential corrosion problems and taking appropriate measures to prevent them, (4) Conducting failure analysis & recommends maximizing interval between intrusive inspections on turnaround (TA) equipment, (5) Developing and maintaining corrosion control documents and provide timely Material & Corrosion inspection reports and ensuring the highest standards are applied at all times as per procedures, specifications, applicable code & standard, and (6) Guide young engineers in related matters; in order to ensure that equipment and infrastructure remain safe, reliable, and efficient through the prevention and management of materials and corrosion-related issues,
The position will act in accordance with the Group’s Mission, Vision, Values & Strategies, as well as, policies, guidelines, and standards, supported by an IT Technology platform, HSE standards, Omani’s government & other legal justifications, and best international practices in consonance with national objectives.
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Main tasks and responsibilities
Scope:
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All RPI Assets: Suhar Refinery, Aromatics & Polymer, Olefin Cracker, NGLE, MAF, Utilities.
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Material & Corrosion
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- Multidisciplinary approach involving materials science, chemical engineering, and corrosion engineering to ensure the safe and efficient operation of the equipment while maximizing the life of the equipment and minimizing downtime and maintenance costs.
- Applicable to RPI equipment / assets materials such as carbon steel, stainless steel, nickel alloys, and various types of polymers based on their resistance to corrosion and their ability to withstand high temperatures and pressures.
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Material Management
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- Evaluation of the compatibility of materials with the process fluids, temperatures, pressures, and other factors
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Corrosion Management
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- Identify the gradual deterioration of a material in various equipment and piping systems due to the harsh operating conditions and exposure to corrosive chemicals or electrochemical reaction with its environment.
- Monitoring techniques to evaluate the integrity of the equipment, including:
- Corrosion inhibitors,
- Protective coatings,
- Cathodic protection systems,
- Corrosion prevention and mitigation to reduce the rate of corrosion and extend the life of the equipment.
- Failure analysis to investigate the root cause and recommend appropriate corrective actions to prevent similar failures from occurring in the future.
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Accountabilities:
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Materials selection
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- Selecting the right materials for various applications at RPI to ensure long-term durability, resistance to corrosion and damage caused by high temperatures, pressures, and other process conditions. Consider also in the analysis factors like cost and availability of the materials.
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Corrosion Monitoring
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- Executes daily monitoring of identified critical process parameters/ Integrity Operating Windows (IOWs) are sets of limits used to determine the different variables that could affect the integrity and reliability of a process unit and co-ordinates with Process/ Ops team for action on any abnormalities or upsets and communicates findings.
- Executes of online corrosion monitoring and control program for critical process equipment, piping, and circuits.
- Conducting failure analysis to determine the root cause of the problem and develop appropriate corrective actions.
- Executes corrosion rate and identifies possible causes and remedies to bring the corrosion rate under control. Communicates findings and observations with other divisions.
- Executes proper preventive actions in agreement with Plant inspection team for any corrosion related failures, which includes but not limited to combined site visit, collecting sludge samples/failed samples, and providing corrosion input to the inspection report.
- Collect and analyse all documents related to corrosion loops area prepared, filed and maintained, including:
- PFD (foundation control documents for the process design),
- P&ID (foundation control documents for engineering design used for laying out the process control installations),
- Isometrics (during the erection and installation process and prior to stress analysis studies),
- Measures the thickness review Level (using actual pipe samples removed from a pipeline and calculating metal loss over time)
- Integrity Operating Windows to determine the different variables that could affect the integrity and reliability
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Corrosion Control
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- Executes and follow up appropriate material selection recommendations for the running plant.
- Executes and follow up with Process Department in evaluating the effectiveness of Corrosion Inhibitor programs by setting and evaluating KPI’s and provide feedback/recommendations.
- Work on site with Cathodic Protection Team to monitor cathodic protection systems in the plant to ensure proper corrosion protection and function
- Executes recommendations of suitable painting and coating systems for external, immersed, and high temperature applications etc.
- Executes failure investigation and Root Cause Analysis as required for assigned area/units.
- Participate in Risk Based Inspection process by identifying corrosion loops and degradation mechanisms and provide the Material & Corrosion input to the RBI analyst as and when required.
- Collect and review documents of new projects / modifications related to material selection, corrosion control & plant inspection monitoring, etc.
- Developing and maintaining corrosion control documents including corrosion control manuals, procedures, and standards, to ensure that RPI’ corrosion prevention and management activities are consistent and effective.
- Conduct research and development to develop new materials or corrosion prevention techniques that can improve the efficiency, safety, and reliability for RPI assets
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Key interactions
Internal: All TSD Team Leaders and Engineers, Operations, Maintenance, Procurement and HSE
External: Contractors, 3rd Parties, Consultants, Vendors and Suppliers
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Notable Working Conditions. Field Operations and office environment, Moderate to intensive computer screen use.
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Education requirements
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Minimum Qualifications for this position is bachelor’s degree in engineering or similar.
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Language requirements
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Excellent knowledge of written, read, and spoken English (required) | Arabic - Native (desirable)
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Background and experience
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Competencies and skills
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Bachelor
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Snr Engineer
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8+ years of relevant experience
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- Working knowledge of design, manufacture, metallurgy, applicable code and standard associated with inspection of plant/equipment and familiar with QA/QC systems and procedures.
- Experience and well versed in field investigation, inspections, troubleshooting, performance checks, data compilation, etc.
- Inspection experience specifically in the areas of Pipe Fitting, Welding, Welder Qualification, Welding Procedures, Non-Destructive Testing and Hydraulic Testing in the field of Static and Piping works.
Knowledge of :
- Knowledge and experience in NDT (Non-Destructive Testing) and specialized equipment inspection techniques.
- Knowledge of inspection, corrosion engineering, welding, and materials.
- Understanding of Process Plant (P&ID / PFD) and Engineering drawings and OEM (original equipment manufacturer) manuals
- Good knowledge of relevant of the following standards / codes:
- API (American Petroleum Engineering) standards
- ASTM (American Society for Testing and Materials)
- NACE (National Association of Corrosion Engineers)
- ASME (American Society of Mechanical Engineers)
- TEMA (Tubular Exchangers Manufacturers Association) :
- Class R: for the severe requirements of petroleum processing (and usually including most large-scale processing applications).
- Class C: for general commercial application.
- Class B : for chemical process service
- Risk Assessments, HAZOPS and Safety
- Good knowledge in QA/QC, ISO 9001, ISO 1400 and HSE plans.
Certifications:
- API 510: Pressure Vessel Inspection. National Board for Boiler Inspection.
- API 653: Above Ground Storage Tank Inspection.
- API 570: Pressure Piping Inspection.
- American Society for Nondestructive Testing ASNT / NDT Level II
- API 571: Damage mechanism affecting the refining industries.
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Soft:
- Communication skill (verbal and written)
- Personal and Team Accountability
- Effective planning and organizing skills
- Problem Solving Skills
- Result orientation
- Planning and Organizing
- Decisiveness
- Exercising influence
- Attention to Details
- Teamwork
- Quality focus.
Technical:
- Computer literacy including MS Office
- Co Good knowledge and skills in Computerized Maintenance Management Systems (CMMS), MS project, Meridium.
- Good knowledge of SAP
- Proficient at interpreting Technical Drawings
- Equipment Inspection Failure Diagnosis/Analysis
- Acute Observation / Inspection skills
- Accurate Reporting skills
- Proficient at interpreting Technical Drawings
- Quality Control Procedures/Methodologies & Inspection Test Plan (ITP)
- Management of Material Resources
- Applicable Code & Standards and Government Regulation
- Non-Destructive Testing and Welding Inspection Technique and Procedure.
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