Inspection Engineer

The Inspection Engineer is accountable for oversight of the risk profile of facility assets through the organization of integrity related work programs and implementation of applicable codes, standards and best practices.

Job Summary

Reporting to the Asset Integrity Superintendent, the Inspection Engineer is accountable for oversight of the risk profile of facility assets through the organization of integrity related work   programs and implementation of applicable codes, standards and best practices. The incumbent shall demonstrate competence in equipment risk assessments, root cause failure analyses, maintenance, construction and inspection techniques as well as in estimating, planning and scheduling.  All activities are expected to be conducted safely, cost-effectively, and reliably and must be delivered in a manner that consistently adds value to PPGPL's overall business process. The position is also required to provide related support to the group of companies, its subsidiaries and new business ventures as required.

Dimensions

The Inspection Engineer is responsible for ensuring that RBI inspection plans are developed and improved when required and the results used to provide more effective inspection strategies. The incumbent shall also ensure that data is available at any time to the Maintenance Manager so that he has an oversight of the overall risk of the plant facility. The position is integral in increasing Asset Integrity awareness, knowledge and capability in the department. In addition, the position provides technical guidance on various maintenance activities including welding, blasting, coating and other general Fabric Maintenance related activities. The incumbent ensures that strategic goals and objectives are formulated in conjunction with the Asset Integrity Superintendent. The Inspection Engineer also has direct access to technical direction and support at the level of the Asset Integrity Superintendent.  The discharge of responsibilities is bounded by budgeted work plans, established maintenance procedures, schedules, adopted standards and best practices, corporate procedures, company policies, corporate core values and performance standards. The position is also bound by clear performance expectations and has no financial authority.

Individual’s Safety Responsibility

It is the responsibility of each employee to protect oneself as well as fellow workers from injury. Work shall be conducted according to established safe practices and procedures. Please refer to PPGPL’s Safety Manual. Understanding of major functions within the plant and the ability to work directly with all levels and functions.

Nature & Scope

Key metrics of the function are to deliver best in class reliability, availability and uptime as a differentiating strategy. The maintenance function is essentially an enabler to achieve the Operations Department’s Strategic Management Plan (Operations Excellence initiatives) and by extension the Organization’s Strategic Management Plan. The position shall demonstrate strong process safety leadership, sound interpersonal, advanced technical skills and, significant experience and capability in planning and coordinating the activities of the inspection personnel within the Asset Integrity Team.

The position plays a key role in the formulation of PPGPL’s various Asset Integrity programs e.g., Static Equipment, Asset Management Systems, Audits, etc. The Inspection Engineer also oversees key Asset Improvement initiatives and as such is expected to provide Inspection oversight, under the technical guidance of the Asset Integrity Superintendent for major maintenance and other projects within the Organization.

The incumbent must possess the ability to develop Maintenance Operating and Capital (Capex) Expenditure budgets, cost justifications for inspection projects; internal inspection audit systems; obsolescence management; co-ordinate inspection activities during turnarounds; actively participate in risk assessments; PHA activities and audits. The position reviews and provides inputs into developing the philosophy to be used in the development of Inspection schedules and plans, and also monitors and participates as required in the execution of Inspection, vibration and lubrication activities for all plant assets (e.g., Process piping, Heaters, Heat Exchangers, Tanks, Pressure Vessels, PSV’s, etc.).The position interfaces internally with all Maintenance Groups Processing, Technical Services, Operations Improvement, Engineering, Supply Chain Management, Finance, Technology & Risk, Business and Market Development, Health, Safety, Security and Sustainability and externally with contractors, manufacturers, suppliers, Engineering & Maintenance consultants, EPC contractors and local/foreign industry personnel and equipment OEMs. 

The position encompasses  but  is  not  limited  to:  promotion  of a  safety culture  in  all inspection  related  activities;  management  and  co-ordination  of  all statutory  and static  inspection; management of all inspection  registers; QA/QC of all inspection, welding  and painting activities; use of accepted Safety programs and initiatives that are instilled in the Company’s policies, procedures and, as an extension, the safety culture and ensuring that all anomalies are entered into the Asset Management System.

Duties & Responsibilities:

1. Develops mechanisms to quantify the overall risk profile of the facility assets.
2. Development of strategies, policies and procedures to support the Company’s Asset Management System in alignment with applicable codes and best practices.
3. Review and formulate inspection plans and frequencies and update equipment and facility risks using the TWI RiskWISE software as required based on data collected.
4. Reviews Decision Support Packages for projects managed by other teams e.g., Engineering for works directly related to static equipment packages.
5. Co-ordinate the condition monitoring programs of all plant piping, tanks and pressure vessels using the API RBI 580 approach and the TWI RiskWISE Software. This includes reviewing the inspection work plans and modifying them to achieve desired risk profiles.
6. Participates in Root Cause Failure Analyses for the Maintenance Department. Implements recommendations where applicable.
7. Responsible for performing Level 1 & 2 Fitness for Service (FFS) calculations and reviewing Level 3 reports and calculations from their-party vendors.
8. Assisting with the close out of all actions coming out from incident investigations, PHA studies, insurance reports, etc.
9. Review all subcontractor procedures related to inspection, coating and repairs to be executed on the facility and gives the final approval.
10. Work alongside the Operations Improvement Team, specifically 4i Apps to progress the development of the Inspection App.
11. Calculating equipment and facility risks utilizing the TWI RiskWISE software.
12. Participates in bid evaluations, prepares IOC recommendations of award for inspection contracts through involvement with bid evaluation teams.
13. Participate as an evaluator (subject to the review of the Asset Integrity Superintendent) in the granting of Management of Change (MOC) requests for plant modifications.
14. Consults with subject matter experts to provide input for the development and implementation of programs with regard to equipment long term planning such as end of life, repair or replace and decommissioning decisions for plant equipment and assets.
15. Support and provide suitable guidance to the Plant Inspectors as it pertains to engineering policies, procedures, and practices to ensure compliance with regulatory, industry, and/or operational standards. Also reviews specifications, procedures, drawings, etc.
16. Leads and or participates in Committees and cross-functional teams in accordance with roles and duties identified as per workplan and or team charters. 
17. Provides support to PPGPL’s subsidiary business units on an as-needed basis as part of the shared services model between PPGPL and its subsidiary entities.

Job Specifications

Minimum Acceptable Academic Qualifications

A Bachelor’s Degree in Mechanical Engineering from an accredited tertiary institution.

The following will be considered an asset.

• Registered Engineer status (REng) with the Board of Engineering
• Chartered Engineer (CEng) status with the Institution of Mechanical Engineers (IMechE)
• Certification in either API 510, API 653, API 571 or API 580/581

Minimum Number of Years of Relevant Experience

Eight (8) years demonstrated experience in Inspection Services within the Maintenance/ Asset Integrity Function in the Energy Sector.

Specific Skills and Knowledge Requirements:

• Knowledge of process plant equipment and inspection practices
• Knowledge of contract management
• Demonstrated project management, trouble shooting and problem-solving skills.
• Working knowledge of root cause failure analysis techniques
• Working knowledge of Failure mode and effect analysis
• Working knowledge of industry pressure vessel and piping codes
• Knowledge of PSM requirements
• Familiar with the use of P&ID's and process flow diagrams
• Familiar with PHA and PSSR reviews
• Must be able to work at height, in confined spaces and over water.
• Must be physically able to ascend a 200ft tower and enter vessel through an 18" manway.
• Must be able to work weekends, or nights as required during periods of high maintenance activity.
• Must be able to don and use SCBA/SABA in a confined space.
• Must be able to work in a multi-disciplinary team of craft, technical and professional staff.
• Excellent communication and report writing skills are mandatory.
• Working knowledge of CMMS, Risk software.

Disclaimer

“The above statements are intended to describe the general nature and level of work being performed by people assigned to this job. They are not intended to be an exhaustive list of all responsibilities, duties and skills required of personnel so classified”