Plant Inspector

The Plant Inspector is accountable for the execution of integrity related work programs and coordination of contractor work teams to ensure the availability and reliability of plant and infrastructure.

Job Summary

Reporting to the Asset Integrity Superintendent, the Plant Inspector is accountable for the execution of integrity related work programs and coordination of contractor work teams to ensure the availability and reliability of plant and infrastructure. The incumbent shall demonstrate competence in inspection techniques as well as job planning and scheduling for activities under the role. 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 Plant Inspector supports the efforts for ensuring that the facility is inspected in a timely, safe and efficient manner and is required to conduct the facility inspection routines as per schedule or inspection plan and support the register of the inspection history. In addition, the position provides guidance on all types of activities including welding, blasting, coating and other general Fabric Maintenance related activities. The incumbent ensures that anomalies are entered into the Asset Management System in a timely manner consistent with approved processes. The Plant Inspector also has direct access to technical direction and support at the level of the Senior Plant Inspector, Inspection Engineer and 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 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

The Plant Inspector is responsible for ensuring the inspection of all static equipment as per schedule as the position plays a key role in the execution of PPGPL’s Asset Integrity Management Program. The Plant Inspector also oversees key Asset Improvement initiatives and as such is expected to perform research and leverage updated technology and techniques whilst providing Inspection oversight, under the technical guidance of the Asset Integrity Superintendent, Inspection Engineer and Senior Plant Inspector for major maintenance and inspection projects within the Organization. A key performance metric of the function is to deliver best in class reliability and plant availability as a differentiating strategy. The Asset Integrity Team functions as an enabler to achieve the Maintenance Department’s Strategic Plan (Operations Excellence initiatives) which are aligned to PPGPL’s Strategic Management Plan.

The position must demonstrate strong process safety leadership, sound interpersonal, advanced technical skills and significant experience and capability in coordinating inspection activities of both in-house personnel and Third-Party contractor staff. This shall be achieved by using the latest Non-Destructive tools and techniques. The incumbent must possess the ability to develop cost justifications for inspection projects, implement obsolescence management plans, co-ordinate inspection activities during turnarounds, actively participate in risk assessments, PHA studies and compliance audits.

The position aids with developing the philosophy to be used for Inspection scheduling, planning, and monitoring activities. The incumbent also participates in the implementation of Inspection activities for all plant static assets (e.g., Process piping, Heaters, Heat Exchangers, Tanks, Pressure Vessels, PSV’s, etc.). The position also coordinates the work execution of contractors (both in-house and contracted) whilst also interfacing with all other teams within the PPGPL and PPEM organizations. This role also has responsibility of building relationships with external service providers and OEM’s. The scope of 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  and ensuring that all anomalies are entered into the Asset Management System.

Duties & Responsibilities:

1. Co-ordinate the field execution of the annual inspection and statutory inspection of all air capacity tanks, davits, cranes and hoists.
2.  Execute the field inspections of all PSVs as per schedule. 
3. Execute the condition monitoring of all plant piping, tanks and pressure vessels using a risk-based approach. 
4. Conduct NDE inspections of all static equipment and produce inspection reports outlining any anomalies and provide recommendations to address the findings. 
5. Ensure work orders are created or updated to address all findings.
6. Provide oversight for all welding related activities on the facility inclusive of review of the material selection, PQR, WPQ, WPS, project tender documents, etc. This will be done with guidance from the Asset Integrity Superintendent. 
7. Create SOWs and conduct QA/QC audits on all inspection, welding and painting activities.
8. Create procedures and Job Safety Risk Assessment (JSRAs) for all inspection and repair related activities.
9. Conduct Site visits for all inspection and repair scope of works. 
10. Create Material Take Off (MTO) as part of the inspection recommendations.
11. Conduct material receipt inspection of incoming materials to ensure that material and other specifications are correct.
12. Assist with all above ground and underground pipeline related inspections and repairs. 
13. Develops technical specifications, scope of works, bid packages, analyses bids, and prepares recommendations of award for major inspection contracts.
14. Spearhead the closure of Maintenance Backlog items from the Oracle CMMS System.
15. Provides inputs for facility Turnaround (Shutdown) Planning & Execution which includes inspections, repairs, alterations, commissioning and start-up for plant and equipment under his/her purview. Develops turnaround/outage inspection plans inclusive of inspection and repair Scope of Works and completes contractor performance evaluations.
16. Monitors the application of established engineering policies, procedures, and practices to ensure compliance with regulatory, industry, and/or operational standards. Also reviews specifications, procedures, drawings, etc.
17. Leads and or participates in Committees and cross-functional teams in accordance with roles and duties identified as per workplan and or team charters. 
18. 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 UTT or NEC National Technician's Diploma in Mechanical Engineering.
• The following certifications are also required for the role:
  • AWS Certified Welding Inspector
  • NACE Coating Inspector Level I, or 2
  • API 510 and API 570

• The following certifications will be considered an asset:
  • API 653
  • API 580/581

Minimum Number of Years of Relevant Experience

Five (5) years’ demonstrated experience within an Inspection & Reliability Function in the energy / natural gas sector.

Specific Skills and Knowledge Requirements:

• Knowledge of process plant equipment and inspection practices
• Knowledge of contract management
• Demonstrated trouble shooting and problem-solving skills.
• Working knowledge of root cause failure analysis techniques
• 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 pass UKOOA Medical and meet other applicable medical requirements for vessel entry (Blood pressure within normal limits, non-claustrophobic, Drug and Alcohol Screen, Audiometry and Spirometry), etc.
• Near-vision performance should be the equivalent of 20/20 with no impairment of color vision.
• Must be able to work weekends, nights and/or public holidays as required to meet the Maintenance Department deliverables.
• 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.

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”