Mechanical Integrity Inspector – Shell Qatar

Priority in the employment shall be given to the Qatari workers. Non-Qatari workers may be employed in case of need.
– Qatar Labour Law (Article 18)

Purpose & Accountabilities:

The essence of the pressure equipment inspection function is to be predictive with regard to equipment integrity. The inspector must analyze the data to understand the actual corrosion or degradation mechanisms. This analysis may include but is not limited to:

– Knowledge obtained by monitoring equipment for physical degradation.

– Recognizing operational upsets or changes which could lead to changes in corrosion rates or patterns.

– Comparing the data with pressure equipment records.

– Consultation with the technical staff to develop equipment inspection intervals, alterations of operations to reduce pressure equipment degradation rates, and when required, maintenance recommendations.

SCHEDULED INSPECTION

1. MI inspector is responsible to execute inspection task assigned to him/her. The person will have unit responsibility for the GTL trains Inspects and monitors the condition of pressure equipment (vessels, columns, piping, exchangers, relief valves, tanks, etc.) with the purpose of detecting corrosion or other physical phenomena that may lead to an unacceptable level of risk, an unsafe condition, failure of the equipment, or deterioration of its intended function.

2. Engages Inspection Lead and/or Pressure Equipment Integrity Engineer when inspection data reveals equipment near or past retirement, due to wall loss or other damage mechanisms.

3. Surfaces known preparatory work that must be performed before an inspection can be performed and highlights inspection support requirements.

4. Inspects all non-pressure retaining components that affect the integrity of the pressure equipment including, but not limited to, foundations, fireboxes, stacks, structural members, tank seals, spring hangers, etc.

5. Documents inspection findings (thickness readings, visual inspections, and specialized NDE inspections) in the wIMS.

6. Establishes renewal thickness for equipment using the guidelines outlined in company procedures and by consultation with the pressure equipment engineer where needed. Uses these renewal thicknesses to calculate the remaining lives of piping and equipment.

7. Keeps and maintains inspection schedules and strategies up to date in wIMS.

8. Develops and maintains equipment inspection drawings, including equipment diagrams, piping isometrics, corrosion and material diagrams, etc., in accordance with site procedures.

9. Analyzes inspection data against expected corrosion and damage mechanisms to determine the condition of the equipment.

10. Communicate inspection results with RBI Focal Point to update model, inspection strategy, and schedule.

11. Reviews equipment histories and develops technical basis for Inspection Interval Extension Requests.

12. Record leaks and pressure equipment failures in wIMS, and is responsible for comparing with the RBI model to determine if any revisions are required.

13. Issues recommendations and develops repair procedures for pressure equipment based upon inspection findings and the expected performance for the equipment.

14. Involves the pressure equipment engineer and supervisor in all repairs or alterations to pressure vessels.

15. Supports the Pressure Relief Device Servicing Work Process, including specification sheet review and updating.

16. Performs quality assurance on repairs and new fabrication of pressure equipment.

17. Participates in and supports unit specific activities such as MOC Technical Review and CCD revalidations.

18. Makes metallurgical, material, and protective coating recommendations based on tests, research, experience, and/or communication with specialists. Makes sure that all the proper personnel have been involved in making these recommendations.

UNIT SUPPORT

1. Maintains contact with operations and maintenance personnel daily to be aware of changes in operating conditions that could affect the performance of the pressure equipment.

2. In the area Production Team, communicates current efforts to solve problems, listens to the needs of customers, and discusses corrosion concerns or operating events that could have detrimental effects on equipment with the appropriate personnel.

3. Monitors the identified Ensure Safe Production (ESP) variables within the process units that may affect corrosion rates in piping and pressure equipment.

4. Makes recommendations based on deviations from ESP limits or unit surveillance findings.

TURNAROUND/UNIT OUTAGE SUPPORT

The MI Inspector is expected to drive the MI turnaround scope in the area of responsibilities and support the execution of the activities during turnaround. It is anticipated that the incumbent will spend 25% if his/her time in turnaround support activities. The MI inspector should:

1) Ensure all the Level 2 inspection scope is completed timely to support the turnaround activities.

2) Review T/A scope and raise addenda as when required.

Support work scope challenges and RBI revalidation.

OTHERS

1. Participates in investigations of all failures of pressure equipment items. Help determine the cause or suspected cause and document the results in the inspection records.

2. Participates in and supports unit specific activities such as Level 2 Investigations, 5-Why Investigations, and RCA’s.

3. Recommends engineering or technical studies to eliminate recognized design and/or maintenance problems.

Dimensions:

Support integration of Shared Stewardship of Assets for Mechanical Integrity across entire organization and help others in the organization understand their role in maintaining equipment integrity as related to corrosion control and proper design and maintenance of pressure equipment