AJAY KUMAR

Corrosion / Cathodic Protection Engineer

Engineering / Architecture

Bhurbhur, Maharashtra

About AJAY KUMAR:

Strong technical knowledge of corrosion, corrosion mechanisms, environmental assisted cracking and materials in the upstream Oil and Gas industry
Detailed knowledge of relevant NACE/API/ASME/ISO codes and standards
Strong understanding of materials, failure mechanisms, and corrosion issues as they pertain to the oil & gas industry
Capable of selecting and designing of corrosion management, corrosion mitigation and monitoring programs
Work with Worldwide Engineering Group to share best practice and implement company standards throughout the business unit
Able to communicate well across teams and functional groups at all levels
Strong decision making skills
AC and DC interference study, CP auditing and analysis of CIPS / DCVG / PCM survey result.
Costing & tenderin
Corrosion Risk Assessment Study and Corrosion Monitoring
Impart CP training to construction team of Engineers and technicians.
Making tender specification, estimation & Costing and technical evaluation.
Monitor, investigate and study corrosion status of plant equipment, structures, pipeline, piping etc.

Experience

M/S. Sterna India Oil & Gas Private Limited January 2019 to Dec 2021

Worked with STERNA INDIA OIL & GAS Pvt Ltd (TAHAL GROUP) as a Corrosion & Cathodic Protection from 07th Jan 2019 at 30”Bokaro Angul Pipeline Project at Jharkhand, Currently posted in HO for look after as manager estimation and technical proposal projects in India & overseas.

Responsibilities:

Co-ordination & interaction with client and construction team, over all planning & execution and resolution of general issues like ROU / ROW, Welding inspection, Joint coating and Lowering and Backfilling, Hydro testing, villagers problems, material billing, material management and overall reconciliation of entire project. I also handled the issues of HDD crossings (like national highway, railway crossing, river crossing & open cut of road and canal), Cathodic Protection (TCP & PCP), Corrosion Monitoring System, OFC Duct laying and OFC Blowing including testing. Final acceptance and handover project to client.
Effectively communicate with other engineering firms and client companies to obtain proper information to complete detailed design packages and coordinate installation activities
Apply knowledge of engineering principles and corrosion theory to execute projects or complete various aspects of projects
Prepare cathodic protection designs including calculations, material and installation specifications and bid preparations, Conduct commissioning surveys, Prepare final client report including service recommendations
Conduct interference testing and coordinate electrical continuity with client and affected companies
Report findings, recommendations and cost estimates for additional engineering services
Assist in training entry-level technical staff

Punj Lloyd Sdn Bhd, Malaysia Jun 2016 to March 2018

Position: Manager - Corrosion & Cathodic Protection

Location: Johor Bahur, Malaysia

Client: PETRONAS RAPID PROJECT REFINERY TANK FARM, Detail Engineering Projects for Pipeline / Piping, Tank / vessel (internal & External).

Project: PETRONAS RAPID PROJECT REFINERY TANK FARM

Responsibilities:

Engineering &Consultancy - Specification, Pre design site survey, AC Mitigation and Design for the ICCP system for buried carbon steel pipeline / Piping, Tank / vessel (internal & External). Review Cathodic Protection vendor’s documents
Review & approval of the Corrosion Design documents, drawings and provide comments
Support the Mechanical Integrity, Facilities & Construction and Chemical Teams in the design and specification of materials selection, corrosion assessment, mitigation, chemical injection and corrosion monitoring systems for new construction and/or existing infrastructure where required
Support the Mechanical Integrity and Facilities & Construction groups in the design and specification of new CP systems for new construction and/or existing infrastructure where required
Design, inspect and oversee the drilling of and installation of new ground beds as well as field installation of new CP systems
Review and recommend immediate/temporary/permanent repairs for identified anomalies or deficiencies including upgrade/replacement or corrosion mitigation requirements
Assist with identification and need for inspection and monitoring requirements of field systems and equipment including complete systems review for damage mechanism identification
Manage the Risk Based Inspection (RBI) analysis and revalidation program

Dodsal Engineering & Construction Pte Ltd Nov 2014 to Feb 2016

Position: Corrosion Engineer

Location: Dubai, UAE

Major Projects:
Client: Abu Dhabi Company for Onshore Oil Operations (ADCO), Detail Engineering Projects for well casings, Pipeline/Piping (400Km), Tank / vessel Internal (internal & External).

Project: EPC for Rumaitha / Shanayel Facilities – Phase III

Client: Saudi Aramco, Detail Engineering Projects

Project: MASTER GAS EXPANSION – PHASE I (56” EWG-2 SECTION III SALES GAS PIPELINE (MGS PH-1) AND 30” EWECG-1 SALES PIPELINES)

Client: SONATRACH, FEED &Detail Engineering Projects

Project: COMPRESSION STATION GR5 HRM

Client: Kuwait Oil Company (KOC), Detail Engineering Projects

Project: Effluent Water Treatment and injection plant (NK) - EWTIP

Responsibilities:

Engineering Consultant to EPC Contractor- Specification, Pre design site survey, AC Mitigation and Design for the ICCP system for buried carbon steel pipeline. Preparation of corrosion study and materials selection.
Specification, Pre design site survey, AC Mitigation and Design for the ICCP system for well casings, Pipeline/Piping (400Km), Tank / vessel Internal (internal & External). Review CP vendor documents
Review of the CP vendor Design documents & drawings.
Pre-Bid : Preapare MR for Corrosion Monitoring System & MR for Cathodic Protection System

Tebodin Middle East Ltd. July 2013 to Nov 2014

Position: Corrosion & CP Engineer

Location: Abu Dhabi, UAE

Major Projects:

Client: Abu Dhabi Gas Industries Ltd. (GASCO), FEED and Detail Engineering Projects

Project: Habshan to Ruwais Condensate pipeline project

Client: Zakum Development Company (ZADCO)

Project: HC gas recovery compressor project

Client: BUNDUQ Company Limited (BUNDUQ)

Project: WD3 Water Disposal Well Project (Offshore)

Client: Abu Dhabi Oil Refining Company (TAKREER)

Project: Hamriyah Free Zone, Sharjah - Jetty/Bridge steel pipes & concrete reinforcement

Client: Qatar Petroleum (QP)

Project: QATAR – Additional Fire Water Tank (NGL3) & Replacement of Fresh Water Tank (NGL2)

Client: Abu Dhabi Future Energy Company (MASDAR) & Abu Dhabi National Oil Company (ADNOC)

Project: Carbon Capture & storage Project

Responsibilities:

Engineering Consultant to EPC Contractor- Specification, Pre design site survey, AC Mitigation and Design for the ICCP system for buried carbon steel pipeline. Preparation of corrosion study and materials selection.
FEED - Corrosion study, Material selection &Material selection diagram (MSD), Corrosion Monitoring, coating specification. Cathodic protection system for vessel.
Detail Engineering: Specification for Cathodic Protection System, Pre design site survey, AC Mitigation and Design for the ICCP system for buried pipeline, Piping, Tanks, Vessel& Well casing. Corrosion study and materials selection, Corrosion Risk Assessment report, Material selection guide, Corrosion Rate calculation and material selection diagram. Review CP vendor documents
Jetty/Bridge steel pipes & concrete reinforcement

Punj Lloyd Ltd, Malaysia Jan 2011 to June 2013

Position : Senior Engineer – Cathodic Protection & Corrosion.

Client : Petronas Carigali Sdn. Bhd, Malaysia

Projects : Sabah Sarawak Gas Pipeline (SSGP) (approx. 520KM).

Responsibilities:

Managing all Cathodic Corrosion Protection activities for projects of SSGP Pipeline, BCS (Bintulu Compressor Station), KMS (Kimanis Metering Station), BMS (Bintulu Metering Station) and all Block Valve etc.
Planning such as CP Material, Work Schedule, Man Power, Variation Order, Drawing review.
Preparing technical specification, tender documents, material evaluation and procurement for upcoming Cathodic protection requirements related to Cathodic protection of refinery facilities.
Reviewing technical qualifications, contractor proposals, quotation evaluations, maintaining correspondence to suppliers and cathodic protection contractors.
Coordination with client, vendors & contractors, reviewing all corrosion protection procedures, design & drawing. Technical support for procurement, technical evaluation of vendor proposals, Inspection of equipments, Supervision of installation, in Corrosion Protection Division.
Supervising the installation of sacrificial anode CP system & ICCP system.
Preparing Method Statement for installation of Temporary anode installation, Test post installation & Termination, Ground beds, T/R units, Junction Boxes, and etc.
Providing procedures for Testing &Commissioning of TCP & ICCP system.
Conducting pipe to soil potential (Monitoring) survey every month and ensure the adequate protection level of the pipeline and site survey.
Providing reports for monitoring, site survey & issues.
Supervision of Installation of AC/DC mitigation system, T/R units, foreign pipeline crossings & bonding, Deep well anode ground beds, Pin brazing, stud welding for negative drain point, Test posts, Junction boxes, Polarization Cell replacement, Surge Diverter, Over voltage protection, Termination at Test post, and Temporary anode ground bed Installation.
Zinc ribbon anode, Gradient Control Mat, Gradient Control Wire installation for block valve station & HT AC line crossing.
Testing & Commissioning of ICCP System.

Mitcorr Cathodic Protection Pvt. Ltd. July 2009 to Dec 2010

Position : CP Design Engineer Cum Site Coordinator

Period : July 2009 to Dec 2010

Client : Various Government / Private / Consultants clients.

Projects

4x125 MW Kosti Sudan Project, BHEL.
1x350 MW Hazira Gujrat Project, BHEL
Simhadri Super Thermal Power Prpject, NTPC.
DVPL, 48” dai 145Km. Pipeline, Punj Lloyd.
Meerut City Gas Distribution Project, 45 KM., GAIL GAS
Kota City Gas Distribution Project, 55 KM., GAIL GAS
Bareilly City Gas Distribution Project, 54 KM., GAIL GAS

Responsibilities:

Looking after overall CP projects and business development.

Project controlling, Managing CP crew, cost control.
All engineering activities related to Cathodic Protection,
Prepare cost estimation for the project.
Submitting Tender with quotation.
Make preliminary site visit with CP crew.
Preparing pre-design and submitting the same to the client.
Giving assistance to prepare detailed engineering and design package.
Preparation and follow-up of Cathodic Protection
Specification adapted to the contract requirement,
Preparation and follow-up of Cathodic Protection Datasheet, erection drawings, adapted to the specification and contract requirement, Controlling soil resistivity survey and relevant datas.
Verification, technical support, recommendation, corrective actions during detailed design.
Preparation of MTOs and requisitions.
Review of vendor documents.
Co-ordination with other disciplines, vendors and client.
Preparation of Technical and commercial bid evaluation reports and selection of vendors.
Procurement, Recruitment, billing of the CP system.
Installation, Supervision, Testing & Commissioning of CP systems.
Preparation of As Built Drawings.
Handing over the CP system to client.

Corrosion Control Services (B) Pvt. Ltd. August 2008 to June 2009.

M.Tech. 3rd& 4th SEM Project, 20” Dai – 253 Km. long Pipeline

Position : Engineer – Corrosion & Cathodic Protection.

Period : August 2008 to June 2009

Client : Essar Construction (I) Ltd.

Projects : Joda-Paradeep Slurry Pipeline Project.

Responsibilities:

Preparing Variation Quantity, Man Power Calculation for CP system.
Knowledge of Sub-Contracts activities.
Sub-Contractor co-ordination & follow up, Enquiry preparation, Work Order preparation.
Interaction with Sub-contractor and client.
Prepared CP design documents, engineering, Lay out, work procedures, Quality assurance plan (QAP) and inspection Test plans, Technical reports and Technical Bid for tendering.
Executed site Surveys, Corrosion surveys,
installation, testing, commissioning, Post
commissioning surveys such as CIP, DCVG, Coating conductance, Pearson, CAT, Current
measurement.AC & DC interference survey and mitigations. Project hand over to maintenance and as built.

NIT Jamshedpur July 2007 to May 2008

July 2007 – May 2008 for high study course work M.Tech. (Surface Science & Engineering) with specialization in corrosion and Science of surface Coating from NIT Jamshedpur.

Corrosion Control Services (B) Pvt. Ltd. April 2003 to May 2007

Position : Engineer – Cathodic Protection & Corrosion. Period : April 2003 to May 2007

Responsibilities:

Cathodic Protection for Temporary Cathodic Protection (TCP) system and Permanent Cathodic Protection (PCP) System of Dahej Uran pipeline (DUPL) of M/s GAIL. (500 Km, 30” &24” dia.).Worked as CP Engineer.
Temporary Cathodic Protection (TCP) system and Permanent Cathodic Protection (PCP) System of Dahej-Vijaipur LNG pipeline (DVPL) of M/s GAIL (100 Km, 42” dia., Spread-II). Worked as site in charge.
Close Interval Potential (CIP) & Direct Current Voltage Gradient (DCVG) surveys for their pipelines of approx 1,000 KM.
Supervising the installation of sacrificial anode CP system & ICCP system.
Design assistance for the CP system & submitting the changes to the client, if required.
Provide Method Statements for installation of Pin Brazing, Temporary anode installation, Test post installation, Termination at Test post, Ground beds, T/R units, Junction Boxes, and etc.
Providing procedures for Testing and Commissioning of ICCP system.
Conducting pipe to soil potential (Monitoring) survey.
Providing reports for monitoring, site survey, and issues.
Supervision of Installation of AC/DC mitigation system, T/R units, foreign pipeline crossings & bonding, ICCP anode ground beds, pin brazing, stud welding for negative drain point, electrodes, Test posts, Junction boxes, Polarization cell replacement, Over voltage protection, Termination at Test post, Temporary-Temporary and Temporary anode ground bed, Corrosion Coupon.