Service System Design Process

Ensuring Structural Integrity: Residual Life Assessment of 22 Steel Chimneys at Bokaro Steel Plant

We recently completed a comprehensive Residual Life Assessment of 22 steel chimneys at the Bokaro Steel Plant, ranging from 67 to 122 meters in height. Utilizing industrial rope access, our team conducted meticulous inspections including verticality surveys and infrared thermography to detect structural and thermal anomalies. By integrating this field-captured data—such as actual shell thickness and verticality deviations—with rigorous design verification, we provided a precise evaluation of the assets’ structural health. This data-driven approach allowed for an accurate estimation of the remaining service life, ensuring a proactive and safe maintenance roadmap for these critical industrial structures

BPCL, Mangalore Terminal Expansion: API 650 Floating Roof Tanks

We execute construction, testing, and commissioning of storage tanks strictly adhering to API 650 standards of five nos. 32 Mtr Diameter and 20 Mtr. height. Our process integrates advanced NDT welding inspections with hydrostatic testing and foundation settlement monitoring to ensure structural integrity and with comprehensive functional commissioning and technical documentation.

133.5m Flare Stack Erection | IOCL Baroda

Led the Inspection and Quality Control for the EPCM of a 133.5-meter tripod flare stack, ensuring seamless integration of dual-stream hydrocarbon and acid gas processing systems. I managed rigorous compliance with AWS D1.1, ASME B31.3, and ASME Section VIII for structural steel, piping, and pressure vessels (KOD/WSD), while enforcing a strict “No Field-Fix” policy through high-precision 3D model verification. My role involved supervising the mechanical readiness and NDT clearance for 10 massive modules, utilizing advanced Radiography Testing and layout validation to eliminate structural deviations and ensure 100% alignment during complex high-altitude assembly.

Rail Manufacturing Audit at Jindal and Sail Bhilai

From Jindal Steel in 2014 to the SAIL Bhilai Steel Plant in March 2024, my journey has focused on the technical integrity and process efficiency required for high-grade steel production. Conducting independent audits under the IRS-T-12-2009 standard, I have meticulously evaluated the end-to-end manufacturing chain. This includes critical chemistry control at the Converter and Electric Arc Furnace (EAF), as well as the stringent management of H2 and N2 levels during bloom casting to prevent internal defects. My assessments followed the material through the rolling process into finished rails, ensuring every stage was validated by the rigorous testing protocols mandated by the IRS-T-12-2009 specifications. This decade-long expertise ensures that these industrial giants maintain the discipline and coordination necessary to produce rails that meet the highest global benchmarks for safety and performance.