Projects I contributed
The "Panch Pandav"
The Journey of "Panch Pandav" From Campus to Construction- Mangalore Refinery
The Steel and the Soul: A Journey to Baikampady
Every engineer has one project that defines them. For me, that journey began at the BPCL Mangalore Terminal in Baikampady.
I had just come off a grueling but successful phase of Tank Erection and Hydro-testing at our previous site. It was there that I earned the trust of Mr. Swaroop Pal, or as we all called him, “Palda.” To us, Palda was more than a Planning Engineer; he was a true Dada—a big brother who commanded respect through his wisdom and shielded his team like family.
When Bridge and Roof secured the order for five massive Floating Roof Tanks at Baikampady, Palda chose me as his second-in-command. This wasn’t just a promotion; it was a responsibility to help manage the fabrication and erection of a critical gateway for India’s fuel, where petrol and diesel arrived from the Mangalore port.
The Mentor and the Guardian
At the site, I met Mr. John, a consultant from FEDO. He became a guardian to me, favoring my deep interest in the “Bibles” of our industry: API 650 and ASME Section IX. Under his watchful eye, I refined my skills in interpreting Radiography and Ultrasound testing, ensuring every weld was a testament to quality.
But the true Hero of the Project was Mr. Anil Kumar, the In-charge from BPCL. A man of immense kindness and professional stature, he was someone I looked up to deeply. Mr. Anil Kumar didn’t just overlook the project; he noticed the soul we put into the work. I will never forget the moment he approached Mr. Nirupam Mitra to personally appreciate the hard work and the uncompromising quality I delivered to BPCL. To be recognized by the client in such a way is the highest honor an engineer can receive.
A Legacy of Brotherhood
The Baikampady site was a place of intense work, but also of great brotherhood. It was here that I met three young trainee engineers: Ajoy Rakshit, Asish Banerjee, and Santanu Chowdhury.
In the heat of the Mangalore sun, between the planning sheets and the steel plates, we formed a bond that the years haven’t been able to break. They started as trainees under our wing, and today, they remain at the very top of my friend list.
The Final Reflection
Looking back, the Baikampady project wasn’t just about five floating roof tanks. It was about the transition from a learner to a leader. It was about the lessons from Palda, the precision of Mr. John, the kindness of Mr. Anil Kumar, and the lifelong loyalty of friends made in the field.
When I look at a completed tank today, I don’t just see the steel. I see the planning, the mentorship, and the people who stood by me to make it happen.
The Mangalore Mission: A Story of Engineering Grit
We had just finished the Baikampudy project and were looking forward to a well-earned break. But in the world of heavy engineering, the next challenge is usually just around the corner. That challenge arrived when we noticed a Floating Roof Tank in Mangalore wasn’t just settling—it was failing.
The Discovery
The subsoil had given way, causing the tank to sink by a staggering 450 mm on one side. The distortion was so severe that the tank had turned elliptical, and the massive floating roof was physically jammed against the shell halfway up. EIL halted everything. The situation was critical.
The “Brainstorming”
I was tasked by Mr. Nirupam Mitra (Mitrada) and Mr. Pal to lead a thorough inspection. When I dewatered the tank and presented my findings, the room went silent. The data showed a nightmare: a 450 mm drop at one point, while just 110 degrees away, it had barely moved. The bottom plates were sloping into the earth, and the tank’s circularity was gone.
The Turning Point
Because the soil was too weak to support a traditional lift, we had to think outside the box. Under the guidance of Mitrada and Palda, we proposed a bold plan to EIL:
- We would “force” the tank back into its circular shape by installing two additional wind girders at the midpoint.
- We would trim the deck to free the jam and lift it to 18 meters.
- We would then stabilize and uplift the bottom plates from within.
Mission Accomplished
EIL approved our methodology, and I was given the lead to execute it. It was a high-pressure environment where precision was the only option. We successfully restored the tank’s integrity, proving that even the most “stuck” projects can be moved with the right team.
I still feel a deep sense of gratitude to Mitrada and Palda. Their faith in me to lead this critical rescue is a milestone I carry with pride.
New Height, New Challanges
Tallest Flare Stack at IOCL Baroda
The Road to Baroda
After successfully completing our mission in Mangalore, the call came for a new challenge. My mentor, Paula, had already transitioned to a high-stakes project at IOCL Baroda, and she placed her faith in me to join her. I packed my experience and my tools and headed to Gujarat. I wasn’t just moving to a new city; I was moving toward one of the highest engineering points in the country—a 133.5-meter flare stack that would test every ounce of my technical resolve.
The Giant of Baroda
Entering the Baroda site, the scale of the challenge was immediately clear. This wasn’t just a construction project; it was a high-stakes engineering puzzle. Our scope covered everything—Engineering, Procurement, Erection, and Commissioning.
The system was designed to handle a dual-stream of hydrocarbons and acid gas. These gases would travel from the refinery through a Knockout Drum for sedimentation and filtration, then pass through a Water Seal Drum—the vital heartbeat of the plant that prevents dangerous backfire—before finally reaching the flare tip at the summit to be burned away.
Precision in the Sky
The true test of my skills lay in the “Zero-Tolerance” policy. The 133.5-meter structure was a tripod design made of massive pipe legs. The rules were simple but unforgiving: No gas cutting and no on-site drilling. Every hole had to line up perfectly, even at 100 meters in the air.
As the Inspection Engineer, I became the guardian of this precision:
* The Blueprint: I verified complex layouts against 3D models to ensure that horizontal and vertical deviations wouldn’t ruin the assembly.
* The Invisible Check: Every long seam and field joint underwent rigorous Radiography Testing (RT) to ensure structural immortality.
* The Modular Leap: We erected the stack in 10 massive modules, ranging from 5 to 30 meters. I personally cleared each module for NDT and mechanical readiness, ensuring that when the crane lifted them, they fit together like a master-crafted watch.
Where Fire Meets Precision: The Audit Journey Through Bhilai Steel
In March 2024, my colleague and I, Mr Ananda Mohan Biswas, arrived at the vast SAIL Bhilai Steel Plant for an independent audit under IRS-T-12-2009. Over several days, we moved through the steelmaking universe — from molten metal in towering converters to the final gleaming rails ready for dispatch.
Their journey began with meetings across departments like SMS-II, SMS-III, URM, RSM, and the central laboratory. With every interaction, we observed not just processes but the discipline and coordination that kept this industrial giant running.
Ductile Iron Pipe Audit
Conducted rigorous technical audits and supply chain evaluations for three of the industry’s leading producers—Rashmi Metaliks Ltd., Jai Balaji Industries Ltd. Jindal SAW Ltd., Electro Therm Ltd. and Electro Steel Casting Ltd according to EN 545 and ISO 2531.My objective was to verify that their metallurgical processes, automated manufacturing lines, and testing protocols aligned with international standards for high-performance water and sewerage infrastructure.
Pouring to Converter
Casting of DI Pipe
DI Pipe Verification
Questions & Answers
What services I offer?
I specialize in Mechanical Inspection and Technical Auditing. This includes asset integrity assessments, compliance checks against industry codes (like ASME or ISO), and quality assurance/quality control (QA/QC) for mechanical systems and installations.
How I approach to control the and get the desire quality?
My approach to manufacturing excellence is built on DMAC (Define, Measure, Analyze, Control) and TPM/TQM (Total Productive Maintenance/Total Quality Management) methodologies. DMAC enables me to optimize processes and ensure quality control, while TPM/TQM focuses on proactive maintenance and employee involvement to maximize equipment effectiveness and product quality.
For project management, I rely on the PDCA (Plan-Do-Check-Act) cycle, driving iterative improvement and adaptability. This cyclical approach ensures that projects are thoroughly planned, executed, and continuously improved, resulting in efficient and effective outcomes
which type of product I have knowledge ?
Storage Tank atmosphere tank (Floating Roof, Fixed Roof and Internal Floating Roof), Dome Roof Tank, Steel Structure (Heavy), Tubular Structure, Pressure Vessel (Single layer and Multiple layer), Piping, Heat Exchanger, Cooling Tower, Ductile Iron Pipe, LPG Cylinder and Valve, Oil Exploration Rig, Crane (EOT up to 250 MT), Fastener, Railway Wheel and Shaft, Rail, Wagon
What Industries do I Serve ?
Oil & Gas, Power, Steel, Aluminum, Manufacturing, Rail and Rolling Stock
What standard and code I follow ?
American Society for Mechanical Engineers (ASME), American Society for Testing and Materials (ASTM), American Petroleum Industries (API), International Organization for Standardization (ISO), European Norms (EN) and Indian Standard (IS)