Project Management Process

Inspection of Audit of Three Layered Vessel and high thickness (92 mm) single wall vessel

In 2010, I played a key role in the specialized inspection of high-pressure vessels at the Matix Fertilizer plant in Durgapur, focusing on both three-layered and 92 mm thick single-layer units. Constructed in strict accordance with ASME Section VIII, Division 2, these vessels required advanced non-destructive testing and meticulous design verification to manage the extreme operational stresses inherent in fertilizer production. This project highlighted my expertise in navigating the rigorous safety and quality standards of the ASME code, ensuring the structural integrity of complex, heavy-wall equipment. By applying detailed inspection protocols to both layered and thick-plate configurations, we successfully verified that each vessel was fit for long-term, high-pressure service.

Tilted Tank restoration at Mangalore Refinery

I led the emergency restoration of a severely distorted floating roof tank of 48 Mtr diameter and 20 Mtr height in Mangalore that had settled 450 mm due to subsoil failure. With the tank out of round and the floating roof jammed, I engineered an innovative strategy to restore circularity using strategic wind girders and internal stabilization—avoiding traditional lifting methods made impossible by weak soil. This high-risk project successfully restored the tank’s full operational geometry through precise technical analysis and disciplined field execution.

CDU & VDU Piping Execution-Baroda Refinery

Led the complex piping fabrication and erection for the Crude and Vacuum Distillation Units (CDU/VDU) at the IOCL Gujarat Refinery, ensuring 100% metallurgical integrity across a diverse range of 10+ material grades. I managed the high-precision installation of Carbon Steel, Stainless Steel, and specialty alloys like P91 and P22, adhering strictly to ASME B31.3 standards. By implementing a robust “cradle-to-installation” traceability system and a multi-layered quality assurance framework—including 100% Positive Material Identification (PMI) and specialized PWHT protocols—I successfully mitigated all risks of material cross-contamination and delivered high-pressure circuits fully compliant with stringent IOCL technical audits.

Audit and Inspection of Rail Wagon/Rolling Stock

I played a pivotal role in securing our first NABCB accreditation as a Type A Inspection Body for rolling stock, a milestone that underscores our technical competence and absolute independence. This accreditation covers the comprehensive third-party inspection of Flat Wagons, BOBRN, and BOXNHL variants, ensuring every unit adheres strictly to RDSO guidelines. My work involved managing a rigorous end-to-end oversight process, starting from the critical validation of assembly jigs and individual components to the sub-assembly and final fabrication phases. The process culminated in a 100% final inspection, including specialized brake testing, to guarantee that every piece of rolling stock meets the highest standards of safety. This achievement solidifies our position as a trusted partner in maintaining the structural integrity of India’s heavy freight infrastructure.