Technical Support Process Engineer

Curriculum Vitae

Alaa El-Din M. Ghaly

Biography:

Highly qualified corrosion and integrity engineer possess total field experience of 30+ years in upstream and downstream oil, gas and LNG industry related to corrosion control, material selection and integrity management of static facilities and pipeline networks.

Expert in Commissioning, Decommissioning, Mothballing and Troubleshooting of static facilities and pipelines.

Outstanding experience with hands on practice regarding the following technologies:

•Intelligent pigging surveys (IPS)

•Over 16 years’ experience with an in-line inspection technology and pipeline integrity. developing scope of work, technical evaluation of the submitted technical offers, prepare & execute work schedule, analysis and review inspection data, risk management, site verification of the final inspection data, establish and execute short/long maintenance and repair program/technique for pipeline and the application of industry codes for evaluation of metal loss significance e.g. B31G and RSTRENG, data analysis, and trending. Assessment of pipelines defect types and methods of assessment, fitness for purpose evaluations and methodology.

•Cathodic Protection

•In depth field experience for all Cathodic protection related activities such as CP design (Sacrificial and Impressed current systems), installation, commissioning, monitoring, troubleshooting, data management and CP performance evaluation and coating assessment utilizing CIPS & DCVG techniques (Close Interval Potential Survey & Direct Current Voltage Gradient).

•Coating & Wrapping Activities

•Expert skills in coating/painting selection/review for above & underground steel structure and pipeline, field trials for internal external new coating systems, field application, Quality Control. Development & establish and execute coating rehabilitation program based on CIPS/DCVG and ILI inspection data.

•Chemical Treatment

•Extensive back ground in corrosion inhibition and production chemicals selection, bottle test, field trials, quality control / monitoring, cost optimization, development of KPI to evaluate the chemicals performance and data management.

•Corrosion Monitoring

•Expert skills in selection of the internal corrosion monitoring system Type/Locations for in-plot, off-plot and pipeline, monitoring, performance evaluation, chemical efficiency and internal corrosion monitoring for corrosion inhibition chemicals. Reviews operations and monitors activities to identify needed system modifications for procedural changes.

Responsible for providing technical support to operations and engineering groups; and

•Ensure corrosion monitoring program is effective and meets the international code of practice.

•Failure Investigation

•Evaluating failures issues, their causes and recommended measures for avoiding these failures.

•Material Selection

Ensure that the specified requirements for material selection, coating and welding are adhered to for supplier equipment packages, in offsite pre-fabrication and in construction.

Coordination of corrosion protection related requests and issues.

Review and advice on vendor documentation regarding material selection and specification.

Responsible for site query and site instruction handling on all material related issues

•Long term experience in developing corrosion & inspection data management for static facilities and pipelines utilizing international systems such as CREDOSOFT, RBI, and Pipeline RBA.

•Full conversant with the international industry codes of practice related to corrosion management and inspection such as NACE, ISO, API, ASME, ASTM, etc.

•Outstanding background in Planning & Coordinating Administrative Activities.

•Excellent computer skills with proficiency in Microsoft Office applications

•Excellent interpersonal skills and working well in a team environment.

•Significant Safety and Environment track record.

•Confident leader and mentor.

•Outcome objective focused.

•Strong organizational skills.

•Technically strong Leadership, strategic planning & orientation, project management, good teamwork, fluent in English & Arabic.

Major Accomplishments

Resolves complex technical problems in the field of corrosion affecting operation and maintenance of oil, gas and water injection facilities at ADCO operating facilities and pipeline.

•Maintain sound integrity of ADCO assets adopting Zero Leak philosophy; meanwhile extend its service life.

•Coordinate the implementation of the Risk Based inspection program.

•Introduction, verification and deployment of several new technologies which improve integrity management of ADCO static facilities (RBA Integrity Management Software for Pipelines, Acoustic Emission Survey for tanks, Coating Assessment Survey CIPS/DCVG for Pipelines, Liquid Coating System for rehabilitation of pipelines, RBI Methodology for inspection planning of static equipment).

•Establishment of robust integrity data management system for both major pipeline networks and Export Terminal static facilities including periodical Integrity Reporting System for both facilities.

•Participated in the implementation of the First ADCO/GASCO combined IPS-2000 campaign with sound records of stakeholders’ satisfaction and cost saving of (US$ 1.6MM).

•Implementation of the first structured production chemicals selection campaign adopting structured screening methodology including field trials.

•Provided expert operation experience for several major expansion and/or new projects in coordination with Engineering & Project management teams covering crude oil & gas gathering and processing plants, pipeline and export terminals.

•Advice and assist on designing, construction, operations and maintenance personnel on matters pertaining to a corrosion control and monitoring.

Career History

From Jan 2015 till now

Integrity Group – Cairo Egypt

Technical Support Manager

From Jan 2014 till Jan 2015

Senior Corrosion Engineer

Worley Parsons Angola, ANGOLA LNG PLANT

Roles & Responsibility

Corrosion and materials specialist responsible for corrosion risk and material selection studies for multiple projects on the LNG Plant.

Provides materials and corrosion engineering consulting services.

Develops and communicates expertise on materials selection, damage mechanism reviews, corrosion monitoring and control, failure analysis, interpretation of inspection data, critical reliability variables, welding and fabrication troubleshooting, mechanical design review, and equipment repair strategies.

Participates in the Management of Change process and provides support for shutdown and overhaul planning and execution.

Maintains a high level of HSE to achieve WorleyParsons’Zero Harmexpectation in all stages from conceptual design to commissioning and handover.

Assessment of Service life Corrosion (SLC), Life Cycle Cost analysis (LCC)

Design and review of Cathodic Protection (CP) and Corrosion Monitoring (CM) systems

Corrosion Management/Integrity assessment

Review of Intelligent Pigging (IP) and engineering assessment of identified pipeline defects

Selection and performance evaluation of corrosion inhibitors

Compliance with QA/QC provisions and guidelines

Maintain open and clear communication between all stakeholders

Facilitates cooperation among technical groups to improve reliability

Participate in the planning and executing work plans for shutdowns and overhauls and capital projects

Support and update plant corrosion/damage mechanism reviews as part of the PHA process, Metallurgical Reviews, and Risk-Based Inspection plans

Review, develop or update corrosion and material technical specifications as required

Ensure corrosion programs are accurate, up-to-date, and incorporated into the appropriate equipment inspection plans

Mentor inspectors, engineers, and others in materials selection, welding and fabrication, and corrosion control

Liaise with others including other corrosion engineers to develop common tools, processes, and decision-making criteria

Proactively remain current with latest development in corrosion engineering as it applies to LNG facilities

From Sep. 2012 till June 2014

Integrity Group – Cairo Egypt

Technical Support Manager

Roles & Responsibility

•Work in a team environment with other technical, field operations and maintenance staff, project leaders and engineering contractors with a goal of maintaining safe and reliable operations. Provide ongoing technical support to daily operations such as troubleshooting, problem analysis, technology evaluations for plant, terminal and pipeline

•Responsible for the overall leadership of the asset integrity program for pipelines and terminals. Ensures that the program meets all regulatory, and internal requirements including maintaining appropriate documentation

•Provide technical evaluation of proposed equipment alterations to existing facilities in accordance with Management of Change (MOC) processes and help ensure cost effective solutions are implemented

•Gathers and provide operational expertise to assist in the development and review of conceptual designs of facilities and pipelines. Represent field operations in project design reviews and participates in process hazard analysis (PHA) reviews. Play a key role in identifying optimization and operating cost reduction opportunities in the design/operation of new facilities

From March 1997 till Aug 2012

Abu Dhabi Company for Onshore Oil Operations (ADCO) United Arab Emirates

15+ years field experience in Corrosion Control & Integrity Process Control of Onshore and Offshore crude oil static facilities and pipelines.

Roles & Responsibility

•Accountable for the integrity management of the static facilities & pipelines within the boundaries of the respective work sites.

•Directs, Controls and supervises a team of Corrosion Engineers, Foremen to ensure the technical integrity of the static assets and pipelines.

•Participates in developing and reviewing company standards, specifications and design practices.

•Develops, and supervise the implementation of fit-for-service standards and Quality Control Measures for oil, water and gas productions static facilities.

•Ensures that all technical aspects related to corrosion & quality control management and integrity assessment are undertaken in conformance with ADCO standards and / or industry codes of practice. This includes coaching and monitor of the subordinate team.

•Ensures that all maintenance/ repair plans to all static equipment and pipelines are performed in accordance with industry best practice and quality and HSE standards. Also coordinate with the respective operations department to ensure asset availability and reliability within the approved budget.

•Establish the development all programs regarding the off stream, periodic inspections of field static facilities and pipelines with the objective of assessing plant integrity, reliability & safety and recommend the necessary repair actions to restore the required integrity from corrosion point of view.

•Develop the plans for gauging/cleaning pigging programs and supervises the implementation of intelligent pig surveys in order to establish the internal/external conditions of pipeline networks as part of plant integrity assessment. Review & approve the interpretation of on line inspection surveys and recommends appropriate remedial actions.

•Direct technical investigations regarding Metallurgical failures/ deterioration static equipment and pipelines. Concludes decision regarding critical maintenance work and the best course of action for the breakdown situations to ensure plant availability and continued operations.

•Participate in the technical reviews of the site related projects to ensure adequate Material selection, Corrosion Control measures, and integrity related aspects.

•Materials Selection and Review of Design Basis/Materials Suitability.

•Corrosion Risk Assessment (including commissioning of appropriate databases, where necessary).

•Develop the annual CAPEX and OPEX budgets for the respective activities and ensure systematic expenditure scheme, taking into consideration expected change in service contracts and long term production plans. Prepares justifications for major over/ under spent items as necessary.

•Participate in initiatives and task forces aiming to improve Company business process and quality standards regarding asset integrity management.

•Drive all HSEM’s related activities within his section, and ensures the implementations of the related action items, as per the Division plan. Ensure that work under his control is performed in a safe and environmentally sound manner. Conducts effective accident investigation and follow up. Implements specific Safety Management System Program activities assigned to him.

•Implement a comprehensive maintenance and inspection program for the flowlines in line with the clustering project activities, to ensure minimum cost impact.

•Assist in monitoring costs against budget, and warn Line Manager / TL of potential overruns where appropriate.

•Support the Senior Inspection Personnel in provision of specialist expertise on major onshore facilities, pipeline and subsea projects

Engineering Positions Occupied is:

Senior Corrosion Engineer - ASAB field (2005 - 2012)

Corrosion Engineer Jebel Danna Terminal (1997 - 2005)

Provides evaluation data on capabilities of service providers in the field of corrosion.

Reviews operations and monitors activities to identify needed system modifications or procedural changes.

Supervise Junior Engineers and Technical assistants when required.

Provide special technical service, consulting and assisting in design and construction of corrosion control projects.

Work with concerned area inspectors and process engineers to monitor and control process parameters related to corrosion.

Act as mentor to develop competent Saudi Arab corrosion engineers.

Recommend new technologies in the field of corrosion.

From May 1986 to March 1997:

Bader Petroleum Company (BAPETCO) SHELL – Egypt

Head of Integrity Department (Corrosion and Inspection)

Roles & Responsibility

•Establish, supervise the implementation of Corrosion monitoring / Control / Mitigation Programs and Inspection/Condition Assessment Plans to ensure safe operations of static equipment. Also provides technical advice to other divisions on matters related to revamping and or upgrading of corrosion control systems for the new and/or existing Fields & Terminal facilities.

•Develops, and supervise the production chemicals selection for Oil, Gas & Water facilities including Lab and Field trials.

•Quality control of the selected chemicals as per the original sample.

•Supervise a team of Corrosion/inspection Engineers, Foremen to ensure the technical integrity of the static assets and pipelines.

From 1985 to 1986

Gulf of Suez Petroleum Company (GUPCO) - Egypt

1.5 years, first as Field Process Engineer, then as Field Corrosion Control Engineer

Qualifications

•B. Sc., 1983 in Chemistry – Cairo University.

•Member of the National Association of Corrosion Engineers

(NACE)

•NACE CP Level II and attended NACE level CP III training and Exam (no luck).

•NACE CIP Level I

Key Competencies required

Ability to work effectively in a team environment or independently with little guidance or supervision is required.

Able to interface effectively with other disciplines and to provide deliverables to customer’s requirements.

Knowledgeable of the interface points between design disciplines.

Strong fundamentals in engineering consultation, technical knowledge, failure analysis, interpretation of inspection data, and damage mechanisms

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