Saji Samad is a technical authority for asset integrity management, RBI and inspection planning, FFS assessment and assurance, turnaround planning, and inspection and corrosion control in upstream and downstream oil & gas industries. He has over two decades of hands-on experience in the industry, which included over seven years in a facility integrity technical authority review and approval role, process safety management, and SME for new technologies.
He has experience in both plant and corporate environments, led cross-field SMEs during cost optimization, audits, integrity review and spot verifications, pre-start-up safety reviews, and asset performance management (ONE APM). He has developed and reviewed asset integrity standards, guidelines, and inspection functional procedures; approved annual integrity plan; and scheduled inspection work activities and programs. He also mentored young inspection engineers, aiding in developing necessary skills.
Saji led a team of engineers for FFS assessments for more than 180 equipment items, which included piping, pressure vessels, heat exchangers, and crude storage tanks. He performed factory visits for third-party review, acceptances, and verifications, and conducted internal audits for integrity section as per ISO 55001:2014 and 9001:2008.
Saji also has over 15 years of field experience with static pressure equipment and piping inspection, shutdown SOW preparation, maintenance and inspection planning, NDT, IOW, and corrosion loop development. He is an expert in on-stream and off-stream inspection of static equipment and piping; corrosion under insulation study and assessment; IOW study and monitoring; and installation and testing of process including utility piping work, pressure vessels, and steel structures. He is well experienced in quality assurance and control inspection of static equipment for the nuclear power corporation of India Ltd, Kaiga Site & Tarapur Site; Atomic Power Project, Kota Site; and Reliance Petroleum Ltd, Jamnanagar Site for their main piping package for common service and maintaining all international ISO standards.
Additional training Mr. Samad has performed includes:
- 2024: Process Safety Training
- 2022: ISO 55001:2014 Asset Management System Lead Auditor by TUV
- 2015: Pipeline Inspection Using Intelligent Pigs
- 2014: ASME 579-1/ASME FFS-1 Training Course for Inspectors
- 2014: API 571 Damage Mechanisms Refresher
- 2012: PlantManager API RBI Software Training by Equity Training
- 2012: Offshore Survival (Sea Survival & HUET)
- 2011: Smart Plant Foundation by Intergraph
- 2009: ISO 9001:2008, 29001:2007 QMS by DNV
- 2008: RBI, FFS, and Repair Practices by Haward Technology
- 2007, 2009, & 2011: Shell RBI Training by SGSI for Knowledge and Skill Level
His API RBI projects include:
- 2014-2024:
- RBI specialist for ADNOC Onshore Upstream & Midstream Operations
- RBI facilitator for corrosion loop development
- RBI facilitator for implementation in tank farm and upstream units
- Team lead for development of ADNOC Corporate RBI Guideline and single point of authority for RBI result review and endorsement
- Focal point for ONE APM integrity management implementation
- 2012-2014:
- API RBI study for 450 heat exchangers in ADMA-OPCO
- API RBI study for aboveground storage tanks in ARAMCO
- API RBI study for ARAMCO Riyadh Refinery gas concentration, naphtha, and kerosene units
- API RBI study for SIPCHEM IDC plant including MAN, BDO, and reverse butamer units
- 2007-2012:
- Shell RBI study for OGD-0,1, 2, and 3; AGD-2; Habshan Gas Complex Expansion (HGCE)
- S-RBI study for Ruwais Train-1, 2, 3 and SGP
- Corrosion loop development and S-RBI study for Habshan-5, Shah Gas Development Project (SGD), Offshore Associated Gas Project (piping)
Saji’s other major integrity activities include:
- Piping dead legs management and leading a team for cross-OPCO verification within ADNOC
- Corrosion under insulation surveying for piping loops
- Shutdown activities at ADNOC gas processing OGD-0, 1, 2, and 3; AGD-2; Habshan gas complex expansion (HGCE); Ruwais Train-1, 2, 3 and SGP; Habshan-5; Shah gas development project (SGD); and offshore associated gas project (piping)
