BONKA Santosh Chaitanya
LEAD INTEGRITY ENGINEER OFFSHORE, OIL &GAS
Visakhapatnam,Andhrapradesh
Summary
Integrity engineer specializing in FPSO structural integrity inspection management and offshore asset reliability. Demonstrated success in implementing risk-based inspection (RBI), conducting corrosion assessments, and ensuring compliance with ABS and DNV standards. Aiming to enhance asset performance, safety, and compliance in global offshore oil and gas operations through strong leadership and engineering expertise.
Overview
13
13
years of professional experience
1
1
Certification
Work History
Lead Integrity Engineer
Quest Global
05.2024 - Current
- Performed structural integrity inspections, assessments, and condition evaluation of FPSO hull, risers, mooring systems, and topside structures to ensure compliance with ABS, DNV, and Class requirements.
- Managed Risk-Based Inspection (RBI) programs, including development, implementation, and periodic review of RBI plans, improving inspection effectiveness, and ensuring regulatory compliance.
- Conducted corrosion assessment, thickness monitoring, and degradation analysis to evaluate remaining life and fitness-for-service (FFS) of offshore assets.
- Developed and implemented preventive and corrective maintenance strategies to enhance structural reliability, minimize failures, and extend asset service life.
- Ensured compliance with international standards and regulations including ABS, DNV, LR, IMO, SOLAS, API, and ISO requirements.
- Identified structural risks related to corrosion, fatigue, cracking, and material degradation, and implemented mitigation measures to maintain asset integrity and operational safety.
- Monitored structural health through inspection findings, anomaly tracking, and closure management to ensure timely corrective actions and continuous integrity assurance.
- Coordinated with Class Societies (ABS, DNV, LR), offshore teams, and vendors to support inspections, surveys, and certification requirements.
- Maintained and updated RBI databases and integrity management systems to ensure accurate inspection planning, tracking, and reporting.
- Integrated inspection findings and RBI results into Asset Integrity Management Systems (AIMS) to support data-driven maintenance and risk mitigation strategies.
- Conducted fatigue and corrosion analysis to predict structural performance, enabling proactive maintenance planning and risk reduction.
- Ensured inspection schedules, anomaly closure, and compliance activities were completed in accordance with integrity management plans.
- Evaluated structural anomalies and recommended engineering solutions to maintain compliance with class and operational requirements.
- Supported digital integrity initiatives by testing and implementing DNV Ship Manager Hull integrity tools, enabling 3D mapping and digital inspection records for FPSO compartments.
- Prepared technical integrity reports, inspection summaries, and engineering recommendations for management and class submission.
Senior QA/QC Engineer
DNV
12.2020 - 02.2024
- Performed receipt inspection of raw materials in accordance with project specifications, API standards, and ISO requirements, ensuring full compliance with Mill Test Certificates (MTC) prior to fabrication and installation.
- Conducted QA/QC inspections in line with approved Inspection Test Plans (ITP), Quality Assurance Plans (QAP), and project procedures to ensure compliance with client and regulatory standards.
- Coordinated with client representatives, third-party inspectors, and project teams to resolve quality issues and ensure adherence to project quality requirements.
- Prepared and maintained Daily Progress Reports (DPR), inspection reports, and quality documentation to ensure traceability and compliance with quality management systems.
- Reviewed and verified QA/QC documentation, inspection reports, and test records to ensure compliance with API, ISO, and project-specific requirements.
- Witnessed NAS cleanliness verification and flushing activities for methanol displacement in umbilical systems during pre-commissioning, ensuring system readiness and compliance with cleanliness standards.
- Investigated quality non-conformities, performed root cause analysis, and implemented corrective and preventive actions (CAPA) to improve quality performance.
- Performed inspection of cross-country pipelines, including surface preparation, blasting, coating inspection, holiday testing, peel testing, and NDT inspection in accordance with project specifications and international standards.
- Verified coating quality, surface preparation, and corrosion protection measures to ensure long-term pipeline integrity and compliance with coating standards.
- Conducted product and material specification verification to ensure compliance with engineering drawings, material standards, and client requirements.
- Ensured compliance with API standards, project specifications, and quality requirements during fabrication and installation of drilling rigs, mast structures, and associated equipment.
- Supported fabrication inspection, dimensional inspection, welding inspection, and NDT verification to ensure compliance with quality and engineering requirements.
Technical Engineer
Sembcorp Marine-Singapore
12.2020 - 02.2024
- Coordinated and witnessed Welding Procedure Qualification Records (WPQR) and Procedure Qualification Records (PQR), ensuring compliance with ASME, AWS, and project specifications during FPSO fabrication.
- Managed and supervised Non-Destructive Testing (NDT) activities including UT, RT, PT, and MT, ensuring weld integrity and compliance with Class Society and project quality requirements.
- Oversaw multi-disciplinary inspection activities covering structural, piping, mechanical, and outfitting works, ensuring adherence to approved Inspection and Test Plans (ITPs) and EPC quality standards.
- Reviewed, verified, and approved inspection reports, test records, and quality documentation prior to submission to client and Class Society, ensuring full traceability and compliance.
- Represented the FPSO project as Company Integrity/QAQC representative at the fabrication yard, ensuring compliance with ABS/DNV Class requirements and EPC contract specifications.
- Reviewed and approved contractor Inspection and Test Plans (ITPs), Quality Plans, and inspection procedures, ensuring alignment with project quality requirements and integrity standards.
- Coordinated and witnessed hydrostatic testing, line checks, flushing, and mechanical completion activities, ensuring system readiness and compliance with commissioning requirements.
- Monitored and managed Non-Conformance Reports (NCRs), coordinated with engineering and fabrication teams, and ensured timely closure with appropriate corrective and preventive actions (CAPA).
- Maintained calibration control of inspection and measuring equipment, ensuring compliance with ISO 9001 quality management system requirements.
- Ensured implementation of project Quality Management System (QMS) requirements during FPSO structural fabrication and equipment installation.
- Coordinated with client representatives, third-party inspectors, and EPC contractors to ensure compliance with project specifications, quality standards, and offshore integrity requirements.
- Supported EPC phase integrity assurance by reviewing fabrication quality, welding compliance, and inspection records to ensure long-term structural reliability of FPSO assets.
Piping Inspector
Conceptia Software Technologies
06.2016 - 05.2018
- Witnessed hydrostatic, pneumatic, and pressure testing, flushing, and pre-commissioning to verify piping system integrity.
- Verified piping materials against PMS, isometric drawings, and Mill Test Certificates (MTC) for traceability and compliance.
- Monitored piping fabrication, erection, and installation to ensure compliance with project specifications and offshore standards.
- Verified piping alignment, routing, supports, and mechanical completion as per approved drawings and project requirements.
Mechanical Supervisor
Qatar Engineering & Construction Company
02.2016 - 04.2018
Quality Control Inspector
Ship Building Centre
02.2015 - 01.2016
Assistnat Mechnical Engineer
Team Power Engineering Works
06.2013 - 01.2015
Education
Bachelor of Technology - Mechanical Engineering
Jawaharlal Nehru Technological University Kakinada
Kakinada, IN-AP2013
Skills
- FPSO Structural Integrity Assessment and Management
- Welding Inspection
- Offshore Safety Compliance
- Risk Based Inspection (RBI) and Integrity Management Programs
- Non-Destructive Testing
- GE-APM(Meridium)
- SAP
- DNV Ship Manager Hull
- PLM
- Navisworks
- Corrosion Monitoring, Evaluation and Life Extension
- Lead Auditor
- Vendor Inspection & Third-Party Surveillance
- Root Cause Analysis and Failure Investigation
Certification
- CSWIP 3.1 Welding Inspector, 327977/2, TWI, UK
- ISO 9001:2015 Lead Auditor, Quality management System
- ASNT Level-II, (RT, UT, PT, and MPT)
- Auto-CAD Certification
- SAP QM and PLM, (Product life cycle management)
- Certified in PTW, Permit To work Level I
- Certified in BOSIET-5700, Safety Induction, Sea Survival, First Aid, FIRE Fighting and Self Rescue & HUET
- Course completion in Six sigma, (Green belt)
- Course completion in ISO 45001, Occupational Health & Safety Management
Languages
Hindi
Proficient
C2
English
Proficient
C2
Telugu
Proficient
C2
Timeline
Lead Integrity Engineer
Quest Global
05.2024 - Current
Senior QA/QC Engineer
DNV
12.2020 - 02.2024
Technical Engineer
Sembcorp Marine-Singapore
12.2020 - 02.2024
Piping Inspector
Conceptia Software Technologies
06.2016 - 05.2018
Mechanical Supervisor
Qatar Engineering & Construction Company
02.2016 - 04.2018
Quality Control Inspector
Ship Building Centre
02.2015 - 01.2016
Assistnat Mechnical Engineer
Team Power Engineering Works
06.2013 - 01.2015
Bachelor of Technology - Mechanical Engineering
Jawaharlal Nehru Technological University Kakinada