Ganeswararao Vemula
Visakhapatnam
Summary
A competent professional with over 19 years of rich experience in Chemical Industry spearheading Inspection team and looking after Asset Integrity, Risk based Inspection of Plant Equipment, QA/QC of Critical Fabrication activities and Inspection of Incoming Materials. A quick learner and team player with a firm belief in synergy, seek managerial & technical assignments conducive to learning, value addition and professional growths.
Overview
20
20
years of professional experience
1
1
Certification
Work History
Assistant Manager/Tech Asst - Inspection
COROMANDEL INTERNATIONAL LIMITED
Visakhapatnam
03.2006 - 02.2025
- Inspection of incoming materials of Pipes, Pipe fittings, Plates, Valves, Fasteners, Cast Iron items, PTFE lined items, Bearings, Oil seals, Gaskets, Hoses, Tubes, Rubber lined parts/equipment, Spare parts of Pumps, Conveyors, Rotating Drums, Compressors, Gear Boxes, Acid Coolers and IBR Equipment & Components.
- Inspection of New Tanks and Piping Project jobs
- Prepare/Review of QAP
- Prepare/Review of PQR and WPS
- Conduct of WPQ Tests
- Welding Stage Inspection like Fit-up, Root LPT & Final Weld Inspection as per ASME Sec IX.
- New Project Inspection as per ASME/API standards/Drawings.
- Identifying the Risk of New Equipment/Piping as per API 571/PSMS-SCE (Safety Critical Equipment) and preparing the Inspection Plan which mentions Inspection Intervals, type of Inspection and Inspection Procedure as per PSMS-AI (Process Safety Management System-Asset Integrity).
- Performing/Execution the Inspections of External visual, On-stream, Thickness measurement, Internal visual and CUI as per inspection schedule for all SCE.
- Repair recommendations and inspection as per API 570/API 653.
- Preparing inspection reports contains Remain Life Assessment (RLA) & next inspection interval and documentation.
- Performing Risk Based Inspection (RBI) for Critical Ammonia service equipment.
- Performing internal inspection of major equipment like Sulphur furnaces, Sulphur converters, Heat exchangers, Sulphuric acid towers, Acid circulation tanks, Acid coolers, Acid storage tanks, Boilers, Economisers, Super heaters and process ducting in Sulphuric Acid plants.
- Internal Inspection of all equipment/ducting/piping of various services (Molten Sulphur, SO2, SO3, Sulphuric Acid, Phosphoric Acid, liquid Ammonia, Vapour Ammonia, raw water, salt water, Boiler feed water, HP steam, LP steam, compressed air, LSHS and Kerosene) in Annual Turn Around and as per Inspection schedule.
- Coromandel, Visakhapatnam is an integrated facility comprising Sulphuric Acid, Phosphoric Acid, Granulation Plants and supporting facilities (utilities, ammonia, and molten Sulphur storage facilities) & Wharf. The Raw materials required for the manufacture of phosphatic fertilizers like Rock Phosphate, Sulfur, Potash and ammonia are imported. Coromandel operates its captive berth located 5 km from the Plant for unloading these raw materials.
Operating Engineer
M/s Borg Warner Morse Tech Murugappa Pvt Ltd
Chennai
03.2005 - 02.2006
- Worked as an Operating Engineer in Manufacturing and Quality control Departments of Chain Manufacturing industry in M/s Borg Warner Morse Tech Murugappa Pvt Ltd, Chennai, Tamilnadu.
Education
Diploma - Mechanical Engineering
S.M.V.M. Polytechnic
Tanuku03-2005
SSC -
M.V.N.Z.P.H. School
Undrajavaram03-2002
Skills
- P&IDs
- Isometrics
- Equipment drawings
- Equipment data sheets
- AI (Asset Integrity) schedules
- Inspection strategies
- Visual Inspection management
- Thickness Inspection management
- Root Cause Analysis
- Inspection Plan
- Inspection Procedure
- Remain Life Assessment
- Risk Based Inspection
- API 580
- Damage Mechanisms
- Ammonia Stress Corrosion Cracking
- Galvanic corrosion
- Atmospheric corrosion
- Corrosion under insulation
- Polythionic Acid stress corrosion cracking
- Chloride Stress Corrosion Cracking
- Sulphuric Acid corrosion
- Soil corrosion
- Corrosion
- Erosion
- International Standards
- ASME
- API
- BS
- ASME Sec II
- ASME Sec V
- ASME Sec VIII
- ASME Sec IX
- PCC2
- NACE 0294
- International Inspection codes
- API 510
- API 570
- API 571
- API 574
- API 576
- API 577
- API 598
- API 653
- Process Safety Management system (PSMS)
- OSHAS 18001
- Metallurgy
- Welding
- Fertiliser Industries
Achievements And Recognitions
- Well-done certificates (2 times) received from Corporate Management for best performance.
- No NC (Non conformity) received during PSMS & external audits.
- Performed Internal Inspection, repair inspection and reports preparation of 19 Annual Turn Arounds (Annual shutdowns).
- Special assignment for Internal Inspection of Ammonia Storage Tank (12500 MT) Decommissioning in 2007 at Ennore Plant (Tamilnadu), Coromandel.
- Deployed for Inspection of entire Ammonia system piping and Ammonia Storage tanks (2 X 12500 MT) FFS in 2009 at Coromandel, Kakinada Plant (E.G. Dt, AP).
- CUI (corrosion under insulation) and repair inspection of 5KM cross country Ammonia piping in 2009.
- Inspection of entire Ammonia system piping and Ammonia Storage tanks while FFS (Fitness for service) in 2010 at Coromandel Visakhapatnam Plant.
- Decommissioning Inspection of two Atmospheric Ammonia Storage Tanks (5000MT & 7500MT) and cross-country Ammonia Piping of 5KM in 2012-2015.
- Execution/Inspection of SO3 Converter fabrication in 2008-09.
- Ammonia ship unloader inspection along with OEM inspection executive of M/s Wood field Technologies (England) at ship unloading facility in 2009.
- 80 DN Ammonia Precooling Piping fabrication inspection (5KM cross country piping) during its replacement in 2015.
- Inspection (FFS & RBI) of Ammonia system and cross-country piping along with M/s Lloyds in 2010, 2020 & 2024.
- Received special appreciation award from Top Management, for identifying the circumferential crack in shell of Dryer drum in Complex Plant in ATA 2018 inspection.
- Fabrication inspection of 2 x 12500 MT Sulphuric Acid Tanks along with 300 DN Ship unloading pipeline and 250 DN Sulphuric Acid transfer line from wharf to plant (5KM cross country piping) in 2017-18.
- Execution and Inspection of new piping/tanks in Phosphoric Acid plant-II expansion Project in 2018-19.
- Execution and Inspection of new piping/tanks in Sulphuric Acid plant-III expansion Project in 2022-2023.
- Inspection of Ammonia system and cross-country piping along with M/s TUV in June 2024.
- Inspection of 5KM Ammonia and Sulphuric acid cross country piping along with chemical safety inspection agency in July 2024.
- Eliminated hydrogen grooving in Sulphuric Acid Storage tanks by implementing NACE recommendations.
- Introduced Magnetic crawler thickness inspection for storage tanks to improve safety and reduced scaffolding cost.
- Introduced RLA (Remain life assessment) for equipment and piping.
Father's Name
Vemula Satyanarayana
Languages
- Telugu
- English
Key Skills And Abilities
- Good exposure with P&IDs, Isometrics, Equipment drawings & Equipment data sheets.
- Aligning AI (Asset Integrity) schedules and Inspection strategies with the concept of zero LOPC.
- Visual and Thickness Inspection management.
- Closing of all critical recommendations by rigorous follow up with concerned thereby avoiding unexpected equipment breakdowns, thus meeting Production requirement against budgeted.
- Root Cause Analysis of equipment/piping failures.
- Developing of Inspection Plan and Procedure.
- Performing Remain Life Assessment & Risk Based Inspection as per API 580.
- Knowledge & Experience on different Damage Mechanisms.
- Good knowledge on International Standards of ASME, API & BS.
- Familiar with ASME Sec II, V, VIII, IX, PCC2 & NACE 0294.
- Knowledge on International Inspection codes API 510, 570, 571, 574, 576, 577, 580, 598 & 653.
- Good knowledge on Process Safety Management system (PSMS) & OSHAS 18001.
- Metallurgy and Welding of different Materials used in Fertiliser Industries.
Personal Information
- Notice Period: Not required (will join immediately)
- Date of Birth: 06/09/87
- Gender: Male
- Nationality: Indian
- Marital Status: Married
Certification
API 570 - Piping Inspector
Timeline
Assistant Manager/Tech Asst - Inspection
COROMANDEL INTERNATIONAL LIMITED
03.2006 - 02.2025
Operating Engineer
M/s Borg Warner Morse Tech Murugappa Pvt Ltd
03.2005 - 02.2006
Diploma - Mechanical Engineering
S.M.V.M. Polytechnic
SSC -
M.V.N.Z.P.H. School