Senior Inspection Engineer - Boiler Integrity Specialist

Company:

Location:

Position:

CTC:

1. Job Purpose

Focus point for all inspection and NDT activities, providing expert oversight to guarantee the final installation meets all design, code, and safety standards, thereby ensuring the long-term reliability and safe operation of the power plant boiler.

2. Key Responsibilities

A. Pre-Job & Planning Phase:

• Review and approve all engineering drawings, design calculations, material specifications, and welding procedures related to the boiler modification project.
• Develop and implement a comprehensive Inspection and Test Plan (ITP) for the entire project lifecycle (material receipt, fabrication, erection, pre-commissioning).
• Identify and define all Hold Points (H), Witness Points (W), and Review Points (R) within the ITP in consultation with the project management team.
• Verify contractor and subcontractor qualifications, including welder certifications, NDT personnel certifications, and quality management systems.

B. Material Management & Fabrication Oversight:

• Witness and approve all material (plates, tubes, pipes, fittings) receiving inspections, verifying Mill Test Certificates (MTCs) against project specifications (ASME SA-213, SA-335, etc.).
• Perform positive material identification (PMI) using XRF analyzers to prevent material mix-ups.
• Oversight of all fabrication processes in the workshop, including cutting, bending, rolling, and fit-up, ensuring compliance with dimensional tolerances and welding procedure specifications (WPS).
• Monitor pre-heat and inter-pass temperature controls during welding.

C. Non-Destructive Testing (NDT) Execution & Management:

• Hands-on performance and interpretation

   of critical NDT methods, with mandatory Level-II certification in:

• Radiographic Testing (RT):

   For volumetric examination of welds in pressurized components (e.g., headers, steam drums, thick-walled pipes).

• Liquid Penetrant Testing (DPT):

   For surface breaking defects on non-porous materials.
• Review and validate NDT reports from subcontractors for other methods (UT, MPT, TOFD, etc.).
• Manage the radiographic film/digital data storage, interpretation, and documentation as per code requirements.
• Ensure all NDT equipment is calibrated and procedures are approved.

D. Erection & Site Installation Monitoring:

• Provide continuous surveillance during the erection of boiler pressure parts (superheaters, reheaters, water walls, economizers, headers).
• Witness critical alignment checks, support structure installation, and tube bundle insertion.
• Monitor field welding activities, including the control of welding consumables and the maintenance of pre/post-weld heat treatment (PWHT) records.
• Verify the proper installation of expansion joints, hangers, and supports.

E. Quality Assurance & Documentation:

• Maintain a complete and accurate dossier of all quality records, including:
• Material Certifications
• Weld Maps & Weld Logs
• NDT Reports (RT Films/Images, DPT reports)
• Heat Treatment Charts
• Dimensional Inspection Reports
• Non-Conformance Reports (NCRs) and their closure

F. Compliance & Safety:

• Ensure strict adherence to all applicable codes and standards, including but not limited to 

  ASME Section I (Power Boilers), B31.1 (Power Piping), API 510, NBIC (National Board Inspection Code)

  , and company-specific Asset Integrity procedures.
• Enforce all site safety protocols, with specific emphasis on confined space entry, working at heights, and radiography safety permits.

3. Qualifications & Experience

• Education:

   Bachelor’s degree in Mechanical Engineering, Metallurgical Engineering, or a related field.

• Certifications (Mandatory):

• ASNT NDT Level-II in Radiographic Testing (RT)

  .
• ASNT NDT Level-II in 

  Liquid Penetrant Testing (DPT)

  .
• Certification in 

  Ultrasonic Testing (UT)

   and 

  Magnetic Particle Testing (MPT)

   is a significant advantage.

• Experience:

• A minimum of 5-8 years

   of direct experience in inspection roles within power plants, refineries, or heavy fabrication shops.

• Proven hands-on experience

   with the fabrication and erection of boiler pressure parts is 

  non-negotiable

  .
• Demonstrable experience in managing quality for brownfield plant modifications and tie-ins.

• Technical Knowledge:

• Expert-level knowledge of ASME, API, and ASTM codes.

• In-depth understanding of welding metallurgy, welding processes (SMAW, GTAW, SAW), and PWHT requirements for Cr-Mo steels.
• Proficiency in reading and interpreting P&IDs, Isometric drawings, and fabrication GA drawings.

4. Prequalification Requirements

Candidates must successfully demonstrate the following during the prequalification stage:

1. Practical NDT Test:

    Perform on-site RT and DPT on sample welds, interpret results, and produce a formal report.

2. Document Review:

    Review a sample set of project documents (fabrication drawing, WPS, MTC) and identify non-conformances.

3. Technical Interview:

    A panel interview with the Chief Inspector and Plant Manager to assess technical depth, problem-solving skills, and knowledge of boiler failure mechanisms.

4. Code Knowledge Assessment:

    Written or oral assessment on the application of ASME Section I and B31.1.

• For Apply

  hr@edlipse.com