Fuel Tank Inspector

Overview of CTG:

• CTG support and manage humanitarian projects in fragile and conflict-affected countries around the world. With past performance in 15 countries – from the Middle East, Africa, Europe, Asia and Central and South America – we offer a holistic fabric of project management, implementation and support. Skilled in emergency response to crises such as the Ebola outbreak in West Africa, we have the ability to act quickly (crisis response teams can be on the ground in 24 hours) and to establish structured operations in high-risk environments. CTG recruit and manage qualified, skilled teams with extensive experience operating in challenging conditions.

Overview of the position:

• Our client is currently engaged with the Ministry of Affairs of Norway in implementing an above ground 10 million liter steel fuel tank at the Gaza Power Plant in Gaza, oPt. They contracted a local construction company to perform the design, manufacturing, installation, testing & commissioning of the tank. The design stage of the project is already accomplished & it was made according to the API 650 standards & was certified by a 3rd party design reviewer. Currently the project at the stage of installation in Gaza.
• The scope of this contract is related to a 3rd party inspection assignment for the newly constructed 10 million steel fuel tank & its connections to ensure its safety & reliability use. The Inspector will be responsible to certify that the tank & all of its components, connections & connected devices meets the requirements of API 650 standards - 12th edition & its subsequent addendums & other relevant related standards.

Role objective:

The main responsibilities of the Fuel Tank Inspector are:

• Adhere to project’s technical specifications, design drawings, technical codes & standards.
• Inspection procedures, tests in accordance to API 650 standards.

Responsibilities:

• Put in place an “Inspection & Test Plan (ITP)” in accordance with API 650 requirements, for the complete tank inspection, this plan shall be finalized in agreement with our client, the manufacturing factory & the main contractor. The ITP should consider the required inspections & tests for the final inspection of the tank before certifying for operation.
• On Site inspection (in GPP – Gaza), including witness & verification for all important tests & inspections in accordance with API 650 requirements such as, alignment inspection, welding inspection, dimensional control, hydrostatic testing, mechanical running testing, performance testing, painting inspections, fitting & accessories inspection, pipe connection test, etc.
• Testing & commissioning control, the Inspector is also required to control the final testing & commissioning for the tank, for compliance with API 650 before its cleaning & first fill with fuel.
• The testing & commissioning shall include leakage testing & workmanship for the tank & all associated pipe connections & fittings.
• During the installation, testing & commissioning phases the Inspector shall work closely with our client on site team & the contractor in order to ensure that the welding & installation activities are performed up to standard with high quality workmanship. The agency shall also be responsible for giving advice, corrective actions & best practice procedures to the contractor.
• Weekly progress reports during the period of on site installation, testing & commissioning phases, shall be submitted within 3 calendar days after the end of each working week.
• Upon completion of all tests, inspections & up to the satisfaction of the Inspector, S / He shall provide our client & its partners with a final report including an official certification for the tank in accordance with API 650, in order to allow it to be put into operation.
• In order to facilitate the Inspector role, the Inspector will be granted access to all parts of the job & will also be given reasonable facilities to ensure that S / He performs her / his role efficiently.
• In relation to the tests stated in point (l) below, that are required from the manufacture / contractor as per the API, the Inspector shall be able to perform any required tests independently as follows:

Events the agency to execute independent testing:

• If the Inspector requires additional tests to the ones specified in API 650.
• If the contractor / manufacture fails to perform the required tests for any reason, such as lack of capacity, lack of equipment, uncertainty of the calibration of the testing equipment used.

Procedure for executing independent testing:

• The required tests shall be determined in the Inspection Test Plan (ITP).
• The Inspector shall send highlights to our client if the performed testing by the manufacturer / contractor is not taking place as should be or if performed in an inappropriate manner.
• The Inspector shall obtain our client approval prior to executing any NDT test.
• The NDT test results should form part of the issued reports by the Inspector to our client.

The Inspector’s responsibilities when executed Independent testing:

• Listing & specifying of all required specialized tools & testing equipment as required by API 650, such as but not limited to, radiographic / ultrasonic testing equipment (if necessary), calibrated vacuum test kits, calibrated pneumatic test kits, calibrated hydrostatic test kits, etc.
• If the contractor was not able to provide any tool / equipment requested in the list due to restriction in Gaza, then the Inspector shall propose an alternative as per the API code.
• Execute the tests & analyze the test results.
• Provide corrective advice to the manufacturer / contractor.
• Report the test results to our client.

The contractor responsibilities when the Inspector executes independent testing:

• Preparing the tank / or tank components for testing.
• Facilitating any required labours to perform tests.
• Cleaning, rinsing, drying, or any other requested activity by the Inspector.
• Filling & emptying of the tank.
• Provide fluids required to perform the tests such as, water supply, penetrating oil, etc.
• Providing general purpose equipment, such as, air compressors, water pumps, etc.
• The quantity & type of welding tests & inspections to be performed shall be in accordance with API 650, including but not limited to the following:

Butt welds:

• Complete penetration & complete fusion are required for welds joining shell plates to shell plates. Inspection for the quality of the welds shall be made using either the radiographic method specified in 8.1 of the API code or alternatives advised by the Inspector using the ultrasonic method specified in section 8.3.1 of the API 650 standards. In addition to the radiographic or ultrasonic examination, these welds shall also be visually examined. Furthermore, the Inspector may visually inspect all butt welds for cracks, arc strikes, excessive undercut, surface porosity, incomplete fusion & other defects. Acceptance & repair criteria for the visual method are specified in section 8.5 of the API 650 standard.

Fillet welds:

• Fillet welds shall be inspected by the visual method. The final weld shall be cleaned of slag & other deposits prior to inspection.

Examination & testing of the tank bottom:

• Upon completion of welding of the tank bottom, the bottom welds & plates shall be examined visually for any potential defects & leaks. Particular attention shall apply to areas such as sumps, dents, gouges, 3 plate laps, bottom plate breakdowns, arc strikes, temporary attachment removal areas & welding lead arc bums. In addition, all welds shall be tested by 1 of the following methods:

• A vacuum box test in accordance with section 8.6 of the API 650 standard.

• A tracer gas test in accordance with section 8.6.11 of the API 650 standard.

• After at least the lowest shell course has been attached to the bottom, water (to be supplied by the contractor) shall be pumped underneath the bottom. A head of 150 mm (6 in.) of liquid shall be maintained using a temporary dam to hold that depth around the edge of the bottom. The line containing water for testing may be installed temporarily by running it through a manhole to one or more temporal), flange connections in the bottom of the tank, or the line may be installed permanently in the subgrade beneath the tank.

Inspection of reinforcing plate welds:

• After fabrication is completed but before the tank is filled with test water, the reinforcing plates shall be tested by the contractor by applying up to 100 kPa (15 Ibf / in2) gauge pneumatic pressure between the tank shell & the reinforcement plate on each opening using the telltale hole specified in section 5.7.5.1 of the API 650 standard. While each space is subjected to such pressure, a soap film, linseed oil, or another material suitable for the detection of leaks shall be applied to all attachment welding around the reinforcement, both inside & outside the tank.

Testing of the shell: After the entire tank & roof structure is completed, the shell shall be tested by 1 of the following methods:

• If water is available for testing the shell, the tank shall be filled with water as follows: (1) To the maximum design liquid level, H. (2) For a tank with a tight roof, to 50 mm (2 in.) above the weld connecting the roof plate or compression bar to the top angle or shell. (3) To a level lower than that specified in subitem 1 or 2 when restricted by overflows, an internal floating roof, or other freeboard by agreement with the GPP, or 4) To a level of seawater producing a bottom of shell hoop stress equal to that produced by a full height freshwater test. The tank shall be inspected frequently during the filling operation & any welded joints above the test water level shall be examined in accordance with Item (b) below. This test shall be conducted before permanent external piping is connected to the tank. After completion of the hydrotest, only nonstructural small attachments may be welded to the tank in accordance with section 7.2.1.11 of the API 650 standard.
• If sufficient water to fill the tank is not available, the tank may be tested by (1) Painting all of the joints on the inside with a highly penetrating oil, such as automobile spring oil & carefully examining the outside of the joints for leakage. (2) Applying vacuum to either side of the joints or applying internal air pressure as specified for the roof test in section 7.3.7 of the API 650 standard & carefully examining the joints for leakage. (3) Using any combination of the methods stipulated in this section, subitems 1 & 2.
• The requirements of this hydrostatic test shall be in accordance with section 7.3.6 of the API 650 standard.

Testing of the roof: Upon completion, the roof of the tank shall be tested by 1 of the following methods:

• Applying internal air pressure not exceeding the weight of the roof plates & applying to the weld joints a bubble solution or other material suitable for the detection of leaks.
• Vacuum testing the weld joints in accordance with 8.6 to detect any leaks.

Project reporting:

The inception report: After signing contract, the Inspector shall carry out a reconnaissance of the tank design & submit to our clients review an inception report for the inspection works, this report shall be based on the inspection requirements for above ground fuel storage tanks according to API 650 / 653 & include but not limited to the following:

• The fulfilment of the implementation of the activities listed in “the expected outputs” of this TOR.
• Explain & elaborate on the Inspector’s approaches & methodologies to be utilized in the development of the inspection work.
• The Inspection & Test Plan (ITP) includes listing of recommended tests, schedule of the tests & the resources needed for each test (technicians, tools, equipment).

On site weekly progress report(s):

• During inspection of the works on site in the installation, testing & commission phases of the project, the Inspector shall submit weekly progress reports highlighting the progress of works on site & provide an overview regarding the inspections work activities performed at each stage, the results of those inspections & the compliance with API 650. The weekly progress reports shall also highlight any issues found and advice on appropriate remedial works.

Monthly inspection report(s):

• Those reports shall include an overview of the physical & technical accomplishment during the working month & compare that with the agreed schedule of work with the contractor. The monthly reports shall also highlight any pending issues related to the inspection of the works & advice on required actions. Each monthly report shall include an updated schedule for the inspections of works 1 month ahead.

Final inspection report:

• This report shall be produced at the end of the assignment & shall include all the inspection works conducted during all the construction & installation phases of the tank, list of inspections performed, inspection results & the final recommendations.
• The final recommendation of the Inspector to our client for acceptance of the readiness of the tank & its related works for operation, shall be joined with an official certification from the Inspector regarding compliance of the steel tanks & its related works against required standards & specifications.

Nondestructive testing:

• Upon our clients written confirmation, the Inspector shall execute pre agreed 3rd party nondestructive test & submit the results to our client, those tests shall form part of the mentioned above reports.

Team management:

• S / He will not be asked to manage any team member.
• Although no direct formal management is foreseen, good managerial & coordination skills are necessary for the fulfilment of daily work with the contractor.

Geographical experience:

• Minimum of 7 year of experience in Middle East (desirable).

Education:

• Diploma in relevant Engineering discipline from a reputable college / university.
• Bachelor in relevant Engineering discipline from a reputable university.

Certification:

• Inspectors shall hold API 653 certification or similar.
• Inspector shall be ISO 9712 certified, ASNT certified or similar.

Experience:

• Excellent expertise in site construction of steel storage tanks as per API regulations, silos, pressure vessels & structural steel works.
• Engineering, construction, pre commissioning, commissioning, start up & performance test experience of storage tank with minimum capacity of 5,000 m3.
• Familiarity with potential safety & health hazards associated with project activities & ability to advise management on the procedures to mitigate in case of concerns.
• Candidates with experience working with UN or other humanitarian / development agencies will be well regarded.
• Minimum of 7 or more years of prior relevant experience.
• Minimum of 5 or more years of prior relevant experience, for a Bachelor degree holder.

Languages:

• Strong written & verbal communication skills in English, Arabic will be an advantage.

Technical knowledge:

• The Inspector shall have proven previous experience in tanks inspection in accordance with API 650 / 653.
• The Inspector shall have experience in comprehensive assessment techniques for inspection of storage steel tanks various components, including but not limited to, tanks shells, floors, roofs, welds, internal / external corroded elements, foundation, pipework connections, valves & fitting, etc.
• The Inspector shall have a comprehensive experience in applied Engineering Inspection & supervision for non destructive testing, such as but not limited to: radiography, ultrasonic (phased array PAUT, time of flight diffraction TOFD , etc.), Magnetic Particle Inspection (MPI), Dye Penetrant Inspection (DPI), eddy current testing, visual testing, corrosion mapping, vacuum inspection, etc.
• The Inspector shall have 2 similar inspection experiences of tanks with similar or greater capacities.

Core values / competencies:

• Professionalism.
• Respect for diversity.
• Creativity & innovation.
• Commitment to continuous learning.
• Organizing & quality.
• Results orientation.
• Communication skills.
• Teamwork skills.
• Client focus.

Functional competencies:

• Ability to work to meet tight schedules under stressful environment & varied cultural context.
• Good team player attitude.
• Ability to perform work with professionalism, integrity & commitment to project demands.
• Excellent communication skills in English both verbal & written.
• Demonstrated computer ability in using MS Office Suite, Technical Software (AutoCAD, MS Project).
• Good presentation & planning.
• Ability to participate in technical presentations whenever needed.
• Self-motivated to 'close the loop' with actions & administrative responsibilities.
• Efficient in proper documentation & reporting to meet ISO standards.
• Able to build & maintain both internal & external relations on various levels.

Other relevant information:

• The incumbent must be mentally & physically fit.
• The incumbent must have a clean criminal record.
• When visiting the construction sites, all duties are performed in PPE, safety hat, boots & high viz.
• Duties may require long periods of standing.
• Qualified female candidates are strongly encouraged to apply.

How to apply:

Candidates interested in applying for this role need to register on CTG website as a candidat e& apply for this role using the below link:
https://recruitmentctg.force.com/xcdrecruit__Site_ExternalPositionDetails?id=a113W000000Hk6R