1. SUDHANSU BHUSAN MOHAPATRA
Mobile: +971-528904293 / E-Mail: M_SUDHANSU@HOTMAIL.COM
Address: Flat- 157-08-08, Ruwais Housing Complex Abu Dhabi-11885, UAE
Seeking challenging assignments in Refinery Asset Integrity Studies, Corrosion Studies , Material Failure
Analysis with an organization of repute
Core Competencies
 Static Equipment Inspection  Corrosion Study  Material Selection
 Material Failure Analysis  Remaining Life Assessment  Condition Monitoring
 Mechanical & Metallurgical laboratory Testing  Project Management
Profile Summary
 Result oriented professional with over 25 years of experience in Inspection Engineering, Material Studies,
Corrosion Monitoring, Failure Analysis , Remaining Life Assessment and Condition Monitoring of Static
Equipment.
 Extensive Understanding of Codes and Practices associated with Refining Sector, viz, API (Mainly: 571, 510, 570, 580 &
581 etc.), NACE (Mainly MR-103, 175, RP-170,300,198,189 etc.), ASTM, ASME, API
 Understanding of International Safety Rating System (ISRS), ISO and TPM Protocols.
 An effective communicator with excellent relationship, management skills and strong analytical, problem solving and
organizational abilities.
 Skilled at establishing professional credibility in the areas of quality system management.
Key Work Experience
 Static Equipment Inspection
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2.  Periodic / shut down inspection, recommendations for repair / replacement, Quality assurance
during repair / replacement etc. Worked for the following area: Offsite facilities, Refinery process
units: Fired Heaters, Distillation columns, Reactors, Storage vessels, Boiler component
 Failure Analysis & Corrosion Studies
 Failure Analysis of Overhead condenser tubes: Study indicated failure of cu-Ni tubes in H2S environment
prevailing in shell side (Tube side fluid- Seawater). Metallurgy up-gradation to Duplex SS and Titanium Tubes
suggested.
 Failure Analysis of Overhead air fin-cooler tubes: Study indicated failure of carbon steel tubes due to under
deposit corrosion at inlet end in presence of Ammonium Chloride salt. Inadequate wash water injection is the
primary cause of deposit leading to corrosion. Improvement in wash water system and proper corrosion
inhibitor dosing suggested.
 Failure of Coker tube: Long Exposure to high temperature due to malfunction of burner arrangement. Creep
voids noticed in the failed component which was the reason for tube failure. Burners adjusted and damaged
tube replaced. Strict skin temperature monitoring suggested.
 Failure Analysis of CO-duct of FCCU: External stress corrosion cracking due to leaching of chloride ion from
insulation noticed. Proper leak proof insulation and chloride free insulation material suggested
 De-zincification of Brass tube: Failure analysis indicated failure due to de-zincification. Recommended for use
of Admiralty brass.
 Cooling Water Corrosion study: Identification and quantification of Microbiological growth in re-circulating
cooling water system. Study on the effectiveness of dosing system to control such corrosion.
 Crude overhead system corrosion study: Effectiveness of De-salter, Corrosion inhibitor injection
 Failure study of Hydrogen Reformer tubes: Failure due to Mid-wall creep formation and growth.
Recommendation given for Automatic Ultrasonic Scanning (AUS) for early detection of creep formation and
planning of corrective actions.
 Failure analysis of Boiler water wall tube: Failure due to high temperature exposure. Microstructure indicated
globular carbide resulting from dissolution of pearlite colony. Sudden feed water starvation is the reason of
high heat flux
 Review of Neutralization procedure of Austenitic Stainless Steel Equipment during Plant Shutdown.
 Review and monitoring corrosion parameters of important process stream on daily basis.
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3.  Condition Monitoring of Critical Equipment
 In-situ Metallography of FFCU Plenum Chamber: Extensive Sigma-phase notice on the SS-304 material
which indicated significant drop in room temperature impact property. The chamber was replaced as per
recommendation.
 In-situ Metallography of Kero Hydro de-sulphurization Heater tube: Polythionic acid attack noticed. Suitable
passivation as per NACE RP 170 recommended before heater is opened to atmosphere
 In-situ Metallography of Heater tube at KNPC: Polythionic acid attack noticed. Suitable passivation as per
NACE RP 170 recommended before heater is opened to atmosphere
 Metallurgical condition monitoring through In-situ metallography & Hardness check on critical high
temperature equipment during turnaround.
 Remaining Life assessment (RLA) Studies
 Remaining Life Assessment (RLA) studies of Hydrogen Reformer Tubes: Assessment carried out on HP
modified micro-alloyed (H39WM - Paralloy make) tubes after 12 years of operation through mechanical and
metallurgical property evaluation. Significant deterioration in mechanical property and initiation of creep
damage noticed. Recommended for replacement after 15 years of operation.
 Remaining Life Assessment (RLA) of heater: Associated with RLA of process heater tubes. In-situ
metallography, Hardness survey, OD gauging and Accelerated Stress Rupture Test (ASRT) on sample tube
was conducted. Damage mechanism was identified form the observed degraded metallurgical structure as
well as from hardness values. Results of ASRT plotted in the published stress curve to get Larsen Miller
Parameter and from there the evaluation of remaining life was estimated.
 Remaining Life assessment (RLA) of Boiler Tubes: Associated with RLA Boiler Tubes. In-situ metallography,
Hardness survey, OD gauging and Steam side scale thickness measurement carried out. Damage
mechanism was identified form the observed degraded metallurgical structure as well as from hardness
values. Highest temperature of exposure was plotted in ASRT plot and RLA was estimated
 Health Assessment of Vis-breaker Tubes. : In-situ metallography, Sample tube metallography and
Accelerated Stress Rupture Test (ASRT) indicated Carburization from inside to outside. It was accompanied
with loss of room temperature impact properties. No significant loss of high temperature property was noticed.
Recommended to avoid shock loading and excessive hammering during shutdown to avoid brittle failure.
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4.  Project Management
• Material Selection
 Review of material selection for 15 Million Ton grass root refinery that include : Crude & Vacuum Distillation
unit, Catalytic Reforming unit, Fluid Catalytic Cracking Unit, Hydrocracker Unit, Hydrogen Reformer unit ,
Coker Unit, Sour Water Stripper unit and related piping circuit, Tankages and offsite piping.
 Part of the team for selection of material for Indian Oil developed FCC unit (Indmax Unit)
• Review of Quality Assurance Plan
 Fabrication quality assurance Plan for Pressure vessel, Heat Exchangers, Piping ( Low temperature, High
Temperature, Sour service)
 Welding Procedure and welder Qualification approval
• Vendor Interface
 Interface between manufacturer and PMC in expediting all Engineering issues like approval of manufacturing
drawings and other documents. Visit to vendor shop to Review the fabrication facilities, review of the
fabrication plan, Review of raw material status, Sub-vendor supply status and review of third party inspection
plan and expediting the dispatch of the fabricated equipment.
Employment History & Growth Profile
Company Designation Period
Takreer Refinery - Abu Dhabi Oil Refining
Company
Senior Corrosion Engineer – Inspection
Department
November 2012 - till date
Indian Oil Corporation Limited. Ltd
-Refineries HQ
Chief Project Manager – Project
Department
2007 - 2012
Indian Oil Corporation Limited - Digboi
Refinery
Senior Inspection Manager – Inspection
Department
2004 - 2007
Indian Oil Corporation Limited - Research
and Development Centre
Inspection Manager 1999 - 2004
Indian Oil Corporation Limited - Research
and Development Centre
Deputy Manager Inspection 1995 - 1999
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5. Indian Oil Corporation Limited - Research
and Development Centre
Senior Inspection Engineer 1991 - 1995
Indian Oil Corporation Limited - Haldia
Refinery
Inspection Engineer 1985 - 1991
Academia Credentials
1983 B.Sc. Engineering (Metallurgy) from Regional Engineering College, Rourkela, Orissa
2001 Degree – Master of Business Administration, University of Ljubljana, Slovenia
Professional Certifications
1987 Industrial Radiography and Safety by Bhaba Atomic Research Centre, India
1992 Ultrasonic Testing Levels: I & II by Indian Society for Non-Destructive Testing (ISNT), Mumbai
2015 API 571 - Corrosion & Material
Publications
• Co-author of “Corrosion Manual” published by Indian Oil Corporation Ltd.
• Master’s Degree Thesis on “The Effectiveness of Risk Based Inspection System for refineries at Indian
Oil Corporation. Ltd,”
Feats
• Article presentation in NACE-India workshop
• Faculty member in the Material failure analysis training program conducted by Indian Oil R&D Centre for Indian and
overseas Refinery engineers
Personal Details
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6. Date of Birth: 8
th
November 1960 Languages Known: Proficient in English, Hindi and Oriya
Passport No.: H0971141 (Date of Expiry: 09.10.2018) Nationality: Indian
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7. Date of Birth: 8
th
November 1960 Languages Known: Proficient in English, Hindi and Oriya
Passport No.: H0971141 (Date of Expiry: 09.10.2018) Nationality: Indian
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