What I Offer
Comprehensive engineering solutions for your industrial needs
Performance Monitoring
Continuously monitor the operational performance of all unfired pressure vessels and boilers on a monthly basis to ensure optimal functioning and early detection of potential issues.
- Monthly performance tracking
- Early issue detection
- Trend analysis
Documentation Management
Locate and organize all relevant technical and maintenance documents for each piece of equipment, maintaining a well-structured and accessible record of asset history.
- Technical document organization
- Asset history records
- Digital archive system
Repair Record Keeping
Document and track all repair and maintenance activities performed on the equipment, ensuring a comprehensive and up-to-date maintenance log.
- Maintenance logging
- Repair history tracking
- Complete service records
Condition Analysis
Conduct in-depth analysis of equipment conditions as appropriate, to determine the most suitable maintenance schedule and intervention strategies.
- Root cause analysis
- Maintenance scheduling
- Intervention strategies
Quarterly Reporting
Provide detailed quarterly reports summarizing performance trends, maintenance activities, and any findings or recommendations for further action.
- Performance trend reports
- Maintenance summaries
- Recommendations
Yearly Inspection
Carry out thorough annual inspections in accordance with relevant standards and regulations to assess the structural integrity, safety compliance, and overall condition of the equipment.
- Annual safety inspection
- DOSH compliance
- Integrity assessment
Engineering App Suite
Custom-built engineering applications based on 22+ years of practical experience — streamlining quality, compliance, and field efficiency.
Quality Management Center
Complete document control and quality assurance system for pressure vessel and boiler projects.
Method Statements:
- MS-001: Fabrication & Welding Procedure
- MS-002: Hydrostatic Testing Method
- MS-003: Pneumatic Testing Method
- MS-004: Heat Treatment Procedure
- MS-005: Non-Destructive Examination (NDE)
- MS-006: Deaerator Repair & Testing
Inspection Test Plans (ITP):
- ITP-01: Pressure Vessel Fabrication
- ITP-02: Steam Boiler Installation
- ITP-03: Thermal Deaerator Repair
- ITP-04: Piping & Fittings
- ITP-05: Welding & NDT Inspection
Job Safety Analysis (JSA):
- JSA-001: Confined Space Entry
- JSA-002: Lifting & Rigging Operations
- JSA-003: Hot Work & Welding
- JSA-004: Pressure Testing Safety
- JSA-005: Radiography Safety
- JSA-006: Working at Height
Inspection & Test Forms:
- 📄 Hydrostatic Test Report Form
- 📄 Bubble Test Report Form (Deaerator/Leak Test)
- 📄 Visual Inspection Form (Pre-Weld, Post-Weld)
- 📄 Dimensional Inspection Report
- 📄 NDT Report (UT, MT, PT, RT)
- 📄 Heat Treatment Chart Recorder Log
- 📄 Welding Inspection Report
Thickness Easement Report App
Calculate minimum required thickness, remaining life, and corrosion rates for pressure vessels and piping systems.
Key Calculations:
- 📐 Minimum Required Thickness (ASME VIII UG-27)
- 📐 Remaining Life Assessment (Corrosion Allowance)
- 📐 Corrosion Rate (Long-term & Short-term)
- 📐 Maximum Allowable Working Pressure (MAWP)
- 📐 Retirement Thickness Calculation
- 📐 Hydrostatic Test Pressure
Features:
- ✔ Input actual thickness readings from UT
- ✔ Automatic minimum thickness calculation
- ✔ Generates printable easement report
- ✔ Trend analysis with corrosion charts
- ✔ API 510 compliant reporting
- ✔ Excel export for record keeping
tmin = (P × R) / (S × E - 0.6 × P) + CA
WPS / PQR / WQT Form App
ASME Section IX compliant welding procedure and welder qualification management system.
Welding Procedure Specification (WPS):
- WPS Generator (SMAW, GTAW, FCAW, SAW)
- Preheat & Interpass temperature tracking
- PWHT parameters & monitoring
- Essential & Non-essential variables checker
- Automatic ASME IX compliance verification
Procedure Qualification Record (PQR):
- PQR template with ASME IX Section QW-200
- Mechanical test result logging (Tensile, Bend, Impact)
- Macro-etch & hardness test tracking
- Digital signature & approval workflow
- Welder continuity log & renewal alerts
Welder Qualification Test (WQT):
- Welder performance tracking & renewal dates
- Test coupon tracking & results logging
- Qualification scope management (process, thickness, diameter)
- Digital welder ID cards & certification expiry alerts
- Welder continuity log & renewal alerts
Assessment Analysis App
Risk-based inspection (RBI) and fitness-for-service (FFS) assessment for pressure equipment.
Analysis Modules:
- 📊 Remaining Life Assessment (RLA)
- 📊 Risk-Based Inspection (RBI) scoring
- 📊 Fitness-For-Service (API 579 / FFS)
- 📊 Corrosion growth projection (Linear/Non-linear)
- 📊 Fatigue & Creep analysis (where applicable)
- 📊 Probability of Failure (POF) calculations
Reporting Outputs:
- ✔ Risk matrix (Likelihood vs Consequence)
- ✔ Inspection interval recommendation
- ✔ Mitigation action plan & priority ranking
- ✔ PDF & Excel report export
- ✔ Equipment criticality ranking
- ✔ Maintenance strategy optimizer
AI Integration:
- 🤖 Predictive failure mode analysis
- 🤖 Anomaly detection from historical data
- 🤖 Automated maintenance strategy generator
- 🤖 Risk score prediction from sensor data
Success Stories
Real-world examples of how I've helped clients solve complex engineering challenges
Restoring Zero-Oxygen Performance at Palm Oil Mill
The Challenge
A 15-year-old thermal deaerator at a palm oil mill in Malaysia was experiencing recurring oxygen breakthrough, with dissolved oxygen levels exceeding 15 ppb (target: <7 ppb). This caused severe pitting corrosion in the boiler system, leading to frequent tube failures, increased maintenance costs, and unplanned downtime averaging 48 hours per month.
Root Cause Analysis
Upon investigation, I identified multiple issues:
- Degraded spray nozzles with 60% blockage
- Corroded tray support structure causing tray misalignment
- Worn inlet baffles disrupting water distribution
- Inadequate vent capacity causing excessive steam loss
The Solution
I developed a comprehensive repair plan including:
- Complete replacement of spray nozzle assembly
- Tray system realignment and structural reinforcement
- New inlet baffle design with optimized flow distribution
- Upgraded venting system with automatic control
- Post-repair performance validation testing
ASME Compliance for Industrial Plant
The Challenge
A chemical processing plant required urgent repair to their main storage vessel after a pressure safety valve discharge incident. The vessel had not undergone proper documentation for 8 years, and the client needed urgent DOSH compliance and NBIC R-Stamp recertification to resume operations.
Assessment & Planning
Initial assessment revealed:
- No historical documentation available
- Minor external corrosion on shell course
- Required thickness testing across all sections
- Weld repair needed on nozzle attachment
The Solution
Comprehensive repair scope:
- Complete thickness survey using ultrasonic testing
- Weld repair with qualified ASME IX welders
- New pressure relief valve installation
- Full documentation package per NBIC requirements
- DOSH permit renewal and inspection coordination
Machine Learning System for Boiler Failure Prediction
The Challenge
A multi-site palm oil mill group was experiencing unpredictable boiler failures causing production losses. Traditional preventive maintenance was costing RM 2.1M annually in unplanned downtime, and they wanted to transition to predictive maintenance using their existing operational data.
Data Analysis
After collecting 3 years of operational data:
- 150+ failure events recorded
- Key failure indicators identified: stack temperature, feedwater conductivity, combustion efficiency
- Correlation between operating parameters and failure events established
- Baseline performance metrics defined
The Solution
Implemented AI-powered predictive system:
- XGBoost model trained on historical data with 94% accuracy
- Real-time data integration with existing SCADA system
- Custom dashboard for maintenance team with alerts
- Weekly automated reports identifying at-risk equipment
- Integration with CMMS for work order generation
Method Statement Development for Pressure Vessel Repair
The Challenge
A new palm oil mill contractor needed comprehensive method statements for DOSH compliance on their first boiler installation project. They lacked in-house expertise to develop the required technical documentation for regulatory approval.
Scope Definition
Consultancy scope included:
- Boiler erection method statement
- Hydrotest procedure and acceptance criteria
- Steam blow procedure
- Welding procedure specifications
- Quality control inspection and test plan (ITP)
- Risk assessment and JSA
The Solution
Delivered complete documentation package:
- 8 comprehensive method statements
- 15 supporting procedures and forms
- WPS for all applicable weld types
- Complete ITP with hold points
- DOSH submission and approval coordination
- On-site training for QA/QC team
Engineering Tools & Codes
Design Software
PV Elite – advanced pressure vessel design & analysis
AutoCAD Mechanical • Autodesk Inventor
ASME Codes
ASME Section VIII Div. 1 • Section IX • Section V • Section II
BS1113 • BS2790 • NBIC • DOSH
AI & Automation
Python • scikit-learn • XGBoost • Data visualization
Predictive maintenance models
Recent Projects
A selection of my recent engineering work
Deaerator Repair - East Palm Oil Mill
Complete restoration of thermal deaerator, restoring zero-oxygen performance.
Water Tube Boiler Tube Replacement - Golconda Palm Oil Mill
Remove, clean, installation new tube testing & commissioning.
Predictive Maintenance System
ML-based failure prediction system reducing unplanned downtime by 25%.
Steam Receiver Audit - Liquid Palm Gua Musang
Comprehensive safety inspection and documentation for regulatory compliance.
Oblique Steriliser Fabrication - Pagoh Palm Oil Mill
Complete steriliser from Design Calculation, drawing, fabrication, installation, testing & commissioning for mill expansion.
Method Statement Development
Comprehensive repair method statements for pressure vessel and boiler systems.
Frequently Asked Questions
A thermal deaerator removes dissolved oxygen from boiler feedwater to prevent corrosion. Over time, tray systems and spray nozzles degrade, reducing efficiency and allowing oxygen breakthrough. This leads to pitting corrosion, boiler tube failures, and increased maintenance costs.
Most deaerator repairs can be completed within 2-4 weeks, depending on the extent of damage and availability of parts. We provide a detailed timeline after initial assessment. Post-repair validation testing typically takes 1-2 days.
Yes, I provide both on-site and remote consulting services worldwide. For on-site work, I've completed projects in Malaysia, Indonesia, and surrounding regions. Remote consulting is available for documentation review, method statement development, and AI implementation guidance.
I hold ASME certifications in Section VIII (Pressure Vessels), Section IX (Welding), Section V (Nondestructive Examination), and Section II (Materials). I'm also certified in NBIC (National Board) and familiar with DOSH regulations in Malaysia and equivalent standards in other jurisdictions.
AI-based predictive maintenance analyzes historical operational data to predict equipment failures before they occur. This can reduce unplanned downtime by 20-35%, lower maintenance costs by 10-25%, and extend equipment life. I can implement a customized solution based on your existing data infrastructure.
For an accurate quote, I typically need: equipment type and age, current issues/symptoms, any existing inspection reports, your timeline requirements, and site location. I offer free initial consultations to assess your needs.
Let's Solve Your Problem
Reach out for consulting, site inspection, or AI maintenance integration.
Available for on-site & remote projects worldwide