Curriculum Vitae
Inspection/Asset Integrity Manager
Eng. Zakarya Hiba
23 Taksiem Gamayet El-Draaeb , El-Slam Bldg..
EL-Syouf , Elsaah , Alex. , Egypt.
002 03 5297339
002 0100 5313394
Zakaryahiba@hotmail.com
(Home)
(Mobile)
(E-Mail)
I-Introduction
I graduated from faculty of Engineering in May, 1996 (BSc. Of Mechanical Power Engineering), completed military service
by the 1997, then started my work in (Petroleum, Refinery, Gas Plant, and Petrochemical) Industries since 1998 till now
(About # 16 years of Experience) as summarized hereinafter:
Company
Main Position
Egyptian Maintenance Company (EMC)
Dolphin Energy – Gas Plant (RasLafan –Qatar)
Alexandria Petroleum Maintenance Company (APM) – ELNG Site)
Amrya Petroleum Refinery Company (APRC)
Petrojet – MIDOR Site
Period
Inspection Department Manager
Risk Based Inspection Team Leader
Inspection Section Head (Supervisor)
Inspection – Technical Office) Engineer(
QA/QC Engineer
2007-2014
2006-2007
2005-2006
1998-2005
1998-1998
Most of my Experiences are related to (In-Service inspection, Risk Based Inspection, Fitness for Service, and development
of Asset Integrity solutions) including #6 years as a Project Manager for the following successful Projects:
In-Service Inspection Project
My Company / Owner
Reliability Centered Maintenance Project
Risk Based Inspection Project
Fitness For Service Project –Phenol Extraction Unit (14)
Base Line Survey Projects
Base Line Survey Projects
EMC / E-Styrnics
EMC / Petrobel
EMC / APRC
EMC / GASCO
EMC / Rashpetco
Period
2012-2013
2011-2012
2010-2011
2009-2010
2008-2009
During my working with EMC, I leaded the 1st Egyptian (Risk Based Inspection) software creation (2010-2011) as well as
the 1st Egyptian (Reliability Centered Maintenance) Program with successful implementation at Petrobel & E-Styrnics.
I am member board of the following International Societies:
American Welding Society (AWS)
Membership No. 563952
American Society for Non Destructive Testing (ASNT)
Membership No. 185117
American Petroleum Institute (API)
Membership No. 18715 / 199
Egyptian Engineering Syndicate.
Membership No. 06422 / 35
I shared in many of consultation studies with multi-national companies as summarized hereinafter:
Field of Consultation
Development of Risk Based Inspection Program
Repeated piping failure due to Flow Induced Vibration
Metallurgical Investigation for Hydrogen Reformer Failure
Investigation of HIC-SOHIC and piping Material Upgrading
RCA of Repeated failure of Main Compressor of medicinal oil unit
Owner
Period
EMC
ELNG-SABIC-Dolphin-Rashpetco
APRC with Tabbin Institute
APRC with Facility of Engineering
APRC with ABB
2010-2011
2005-2006-2007-2009
2004
2003
2002
I shared in transferring In-Service Inspection technology & Experience via conducting a lot of free seminars in Egypt
(Engineering Syndicate) & prepaid seminars in middle east with official contract between EMC & Haward Technology.
I am Authorized (API-AWS-ASME) Instructor for Haward Technology Middle East & Lahaye International University.
During my work life, I gained a lot of International appreciation certificates as well as two post graduate certificates from
Alexandria University & Tabbin Institute of Metallurgy ( Diagnostic Engineering & Welding Engineering).
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II- Certification & Qualification
Certification:
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B.Sc. Of Mechanical Power Engineering 1996
Diploma in Diagnostic Engineering 2000
Menofya University
Alexandria University
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Preliminary Master in Welding Engineering 2005
Tabbin Institute for Metallurgy
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Certified API-570 (Authorized Piping Inspector).
Certificate # 29996
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Certified API-653 (Authorized Storage Tank Inspector).
Certified API-510 (Authorized Pressure Vessel Inspector).
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Certified Welding Inspector (CWI).
Certificate# 30428
Certificate# 33471
Certificate# 07041431
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Certified ASNT Level II in (RT, PT, MT, UT and VT).
Cert. of L. III# 74268
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Certified as Category II in vibration from American Vibration Institute.
Cert.# GOES 3661
Qualification &Training Courses:
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Project Management Professional (PMP)
Pressure Relief devices (Design – Inspection Maintenance)- API-527/576
Inspection of fired boilers and Heaters (API-573).
Codes & Standards (ASTM-API-ASME-NACE-DIN-JIS-BS-…)
Pressure Vessel Design & Construction (ASME VIII-Div-1).
Process Piping Design & Construction (ASME B31.3)
Piping & Pressure Vessel Inspection Technology
Application and Inspection of Cathodic Protection, Lining & Coating.
Root Cause Analysis.
Piping Vibration analysis
Diagnostic methodology (Pressure – Temperature – Noise – Oil – Vibration) analysis
Storage tank Inspection (API-653, API-620, and API-575)
Welding Inspection Technology & Welding metallurgy.
Corrosion prevention and damage mechanism
Application of Risk Based Inspection API-580 / 581 (E2G).
Fitness for Service API-579
Environmental Management System.
Credo –RBI Software.
Non Destructive Examination (Basic- Level III)
Crises Management
Project Management training Program (PMP)
Presentation & Communication skills
ISO-17020 (EGAC-ILAC) Lead Editor
HSE (Fire fighting – First aid – PTW – TRA – Working at height – Confined Space – Defensive driving – Process
Hazards analysis - Tag out – Look out…).
Process Safety Management (PSM).
Advanced Inspection techniques for non-Intrusive Inspection (UT-Guided wave- Intelligent Pig – Robotic tank
Inspection – Thermograph Inspection )
III- Work Experience
2007 –Till Now
1. Egyptian Maintenance Co. (EMC)
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Asset Integrity (Acting R&D) Sector Manager (from Apr. 2010 till now)
Inspection Department Manager (From Nov. 2007 till Apr. 2010)
2. Dolphin Energy Limited (Qatar / Ras Lafan)
 RBI / FFS Team Leader
2006-2007
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3. PETROMAINT / Egyptian Liquefied for Natural Gas (ELNG Site)
 Inspection Section Head
2005-2007
4. Amrya Petroleum Refining Company (APRC)
 Inspection Engineer
1998-2005
5. PETROJET / Middle East Oil Refinery (MIDOR Project)
 QA/QC Engineer
1998-1998
6. Part Time Activities (Inspector-S/D Mgr.- Instructor - FFS / RBI Consultant)
Part Time activities as Asset Integrity Consultant:
I conduct a lot of Inspection consultation with (SABIC- ARAMCO-Yemen LNG- Carlo Gavzzi- Syncor Oil).
Field of consultation cover the following items:
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Conduct initial RBI studies and define damage mechanisms for critical equipment and piping loops.
Build up Asset Integrity strategies for new Plants.
Fitness for service calculation for major inspection finding after intrusive inspection.
Assessment of fire damage for the equipment which subjected to fire failure.
Prepare Inspection procedure and recommended NDT for critical equipment.
Calculate actual remaining life for special damage mechanisms like Flow induced vibration and thermal fatigue.
Part time activities as Instructor
Acting as senior Instructor with HTME, TUV, ITC, and Lahaye International University to teach the following courses
related to QA/QC , NDT, Welding, Corrosion, Metallurgy, In-service Inspection, RBI, FFS, and Asset Integrity since Jan.
2005:
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Risk Based Inspection API-580 / API-581
Fitness for Service (FFS)- API-579
Certified Welding Inspector (CWI Preparatory Exam Course )
Welding Design & Inspection codes.
Inspection Codes and Standards.
Piping Inspection Codes (API-570 exam preparatory course)
Pressure Vessel Inspection Codes (API-510 exam preparatory course)
Above Ground Storage tank Inspection (API-653 exam preparatory course)
Pressure Relief Valve Inspection (API-576)
Pressure Vessel Design (ASME VIII Div.1)
Process piping design and construction (ASME B31.3)
Piping Vibration analysis
Material verification & selection
Vibration Measurement and analysis (Level I and II)
Non Destructive Testing – ASNT (Level I and II) for PT,MT,UT,RT, and VT
Metallurgy for Non-Metallurgist.
Inspection of fired Heaters – API-573
Diagnostic Engineering (Noise-Vibration- Temperature- Pressure –Oil) analysis
Thermograph Inspection Techniques for in-service (On Line Inspection)
IV- Duties & Responsibilities
1. Egyptian Maintenance Co. (EMC)
Asset Integrity (Acting R&D) Sector Manager
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Prepare Inspection strategy to keep the integrity of (Static & Rotating Equipment).
Prepare Asset Integrity Plan and related work flow and work procedures.
Prepare the sector Budget & Manpower development plan.
Development and improvement of inspection equipment such as (Eddy current, thermograph, profile radiograph,
etc).
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Sharing in technical conferences for (API, ASNT, AWS)
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Develop Asset Integrity programs such as (RBI , FFS , Corrosion , RCA & RCM)
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Manage all Asset Integrity activities (Inspection – RBI – RCM-Corrosion monitoring-….).
Ensure smooth execution of contact project schedule.
Assign the asset integrity project execution plan
Provide and deliver all assessment report as per API-579 to client
Participates in the development of design and installation specifications along with commissioning plans.
Develops acceptance tests and inspection criteria.
Follow up the duties of project manager for different inspection projects with different clients as mentioned
hereinafter:
Develops project objectives by reviewing project proposals and plans; conferring with management.
Determines project responsibilities by identifying project phases and elements; assigning personnel to
phases and elements; reviewing bids from sub-contractors.
Determines project specifications by studying product design, customer requirements, and performance
standards; completing technical studies; preparing cost estimates.
Confirms product performance by designing and conducting tests.
Determines project schedule by studying project plan and specifications; calculating time requirements;
sequencing project elements.
Maintains project schedule by monitoring project progress; coordinating activities; resolving problems.
Controls project plan by reviewing design, specifications; plan; schedule changes; and recommending
actions.
Controls project costs by approving expenditures; administering contractor contracts.
Prepares project status reports by collecting, analyzing, and summarizing information and trends;
recommending actions.
Maintains safe and clean working environment by enforcing procedures, rules, and regulations.
Maintains project data base by writing computer programs; entering and backing up data.
Maintains product and company reputation by complying with federal and state regulations.
Contributes to team effort by accomplishing related results as needed.
Inspection Department Manager
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Supervision of engineers and technicians qualification to increase their performance.
Development of Inspection staff by follow up the continuous internal and external training.
Supervising/ evaluating staff and upgrading their capabilities by conducting the on- job- training especially for the
new helpers.
Manage inspection activates.
Analyze Inspection reports and initial review of anomalies by the Inspection Engineer/Plant Inspector
Review and approve of the inspection reports.
Ensuring that good safety performance is recognized and recorded especially for the work permits and isolation
certificates before inspection activities commencement.
Identify data that is missing to perform a Fitness for Purpose evaluation.
Preparing Assessment procedures for pressure vessels, process piping, and carrying out and implementation of
Assessment Process Flow Diagram.
Prepare & issue the work packs required for corrosion monitoring & base line inspections.
Compile and Issue Inspection Workpacks and associated drawings to the Inspection Engineer/Plant Inspector.
Use trends, where available, to develop the periodic re-inspection program.
Prepare & issue the work packs required for corrosion monitoring & base line inspections.
Analyze Inspection reports and initial review of anomalies by the Inspection Engineer/Plant Inspector.
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2. Dolphin Energy Limited (Qatar / Ras Lafan)
Risk Based Inspection (RBI) & Fitness for Service (FFS) Team Leader
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Assign failure mode and failure mechanisms per each corrosion Loop
Assign Probability of failure per each corrosion loop.
Assign Consequence of failure for each function group.
Risk assessment and risk mitigation.
Prepare Inspection strategy as per RBI Recommendation to keep the integrity of equipment.
Prepare Asset Integrity Plan and related work flow and work procedures.
Determine the critical location and active damage mechanisms.
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Supervise Base line survey and RBI team
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Prepare inspection procedures including alternative of intrusive and non-intrusive inspection with different
alternative techniques (Highly effective- Effective –Slightly effective).
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Supervise all Asset Integrity activities (Inspection – RBI – RCM-Corrosion monitoring-….).
Provide and deliver all assessment report as per API-579 (Fitness for service)
Develops Root Cause analysis for major and critical finding during Inspection.
3. PETROMAINT / Egyptian Liquefied for Natural Gas (ELNG Site)
Inspection Section Head
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Supervise Inspection activities inside ELNG plant for all equipment such as columns, heat-exchangers, pressure
vessels, boilers, heaters, reactors, strippers, safety valves & valves, storage tanks, process piping, steel structure,
& Jetty, etc.
Co-ordinate and following up on inspection and related activities carried out by specialized independent inspection
authorities and surveyors for critical inspection or for insurance purposes.
Highlight to the Project Site Coordinator and Deputy Project Manager issues that require external resources,
Corrosion Engineering, Software Specialist, etc.
Approves and / or recommend methods of repairs necessary to be implemented on plant equipment has shown
unsatisfactory conditions and or advise on or approve materials, welding procedures, heat treatment and inspection
methods related to repair work and follows up to ensure they are carried out satisfactory.
Review the thickness survey and calculate corrosion rate and remaining life for piping and equipment according to
API 570&510andAPI 653 codes.
Conduct failure analysis and recommended to change or modify materials operating conditions based on
investigation result.
Reports all accidents, incidents or near misses to QHSE manager.
4. Amrya Petroleum Refining Company (APRC)
Inspection Engineer
 Carry out inspections and testing of all static equipment of plant facilities including NDT, hydro test, and
performance qualifications of welders, testing of lifting equipment etc.
 Follows daily work schedule and instructions received from the Senior Inspection Engineer. Ensures that all
inspection and testing is completed according to specific instructions, applicable work methods and procedures,
and in compliance with QHSE standards.
 Issues inspection reports and certificates if applicable, on successful completion and verification of the work done
in line with statutory requirements and approved policies and procedures.
 Monitors and inspects execution of repairs and modifications, providing advice on material selection, welding,
painting, insulation, wrapping, etc., and performs relevant testing prior to final acceptance by Inspection
Superintendent.
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 Maintains and updates Inspections database and processes Work schedule.
 Conducts inspection/survey of facilities, using various inspection techniques including visual inspection, NDT, etc.
Evaluates and records findings, accepting or rejecting inspected components.
 Follows up the Inspection findings during previous turn-around surveys, for finalization of shutdown work lists.
 Review / prepare welding (WPS, PQR & WPQ), heat treatment and NDT procedures for different metals such
carbon steel, stainless steel and non -ferrous as well as solving problems related to the welding and materials
 Stage-wise inspection of construction of Tanks and Pressure Vessels, vacuum box testing of Tank bottom,
dimensional inspection, plumpness, peaking, Banding & Roundness check of Tanks, etc.
 Follow up and manage pressure relief valves inspection activities (pop test, leak test, and set pressure calibration.
5. PETROJET / Middle East Oil Refinery (MIDOR Project)
QA/QC Engineer
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Inspection of materials, procured for the projects & maintenance, like pipes, pipe fittings, codes (ASTM, API,
NACE, etc.).
Inspection of Tank accessories like Safety valves, Emergency vents, Breather valve, Pressure gauges, Pressure
control valves, Foam pourers, etc.
Review of Welding Procedure Specification (WPS) & Procedure Qualification Test & Records (PQR).
Witnessing Welder Qualification Test and review of records.
Interpretation of radiographs, Non destructive testing (UT, MT, PT, & RT).
Welding inspection for the construction of Crude Oil storage Tanks, Plant piping, Pipelines and Pressure Vessels
as per API 650, ASME B 31.3, API 1104, ASME Section IX, ASME section VIII Div-1, etc.
Witnessing the pressure test for Valves and Emergency vents.
Hydro-testing of pipelines, Plant piping, Tanks, Pressure vessels, etc.
Pneumatic testing for tank roof, Reinforcement pads, etc.
Stage-wise inspection of construction of Tanks and Pressure Vessels, vacuum box testing of Tank bottom,
dimensional inspection, plumpness, peaking, Banding & Roundness check of Tanks, etc.
Painting inspection of Tanks, Piping & Pressure Vessels including surface preparation and environmental check,
WFT/DFT check, holiday and Pinhole detection, Adhesion test, etc.
Identification of non conformances & Corrective actions.
V- Appreciation Certificates
During my work period, I gained the respect of my employers and got a lot of appreciation
certificates (Some of these certificates are internationally registered under Continuing Education
Units CEUs as Professional Development Hours) as mentioned Hereinafter:
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Risk Based Inspection –API-580/ 581 (Abu Dahbi – HTME - Apr. 2011)
Certificate # INS000038/RE550/AUH/14.04.11
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Tank Inspection Code –API-653 (Dubai – HTME - July 2011)
Certificate # INS0000131/RE320/DXB/07.07.11
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Application of Codes & Standards in BPV & Piping (Abu Dahbi – HTME - Aug. 2012)
Certificate # INS0000251/ME138/AUH/30.08.12
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Pressure Vessel Design, Fabrication & Testing – ASME VIII (Abu Dahbi – HTME - Oct. 2012)
Certificate # INS000252/ME045/AUH/11.10.12
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Fitness for Service (FFS) of Piping, Vessels & Tanks (Dubai – HTME - Nov. 2012)
Certificate # INS000256/FE580/DXB/08.11.12
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Pipe Line Rules of Thumb – Design -Operation- Inspection-Integrity (Dubai– HTME - May. 2013)
Certificate # INS000281/FE160/DXB/25.04.13
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Metallurgy for Non- Metallurgist (Doha, Qatar– HTME - May. 2013)
Certificate # INS000297/FE330-4D-IH/ DOH/29.05.13
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Piping Inspection Code – API 570 (Yemen LNG – HTME - Aug. 2013)
Certificate # INS000300/FE700-IH/ SAH/24.08.13
VI- Managerial SKILLS
 Ability to listen, writes, and speaks effectively.
 Highly analytical thinking for identifying, improving, and streamlining complex work processes.
 Computer-literate performer with extensive software proficiency covering wide variety of applications.
 Ability to manage multiple assignments and tasks, set priorities, and adapt to changing conditions and work
assignments.
 Ability to mitigate conflict with co-workers.
 Goal-driven leader to maintain a productive climate and confidently motivates, mobilizes, and coaches employees to
meet high performance standards.
 Ability to plan, organizes, and implements Inspection tasks within specific timeframe.
 Innovative problem-solver and have the ability to work with others in a professional manner while attempting to
achieve a common goal.
 Highly adaptable, mobile, positive, patient risk-taker and open to new ideas.
 Dependable, responsible contributor committed to excellence and success.
 Highly motivated self-starter to take initiative with minimal supervision.
VII- From The Archive
In-Service Inspection Development & Basis of RBI
Weekly Free Seminar at Engineering Club-Saba Basha
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Letter of Authorization from Lahaye International University
In-Service Inspection Development Plan
AWS Membership Certificate
Practical Seminar for LINOLN for welding Process
Piping Vibration Analysis – Appreciation Certificate
Development of 1st Egyptian RBI Software
All Support documents are available upon request.
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