AHMED ABDELSAMAD
Kuwait
Summary
Metallurgical specialist with extensive expertise in corrosion studies, welding and fabrication techniques, and chemical process control. Proficient in heat treatment processes, metallurgical innovation, and non-destructive testing, with a strong focus on quality assurance management and health and safety compliance. Adept at conducting metallographic and failure analyses to optimize materials science applications while ensuring risk assessment capacity. Committed to driving advancements in metallurgical analysis and fostering conflict resolution within technical environments.
Overview
20
20
years of professional experience
6
6
years of post-secondary education
1
1
Certification
Work History
Corrosion & Metallurgy Engineer
Kuwait National Petroleum Co. (KNPC) - MAA Refinery
, Kuwait
03.2016 - 04.2025
- Experts in API, NACE, ASME, SHELL DEPs, ASM, AWS, TEMA, NBIC Standards & Best Practices
- Highly experienced Corrosion & Metallurgy Engineer with extensive expertise in material selection, failure analysis, and integrity management. Adept at optimizing manufacturing processes through innovative metallurgical solutions while ensuring compliance with industry standards (API, ASME, NACE, etc.).
- Proven leader in mentoring junior engineers, conducting risk-based inspections (RBI), and driving corrosion mitigation strategies to enhance plant reliability and safety. Strong background in turnaround inspections, fitness-for-service assessments (API 579), and root cause analysis (RCA).
- Corrosion & Metallurgy Senior via Delegation
- Provided expert technical guidance to Operations, Maintenance, Engineering, and Projects teams on material selection, upgrades, and corrosion prevention strategies.
- Led failure analysis and root cause investigations (RCA) to improve equipment reliability.
- Developed and monitored Integrity Operating Windows (IOW) to ensure safe operational limits.
- Recommended corrosion mitigation methods, including protective coatings, inhibitors, material upgrades, and chemical treatments.
- Performed RBI (Risk-Based Inspection) studies and implemented inspection plans to optimize maintenance strategies.
- Participated in PRIME workshops (RBI, RCA, RCM, MTA) for corrosion management programs.
- Led inspection teams during major turnarounds (LPG Plants, ARD, VR, FCC, Utilities) as Inspection & Corrosion Group Leader.
- Prepared Inspection Work Scopes, NDT Requests, and Final Reports (ICR) for shutdowns.
- Reviewed WPS, PQR, WQR, and Third-Party Inspection (TPI) reports for compliance.
- Calculated corrosion rates, remaining life assessments, and next inspection due dates.
- Reviewed P&IDs, PFDs, MSDs, and Process Safety Management (PSM/ISHEMS) documents.
- Raised Project Modification Requests (PMRs) for metallurgical upgrades based on failure analysis.
- Participated in HAZOP, PHA, and MOC reviews to ensure process safety compliance.
- Spearheaded metallurgical upgrades, improving equipment lifespan .
- Reduced unplanned downtime by through proactive corrosion management.
- Led Multiple turnarounds, ensuring on-schedule completion with zero safety incidents.
- Review and study engineering committee queries, updating of Inspection and corrosion manual, and TPI scope
- Recommendations for the prevention of corrosion by protective coating, inhibitor, material upgrading, design change, neutralizer addition, Mothballing, chemical cleaning, etc.
- FITNESS FOR SERVICE assessment as per API 579
- Team member in PRIME workshops related to corrosion management programs (RBI, RCA, RCM, MTA, TA, PMR, etc.) for existing process units and mega projects (FEED)
- Establish and monitor corrosion control company KPIs
- Analyses inspection findings, with recommendations for repairs / replacements / preventive measures as deemed necessary
- Conducts metallurgical studies and investigations to determine the cause and type of metal failure
- Review of CP systems and survey reports
- Establishing and monitoring of Integrity Operating Window (IOW)
- Review of process safety Management system PSM& ISHEMS related documents (PSI, SWP, PHA, Incident investigation, MOC, etc.)
- Lead, guide, supervise, and appraise the inspection team during normal operation (on stream), turnaround/shutdown, and during fabrication/repair in a workshop and the field of all Refinery & and LPG plant static equipment (fired / unfired) and piping
- Participated in many major overhauls of various units [LPG Plants, ARD, VR, ERU, FCC& utilities (Boilers & Evaporators)] as an inspection and corrosion group leader and an inspection engineer
- Advice on repair techniques, materials selection, welding procedures, inspection & testing
- Preparation of NDT request for suitable methods including special NDT (TOFD, phased array, ECT, IRIS, MFL… etc.) based on the expected deterioration mechanism and history
- Reviewing project engineering documents, WPS, PQR, WQR, and third-party reports (TPI) for incoming material / Equipment
- Prepare data to implement & and update RBI methodology
- Calculation of Corrosion rate/Remaining corrosion allowance and endorse the equipment's next due date
- Preparation of final Inspection and corrosion report ICR and general turnaround report
- Follow up the inspection plan generated from the RBI study & evaluate the adequacy of inspection methods to ensure that inspection adds value to risk management
- Participate in many failures analysis and Root cause analysis RCA workshops
- Advice for corrosion mitigation techniques (material upgrading, chemical inhibitors…etc.), as well as inspection monitoring techniques
Inspection Engineer
Kuwait National Petroleum Co. (KNPC) - MAA Refinery
03.2010 - 03.2016
- Conducted comprehensive inspections of refinery static equipment (vessels, piping, tanks) during shutdowns, fabrication, and field repairs, ensuring compliance with ASME, API, and Shell DEPs standards.
- Performed welding, painting, and material receiving inspections, verifying quality and conformance to specifications.
- Developed, issued, and reviewed Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR) in accordance with ASME Section IX.
- Witnessed and certified Welder Performance Qualifications (WPQ), ensuring adherence to applicable codes.
- Prepared Inspection & Test Plans (ITP) for pressure vessels per ASME Section VIII requirements.
- Assisted in the development of the Company Quality Control Manual
- Monitored workshop and field implementation of WPS, tracking welder performance and repair rates.
- Reviewed Post-Weld Heat Treatment (PWHT) procedures, charts, and records per ASME Section VIII.
- Supported external petroleum projects in Egypt, supervising inspection activities during major shutdowns to ensure asset integrity.
Inspection Engineer
Cairo Oil Refining Company (CORC), Egypt.
03.2005 - 03.2010
- Liaised with various departments for seamless communication of inspection findings.
- Provided expert advice on maintenance strategies, resulting in extended equipment lifespan.
- Improved safety standards by conducting rigorous equipment inspections.
- Recommended upgrades and modifications to optimize machine performance.
- Conducted comprehensive inspections of refinery static equipment (vessels, piping, tanks) during shutdowns, fabrication, and field repairs, ensuring compliance with ASME, API, and Shell DEPs standards.
- Performed welding, painting, and material receiving inspections, verifying quality and conformance to specifications.
- Developed, issued, and reviewed Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR) in accordance with ASME Section IX.
- Witnessed and certified Welder Performance Qualifications (WPQ), ensuring adherence to applicable codes.
- Prepared Inspection & Test Plans (ITP) for pressure vessels per ASME Section VIII requirements.
- Assisted in the development of the Company Quality Control Manual under Lloyd’s Register supervision.
- Led preparations for ASME R-Stamp & U-Stamp audits, ensuring compliance ahead of certification reviews.
- Monitored workshop and field implementation of WPS, tracking welder performance and repair rates.
- Reviewed Post-Weld Heat Treatment (PWHT) procedures, charts, and records per ASME Section VIII.
- Supported external petroleum projects in Egypt, supervising inspection activities during major shutdowns to ensure asset integrity.
Education
B.Sc. - Metallurgy & Material Engineering
Suez Canal University
01.1998 - 01.2004
Skills
- Corrosion studies
- Welding and fabrication techniques
- Chemical process control
- Heat treatment knowledge
- Metallurgical innovation
- Metallurgical analysis
- Non-Destructive testing
- Risk assessment capacity
- Metallographic analysis
- Failure analysis
- Quality assurance management
- Materials science
- Health and Safety Compliance
- Conflict Resolution
- Analytical
Certification
- NACE Senior Corrosion Technologist, 42130
- NACE Senior Internal Corrosion Technologist, 42130
- NACE CP1, 42130
- API 571 Corrosion & Materials professional, 44175
- API 580 Risk-Based Inspection professional, 52708
- API 570 Piping inspector, 41253
- API 510 Pressure vessel inspector, 38589
- ASM Principle of failure analysis, Level II (RT, UT, PT& MT)
- ASME SEC IX, American University in Cairo (AUC)
- ISO 9001:2000 Internal Quality Auditors, (SGS)
- RBI - The Methodology -Risk and Reliability Management, Shell global solutions
- Shell RCA Facilitator
- Environmental & Radiation Monitoring for Industrial & Petroleum Facilities
- IELTS, Band 7.0
Languages
English
Arabic
Timeline
Corrosion & Metallurgy Engineer
Kuwait National Petroleum Co. (KNPC) - MAA Refinery
03.2016 - 04.2025
Inspection Engineer
Kuwait National Petroleum Co. (KNPC) - MAA Refinery
03.2010 - 03.2016
Inspection Engineer
Cairo Oil Refining Company (CORC), Egypt.
03.2005 - 03.2010
B.Sc. - Metallurgy & Material Engineering
Suez Canal University
01.1998 - 01.2004
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