Materials and Corrosion Engineer – Wet/Dry Systems

The Materials and Corrosion Engineer (Mid-Level) plays a key role in assessing, preventing, and mitigating material degradation and corrosion in both wet and dry systems (e.g., pipelines, tanks, heat exchangers, HVAC ducts, and steam/gas systems). This role involves applying engineering principles, industry standards, and field data to ensure mechanical integrity, reliability, and regulatory compliance of plant assets. The engineer is expected to work independently on moderately complex tasks and collaborate across disciplines.

Key Responsibilities:

1. Corrosion Risk Assessment & Monitoring:

• Conduct corrosion assessments across wet and dry systems such as water pipelines, steam lines, process vessels, cooling towers, and storage tanks.

• Develop and implement corrosion monitoring programs using tools like ultrasonic thickness testing (UTT), corrosion coupons, ER probes, and smart PIG data.

• Interpret corrosion trends and recommend risk mitigation actions.

2. Materials Engineering & Selection:

• Evaluate and specify materials for new systems, upgrades, and repairs based on process conditions and corrosion environment.

• Provide materials compatibility reviews for chemical injection, gas treatment, water quality, and temperature/pressure variations.

• Support procurement in material requisition reviews and vendor qualifications.

3. Failure Analysis & Root Cause Investigation:

• Lead or support metallurgical investigations of material failures (e.g., erosion, MIC, SCC, hydrogen damage).

• Perform lab and field-based failure analysis and document findings with recommendations.

• Liaise with external labs or third-party experts when necessary.

4. Corrosion Mitigation Strategies:

• Design and review mitigation measures such as coatings, linings, chemical inhibitors, cathodic protection (CP), and material upgrades.

• Coordinate with maintenance and operations to ensure proper application and maintenance of mitigation systems.

5. Compliance & Documentation:

• Ensure engineering activities adhere to applicable standards (e.g., NACE, API 571/580, ASME, ASTM).

• Prepare corrosion management plans, inspection work packs, and technical reports.

• Participate in audits, HAZOPs, risk assessments, and integrity reviews.

6. Project & Operational Support:

• Provide corrosion and materials input during design reviews (FEED, detailed engineering) and commissioning.

• Interface with inspection, operations, and maintenance teams for resolution of in-service issues.

• Assist in RBI (Risk-Based Inspection) planning and implementation.

Key Focus Areas:

1. Corrosion Assessment in Wet (Water, Sludge, Chemicals) & Dry (Air, Gas, Steam) Systems

2. Materials Selection & Compatibility for Corrosive Environments

3. Root Cause Analysis (RCA) and Metallurgical Failure Investigations

4. Design and Implementation of Corrosion Monitoring & Mitigation Techniques

5. Development of Corrosion Control Documents & Management Plans

6. Support for RBI, CP Systems, Protective Coatings, and Chemical Treatment Programs

7. Standards Compliance (NACE, API, ASTM) and Technical Documentation

Qualifications & Experience:

• Bachelor’s Degree in Materials Science, Metallurgy, Corrosion Engineering, or Mechanical Engineering.

• 4–8 years of relevant experience in corrosion/materials engineering within utilities, oil & gas, water treatment, or process industries.

• Experience with failure analysis, corrosion mechanisms, and mitigation practices.

• Familiarity with relevant industry codes and software (e.g., API 579, NACE SP0106, CAESAR II, COMSOL, etc.).

Skills & Competencies:

• Strong analytical and diagnostic skills in corrosion and materials behavior

• Field experience in corrosion inspection and monitoring

• Knowledge of coatings, CP systems, and chemical treatments

• Effective communication and report writing skills

• Proficiency in interpreting isometric drawings, P&IDs, and data logs

• Commitment to safety, integrity, and collaborative problem-solving