Hydrotest & Pre-commissioning Engineer

Role Overview

Hydrotest & Pre-commissioning Engineer at Ali & Sons Holding LLC. This role plans, supervises, and executes hydrotesting, flushing, cleaning, dewatering, drying, and pre-commissioning activities for pipelines, process systems, tanks, and equipment on oil & gas projects.

Role Purpose

To ensure pipelines, process systems, tanks, and equipment are safely tested, compliant with project requirements, and fully ready for commissioning and operational handover through planned and supervised hydrotesting and pre-commissioning activities.

Key Responsibilities

Planning & Preparation

• Review P&IDs, isometric drawings, project specifications, and commissioning procedures for pipelines and process equipment.
• Prepare hydrotest and pre-commissioning plans, schedules, method statements, and test packages.
• Identify manpower, materials, tools, equipment, pumps, gauges, hoses, and other resources required for testing activities.
• Coordinate with QA/QC teams to ensure systems and documentation are ready for testing.

Hydrotesting & Pre-Commissioning Execution

• Supervise hydrostatic, pneumatic, and leak testing of pipelines, tanks, vessels, and process equipment in accordance with project specifications and applicable API, ASME, and ISO standards.
• Execute and supervise cleaning, flushing, dewatering, drying, and other pre-commissioning activities.
• Monitor test pressure, temperature, duration, and other parameters to ensure compliance with project and client requirements.
• Record test results, identify deviations, and recommend appropriate corrective actions.
• Ensure proper installation and operation of temporary connections, supports, test manifolds, pumps, hoses, and instrumentation.

Health, Safety & Environment

• Ensure strict compliance with HSE procedures, site safety requirements, and client standards during hydrotesting and pre-commissioning activities.
• Conduct and review risk assessments for pressurized system testing and ensure appropriate mitigation measures are implemented.
• Ensure personnel understand hazards associated with high-pressure testing, pressurized systems, and confined spaces.
• Stop unsafe activities and ensure testing is carried out within approved safety limits.

Coordination & Reporting

• Coordinate with project management, construction, QA/QC, commissioning teams, and client representatives for safe and timely execution.
• Participate in project meetings, provide progress updates, highlight technical challenges, and support resolution of site issues.
• Prepare daily and weekly progress reports covering hydrotesting and pre-commissioning activities.

Documentation & Quality Assurance

• Maintain accurate hydrotest records, test packs, logs, inspection records, and as-built documentation.
• Ensure non-conformances, punch items, and deviations are properly documented and closed in coordination with QA/QC.
• Verify that completed testing and pre-commissioning activities satisfy design, operational, quality, and client requirements before system handover.

Continuous Improvement & Technical Support

• Identify opportunities to improve hydrotesting and pre-commissioning procedures, safety, efficiency, and execution quality.
• Provide technical support to construction and commissioning teams throughout project execution.

Qualifications & Experience

• Diploma or Bachelor's Degree in Engineering.
• Mechanical Engineering preferred.
• 5–10 years of relevant experience in hydrotesting, pre-commissioning, commissioning, pipelines, process systems, or oil & gas projects.
• Strong knowledge of hydrostatic and pneumatic testing, flushing, cleaning, dewatering, drying, and system preparation.
• Familiarity with relevant API, ASME, and ISO standards.
• Strong understanding of HSE requirements for high-pressure testing and pre-commissioning activities.
• Ability to read and interpret P&IDs, isometric drawings, specifications, and technical documentation.
• Strong coordination, reporting, problem-solving, and site supervision skills.
• English language proficiency.