Rajan Rekhi, P.E.

Expert QuestionS & AnswerS

Your career spans spars, semi-submersibles, FPSOs, and fixed platforms — what structural challenges exist offshore that onshore engineers never encounter?

The design parameters are much more numerous and more complex for offshore vs onshore structures. There are significantly more load cases and design conditions to be addressed with offshore structures. In general, offshore structures are welded structures, whereas on onshore structures you will find many bolted connections. Additionally, space is at a premium on offshore structures, which have a big impact on design.

You’ve worked offshore megaprojects and residential windstorm inspections — how does big-project discipline sharpen your eye on smaller forensic assignments?

Offshore megaprojects and deepwater oil & gas field development are highly capital intensive. So cost, scheduling and quality, along with HSE (Health, Safety, & Environment) factors are crucial. Even a one percent error can cost a lot in terms of construction or operational costs. However, the same level of accuracy and attention to cost, quality, schedule, and safety is brought to smaller forensic assignments.

Having worked every project phase from R&D through installation, where in the project lifecycle do you see the seeds of disputes most often planted?

The initial project phases: Conceptual & Pre-FEED (front end engineering design) are the project phases where all the project aspects need to be thoroughly evaluated, and the chosen concept needs to be taken forward to the next phase. All concepts need to be thoroughly evaluated; planning, operations, subcontractor selection, construction, and other stakeholders’ alignment is needed before we step into more detailed engineering and construction phases to avoid cost and project overruns at a later stage.

What’s the most surprising failure you’ve investigated in an energy or industrial structure?

We thoroughly investigate, review all documents and drawings, conduct inspections and provide our unbiased detailed reports with our professional opinions. Sometimes, the most talented and highly qualified engineers make mistakes when trying to do tasks faster and more cheaply, introducing minor design flaws which end up having have major consequences. For example, I had a case where the incorrect selection of elements in a Finite Element Analysis (FEA) design caused a fatigue cracks in a structural element, and due to lack to regular inspections, the minor crack expanded and ended up resulting in a catastrophic failure.

What’s one thing about windstorm damage assessment that property owners most often get wrong?

All properties located in the coastal areas need Windstorm Certification as per Texas Department of Insurance (TDI), and similar provisions exist in some other states. All substantial new repairs or new construction needs to follow the engineering design codes and construction requirements & procedures in place at the time they are performed to get this certification. There are times when property owners get contractors do the work without having knowledge of the TDI requirements and this makes it much more difficult to get the needed certification.

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