We are delighted to welcome Prashanth Kadaba, a seasoned expert in pipeline safety, gas engineering, and environmental compliance, to OnestopNDT today. With over 20 years of experience, primarily at Con Edison in New York, Prashanth has built an impressive career leading teams and initiatives that enhance the safety and integrity of natural gas systems through welding and nondestructive testing (NDT). His unique blend of technical expertise in mechanical engineering and strategic insight, reinforced by an MBA in Finance, has empowered him to drive innovation and operational excellence in one of the most critical sectors of energy infrastructure.
In this exclusive interview, Prashanth shares his journey from environmental project management to leading the Gas Engineering Welding Center of Excellence, offering valuable perspectives on the evolving role of AI and automation, the challenges of large-scale safety management, and the importance of regulatory compliance and collaboration within the NDT community. He also provides thoughtful advice for industry stakeholders on embracing innovation while maintaining rigorous safety standards, and sheds light on how emerging technologies will shape the future of pipeline safety and environmental audits.
Join us as we explore Prashanth’s insights on strengthening pipeline integrity, the pivotal role of human expertise alongside AI, and the continuous pursuit of excellence that drives safer and more sustainable energy systems.
Welcome, Prashanth! It’s a pleasure to have you with us today at OnestopNDT. Your name is well-known in the industry, but for those who may not be familiar, could you share a brief introduction of yourself and your journey so far?
Thank you for the warm welcome! I’m an engineer by training, and I have over 20 years of experience in pipeline safety, engineering, and environmental compliance, primarily with Con Edison in New York.
My career began with a small environmental management company, where I served as a Field Supervisor/Project Manager, guiding field crews in managing hazardous waste projects. I then transitioned to Con Edison, where my journey took me through various leadership roles. In my current role as the Department Manager of Gas Engineering Welding Center of Excellence, I established a centralized group providing welding and nondestructive testing (NDT) related guidance, ultimately enhancing our operational efficiency. We developed standard manuals that improved quality, not only streamlined our processes but also bolstered the integrity of our natural gas system.
My academic background includes a Bachelor's and a Master’s in Mechanical Engineering, complemented with an MBA in Finance.
From a career standpoint, what led you to the energy sector? Was working in this field always part of your dream, or did you find your way here through different experiences?
My journey into the energy sector has been quite organic and fulfilling, stemming from a strong foundation in engineering and compliance. Early in my career, I realized the significant impact the energy industry has on society and the environment.
Initially, I started in the environmental field, working as a Field Supervisor, where I managed large-scale projects for various public and private companies in New York. This role was pivotal for me, as I led field crews delivering hazardous waste management services, ensuring compliance with numerous regulations. The challenges I faced here solidified my desire to work at the intersection of safety and technology in the energy sector. When I joined Con Edison, I fully committed to this path. Over the years, I’ve held multiple roles that provided me with invaluable experience and a comprehensive understanding of gas engineering and compliance.
In my current role as Department Manager at the Gas Engineering Welding Center of Excellence, I focused on establishing a centralized team to support the welding and Nondestructive Testing (NDT) operations across Gas Operations. This centralization not only improved operational efficiency but also enhanced the safety profile of our transmission and distribution systems. These experiences have solidified my commitment to the energy sector, and I am dedicated to driving impactful solutions that align with regulatory requirements while also supporting environmental sustainability.
Your work involves a lot of manual tasks. Do you think bringing AI and automation will streamline the process and increase the output?
Absolutely, I believe that integrating Artificial Intelligence (AI) and automation into our processes can significantly streamline operations and enhance overall output.
In my previous role as Department Manager for Gas Engineering System Planning at Con Edison, I oversaw the design and analysis of gas transmission and distribution projects. Here, my team utilized models of our natural gas system to perform hydraulic analysis and predict the reliability projects needed to bolster our winter operations. Although not a true digital twin, these models were close to that and assisted in data-driven decision-making processes that improved project planning efficiency. By leveraging smart data sensors, we could analyze network data faster and more accurately, enabling us to develop more effective reinforcement plans for our gas systems. Such improvements directly align with enhancing our compliance with New York State climate change policies.
In my current role, we are exploring the transformative role of AI in NDT for pipeline girth welds. AI-driven solutions are revolutionizing defect recognition, enhance inspection accuracy, and optimize performance in pipeline integrity management. By leveraging machine learning and advanced analytics, we can detect anomalies faster, reduce false calls, and make data-driven decisions with greater confidence. Although AI can enhance NDT processes, human oversight remains crucial, and that is why we are looking into the “human in the loop” concept and the need for explainable AI systems.
In conclusion, effective decision making in NDT requires a balance between human expertise and technological advancements, ensuring reliability and safety.
With your extensive expertise in gas pipeline safety and compliance, we know safety is a cornerstone of your career. In your opinion, what are some of the biggest challenges energy professionals face when it comes to ensuring safety on a large scale?
Ensuring safety on a large scale is indeed a significant challenge in the energy sector, particularly in gas pipeline operations. One of the biggest challenges we face is keeping up with evolving regulations. With regulations frequently changing, energy professionals must constantly adapt to ensure compliance. This can be accomplished through strategic planning, thorough training, and continuous communication with our compliance specialists and cross-functional teams.
Another significant challenge is managing operational risks while maintaining efficiency. As a Department Manager of Gas Engineering System Planning, I was responsible for designing and analyzing projects for the planning of gas transmission and distribution systems. My team developed system reinforcement plans for a gas distribution network that spans over 4500 miles. This required careful balancing of safety measures with project timelines and budgets, particularly for non-pipeline solutions that align with New York State's climate goals.
Additionally, ensuring a culture of safety throughout the organization is vital. I was assigned to develop and oversee the Gas Engineering Career Path for all incoming engineers, emphasizing the importance of safety from the outset of their careers. By establishing quality standards and providing ongoing training, we not only improved compliance but also fostered a more robust safety culture across departments. This holistic approach is crucial as it motivates professionals to prioritize safety at every operational level.
As someone with a comprehensive understanding of gas pipeline safety, what are some of the most overlooked risks in pipeline management, and how can companies address them proactively?
In my experience managing gas pipeline safety and compliance, I've observed several overlooked risks in pipeline management that can lead to significant safety and operational challenges. One notable risk is the lack of knowledge and education in the field of Non-Destructive Testing (NDT). In my current role as the Department Manager of the Gas Engineering Welding Center of Excellence, I manage a team responsible for establishing centralized guidance for welding and NDT-related practices. This team’s presence and support has significantly increased the quality of welds as well as brought in innovation through the adoption of digital means to conduct NDT.
Another risk that is often overlooked is the effective implementation of regulatory compliance processes. By fostering collaboration with cross-functional teams and proactively addressing changes in regulations, we managed to demonstrate how a structured approach to compliance can significantly enhance operational safety and reduce legal liabilities.
Furthermore, pipeline operators often underestimate the importance of comprehensive training for their workforce on regulatory changes and safety protocols. Investing in training not only improves safety outcomes but also enhances employee confidence and performance, thereby fostering a culture of safety throughout the organization.
To address these risks proactively, companies should prioritize regular audits of their processes, integrate robust compliance tracking systems, and invest in ongoing training for their workforce. By taking these steps, organizations can mitigate risks effectively and ensure the utmost safety in gas pipeline operations.
As an Asset Owner, how do you approach selecting the right inspection methods, vendors, or technologies for maintaining asset integrity? Is it a straightforward process, or does it come with its own set of challenges?
As an Asset Owner, my approach to selecting the right inspection methods, vendors, or technologies for maintaining asset integrity is comprehensive and multifaceted. An essential first step in my process is to conduct a thorough assessment of the specific needs related to the asset and create a scoping document for the work that needs to be performed. Our supply chain department supports the business need by conducting a risk assessment of the vendor and developing a contract based on the scoping document.
Moreover, I find it vital to maintain ongoing communication with vendors and industry peers. For instance, my involvement as a member of the AGA/API 1104 Joint Committee on Welding has equipped me with a network of industry experts and access to emerging inspection technologies, which enables me to select vendors that have a proven track record in delivering high-quality results.
However, the selection process does come with its challenges, including balancing cost-effectiveness with the need for high-quality inspections. By aligning our inspection methods with well-defined performance goals, we have continually measured success against specifications and made necessary adjustments in real time. This approach not only ensures robust asset integrity but also fosters a culture of continuous improvement across the organization.
When evaluating equipment, services, or technologies for asset integrity, what are the key demands and concerns that influence your decision-making? What do you expect from the NDT industry to meet the needs of stakeholders like yourself?
When evaluating equipment, services, or technologies for asset integrity, my key demands and concerns revolve primarily around regulatory compliance, the effectiveness of Non-Destructive Testing (NDT) methods, and cost-efficiency.
Moreover, the effectiveness of the NDT methods used is critical. I oversee contractors performing NDT on high-pressure natural gas lines, so I prioritize technologies that not only ensure safety but also enhance the efficiency of our operations.
From the NDT industry, I expect a commitment to continuous improvement and innovation. The challenges faced by stakeholders like me include keeping pace with evolving regulations and technology advancements. For instance, recommendations for improvements in NDT technology that improve real-time data analysis could significantly enhance our decision-making process and asset management strategies. Ultimately, I believe a proactive approach to NDT solutions will not only meet stakeholder needs but also ensure the long-term safety and reliability of our natural gas infrastructure.
If a CXO from an NDT inspection service company were reading this interview, what advice or insights would you share with them to help improve collaboration and services for asset owners like you?
In my current role, I have learned that effective collaboration between asset owners and NDT inspection service companies is crucial for ensuring the safety and reliability of our gas pipeline operations. Based on my experience, I would advise that NDT companies prioritize seamless communication and understanding of specific asset owner needs. By aligning inspection services with our procedural documentation, NDT companies can enhance the quality of their inspections and provide invaluable insights that lead to fewer compliance issues.
Additionally, during my tenure overseeing both gas transmission and distribution projects, I found that developing a partnership approach with NDT contractors led to more efficient project execution. When our contractors understood the nuances of our business goals and regulatory requirements, we saw an uptick in efficiency. This efficiency not only saves costs but also improves overall project satisfaction for stakeholders.
Therefore, I recommend that NDT companies emphasize creating robust feedback loops with asset owners, allowing for continuous improvement in services. Regular audits and collaborative review sessions can lead to identifying compliance gaps early and designing innovative solutions.
Fostering strong partnerships, enhancing communication, and developing tailored strategies are essential for NDT inspection service companies to deliver higher value to asset owners like Con Edison.
The next few years are bound to bring innovations that could disrupt the way we handle safety in gas pipelines and environmental audits. How do you see these technologies shaping the future of these areas over the next 5 to 10 years?
Over the next 5 to 10 years, I see innovative technologies significantly transforming safety management in gas pipelines and environmental audits. These technologies will enhance monitoring, predictive analytics, and regulatory compliance, ultimately leading to safer operations and higher operational efficiency.
For instance, the adoption of advanced sensor technologies and real-time data analytics will allow us to monitor pipeline integrity continuously. By embedding sensors along our gas transmission lines, we could proactively identify vulnerabilities before they escalate into serious issues.
Moreover, technologies such as drones and automated inspection tools in some energy sectors are allowing us to conduct more frequent safety audits and environmental assessments, yielding higher accuracy.
Lastly, employing artificial intelligence (AI) for regulatory compliance could streamline processes. This would not only save time but also provide real-time insights that inform strategic decisions and initiatives. The lessons learned from across the industry will be instrumental in shaping these AI frameworks. As we navigate these technological advancements, collaboration with cross-functional teams and initiating R&D projects will be vital to align with best practices in the industry while meeting regulatory requirements.
What is your view on the role of government regulations in shaping the future of gas pipeline safety, and do you think the current regulatory frameworks are sufficient to address emerging risks?
In my view, government regulations play a crucial role in shaping the future of gas pipeline safety. They not only set the baseline standards for safety and compliance but also encourage continuous improvement and innovation in our industry. While the current regulatory frameworks have been instrumental in advancing safety measures, I do believe there are emerging risks that require ongoing attention and adaptation to these frameworks.
A proactive approach from asset owners/operators to increase their quality standards will not only meet the baseline standards but also push for better performance from vendors. This quantifiable impact demonstrates not only the effectiveness of adhering to regulations but also the need for these standards to evolve alongside emerging risks.
The integration of regulatory compliance with forward-looking environmental standards exemplifies how regulations should adapt to emerging challenges, ensuring pipeline safety while meeting the evolving needs of our communities and environment.
While I appreciate the foundation that current regulatory frameworks provide, I believe that they must continuously evolve to address not only existing risks but also those that may arise in the future. This approach ensures that public safety remains the utmost priority while fostering innovation and responsible operation within the gas industry.
How did you find out about OnestopNDT? Do you think our efforts to provide real, authentic and accurate content are helping the industry?
I discovered OnestopNDT while researching best practices and developments in Nondestructive Testing (NDT), specifically to enhance the compliance and quality standards we implement at Con Edison. Staying informed about the latest advancements and resources in NDT is paramount, and I wanted to ensure that my team leverages accurate and authentic content to improve our processes related to natural gas pipelines.
I truly believe that OnestopNDT's commitment to providing real and authentic content significantly aids the industry. Additionally, by promoting such accurate resources, OnestopNDT is equipping professionals across the industry with the necessary tools to implement effective NDT strategies, ultimately leading to safer and more reliable pipelines. I think the collaborative efforts to share authentic experiences and insights in NDT will foster continuous improvement throughout the sector.
Finally, any last thoughts you would like to share with our NDT community?
As someone deeply embedded in the pipeline safety and engineering community, I want to emphasize the importance of continuous improvement and regulatory compliance in our field, particularly in nondestructive testing (NDT). At Con Edison, I manage a team responsible for establishing welding and NDT guidance and ensuring adherence to standards like API 1104. This experience has reinforced my belief that developing robust standard manuals, strategic innovation, and implementing straightforward processes that align with industry best practices is crucial for minimizing safety risks and enhancing efficiency across our operations.
Moreover, my role in the industry committees has highlighted the necessity of collaboration between organizations like ours, industry peers, and regulatory agencies. Engaging in these conversations ensures that our industry evolves in a manner that is safe, efficient, and sustainable, reflecting our commitment to protecting public safety. I believe that sharing knowledge and best practices within the NDT community can drive further advancements in our operations, ultimately enhancing the safety and reliability of our gas systems.
