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Post Applied: Sr. Inspection Engineer
Expérience: 13 Years with Onshore & Off shore, OIL & GAS refinery Project & Shutdown.
Area: Middleeast & India
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Aspire to pursue senior level assignments in Quality Assurance/ Quality Control with a frontline organization
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An incisive professional with over 13 years of enriching experience in Quality Assurance, Project Management as well as Maintenance & Operations.
Experienced in managing cross functional activities encompassing quality of the parts, processes & bought-out items and proficiency in coordinating with the vendors, enhancing their process operations; thereby achieving the required quality level.
Adroit at structuring & implementing quality assurance activities & systems across all sections.
Significant experience in end-to-end deliverables of the project/ campaign, analysis of client requirements, estimations, risk, metrics identification, workforce management & effective utilisation of teams.
Proven skills in executing 4 shutdowns in India and abroad.
An excellent performer with demonstrated troubleshooting aptitude in managing maintenance and break down of various plant equipments.
Experienced in handling procurement stage to finalization and execution of the orders, Quality assurance activities from pilot stage to supply in bulk.
Conversant with ASME – II Part – A, B, and C, ASME – V, ASME – VIII Div I, ASME –IX, ASME B31.1, B 31.3, API 510, API 570, API 650, API 653 and API 1104.
Deft at handling the preparation of specifications, quality assurance instructions and inspection and test procedure for project executions.
An effective communicator with excellent interpersonal and relationship management skills.
EMPLOYMENT PROFILE
Organization
M/s. Ramsis Engineering Co. W. L. L.-
Kingdom of Bahrain Quality Manager
Oct''2008 to till date A
pprox-.5 Year
M/s. EQUATE Aromatics project -
Kuwait
QC Manager Aug'2007–Sep'2008
Approx- 1 Year
M/s. Reliance – Refinery
QA/QC Manager
Oct'2003–July'2007
Approx- 5 Years
M/s. Welspun – Pipes & Equipments Fabrication
Sr. QC Engineer
March'99–Sep'2003
Approx- 5 Years
M/s. Larsen & Toubro-Heavy Static Equipments Fabrication
QC Engineer
June'98-March'99
Approx- 1 Year
Experience Summary:
Ramsis Engineering Co. W. L. L., Kingdom of Bahrain - Position: Quality Manager
Ramsis Engineering is a leading heavy fabrication / construction industry in Bahrain & UAE, serving oil & Gas industries and Petrochemical industries. The major products of the company are all the process plant equipment like, Pressure Vessels, Columns, Heat Exchangers, Storage Tanks, Piping, Pipelines, Stacks, Structural, etc. Also, In- Service Field & Shop Repair & Maintenance of above products and Plant Shut Down maintenance.. Ramsis Engineering, an ISO 9001:2000 certified Organization, accredited for ASME Code U, U2, PP, S, A, R & NB stamped pressure vessel fabrication.
Present Responsibilities:
Responsible for over all managing the QA&QC and Welding Engineering functions related to Manufacturing, Construction & Maintenance activities of the organization at Bahrain operations and UAE operations.
Responsible for implementation of ASME QC Program for ASME Code Stamped Pressure Vessels fabrication at our Bahrain Facilities and maintenance of ASME accreditation.
Responsible for implementation of QMS for all our Manufacturing, Construction & Maintenance activities at our Bahrain operations & UAE operations and maintenance of ISO 9001:2000 certification.
Responsible for all R&D functions related to System and Technology up gradation for the organization, including the development and implementation of new welding techniques & procedures for better productivity.
Leading a strong and dedicated team of 18 QA/QC professionals.
Reporting to Managing Director of the organization.
Special Assignments carried out in Ramsis Engineering:
Successfully organized ASME certification renewal Audit for U, U2, A, PP, S, R &NB stamps during 2008 at our Bahrain Facility and obtained the Renewal.
Successfully organized ISO 9001:2000 Surveillance audits during 2008 & 2009 at our Bahrain & UAE operations and the audit results satisfactory.
Development of In-House PT, MT & UT facilities, thus eliminating the Sub-Contracting.
Development of In-House PWHT facility, both permanent furnace & Expandable type with Electrical Heating for Stress Relieving of Pressure vessels, Heat Exchangers, Columns, etc, thus eliminating the Sub-Contracting.
Development of In-House PWHT facility for Local stress Relieving of Piping weld joints, thus eliminating the Sub-Contracting..
Aromatics Project - EQUATE Petrochemicals, KUWAIT– Position: Site QC Manager
Main Roles & Responsibilities
Activities involved in total complex Turnaround 2007-2008 projects:
Establishing, implementing and maintaining Quality Management System to ISO 9001: 2000. Conducting internal & external audits.
Preparing Quality Assurance Plan (QAP), Inspection and Test Plan (ITP).
Preparing Procedures and inspection related formats as per specification & code requirement.
Reviewing vendor documents and material test certificate.
Conducting vendors and contractors audit.
Regular monitoring and reviewing daily site activities & requirement.
Installation inspection of Column, Vessels and heat exchangers, structure, Piping & Tray Inspection.
Managing site activities with inspection team.
Inspection of above ground & under ground piping as per requirement of Code and specification
Stage wise fabrication and inspection. i.e.: Material Identification (Pressure parts), fit up, welding, visual inspection, NDE, PWHT, hydro-test, surface preparation and painting, wrapping & coating, cathodic protection, civil, electrical, insulation inspection & Certifying inspection reports.
Comprehensive Knowledge On Blasting, Painting, which includes verify / certify the Painting / Blasting Operators, Surface Preparation, Temperature and Relative Humidity, Blast Surface Profile, Paint Application, Familiar with use of Wet / Dry Film Thickness Gauges.
Witness of DPT, MPT, Interpretation and Evaluation of Ultrasonic Testing & Radiographic films.
Monitoring of class wise, welder wise NDE % coverage & analysis of repairs.
Involved with Heat treatment process activities
Hydro test & service test witness.
Preparation of Test Pack & summation Dossier.
PREVIOUS ASSIGNMENTS
Reliance Industries Ltd, Jamnagar - Position: QA/QC Manager (Onshore & Off shore)
Projects:
1) JERP – Jamnagar export oriented refinery Project
2) VMP-Value maximization project
3) Quality Yield Improvement Project –II
4) Quality Yield Improvement Project –I
5) Jetty Expansion
* QMS development at fabrication shop at RIL.
* My involvement for vendor document review, field & shop inspection for static equipment, piping (UG & AG), welding, NDE, testing, contractor & vendor inspection, audit, preparation of test pack & summation Dossier etc for above projects.
Involvements in various areas at Shop & Site.
QA / QC Activities and document review for above projects. (CIVIL, STRUCTURAL, TANKAGE, PIPING, PIPELINES AND EQUIPMENTS).
Vendor/contractors documents review (QAP,ITP,WPS, PQR, and MT, PT, RT, VT, UT, Surface preparation and painting procedures)
Detail drawing study with P&ID, Specification, codes, standards and method of work execution.
In coming material inspection as per PO & drawings.
Establishing, implementing and maintaining Quality Management System to ISO 9001: 2000. Conducting internal & external audits.
Carryout all inspection works after taking relevant safety permits from the client and follow company HSE policies.
Welding activities: Onshore & off shore
Involvement to development & establish the following activities at shop & site.
Project based welding Consumable planning, estimation and monitoring. (Planning v/s arrival v/s actual consumption v/s forecast requirement for monthly, quarterly and % of completion project).
Establish procedure for consumable testing & approval of vendors.
Vendor's audit for system checking & consumable testing and its approval as per code requirementat.
Forecasting requirement for developing Welding Procedure Specification (WPS) and Procedure Qualification Record (PQR).
Conducting and witnessing CS, SS, LAS-P11, P22, P5, P9 & P91, dissimilar material (SS to Alloy steel) etc. PQR and preparing new WPS.
Inspection of in coming consumables i.e. test certificate review, preparing sample for batch testing and review of testing results, colour coding of filler wires, PMI carried out for LAS & SS consumable etc.
Monitoring & controlling of consumable storage, handling, backing & holding requirement.
Established Vacuum pouch packing electrodes for through out Reliance complex and developed new concept for avoiding backing problems and achieved faster productivities.
Field consumable problems monitoring and resolving by time to time co ordination with batch testing of consumable.
Welder training and Welder Performance Qualification & certification.
Development of process automation for faster Production i.e FCAW for field piping in 6G position, twin head & tendom SAW, Strip cladding, ID overlay welding etc.
Welding of various materials i. e. Carbon Steel, LTCS, Low alloy Steel and Stainless Steel, Nickel, alloys, Nace etc.
Hands on experience with SMAW, GTAW, FCAW, SAW AND PAW.
Inspection activities: Onshore & off shore
Static equipment:
Involved inspection activities of fabrication, erection, installation & shutdown of following equipments as per ASME, TEMA, IBR and API & Owner specification for special requirement.
Pressure vessels
Columns
Heat exchangers
Fired Haters
Storage Tanks
Involved to carry out stage wise fabrication inspection activities at vendor- fabrication shop. (Document covered QAP/ITP/WPS/PQR/NDE procedures/Welder qualification/blasting & painting & final dossier)
Involved to carry out inspection for erection & installation at site location.(Civil foundation checking/ Orientation/Alignment/Internals/accessories/Insulation/Fire proofing /Painting/Earthing & final dossier)
Inspection of vessels internal tray supports ring by laser alignment and internal trays.
Thickness survey or laminations check on Static equipments crude/Aromatics/FCC unit under operation.
Activities involved in VMP project (FCCU Static equipments, reactor and regenerator Alterations and repairs):
Major internal and external modification in all FCCU static equipments, Reactor and Regenerator.
NDE on nozzle modification (Alteration) on vessels and columns.
Root inspection with optical bore scope for nozzle (Set-on type joint configuration) before opening of nozzle Shell to Nozzle joint
Welding on live equipments before hot tapping.
Welder training and qualifications, mockup practice as per joint cnfigurations.
NDE on nozzle modification (Alteration) on vessels and columns.
Hydro and leak test preparations and witness of leak and hydro tests.
Monel corroded area repaired with Monel plates by laired type NDE (PT) for repair welding.
Witness of PWHT and Hardness testing.
NDE mock up blocks Design review, Blocks Fabrication and NDE of fabrication.
Witnesses of dry MT application on intermediates weld runs in preheat condition.
Inspection activities related to Regenerator First stage cyclone separator bottom section replacement.
Crude column top dome 3 mm Monel claded corroded as repair existing dome replacement with new 5 mm thick Monel claded dome.
Inspection of hex mesh welding and refractory applications.
Rotary equipment:
Involved inspection activities of erection, installation of following equipments as per API & Owner specification of following.
PUMP
Compressor
Piping: Onshore & Off shore
Involved stage wise inspection activities of CS, LAS, SS, NI, Alloy, CI & GRP Piping
Above ground & under ground piping as per requirement of ASME B31.1, B31.3 and specification
Stage wise fabrication and inspection (shop & field). Material Identification (Pressure parts), fit up, welding, visual inspection, NDE, PWHT, hydro-test, surface preparation and painting, wrapping & coating, cathodic protection, back filling, earthling, insulation inspection & Certifying inspection reports.
Comprehensive Knowledge On Blasting, Painting, which includes verify / certify the Painting / Blasting Operators, Surface Preparation, Temperature and Relative Humidity, Blast Surface Profile, Paint Application, Familiar with use of Wet / Dry Film Thickness Gauges.
Witness of DPT, MPT, Interpretation and Evaluation of Ultrasonic Testing & Radiographic films.
Involved with Heat treatment process activities.
Qualifying pipe bonders for GRP piping & carried out visual inspection for joints.
Certifying reports and preparation of test pack & summation dossier for piping system.
Pipe bends:
Preparation of BPS(Bending procedure Specification)
Involved inspection activities of various size of pipe bends for visual inspection, marking & punching, ID/OD dimension checking, hardness testing, Ovality as per ASTM, IS standard & specification.
Steel structures: Onshore & Off shore
Involved inspection activities of erection, installation of steel structure as per ASME D1.1, IS & specification.
It involved foundation, alignments, welding, assembly, verticality, bolt tightening,
M/s Welspun – Pipes Mfg unit, Bharuch – Position: QC Engineer
Preparing ITP / QAP / Procedures
Carried out stage wise inspection activities of dia.16"' to 94'' dia. Pipes.
It involved material identification, bevelling, pre punching, bending/rolling, tack welding, inside/outside welding, expansion, hydro test, NDE & final inspection & summation dossier as per API 5L
Calibration of ultrasonic system for weld, body lamination.
Operation of real time radioscopy (fluoroscopy), magnetic particle testing machines.
Interpretation of radiography films.
Handling inspection team with team work.
Co ordination with various third party inspection like EIL, BV, LOYYIED, ABS, SGS
Welding
Preparing Welding Procedure Specification (WPS) and Procedure Qualification Record (PQR).
Preparing of welding plan & testing plan.
Welder Performance Qualification & certification.
Welding Consumable selection, planning, estimation.
Repair & root cause analysis.
Welding electrodes and Filler wire testing and its approval.
Hands on experience with SMAW, GTAW, FCAW, SAW AND PAW.
Planning & monitoring of consumables and its storage, backing and holding requirement.
M/s. Larsen & Toubro -Heavy fabrication unit, Surat – Position: QC Engineer
Involved to carry out stage wise fabrication inspection activities of Columns, Vessels and heat exchangers at fabrication shops.
Inspection involved material Identification (Pressure parts), pre punching, rolling, fit up, tack welding, ID/OD welding, visual inspection, NDE, Tube to tube sheet welding, tubes expansion, tube bundle assembly, pre heating, post heating, PWHT, hydro-test, surface preparation and painting & Certifying inspection reports.
SKILLS
Very good co ordination skill with subordinate, contractor and management.
Problem solving skills
Good interpersonal Skills
Self confident & motivated
PROFESSIONAL ENHANCEMENT INITIATIVES
Certification in CSWIP 3.1 from TWI, the Welding Institute, Cambridge, U.K.
API 570 - Authorized Piping Inspector, American Petroleum Institute, USA –R.A
Radiography Testing, ASNT Level – II.
Magnetic Particle Testing, ASNT Level – II.
Dye Penetrant Testing, ASNT Level – II.
Ultra Sonic Testing, ASNT Level – II.
Visual Testing, ASNT Level – II.
Welding Inspector Training Course by Moody-India.
Computer knowledge in MS-OFFICE.
Internal auditor as per ISO 9001:2000.
ACADEMIC OVERVIEW
Bachelor of Engineering – Mechanical
PERSONAL SNIPPETS
Date of Birth: 26th May 1975
Nationality: Indian
Marital Status: Married
No. of Dependents: Three
Driving License Details: Indian & Kuwait Driving licence
Languages: English, Hindi, Gujarati and Manageable Arabic
Permanent Address: 58, Mangalmilan Park Society, Near Borsad charrasta, Anand, Gujarat, India
REFERENCES & DOCUMENTS AVAILABLE ON REQUEST
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