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In the course of my earlier and present career assignments I have imbibed subject (welding) knowledge, problem solving skills and cross-functional abilities. I have had a penchant for identifying and tackling key issues in the organizational functioning and that has seen me pick up and learn new skill sets.
I believe that my educational background has instilled in me the qualities required to meet the rigor of this demanding profession. Graduation in Metallurgical Engineering has provided a strong foundation in metallurgy which is one of the foundation courses for Welding engineering. During the course of my career, I have worked with various organizations in the functions of sales, production, QA/QC and Marketing, all of them related to my core competency of welding. This inculcated in me, welding and quality requirements of fabrication and problem solving abilities. I am a CSWIP senior inspector and a member of the AWS committees on Procedure qualification and software for welding. In addition to education from one of the most prestigious institutes in India, Institute of technology, Banaras Hindu University, I have experience with quality tools like TQM, ISO 9000, NDE techniques, SQC/SPC etc.
I have been actively participating in Bids inputs for major pipelines for other clients in the past six months. I have worked in providing lay rates, consumables/testing cost inputs, developmental costs and costs and critical reviews for offshore NDE at bid stage and have been actively involved in the generation of inputs for ECA and AUT defect sizing programs.
I am currently in process of doing my MSc in welding Engg(Distant learning Program) from the University of Cranfield. The program is scheduled to start from 4th October 2004 and my application for the same has already been accepted.
I have experience with materials like cs, austenitic/duplex/superduplex stainless steels, inconel, monel, Al and alloys, Ti and alloys, CuNi, LAHT steels etc. I have experience on manual and automatic welding and qualifications of pipelines(API 5L X60/X65/X70 or equivalent material, Inconel clad pipelines and have worked on pipeline bids with duplex material and ss 316 clad material).
I am proficient in the practical use and interpretation of AWS D1.1, ASME Section VIII Div 1, Section IX, B31.3, B31.4, B31.8, API 1104, API 510, DNV OS F101, and client specifications like TFE, QP, QLGC, Aramco, BP, Shell, and Conoco.
SAYEE PRASAD RAGHUNATHAN CEng MWeldI MIOMMM
Career Summary
Specialization in metallurgical engineering and over 10 years professional experience as welding engineer in construction, fabrication and installation of Offshore Oil & Gas facilities, pipe lay and Power Generation, and fabrication of pressure vessels & Heat exchangers.
Experience
Project Q.A.Supervisor B (Grade: Senior Professional Level 3) (Offshore QC/NDT/Welding coordinator):
J. Ray McDermott Middle East, Inc.
September 2004 to date
Responsibilities include coordination of all offshore activities with regards to QC, NDT and welding matters.
Key tasks and responsibilities include:
- Planning and support of all QC/NDT field activities including major work barges, hook up barges at vendors/suppliers and regional coating yards.
- Sourcing & selection of suitably qualified and experienced QC & NDT personnel to meet project requirements for onshore fabrication and offshore installation/hook up based on workload.
- Preparation/assessment of NDT subcontractor RFQ/ TBE and award. Assists in evaluation and coordination of all subcontractor activities prior to mobilization, during project/spread and upon demob.
- Maintain records of weld procedures, welder qualifications, offshore welding performance and NDT subcontractor's performance.
- Provide Offshore QC, NDT input for bid preparation.
Welding Engineer A (Grade: Senior Professional Level 1):
J. Ray McDermott Middle East, Inc.
March 2004 to August 2004
Responsibilities also include covering project welding engineering requirements for various work phases (i.e. construction, installation, hook-up, pre-commissioning, mechanical completion and hand over activities) both in onshore and offshore facilities. Additional responsibilities include verification of performance of quality system and process audits to verify compliance to project requirements.
Currently providing welding technical support for bids. Inputs include lay rates, costs for procedures and welders' qualification and training, consumables/testing cost inputs, developmental costs and critical reviews for onshore/offshore fabrication/installation.
Involved with writing welding procedure specifications, method statements and technical queries and auditing to check and verify the compliance of working methods to specifications.
Projects currently being handled:
- Ras Laffan LNG Company Limited (RASGAS)-Wellhead Platforms and topsides, WH4, WH5 and WH6.
Welding Engineer B (Grade Professional Level 3):
J. Ray McDermott Middle East, Inc.
August 2001 to March 2004
As a welding engineer, the key function is to review customer drawings/specifications for material and welding requirements to determine the necessary WPS/PQR required assuring the integrity of weld and supervising welding procedure and welder qualifications through the execution of welding plan. This includes consumable selection and estimation, sourcing materials for WPS/PQR's, determining joint design, optimizing welding process, applying code and specification requirements to the proposed WPS, supervising PQR's on site and witness testing at laboratory, preparing WPS, reviewing welder qualification tests and approves documentation, assessing quantity of production testing required and ensuring timely performance and testing, consulting with customer's engineer and production supervisor on metallurgical and welding problems to ensure resolution, assisting in development of automatic welding systems and new methodology, supervising/monitoring work at the metallurgical laboratory and supervising welding school activities and Welder Training.
Projects Handled/worked on:
- Qatar General Petroleum Company (QGPC) (MM-105 WHJ, topsides, spur lines tie-ins and two pipelines in the MM field);
- Amenam/ Kpono AMP 1 Platform;
- Ras Laffan LNG Company Limited (RASGAS)-Wellhead Platforms, topsides, risers and pipelines, WH7;
- Spar / Hull Medusa Deep Water Project (Gulf Of Mexico);
- Spar/ Hull, Front Runner Deep Water Project (Gulf Of Mexico);
Dy. Manager- Tech. Marketing (Welding Consumables)
ADVANI OERLIKON LTD., MUMBAI, INDIA.
December 1999 to August 2001
Responsibilities included marketing of stainless steel, low alloy steel, customized consumables and hardfacing consumables all over India. Technical marketing for customer need & application based customized consumables. In addition, involved in product development for 9% Ni steel, development of 2.25Cr1Mo consumables with step cooling requirements and temper embrittlement tests(J/X factor and impact curves), qualification and approval of tests for consumables, Training & qualification of welders and supervisors as a service to customers as a part of ADOR Institute For Welding Training (AIWT)
Production Executive (Welding Engineering department):
GODREJ & BOYCE MFG. LTD, MUMBAI, INDIA.
August 1995 to November 1999
Welding Engineer for heat exchangers, pressure vessels and columns. Responsibilities included: Enquiry review(welding related aspects), preliminary welding estimate, contract review, design review (welding/PWHT related aspects), material review(weldability), Selection of welding process(es) and consumable(s)(weld planning), Welding procedure -qualification, testing and approval, Welders - training and qualification, estimation of consumables, technology development- new machines, new processes, new consumables, working environment -health and safety, weld procedure-monitoring and auditing, PWHT-design review, plan, implement., carry out in-house heat treatments, equipment - calibration and validation, fabrication procedures (welding related aspects), visual inspection, interpretation of radiographs, weld repairs.
Key achievements were: Tube to tube sheet automation, qualification of procedure and shop floor tube to tubeplate(Titanium) welding for Nirma pure water project and welding of more than 15000 tubes using Protig 315 and POC tool of Esab make. Tube to tube (316L) welding using Protig 315 and POA tool of Esab make. Procurement, customization and implementation of welding software (Prowrite ) from Computer Engg. Computerization of welding data: 513 PQR's and 1000 WPQ's. Selection and implementation of latest technology: BODE Long Seamer, Cypress Nozzle welder, Pipe ID overlay for small bore pipes using indigenously developed machine (system was developed as per our specifications based on continuous interaction with supplier), strip cladding using ESW as well as SAW on Soudometal head New processes developed included Stainless steel welding (GTAW) with flux Backing, strip cladding, tandem welding, narrow gap welding, twin arc welding, manual tube to tubesheet welding. ISO and U/R stamp activities. Defect analysis using tools like TQM and SQC to control defect rates below 3%. For six months I was deputed to site at Reliance India Ltd (site fabrication of 11 columns). I handled all functions for the site including production, inspection, welding. This project gave me an insight into planning, execution and control for site jobs. Received individual awards for top 30% performers in the year 1996-97 and 1997-98
Executive - Sales
Esab India Ltd., MUMBAI, INDIA.
July 1994 to July 1995
Handled potential customers like Rashtriya Chemical Fertiliser, Hindustan Petro Chemical Ltd., Bharat Petrochemical Ltd., Tata Electric, Babha Atomic Research Centre and Larsen & Toubro ECC.
Education
Bachelor of Technology in Metallurgical Engineering
Institute of Technology, Banaras Hindu University, India (1994)
CGPA: 8.03/10.00
Professional Qualifications
- Chartered Engineer (CEng) Registrant no: 549923
- Elected Member Of Welding Institute, 3rd December 2003
- Elected Member Of Institute of Materials, Minerals and Mining
- CSWIP, Senior Welding Inspector (Cert no 6809)
- Registered Senior Welding Inspector (Registration No. 1727)
- European Welding Inspection Specialist (Diploma No. EWIS/GB/03116)
- International Welding Inspector: Standard Level (Diploma No. IWI-S/GB/03116)
- API-510 Pressure vessel Inspector (Certificate No 25448)
- American Society for Quality- Certified Quality Engineer (Certificate Number 46001).
- Internal Quality Auditor - Lloyd's Register, 12th-13th April 1999
Professional Training
- Leadership skills (In-house): 24th October 2004
- Time management (In-House): 25th October 2004
- Basic Metallurgy: The Welding Institute, 23rd-27th February 2004
- Dillinger Pressure vessel conference, 19th February 2004
- ECA Course: The Welding Institute, 24th-25th January 2004
- ISO 9000:2000 Transition Auditor Course: DNV, 9th-10th November 2003
- Interpersonal Skills (1996), Godrej In-house Training
- Development and building of Documented Management (1999) Lloyds Register
- Internal Quality Auditing Certificate Course (12th to 13th April 1999) Lloyd's Register, Mumbai, India.
- Quality Education System course in Total Quality Management "Becoming Globally Competitive" (February 1997), Anaar, Mumbai, -By J Nirdosh Reddy.
- Statistical Quality Control (June 1997) Anaar, Mumbai, -By J Nirdosh Reddy.
- Interpretation of Radiographs ? conducted by by ASNT LEVEL III (obtained 90%)
- `Criteria for Nuclear Pressure Vessel Fabrication' conducted Nuclear Power Corporation, Mumbai, India, (Feb. 1997).
- `Continuing Education Programme on Welding Metallurgy' conducted by Indian Institute of Technology., Bombay, India, (July 1996).
Patents & Publications
- Tube-to-Tube sheet welding: presented at an International Level Symposium International Welding Conference -1996 held at Nehru Science Centre, Mumbai.
- Quasicrystals: an overview in Banaras Metallurgist, an International periodical on research in metallurgy. Paper presented at a National level symposium held at Regional Engineering College, Tiruchirapalli.
- Semi wet analysis of YBa2Cu, IT-BHU
Professional memberships
- Member, The Welding Institute
- Member, Institute of Materials, Minerals and Mining
- Member, American Welding Society
- Member, The Minerals, Metals & Materials Society (TSM)
- Member, American Society for Quality
- Life Member, Indian Institute of Welding
- Member, Emirates Welding Society
SUMMARY OF EXPERIENCE
I. Materials I have worked with/qualified procedures with/supervised welding/implemented solutions
1. Ferrous a. Structural materials i. AWS Groups 1 and 2 materials
1. Plates like API 2H/2W Grade 50, BS 7151 Grades S355/S450, ASTM A36, and their equivalents
2. ABS grades like A/AH/E/EH 36.
3. API 5L pipes X52-X70
ii. High Strength materials up to 120 ksi UTS.
iii. Ss and ss clad materials for structural applications iv. Galvanized materials.
b. Pressure vessel/Tanks Materials i. Plates A 516 Grades 60 and 70 and equivalent.
ii. A353 Class 1/A553 Class 1 (worked on developing NiCrMo6 consumables mainly for SMAW and SAW for LNG tankages)
iii. A240/A213/A312 stainless steels-austenitic, martensitic and ferritic (P8, P6 and P7)
iv. LAHT grades of ASME Section IX groups P3, P4, P5A, P5B, P9A, P9B
v. Duplex and super duplex grades S31803, S32554 (P10H)
vi. Low ferrite/Zero ferrite austenitic ss grades for urea application vii. SS for LT (Cryogenic applications, mostly of the 316L types)
c. Piping materials i. Normal CS/LTCS grades like A106/A105/A350LF2/A333Grade6
ii. LT (Ni steels) grades like A333 Grade 3/A350LF3/A334
iii. LAHT grades of ASME Section IX P3, P4, P5A, P5B, P9A, P9B
d. Pipeline materials i. API 5L pipes X52-X70, A694 F52-F65, MSS SP75 WPHY 52-WPHY 65
ii. Duplex and SDSS (25% Cr)
iii. SS and SS clad (mainly 316L)
iv. Inconel clad (625/825)
e. Cast Irons
Note that I gained my CSWIP welding inspector exam without attending any course.
2. Non Ferrous a. Aluminum and its alloys -SB209
b. CuNi (90/10 and 70/30) –P34
c. Monel –P42
d. Inconels P43/P46. Including Ppt hardening alloys like Inc 718.
e. Ti and Ti clad –SB265
Out of the various metals listed above, my strengths w.r.t knowledge on welding is the welding aspects of carbon steels an LT carbon steels, all grades and types of stainless steels, all LAHTs. (I was the technical marketing In-charge at Advani Oerlikon for the consumables for thjese applications). In addition I have a fairly good idea on hardfacing and repairs e.g. repairs of castings.
II. Welding processes I have worked with/qualified procedures with/supervised welding/implemented solutions
1. Manual/Semi automatic a. GTAW/GTAW-pulsed i. Materials: CS/SS (aust+duplex+SDSS)/ Inconels/ Ti/ CuNi/ Monels/ Al ii. Hot wire for cladding/ Tube to Tube sheet welding iii. Conducted training programmes for NPCIL/BARC on GTAW and P GTAW including orbital welding as a part of AIWT
b. GMAW/FCAW
i. Short circuiting ii. Spray iii. STT (Modified Short circuiting)
iv. Worked extensively on MIG welding of SS for H2O2 applications v. Gases for shielding and their effects. Worked extensively on technical marketing of Advani Oerlikon's seamless FCAW wires and GMAW solid wires proving benefits to customers based on specific applications vi. FCAW-GS and FCAW-SS experience. FCAW-Ss worked with the E61T8K6 and E81xx grades)
c. SMAW
i. Cellulosic: E6010/E7010P1/E8010P1 for pipelines of X52-X65 grades (Offshore and onshore applications) – Know nuances of pipeline welding from ILUCs to PFMs to Dolly mix techniques to NDT to lay sequences to heating systems (Induction heating)
ii. LH/Basic iii. Rutile iv. Synthetic types for ss- E3xx-25/26 types v. Hardfacing d. SAW-Hand held for welding of wagon bodies and frames
2. Machine/Automatic a. SAW
i. SAW for welding LS/Cs of Pressure vessels/structural tubular members/fillet welds.
ii. Single wire/Twin arc/Triple wire/Tandem iii. Flux cored SAW wires iv. Agglomerated/Fused fluxes v. Fluxes for high speed welding of pipes at pipe mills-Oerlikon consumables vi. SAW welding system for ID welding of small bore pipes from Polysoude-Worked on a solution for M/s Ratnamani vii. Narrow groove/gap welding
1. Selection of Consumables _Advani Oerlikon as well as Godrej
2. Worked out a solution package for Punj Lloyd for welding 200+mm thick clad mounded vessels
3. Participated in developing NGW including laser/mechanical tracking systems/Grinding system (Farros Blatter), Equipment like Column and booms from Romar, gouging systems from ArcAir viii. Strip cladding using SAW/ESW techniques. Extensively worked during the procurement, development and implementation of Polysoude head for Esw at Godrej ix. Automatic nozzle welders from Cyprus. Using both FCAW/SAW
x. Worked on developing the SAW trolley/track sytems from Advani Oerlikon to meet and exceed competitors product(s).
b. GTAW- Orbital welding i. Tube to tubesheet: cs, Ti, SS
ii. Tube to Tube: ss iii. Torch developed for welding of recessed tubes especially in LAHT for High-pressure heat exchangers. Torch developed for Godrej to suitably work with Esab Protig 315.
iv. Worked with Esab as well as Polysoude sytems v. Carried out special training programme on Orbital TIG welding for NPCIL/BARC as a part of AIWT
c. P-GMAW
i. Worked extensively on P-GMAW welding of pipelines using Automatic welding systems.
ii. CS/316L clad/Inconel 625 clad d. FCAW- Automation especially for overlay applications i. ID bore welding overlay machine developed at Godrej for welding inside pipes of upto 3" for nozzles. Equipment indigenously developed.
ii. Overlay welding of LS/Girth welds for Clad pressure vessels (Especially closing seams) and the automation
III. Codes, specifications and standards I have worked with/qualified procedures with/supervised welding/implemented solutions
1. Pressure vessels:
a. ASME/API
i. ASME Sections III, VIII Div 1 and 2, IX, II A, II B, II C, II D
ii. API 510, API 572, API 576.
iii. A very testimony to the fact that I am well versed with Pressure vessel materials of construction and their welding was when I cleared the API 510 pressure vessel Inspector certificate exam without attending any course for the same with 80+% overall and 91+% in welding.
b. BS 5500
c. PED
d. OCMA
e. Various client specs like TFE (Now Total), QP, Elf, Conoco, BP, Exxon Mobil, Aramco, BG, ONGC
2. Piping a. B31.3, B31.4, B31.8
b. EEMUA 153
c. Various client specs like TFE (Now Total), QP, Elf, Conoco, BP, Exxon Mobil, Aramco, BG, ONGC
d. Piping for nuclear applications, refineries, offshore platforms, fertilizers e. Though maybe incorrect to include here, I have sold solutions in terms of wire, flux and equipment to API 5L Grade B-API 5L X65 pipe manufacturers for applications ranging from water to oil and gas.
3. Structurals a. AWS D1.1
b. EEMUA 158
c. Various client specs like TFE (Now Total), QP, Elf, Conoco, BP, Exxon Mobil, Aramco, BG, ONGC
4. Pipelines a. API 1104
b. DNV OS F101
c. Various client specs like TFE (Now Total), QP, Elf, Conoco, BP, Exxon Mobil, Aramco, BG, ONGC
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