QA/QC Sr. Engineer
Wood Group
Total years of experience :28 years, 1 Months
• Preparation of project deliverable Inspection and Test Plan (I&TP)
• Provides QA/QC technical support to construction team in Welding, Hydro test, NDE, Bolt torqueing/tensioning, Piping installation, Pump flanges alignment and painting of process piping and pipelines for oil and Gas transmission.
• Monitoring calibration of test and measuring instrument and equipment’s and ensuring all active instruments are calibrated with corresponding certificates.
• Implement QMS at site and ensure that all disciplines adheres to the quality objective of the company
• Trained and reminds welders in quality welding by following essential variables in WPS to lower the rejection rate and help the company to save repair cost
• Monitoring welding activities on process Manifold, Well Head hook up, Gas lift Loops, gas lift off plot, Flow line Loops and Flow lines off plot using GTAW and SMAW processes.
• Monitoring of shutdown activities, tie-in, pigging/air blowing/Flushing, Hydro testing and bolt torqueing/tensioning
• Monitoring installation of thermocouple on fire tubes, tack welding of sacrificial SS sleeves, checking loop resistance and NDE of V-pads and clips
• Compilation of documents for Work Pack preparation in compliance with Shell Hand over procedure.
- Acting as QA/QC Supervisor and Piping Inspector simultaneously
- Supervise set up of fabrication shop
- Train pipe fitters and welders to produce a high quality welding with minimum rejection rate.
- Piping material inspection, Heat number monitoring as per MC or MTR.
- Monitoring welding daily production and seggregation of spools with NDE and without NDE to be sent directly for painting
- Dimensional inspection of fabricated Piping spools.
- Prepare NDE Request
- Piping documentation.
- Assigned as Welding/Piping Inspector in fabrication Shop environment
- Conduct Welder Qualification Test on Carbon Steel, Stainless 304L/316L and Dissimilar Metal (CS to SS)
- Preparation of welding history report, key in daily production weld in data base, prepare NDE request, tagging of joints for NDE
- Monitoring fit-up, check bevel or groove angle, gap, cleanliness of weld preparation, in process inspection and weld visual inspection.
- Releasing of pipe spools with cleared NDE to painting, tagging of pipe spools line number and spool number,
- tranferred to site and perform weld mapping, line checking for the final configuration of piping spools and revise isometric drawing as built.
• Project Management team player involve in the construction of LNG modules from structural fabrication/erection and pre-commissioning piping walk down, punch listing/killing, Pressure test and sub-system walk down
• Ensured that all structural and piping materials are in compliance with the approved AFC drawing and specification.
• Monitored welding on Structural materials API-2W Gr 50, ASTM A572, A36, API 5L, JIS G3101, G3106, SS400 by SMAW, FCAW-GS and SAW welding processes
• Joint design verification suchlike TKY connection, Single/double V, J/U groove design and flare bevel groove.
• Regulated structural and piping work by inspecting the joint preparation, cleanliness, in process inspection (if necessary), utilized WPS and essential variables, completed welding work by visual inspection and the required NDE before fit-up (UT Lamination check 25mm and above plate thickness) and after welding UT, PT and MPI
• Ensure correct utilization of welding processes as per WPS to a particular job and monitor correct pre-heating temperature for thicker materials
• Performed dimensional inspection on completed structural sub- assemblies, final visual to check distortion and joint design to match with other assembly.
• Checked the correct type of pipe shoes to be installed, orientation of cavity vent, valves which requires flow direction, CIP (critical Interphase point), plumb-ness, squareness and levelness of installed piping system, setting of spring supports, pipe flange connection and alignment to compressors, Ergonomics or human factor engineering and witnessing of Flange Management activities.
• Reviewed/Approved Structural NDE packs and Piping test packs for welding and NDE completeness before Pressure test
• Scope of work includes Onshore and offshore jobs for the construction of Jetty pipelines, Mono piles, dolphins/ladder, fender rack and cat walk welding and installation, 120 pipe rack modules pipelines welding/installation, review of test packages, line checking/punch listing/clearing, pressure testing and reinstatement.
• Implemented 100% joint fit-up inspection to all pipelines and BCJV was chosen as the best sub-contractor for having RT repair percentage below 1%.
• QA/QC Leader and Administering and recording all welding, piping and NDT records through weld eye.
• Prepared project deliverables I&TP’s, Welder Qualification Test Certificates and ID’s
• Coordinated with engineering and construction personnel for the utilization of correct WPS to be used for both Marine and Topsides activities
• Supervised assigned Welding and Piping Inspectors and provide technical QA/QC support to engineering and construction.
• Re-trained and disqualified welders with significant rejection rate.
• Prepared Monthly and weekly report for welding and NDE repair rate as required by the Main Contractor Chiyoda.
• Monitored Flange management system in the project
• Client representative and Project Management Team player and primary functions are to conduct surveillance, witness and attend hold point inspections in sub-contractor and contractor’s piping/structural fabrication and erection activities.
• Ensured all activities are in accordance with specifications and properly documented according to approved I&TP.
• Witnessed Welder Qualification Test in accordance with ASME IX and Welding Specification.
• Identify all non-conformity workmanship for rectification and ensure satisfactory resolution.
• Take part in weekly Quality Observation Report preparation.
• Enforced strict compliance to safety and Quality aspect of the project.
• Project management team player involved in the fabrication/erection, welding and NDE of cans for legs and braces, pad eyes, mud mats framing, sea fastening, launch runner, beams, girders and bridge of jacket sub-structure project
• Monitored welding activities using FCAW-GS (manual and Mechanized) FCAW-SS, GMAW-S (for root pass), SAW (single/multiple Arc), SMAW and GTAW for piping.
• Closely monitored coping of braces on TKY connection, Buttering of weld gap in excess of 20mm by SMAW (TKY and Butt), welding of long seam and circumferential weld, Narrow groove welding in cans long seam up to 120mm thickness for materials API 2Y Gr. 60 and API 2W Gr. 60 AWS Gr. III and monitored weld overlay for cladding of Inconel 625.
• Knowledge in template preparation for welding profile in accordance with AWS D1.1 2006 Fig. 3.10
• Monitoring of Piping welding activities (For Bridge) on Carbon Steel (P1), SS 316/316 (P8), SS304/304(P8), , Cuni 90/10 (P34), duplex SS UNS 31803 (P10H) and super duplex SS S32750/S32760 (P10H) and Inconel 625 materials.
• Observed and recorded completed NDE by manual UT, TOFD (used for single bevel design in mud mats), MPI, PT & RT and ensured completion in timely mannered.
• Periodic inspection of Welding consumables issuance/withdrawal records, Baking oven holding/heating temperature and Consumables storage temperature in accordance with welding consumables control procedure.
• Review and Approval of documents for completed assembly and sub-assembly for release to erection or painting.
• Third Party Inspector and scope of work includes verification of Materials used in construction of piping, Welding/ NDE monitoring, attend line checking and generate Punch list, witnessing of pressure testing and re-instatement of piping system.
• Conducted line checking and punch listing inspection scheduled in a day to day basis on Cryogenic lines, Flare lines, Steam lines, water lines, , air lines, Nitrogen lines (SWAN) and other flammable and toxic lines.
• Witnessed hydro Test with the client Inspector and ensure pressure gauges and Recorder calibration are Valid with certificates before any pressure test is to be done.
• Verified accuracy of piping system in accordance with AFC drawing and P&ID and check the test limit, locations and ranges of gauges to be used, Chart and recorder ranges, filling point and coordinate with sub-contractor QC Inspector for any deviation or discrepancies
• Reviewed test packages for completeness of welding and NDE in accordance with the AFC drawing and line list for NDE percentage requirements
• Performed visual inspection of welds and update Isometric drawings for additional joints or design change and inform database operator to update welding History.
• Client representative and functional role is overseeing contractor and sub-contractor in quality, productivity and safety aspects in the construction of FPSO conversion project.
• Surveillance inspection on Structural fit-up and welding on Main deck, under deck frames, Main Frames, bulkhead, Crude oil tank refurbishment, Afloat welding, Weld overlay/ cladding, engine room refurbishment and piping installation
• Ensuring high degree of welding works on all structures and piping during construction stage. 100% inspection on all joints for super duplex SS S32750/S32760, monitoring the oxygen content inside pipe by oxygen analyser at a maximum of 0.05%, Cuni 90/10 for potable water, SS 316/316L, Inconel, and other nickel base materials
• Review of documents for sub-assemblies to be released for erection and confirmed that all materials used with corresponding MC, weld numbering/Map on all joints and completed NDE.
• Responded to daily RFI’s schedule generated by sub-contractor and feedback results to Chevron’s QA/ QC Coordinator
• Regular checking of consumables storage, withdrawal and issuance and baking/holding records to comply with the approved welding consumables procedure.
• Performed weld visual inspection, weld counting and reporting daily production joints to pro arc and NEWS
• Assisted the newly hired Welding Inspector to get familiarize with the location when performing line check.
• Verification of punch list items and clearing of documents
• Work as PMT and provide QA/QC technical support to Inspection team, Construction and Sub-contractors
• Review and Approval of project deliverables, witnessed Welding Performance Qualification Test and Welder Qualification test for Tanks and Piping work
• Witnessed and checked the Specimen location taken for bend test, tensile test and Macro test.
• Reviewed and approved WPS/PQR submitted by sub-contractor for Tanks, Piping, Pipeline and structures.
• Respond to all RFI’s related to Welding and Tanks activities.
• Witnessed Vacuum box inspection, Peaking and Banding and weld Inspection of horizontal/vertical seam of Fixed roof tank, Internal floating roof tanks, Domed type roof tanks with diameter up to 45 meters
• Verify correct location of RT films and the extent of testing in accordance with API 620/650
• Review of RT films for tanks.
• Polymer and Ethylene Plant piping fabrication and erection
• Checked and verified types of materials like SS 316/316L, 304/304L, Carbon Steel and Low temp steel A333 to be fabricated and ensure that heat numbers are transferred to the smallest pipe to be cut for traceability.
• Strictly obeyed the 100% material traceability on Steam lines in compliance with the Singapore Ministry of Manpower mandate.
• Monitoring of daily welding production, conduct weld visual inspection, prepared request for NDE, check installation of pipe supports, line checking/punch listing/clearing, Review of RT films, review and releasing of test package for Pressure Test, witnessing of pressure test, reinstatement, and attend final walk down.
• Handover of all collated construction documents, Test packages and RT Films to the client
• Monitoring welding/piping activities in various projects such as Seraya 2 petro-chemical plant (revamp project), R&D Facility pharmaceutical plant, MPP2 pharmaceutical plant, R&D Expansion project, Simvastatin Pharmaceutical plant project and Banyan integrated terminals oil storage tanks project
• Responsibility includes material inspection, arranged and conduct WPQT and WQT of welders, validation check of test, measuring tools & equipment, Weld visual inspection, monitoring and requisition of NDE (RT, PT and MPI), line checking and preparation of punch list, clearing of test packages, witnessing of pressure testing and re-instatement of piping system.
• Cited with excellent performances by Project Managers on every assigned project within Singapore
• Materials Inspected includes A106-B/API-5L Gr X42/X52 (CS), SS 316/316L, duplex and Super duplex, Hastelloy C276, A333 low Temp Carbon Steel and GRE lines.
• Review of RT films as per ASME V/ B31.3 on each project
• Operation/Maintenance Technician in Power generation company operating in Lubang Island with the capacity of 1.0MW Diesel Power Plant
• Monitoring daily plant operational Status, preparation of monthly operational report, environmental hazard report and daily/monthly lube oil consumption report.
• Attend daily shifting schedule and conduct engine preventive maintenance as per schedule
• Assigned as Mechanical Inspector in Shell Tabangao (STAR Project) for pump/coupling/flanges alignment of over 400 pumps
• Assigned as Material Inspector at EEI head office for various project
• Assigned as Welding/Piping Inspector in 2x385 Coal fired Power Plant in Pagbilao, Quezon and was involved in welding of boiler tubes like superheater, girdling, economizer, wall tubes and Turbine piping.
• Assigned as Structural inspector in Mahanagdong Geothermal Power Plant project. Involve in welding fabrication of Girders, Column, trusses and supports using SAW, FCAW and SMAW welding Process. Conduct final visual and dimensional inspection before release for painting
• Assigned as Piping Inspector in PPC refinery expansion project. Monitoring welding and NDE of spools to the required percentage. Releasing of spools to painting and prepare release note for delivery to site.
