Rail Welding & QA/QC Manager
Tekken-Rinkai Nissan JV
Total years of experience :17 years, 0 Months
Review and advice all related staff on Rail Welding Technology (All types).
Preparation of Method Statements, Inspection and Testing Plans, Schedules and all Welding and Trackwork Submittals.
Study and Ensure that the test methods applied for welding are in accordance to applicable standards.
Supervision, Implementation & Execution of Flash Butt and Aluminothermic Welding.
Prepare Methodology, Supervision and Execution of Final Grinding & Ultrasonic Flaw Detector Testing.
Implement procedure & execution of Rail Destressing.
Preparation of all third-party laboratory documents and follow up on testing scheme for welding.
Prepare Factory Acceptance Test Plan, Testing & Commissioning Plan, Test Procedures, Preliminary and Final Handover of Track to Employer and Inspection & Maintenance Manual.
Planning Long Welded Rail allocation plans for stations and mainline.
Propose efficient methods of Welding Production and Trackwork activities.
Support QA/QC staff for Welding, Grinding, Destressing and Track &process necessary submittals.
Assist as an advisor to senior management on Trackwork.
Correspondence to Employer’s and Engineer’s request for inspection and related documentation.
Attend meetings with Employer’s and Engineer’s representative on Welding & Track.
Training of personnel for safe-working measures for Welding & Trackwork.
Track recording chart obtained from Track Inspection Vehicle in accordance to As-built drawing.
• In charge of:-
- All track works and track welding subcontractors on site.
- Complete track work construction on site - Mainline & Depot.
• Supervision of:-
- On-site track installation & Turnout installation, concreting of Plinth Track.
- Flash Butt Welding by Contrail Machinery S.R.L K900G-1 Welding Head.
- Aluminothermic Welding - Railtech PLA Process.
- Rail Destressing - Natural & with Rail Tensors.
• Ensure track and welding activities are in compliance to railways standards.
• Supervise and coordinate activities of workers engaged in Track work, Flash Butt Welding & Aluminothermic welding process, welding - grinding teams and turnouts/ crossovers.
• Follow all Trackwork and welding activities according to the weekly Track-work works program.
• Prepare all inspection documents (inspection sheets, daily reports, site minutes etc.).
• Organizing teams and supervising all track and welding process to enable the best efficiency implemented on site. Conduct training sessions on technical and Safety issues as required.
• Prepare Method statements, LWR schedules, MAR’s and technical submittals.
• Factory acceptance test (FAT’s) and joint site surveillance.
• Pre-Qualification Type Approval Tests for Flash Butt Welding & Aluminothermic Welding Qualification - Type Approval tests for 60E1 rail grade in third party laboratory - RTDL, TISTR - Thailand.
• QA/QC and welding data documentation.
• Supervision of Railway Welding Procedure and Weld Construction Works -Flash Butt Welding - Fixed Plant & Mobile (VAIA Car + SERSA Mobile FBWM GmbH).
• Supervision of Railway Welding Procedure and Weld Construction Works-Aluminothermic Welding (PLA Process & Electro-Thermit).
• Supervision of Rail Destressing - With Rail Tensors by using Flash Butt Welding - VAIA Car (OHL Arabia - Km 110 to Km 290) and Aluminothermic Welding - PLA Process (COPASA - Km 290 - Km 425).
• Supervision of Track Installation - Ballast Track, Ballast-less Slab Track, CDM Q Track & Edilon systems @ KAEC & KAIA Stations.
• Supervision of Production & Unloading of LWR by Work Train. Review of Reports Evaluation of Weekly Bend Tests of Flash Butt Welds on the Welding Train - Railtech Schlatter. Nenchky Press Graphs for Bending. LWR to CWR formation on site.
• Ultrasonic Testing and NDT Methods review on Welding production.
• Supervision of Track Ballasting, Track Alignment/Track Geometry and Surfacing activities.
• Supervision, Monitoring of Final Grinding by OHL and SERSA Gmbh Grinding Teams by using Recti Rail and conventional 1 m ruler. Analysis & Check of Recti Rail Graphs.
• Supervision of Track work & Welding in Depots and Yards (Madinah Depot, Work Base 2 Yard).
• Supervision, Implementation of Turnout Pre-assembly (Conventional & High Speed), Installation & Aluminothermic Welding. Turnouts of Vossloh, Voestalpine & Fabrides ranging from Radius of R318, R760, R1500 & R10000.
• Providing technical guidance with emphasis on Weld requirements and Training of staff, Track Installation and Welding Train.
• Preparation of Inspection and Test Plan (ITP) for supervision and perform on-site inspections with Trackwork contractors & sub-contractors.
• Reviewing Contractor’s QA/QC process for track welding (In-Plant & On-Track).
• Check, Review and Approval of Welding & Trackwork Method Statements.
• Preparing & performing technical audits, control NDT and frequency of Bend Testing of Welds.
• Non-conformance Control and Risk Register Management for Track Welding.
• Preparation of Progress Reports and Inspections for Trackwork Management Team and SRO.
• Review and Inspection of Material Delivery on Site.
• Factory Acceptance Tests (FAT’s).
• Planning & Construction of Track @ New Daud Khan, New Khurja & New Hathras Junction Yards.
• Manual Track Installation inside Yard Limit - 13 m Rails to LWR Panels of 260 m.
• Supervision of Mobile Flash Butt Welding (On-Track) - Holland K920.
• Supervision of Mechanized Track Laying by Harsco Rail NTCE - LWR to CWR on Track - Mainline.
• Turnout Installation - SRJ 1 in 12 RH & LH, Canted 1 in 20 Turnouts.
• Supervision of Aluminothermic Welding (Oxy - Propane) - UIC 60 880 Grade Rails.
• Erection & Commissioning of Reva Crane Gantry (For handling of 260 m LWR) to be loaded into Work Train/NTCE.
• Lead of Phooltas Harsco Rail New Track Construction Equipment (NTC) for LWR & CWR/Automated Track Installation.
• Ballasting - By 35 MT Tippers on Blanket Top for 1st and 2nd layer/ Compaction and by Hoppers for 3rd and 4th Layer.
• Lead a Team of 2 Track Supervisors with 15 Gangmen and 5 Keymen for Track Installation & Ballasting.
• FAT's, QAP's, Joint Inspection with Phooltas Harsco Rail Ltd, Haridwar for Superstructures, Power & Transition Wagon of New Track Construction Equipment (NTC).
• Joint Inspection with North Central Railway (NCR) and DFCC Authorities in Yards.
• Well versed with all Indian Railway Manuals - IRPWM, IRATWM, IRFBWM, IRSOD and LWRM.
Client: Roads & Transport Authority, RTA-Dubai; EPCM - SYSTRA
Job Description: • Supervision of Aluminothermic Welding (Air-Propane) KLK Procedure - 41GPU Grooved Rails, U50E6 Rails and Compromised Welds, Welding of Treated Rails, Junction - Crossroads Welding, Welding Quality Control.
• Rail Destressing - U50 Rails on Viaducts & at Grate - 41 GPU Rails. (Natural Destressing)
• Monitoring of Ultrasonic Flaw Detector Testing - All Weld Profiles & Dye Penetrant Testing - Treated Rail Weld Profile. Monitoring Dye Penetrant Testing (DPT) on Treated Rail Welded Profile.
• Track Warehousing, Rail Logistics, Welding Data Logging / Documentation. Tramway Rail Installation, Formwork Installation, Rail Alignment, Jigs Installation.
• Training new personnel for Quality and Process of Aluminothermic Welding.
• Leading a workforce of 45 men who form track and welding teams with 10 lead welders & grinders.
• Welding Team Includes - 2 Welders (ALSTOM); 2 Welders (Railtech); 2 Welders (ETF Belgium); 2 Welders ( Runway), 2 Welders ( Advance - Dubai)
• Installation of Axle Counters - RSR180 Integrated SK420 Box; Electric Arc Welding - Treated Rail Profile.
• G.I.Pipes - Arc Welding Connectors.
➢ ODEBRECHT CONSTRUCTION INTERNATIONAL INC., LIBERIA, WEST AFRICA
Western Range - DSO Iron Ore 243 Kms, ArcelorMittal Liberian Railroad, Buchanan - Yekepa, Project Liberia Sep '10 till May '12 Designation: Track Engineer/ Welding Supervisor
Client: Arcelor Mittal; EPCM: SNC Lavalin
Job Description: • Aluminothermic Welding ( Air-Propane) - 132 RE, 136RE, 132RE+136RE, In Control of 4Track Welding Teams, Welding Mismatched Joints, Bridges, and Welding Data documentation.
• Rail Destressing (Natural & With Rail Tensors), Destress Thermit Welding.
• Verse Testing of Rail.
• Track Maintenance, Repair & Up gradation of 245 Km Iron Ore Freight Railway Line - Mainline, Sidings, Yards, Balloons, Wyes, Crossings, and Switches.
• Replacing ultrasonically found defects with Joint Bars, Closures.
• Manual Track Laying, Track work, Ballasting Supervision, Tier Replacement, Transposing of Curves.
• Rail Inspection with 3rd party consultants (SNC-Lavalin Inc.)
• Ultrasonic Testing of Rail Welds (Thermit Welds/Flash Butt Welds) by Hand Probing using Sonatest Flaw Detector - 0˚, 45˚ & 70˚ Probes and Ultrasonic Testing of Rail by DAPCO Ultrasonic High Rail Unit using Roller Search Unit ( RSU)
• Monitoring Weld Pre/Post Grinding Alignment.
• Rail Anchor Placement, Joint-Bar Replacement, Logistics, Insertion of Transition Rails, Closure Rails.
• Turnout Installation, Wye Construction, Sleeper/Tie Insertion/Replacement.
• Lead a workforce of 180 men including 8 welding teams and 6 steel gang / track teams.
➢ BARCLAY MOWLEM PTY LTD. (LAING O'ROURKE), SAUDI ARABIA
Civil and Track Works CTW 300 North-South Railway Project, Al-Jouf, Saudi Arabia
Dec '08 till Aug '10 Designation: Welding Quality Engineer
Client: Saudi Arabian Railways (SAR)
EPCM: Implementation Supervision Consultants (ISC - Louis Berger Group SYSTRA CanaRail)
Job Description: • Ultrasonic Testing of Rail Welds (Flash Butt Welds and Aluminothermic Welds) Ultrasonic Testing of Flash Butt Welds on Site as well as in the Flash Butt Welding Plant (both 25 m jointed rails and 400 m LWR), Rail Yard by using GE - USM 35X Flaw Detector SPG3 Trolley using 2 70 degree, one 0˚ probe, two 38˚probes & manual probing by of AT Welded Joints using 45˚& 70˚.
• Aluminothermic Welding Operation (Oxy-Propane) & De-stressing using Tensors, Destress Welding.
• Flash Butt Welding in Barclay Mowlem Flash Butt Welding Yard, Al Jouf
• Supervision, Maintenance and operation of K 1000 FBW Machine, Geismar MAS150 Profile Grinding machine, BRA 32 Rail Brushing Machine in Depot.
• Monitoring Weld Pre/Post Grinding Alignment on Site as well as in the Rail Yard.
• Track Maintenance, Track Alignment, Turn Out Inspection, Depot/Yard Management
• Worked as a Protection Officer on Track Laying Area and ensuring safety.
• Weld Quality and Weld Data Documentation, QA Documentation.
• Monitor Weld Inspection in Depot as well as On-site with Clients (3rd party Consortium Consultants- Implementation Supervision Consultants ISC)
• Supervision of Work Train Movement to-&-fro from yard, scheduling loading/unloading of sleepers and FBW - LWR Rail Strings, checking PCM Sleepers in Rail Yard and PCM Sleeper Factory.
• Also worked as Rotation Supervisor for Track work, Destressing, Butt Welding, and Thermite Welding.
• Lead a team of 5 for Ultrasonic Testing, 20 for Flash Butt Welding and Destress Welding on rotation.
Ultrasonic Flaw Detector Testing of Rails, Welds, Switches.
• Ultrasonic Testing & Inspection of Railway Tracks with Sperry Ultrasonic Walking Stick and Spurt Car SRS 241 on Live Rail, Points & Crossings, Thermit & Flash Butt Welded Joints & Bolt - holes.
• Hand Probing on SEJs, Operated with most modern Ultrasonic Flaw Detectors and Roller Search Unit (RSU). Recording of Raw data, Reporting data back to the Analysis Team in Sperry Rail International, Derby, UK
• Worked on 2 Mobile Ultrasonic Test Vehicles in Sperry Rail International, Derby, UK in 2007.
• Worked for the Commissioning of Ultrasonic Rail Test Vehicle (2007-2008) with Research Design & Standards Organization (RDSO), Lucknow and Northern Railway, DUK Division on the project on “Mobile Ultrasonic Rail Inspection”, Spurt-Car SRS241 used for ultrasonic testing of rails.
• Worked on the Trials (Dry Run) of “Spurt-Car” SRS 241 Vehicle in Lucknow-Kanpur section of track length 76kms with Maximum Speed of 60 Kmph (37 Mph).
• Commissioning and Trials of “Spurt Car” in Ambala- Rajpura- Sirhind section of Ambala Division, Northern Railway.
• Worked with 6 divisions on Indian Railways for Ultrasonic Flaw Detector Testing - Northern Railway (NR), South-Eastern Railway (SER), North-Eastern Railway (NER), South Central Railway (SCR), Western Railway (WR) & Central Railway (CR).
• MBA in Marketing - Oct '07 Pondicherry University, Pondicherry Secured 61%
• Diploma in Railway Engineering - May '07 Indian Permanent Way Engineers (IPWE), Ministry of Indian Railways, Rail Bhavan, New Delhi Secured 70%
B.E (Electronics & Communication Engineering) 2001-2005 Maharishi Dayanand University, Rohtak, Haryana