Project QC Manager
Chicago Bridge and Iron Company , CB&I
Total years of experience :14 years, 7 Months
Conducted/Attended kick off, pre-inspection, pre-audit and post-audit meetings and recorded the minutes.
Managed all aspects of Quality on assigned projects including supervising assigned quality personnel, overseeing the implementation of the Project Quality Plans, acting as primary liaison to client on all quality related issues and responsible for ensuring sufficient training is conducted for project personnel on the Quality Management System and project specific procedures.
Coordinated contract quality activities with the Project Manager including determining resources (Quality personnel, Monitoring and Measuring instruments and their calibration etc), establishing primary objectives and development of the Audit & Surveillance Plan.
Developed and implemented Project Quality Plans (PQP’s), Inspection & Test Plans (ITP’s), Welding Procedure Specifications (WPS’), Procedure Qualification records (PQR’s), Welders Qualification Records (WQR’s), Non-Destructive Testing (NDT) Procedures, Hydro & Pneumatic Test procedures and other documents relevant to Quality Assurance & Quality Control.
Reviewed, coordinated, and approved all contractors’ deliverables such as quality plans, inspection and test plans, method statements, procedures, specifications, materials supplies and certifications, trade tests, third party inspection etc. prior to work commencement.
Collaborated with management for interface on Quality activities with internal or external organizations (customers, suppliers, subcontractors, and others)
Ensured the implementation of QMS through planning, conducting, and coordinating internal, external and subcontractor’s audits for the compliance of ISO 9001 in projects.
Monitored and ensured that a comprehensive record of documentation and certification of work is maintained to support a satisfactory handover of the completed plant to the Client.
Supervised the effective implementation of all test and inspection schedules, ensured adherence to all procedures, and coordinated with various teams to perform quality audits on processes.
Performed and adequately documented Internal Quality Audits of corporate offices, projects, and jobsites, and managed all related follow-up activities. Audits conducted to assure compliance with ISO 9001-2015, Company standards, contract requirements, and applicable codes, specifications, and drawings, including but not limited to: Design, Engineering, Estimating, Procurement, Project Controls, Vendor/Subcontractor. Analysed findings and issued non-conformances identified during audits to determine program quality and identify performance trends. Effectively documented, followed-up and closed corrective actions - both internal and external.
Reduced the quality failures by root cause analysis of the nonconformities and making sure the corrective actions have been taken in time.
Ensured the construction work in compliance with the project specifications and safety standards.
Coordinated with the customers, subcontractors, and third parties to ensure the required quality activities have been carried out by the relevant parties in time.
Carried out static equipment and piping inspections during shutdowns in accordance with API-510, API-653 and API-570
Involved in material inspection including, dimensional checks, stamps verification, PMI and visual inspection. Pre welding inspections like bevel preparation, fit up, alignments, joint cleaning. During welding, monitoring the welding parameters as per qualified welding procedures and after completion of welding carrying out visual inspection, PWHT, NDT, Hydro/Pneumatic testing, calibration, surface preparation and painting as per international standards and project specifications.
Well experienced in welding inspection, materials standards, NDT (RT, UT, PT, MT, VT) methods
Conducted/Attended kick off, pre-inspection, pre-audit and post-audit meetings and recorded the minutes.
Managed all aspects of Quality on assigned projects including supervising assigned quality personnel, overseeing the implementation of the Project Quality Plans, acting as primary liaison to client on all quality related issues and responsible for ensuring sufficient training is conducted for project personnel on the Quality Management System and project specific procedures.
Coordinated contract quality activities with the Project Manager including determining resources (Quality personnel, Monitoring and Measuring instruments and their calibration etc), establishing primary objectives and development of the Audit & Surveillance Plan.
Developed and implemented Project Quality Plans (PQP’s), Inspection & Test Plans (ITP’s), Welding Procedure Specifications (WPS’), Procedure Qualification records (PQR’s), Welders Qualification Records (WQR’s), Non-Destructive Testing (NDT) Procedures, Hydro & Pneumatic Test procedures and other documents relevant to Quality Assurance & Quality Control.
Reviewed, coordinated, and approved all contractors’ deliverables such as quality plans, inspection and test plans, method statements, procedures, specifications, materials supplies and certifications, trade tests, third party inspection etc. prior to work commencement.
Collaborated with management for interface on Quality activities with internal or external organizations (customers, suppliers, subcontractors, and others)
Ensured the implementation of QMS through planning, conducting, and coordinating internal, external and subcontractor’s audits for the compliance of ISO 9001 in projects.
Monitored and ensured that a comprehensive record of documentation and certification of work is maintained to support a satisfactory handover of the completed plant to the Client.
Supervised the effective implementation of all test and inspection schedules, ensured adherence to all procedures, and coordinated with various teams to perform quality audits on processes.
Performed and adequately documented Internal Quality Audits of corporate offices, projects, and jobsites, and managed all related follow-up activities. Audits conducted to assure compliance with ISO 9001-2015, Company standards, contract requirements, and applicable codes, specifications, and drawings, including but not limited to: Design, Engineering, Estimating, Procurement, Project Controls, Vendor/Subcontractor. Analysed findings and issued non-conformances identified during audits to determine program quality and identify performance trends. Effectively documented, followed-up and closed corrective actions - both internal and external.
Reduced the quality failures by root cause analysis of the nonconformities and making sure the corrective actions have been taken in time.
Ensured the construction work in compliance with the project specifications and safety standards.
Coordinated with the customers, subcontractors, and third parties to ensure the required quality activities have been carried out by the relevant parties in time.
Carried out static equipment and piping inspections during shutdowns in accordance with API-510, API-653 and API-570
Involved in material inspection including, dimensional checks, stamps verification, PMI and visual inspection. Pre welding inspections like bevel preparation, fit up, alignments, joint cleaning. During welding, monitoring the welding parameters as per qualified welding procedures and after completion of welding carrying out visual inspection, PWHT, NDT, Hydro/Pneumatic testing, calibration, surface preparation and painting as per international standards and project specifications.
Well experienced in welding inspection, materials standards, NDT (RT, UT, PT, MT, VT) methods.
• Attending the Kick Off Meetings and saving the minutes of meeting
• Going through the scope of work and Client specifications for the planning and allocation of QA & QC resources and understanding the type and frequency of inspection and testing involved in the scope.
• Allocation and leading an Inspection team for the job.
• Preparation of pre-shutdown documents like Inspection and Test Plans (ITP’s), Method Statements, Non Destructive Testing (NDT) Procedures; conducting Procedure & Performance Qualification tests for preparation of Welding Procedure Specifications (WPS’), Procedure Qualification Records (PQRs) and Welding Personnel Qualification Records (WPQRs) and getting them approved from the client.
• Determining the remaining life of the inspected items by applying API-653, API-510 and API-570 standards
• Carrying out inspections during shut downs and repair works including internal and external inspections
• Ensure the use of calibrated inspection, testing and measuring equipments and get them calibrated when expired.
• Co-ordination with client Inspection Team to perform their inspections on the stages specified in ITP’s.
• Monitoring all ongoing activities for the total compliance to the approved procedures; assuring the in time performance of required inspections and Non Destructive Tests through QC Inspectors and NDT agencies.
• Monitoring the hydrostatic tests and preparation of hydro test reports.
• Final inspection of the tested equipments and hand over to the clients.
• Preparing the final Dossiers consisting of all ITP’s, inspection reports, procedures, WPS’, PQRs, WPQRs.
Overall Job Responsibilities:
During maintenance works, I was responsible for;
a- Attending the Kick Off Meetings and saving the minutes of meeting
b- Going through the scope of work and Client specifications for the planning and allocation of QA & QC resources and understanding the type and frequency of inspection and testing involved in the scope.
c- Allocation and leading a QC team for the job.
d- Preparation of pre-shutdown documents like Inspection and Test Plans (ITP's), Method Statements, Non Destructive Testing (NDT) Procedures; conducting Procedure & Performance Qualification tests for preparation of Welding Procedure Specifications (WPS'), Procedure Qualification Records (PQRs) and Welding Personnel Qualification Records (WPQRs) and getting them approved from the client.
e- Co-ordination with client Inspection Team to perform their inspections on the stages specified in ITP's.
f- Monitoring all ongoing activities for the total compliance to the approved procedures; assuring the in time performance of required inspections and Non Destructive Tests through QC Inspectors and NDT agencies.
g- Monitoring the hydrostatic tests and preparation of hydro test reports.
h- Final inspection of the tested equipments and hand over to the clients.
i- Preparing the final Dossiers consisting of all ITP's inspection reports, procedures, WPS', PQRs, WPQRs.
Fabrication and Installation of Piping Systems, Steel Structure and Pipe Supports, Pressure Vessels and Storage Tanks:
Overall Job Responsibilities:
During execution of projects, my responsibilities were including but not limited to;
a- Go through the scope of work, Client specification, relevant drawings, International Codes for the planning and allocation of QA & QC resources and understanding the type and frequency of inspection and testing requirements in the scope.
b- Leading a team of QA & QC Inspectors, NDT Inspectors, data entry operators and record keepers involved in each Project.
c- Give training to QA & QC team regarding project inspection and testing requirements and their applications
d- Prepare the project specific documents like Project Quality Plans (PQPs), Inspection and Test Plans (ITP's), Method Statements, Non Destructive Testing (NDT) Procedures and get them approved from clients/Third Parties.
e- Conduct Procedure & Performance Qualification tests for preparation of Welding Procedure Specifications (WPS'), Procedure Qualification Records (PQRs) and Welding Personnel Qualification Records (WPQRs) and getting them approved from the clients/Third Parties
f- Review and verify the Material test certificates (MTCs) against requirements of ASME-II and project specifications.
g- Ensure the inspection of materials in accordance with project specifications and ASME BPVC requirements.
h- Ensure the material identification by transferring heats to all pieces taken from same heat.
i- Monitor and ensure that the fit up and welding inspection is carried out in a frequency stated in the relevant ITP's and in accordance with applicable WPS and project specifications; welders identification is present on the welding joints.
j- Approach the Third Party Inspectors and NDT subcontractors in time to carry out their respective inspection and testing as per applicable ITP.
k- Ensure the use of calibrated inspection, testing and measuring equipments and get them calibrated when expired
l- Ensure the preparation of stage inspection and testing reports and compile them for the record
m- Monitoring the hydrostatic tests and preparation of hydro test reports.
n- Compilation and review of all project specific reports to prepare Manufacturer's Data Reports (MDRs)
o- Hand over all MDRs to Client through proper transmittals.
HI-TEK Manufacturing (PVT) Ltd. Lahore, Pakistan (Jan, 2007 to Aug, 2008)
Company Profile: HI-TEK Manufacturing (PVT) Ltd. is a Manufacturing and Installation Company providing its manufacturing and installation services to Oil & Gas, Chemical & petrochemical, Cement Plants and Fertilizer Plants. Its speciality is to manufacture pressure vessels and their installation.
Overall Job Responsibilities: As an Assistant QA &QC Engineer, during manufacturing of a large number of LPG Storage Tanks, Cylinders, Bowsers, and Oil Storage Tanks, my responsibilities were;
a- To review the COMPANY quality policies and find plans to improve upon the existing quality standards
b- Fully responsible for the quality control and make sure that all work processes meet (or exceeds) company execution standards & procedures.
c- To prepare Inspection Test Plans (ITP) in accordance with project specifications and International Codes and Standards.
d- To Review the Project documents, like drawings, project Specifications, material test certificates
e- To prepare the welding procedure specifications and conduct procedure qualification tests and welder qualification tests.
f- To prepare method statements for different activities in project execution in accordance with project specifications and International practices.
g- To ensure the material compliance with project requirements
h- To ensure the NDT activities to be carried out according to project specifications and ASME-V.
i- To ensure the Documentation of the different activities to prepare manufacturer's data report (MDR)
◆ B.Sc. in Mechanical Engineering from University of Engineering and Technology Lahore, Pakistan. (2006) Professional Certifications/ Trainings: ◆ API-653 Above Ground Oil Storage Tank Inspector (46326) ◆ API-510 Pressure Vessel Inspector (44648) ◆ API-580 RBI (53357)