Lead Quality Auditor
Freelancer
Total years of experience :37 years, 11 Months
Working as Freelance and performed Quality Audits, on behalf of LyondellBasell, arranged by PrimaSG, for various suppliers, to provide prospect services in the field of Insulation, Painting, Fireproofing, etc.
Assure execution of Project Quality System to build 1000-kta grassroot Ethane Cracker Plant Project (Port Arthur) by implementing quality system and inspection tools for the construction work and equipment installation by EPC Contractor (McDermott/CB&I) and also quality assurance during procurement phase by random checks and arranging inspections at vendor shops at ITP stages thru 3rd party agencies.
Management of complete Quality Program and Inspection System as primary role during Engineering, Procurement, Manufacturing, Construction and Commissioning phases, to build numerous successful and profitable multi billion dollar, mega Plants (Petrochemical, Chemical, Gas, Energy, Steel, etc.), but also executed various other diverse roles, such as Lead project key activities, Project Management & Planning, Supervising & coordinating installations & preservation of mechanical equipment, Continuous Improvement, Change Management, EHS, etc.
1. Ethane Cracker Plant, TOTAL Oil & Gas, Port Arthur, USA $2.3 BB Proj, 2019-21; Contr.: McDermott/CBI, USA.
2. Ammonia Plant, 4300 tpd, Safco-IV-RI Project, Jubail, $ 250 Million Project, 2016-18, contractor: Etec, Korea.
3. Oil Refinery / Hydrocarbon/Polymer Plants, O.T.C. Complex Project, Yanbu, FEED, +$ 30.0 Billion Project, 2014-16.
4. Knowledge Management Center, Subject Expert for TRAININGS on QA/QC, Project Mangmnt., & CDP, 2014.
5. Aromatics, PTA, PET-II & U&O, Petrochemical Complex, IBN RUSHD-II Mega Plant. Yanbu, + 2.1 $ Billion, 2011-14. Contractors: CTCI, Taiwan, SSEC (Sinopec), China.
6. Olefins, EOEG, LDPE, HDPE, Butene, Amines, Phenolics, Polycarbonates, U&O, Petrochemical Plants, Saudi KAYAN Mega Projects, Jubail, +12.0 $ Billion, 2009-10, Contractors: Daelim/Samsung-Korea, TRG-Spain, CTCI-Taiwan, Fluor-USA.
7. Olefins, EOEG, LDPE, HDPE, Butane, U&O, Petrochemical Plants, Yanbu Nat'l. Petrochemicals (YANSAB Projects), Yanbu, + $6.0 Billion Proj., 2006-09. Contractors: Foster Wheeler-UK, Technip-Italy, Toyo Engg-Japan, Aker Kvaerner-Holland. Fluor-USA
8. Ammonia + Urea Plant, Saudi Fertilizer Co.(SAFCO-IV Plant ), Jubail, $850 Million Proj, 2005-06; Contr.: UHDE, Germany.
9. QA / Inspection Consultancy for Engineering & Project Management (E & PM), Jubail, 2004-05.
10. LDPE & BUTENE Plants, Arabian Petrochemical Co Jubail (Petrokemya), $400Million Proj, 2001-04; Contr.:TOYO-Japan.
11. OLEFINS Plant, Arabian Petrochemical Co Jubail (Petrokemya), $950 MM Proj, 1999-2001; Contr.:Mitsui-Jpn, Parsons-USA.
12. METHANOL Plant., AR-Razi-3 & 4 (Saudi Methanol Co), 02 Projs. ea. 2.5K TPD, $400 MM, 1998-99 (thru TUV); Contr.: Mitsubishi, Jpn
13. STEEL Plant, Saudi Iron & Steel Co (HADEED-II ), +1.2 $ Billion Proj, 1997, (thru TUV), Contr.: Voest Alpine-Austria.
Supervise Manufacturing Shops (staff of 90), included Facilities as
Bore & Ball Valve Weld Overlay Cladding, Thermal Spray Coatings, Heat Treatment, Surface Hardening, Regular Fabrication, Conventional & Computer Controlled (CNC) Machining / Boring.
• Manage operation of Advance High Tech Welding Eqpt including Fully Programmable Hot Wire Pulse TIG Welding & Automatic Twin Head Sub Arc Welding
• Assign Daily job instruction to staff, Provide Tech Support. Qualify WPS/PQR & Welders
• Address Metallurgical problems. Improve Quality/Weld Techniques, Train Welders, Control Welding Consumables.
• The applications of High Speed Automated System for Welding Overlay were; Corrosion & wear Resistant (Inconel-625 & Stellite) on Ball Plugs, Valve Body Interiors, Christmas Trees, Flat Gates, Blowout Preventers. Cladding capability for flat components upto 76" & 36” for spherical parts, followed by conventional or CNC machining of Overlays
• Thermal Spray Surface Treatment section had High Velocity Oxy Fuel TAFA-HVOF Flame Spray & Metalllizing. The HVOF produced high density, low oxide & strong bond coatings of WC, Inconel & Cr Alloys for corrosion & wear barrier, used for oil field eqpt, injection molding dies, bushings, valve gates, etc. The flame spray (Spraying+Fusing) applied for coatings of gates. Metallizing spray (Zn, Al & St Steel) coatings on tanks & equipment.
• Metallurgical Heat Treatment shop included Hendrick Seal Quench Furnace for Steel carburizing & hardening, Tempering-Nitriding & Vacuum Heat Treatment Furnaces for surface hardening. The application was for parts used in oil field & drilling. Cooperheat Programmable Oven used for stress relieving welded jobs up to 3 meters long
Assist marketing for Cost Estimates of Weld Shop to bid jobs. Prepare the Dept Quality Procs for ISO 9000. Perform Internal Quality Audit. Develop tools & equipment for welding technology requirement. Approve Job Routings Cards. Prepare daily/weekly production reports
Offer consultancy about advanced Lincoln Electric USA Welding System for construction of mega Underground Strategic Storage Tank for complex welding techniques, troubleshooting, investigation & cost effective solutions.
Supervise QC Inspectors (staff of 45), at shop & Site, to ensure quality as per Int. / Client Stds. for
workmanship (Welding, Manufacturing & Fabrication) of Boilers, Pressure Vessels, Steel Structures, & equipment for Thermal Power Plants (Guddu/Kot Addu) & Cement Plant (Feld Smith-Wah 2000TPD) & other significant industrial project.
• Improve QC deptt. by introducing new SQC & ISO 9000 concepts. Prepare quality procedures & applicable formats.
• Arrange QC measures at shop & site erection fabrication work, including stage Inspections during Shop Fabrication acc. to drawings & Specs. Check WPS, Welding, Fastening, Finishing & assembly at shop, Welding & Painting.
• Prepare & Qualify (WPS/PQR) & WQTR. Arrange 3rd parties inspection e.g. LR, GL, TUV, SGS, etc. for ASME boilers & pressure vessels. Suggest preventive measures beyond general QC checks.
• Materials testing & inspection such as dimensional, non-destructive (NDT), Hardness, Hydro-test, & several other tests.
Supervise the foundry (with staff > 300), producing castings (moulding, melting, pouring & fettling)
of cast iron & high carbon & Cr steel, of sizes up to 20 tons. Assign daily duties of shop staff for various mouldings & castings based on priorities. Check final quality of the cast products before offering to QC. Arrange shop equipment maintenance program, & persevere safe shop practice.
• The castings produced were of various compositions & intricacies, & had applications in Sugar & Cement Plants, Boilers, Valves Bodies, Ingot Moulds, etc. The shop had 2 cupolas (5 ton/hr ea.), 2 induction furnaces (1 & 5 tons ea.), 4 manual molding lines & 2 automated molding lines to process silicate & molasses sand molds. The existing Bradley & Foster, U.K, technology to produce high-Cr cast steel balls (dia. range 25-100 mm), was improved for better yield by re-designing molds for casting of steel balls, extremely high in demand from cement & mining industry.
Suggest advanced aerospace materials against the existing conventional materials in use.
Monitor QC of Supplies, Production & Fabrication for small & large dia. rockets & satellite parts, per relevant Standards. Prepare WPS & Procs. for fabrication of special HSLA steels rockets/missiles. Investigate & analyze Weld Microstructure & Properties through Optical/SEM Microscopy. Mechanical Testing. Propose Welding Defects remedial measures.
Thermo Mechanical Processing of Metals & Alloys
