QA/QC Engineer- Integrity Division
Qatargas
Total years of experience :21 years, 11 Months
• To address technical queries with respect to materials, testing and certification requirements of piping components, valves and other pressure equipment under procurement or installation for upstream and downstream projects of Qatargas facilities.
• To organize shutdown welding inspection and testing as well as routine inspection of pressure component repairs to ASME Sec VIII, ASME B31.3, ASME PCC -1/2/3, API 510, API 570 inspections and other relevant codes and Qatargas internal specifications including NDT jobs. Routine welding inspection and testing experience including shutdown experience in QG1, QG2, QG ¾ and Laffan Refinery downstream facilities.
• Inspection, testing and material procurement experience for various Qatargas Projects like JBOG, PMP, CSP, LR2 Project, FAP, WWTP Project of QG1, LQ Expansion Project of NFB (Upstream).
• To participate in engineering e-management of change (EMOC) requests with respect to material changes and upgradations in view of technical problems encountered in service, piping class requirements and assessing suitability with respect to specific damage mechanisms involved in the concerned service class. To study and take part in failure analysis of in-service materials and components and address metallurgical issues associated with materials.
• To carry out technical bid evaluation of vendor bids for pressure equipment, piping components and valves, under procurement, with respect to order requirements, Specification, drawing, piping material classes and other supplementary requirements for QG1, QG2, QG3&4, LR upstream and downstream facilities and Shutdown items, Plant Maintenance Items and ongoing on-shore and offshore projects.
• To review vendor drawings for pressure vessels, heat exchangers and valves with respect to material and testing requirements. To review and approve Inspection Test Plans and test procedures with respect to purchase order, code requirements and Qatargas specification and managing third party inspection activities at vendor’s premises.
• To attend general meetings on asset integrity and preventive plant maintenance meetings along with piping engineers and other discipline engineers ensuring continual system improvement.
• To attend follow-up meetings with Qatargas vendors and address technical issues if any.
• To review and approve Purchase Requisitions raised by asset maintenance and project team for various piping components and pressure equipment ensuring technical correctness of the ordering information put therein, also ensuring applicable testing and certification requirements in the description.
• To organize receiving inspection of fabricated and welded Pressure Retaining components with respect to purchase order requirements and to provide technical support and timely assistance to inspectors and signing-off the inspection reports.
• To generate Third Party Inspection Authorizations and organize Third Party Inspection services at vendors/supplier’s facilities for pressure retaining components and to review Third party reports and vendor reports for compliances.
• To prepare weekly QA/QC activity progress reports for management information system (MIS).
• To regularize ISO documentation work, attending internal quality audits specific to various projects and also to audit contractor works/ vendor shops.
• To visit project sites and vendor shops for testing and inspection activities as and when required in critical cases, followed by the review of technical repots and certificates.
• To assist site inspectors in review of WPS, PQR and WPQ records to ASME Sec IX, AWS D1.1 and specific code of construction requirements like ASME Sec VIII, ASME B31.3, API 1104 and other applicable codes and when required, for various Qatargas projects as well as approving the welding documents for Qatargas Contractors.
• To issue WPS for site welding under various Qatargas Projects and provide technical assistance to the field inspectors.
Key Responsibilities:
Inspection and Certification:
• To witness Welding Procedure Qualification Tests and Welder’s Performance Qualification Tests at manufacturer’s/ fabricator’s premises against applicable code requirements. Also to witness laboratory tests and to endorse Procedure Qualification Records.
• To carry out welding Inspection/ III Party Inspection of Chemical and Power Projects/ Ferrous and Non Ferrous Products including fabricated/ welded/ Pressure Vessels/ Castings/ Forgings/ Hot Rolled Plates/ Welded Pressure Pipes/ Welded and Seamless Tubes/ Rotary Equipment/ Valves to ASME Sec II code and other ASTM standards. (Holder of CSWIP 3.0 Visual Welding Inspector Certification).
• To carry out welding inspection followed by review of NDT records of welded pressure parts/ piping/ welded structural fabrications/ other items to relevant codes/ specifications/ acceptance standards.
• To visit welding consumable manufacturer’s premises for the purpose of witnessing tests and examinations of batch approvals against ASME Sec II Part D and Lloyd’s Register Marine Specifications/ Regulations.
• To review ITP and Vendor Test procedures to client’s purchase order and specification requirements and Lloyd’s Register regulations as applicable, for welded and fabricated pressure retaining equipment and piping components.
• To carry out inspection to the requirements of ASME Sec VIII, Pressure Equipment Directive 97/23/EC and major ASTM standards applicable to materials, welded fabrication to ASME B31.3, API 660, API 661 and major ASME Sec II/ ASTM standards applicable to materials related to oil and gas service and chemical and power sector industries.
• To review NDT and other test procedures followed by witness of Non Destructive Examination, Pressure Testing, Leak Testing of pressure components and welded RF pads, special tests like Helium Leak Tests and other tests associated to welded Pressure Equipment, valves and welded pressure components. (Holder of Level II Certificates in UT, MT, PT and RT to the requirements of SNT TC 1A and LR written practice)
• To visit Test Houses and Independent Laboratories for witnessing test equipment calibrations followed by issuance of Lloyd’s Register certificates.
• Also conducted technical sessions and seminars for new comers on metallurgical topics in the purview of industrial field inspection and related aspects, welding metallurgy and requirements of various welding codes like ASME Sec IX, API D1.1, basic metallurgy of steel and awareness of alloying elements and heat treatment techniques.
Welding Fabrication and Inspection:
• To review and approve WPS/PQR at various sub-contracted fabrication yards carrying out welding fabrications utilizing A516 Gr 70, Gr. 60, IS 2062, A36 plates rolled in-house and welded pipe fabrications to API 5L Grade B/ 42/ 46/ 52/ 56/ 60/ 65 & 70 and other low alloy steel grades.
• To organize PQR tests and WQT and arrange inspectors for the witness activities at various sub-contractor fabrication yards and maintain records for WPS and WQT and well as organizing PQR tests for weld repairs of Castings followed by mechanical tests.
• Approving Welder Cards and ensuring timely revalidations of welders.
• To organize mechanical testing for PQR and WQT qualifications at in-house testing lab.
• To issue qualified WPS for repair welding activity of Cast Components at in-house Foundry in the blast furnace section utilizing various Carbon Steel and Low Alloy Steel Grades and arrange Inspectors for monitoring of weld repair activity followed by visual inspection and final clearance.
• To address technical queries with respect to weldability issues in HR plates and ensuring the quality to meet the technical delivery conditions of the applicable end product specifications.
Product Inspection and Quality Assurance:
• To ensure that the requirements of product specifications are met by conducting destructive (mechanical and chemical) and non-destructive examination of hot rolled coils/ plate samples at in-house testing laboratory.
• To carry out metallography of steel samples for grain size, phase detection, inter-granular segregations and precipitations to ensure steel quality.
• To handle quality clearance of Hot Rolled Steel coils in SAP/ERP system and regularizing data entries with respect to heat numbers/grades/ coil numbers after quality testing for further clearance to logistics department.
• To allocate inspectors for visual inspection of hot-rolled coils in order to detect rolling and casting defects like dent marks, slivers, surface roughness, buckling, waviness resulting from roll camber, also post pickling inspection to detect slag inclusions and alumina steaks.
• Earned hands on experience in Hot Rolling and Cold Rolling processes and online Heat Treatment of Carbon Steel Grades, Stainless steel and low alloy steels and IF Steel.
Process Quality Control:
To organize visual inspection of slabs and HR coils online by allocating online QC Inspectors for visual online process monitoring by utilizing state of the art UT equipment/precision cameras to ensure surface quality.
• To supervise process quality control by allocating inspectors at Steel Melting Shop, Slab Caster and Hot Rolling Mill to verify process parameters, tunnel furnace temperatures, heat treatment temperatures and other process control measures.
• To control heat diversion at Ladle Furnace by carrying out effective and spontaneous chemical analysis at in-house quality testing laboratory.
• To provide spontaneous decisions on grade diversions to the nearest suitable grade in case of any chemical deviation at Laddle Furnace.
• To finalize aim chemistry of heats based on customer specifications and technical delivery conditions.
• Organize chemical testing of pig iron coming from blast furnace, Laddle Furnace Samples at in-house testing laboratory and ensure controlled chemistry of raw material at electric arc furnace for further steel processing.
Resolution of Customer Complaints:
• To resolve customer complaints on Fabricated Shell Courses, Welded Pipe fabrications, HR coils, to perform Root Cause Analysis and to prepare corrective and preventive action reports.
• To visit customer’s premises to physically verify the product complaints and address technical issues, metallurgical problems related to process and suggest technical improvements to process and quality testing areas accordingly.
• To carry out ISO documentation, Quality Manual regularization work, Audit preparation and compliance.
Welding and Inspection:
• To issue WPS/PQR for fabricated bullet proof steel for defense and armour products and components like: Bullet Proof Head Protection Gear, Election Podium, Mobile Vigilance/ Observation Posts, Observation Towers, Fabricated bodies for Bullet Proof Vehicles. (Material utilized is EN8 - patented by Star-wire India Ltd.) Including carbon steel fabricated structural components in fabrication yard.
• To organize PQR tests and WQT for casting repair procedures followed by mechanical tests and maintain records for WPS/PQR/ WQT.
• To organize and monitor Non Destructive Examinations UT, MPI and DP of welding involved in above components.
• To prepare, review and approve WPS/PQR for repair activities of castings in the in-house foundry.
• Approving Welder Cards and ensuring timely revalidations of welders.
• To organize mechanical testing for PQR and WQT qualifications at in-house testing lab.
• To issue qualified WPS for repair welding activity of Castings in various Carbon Steel and Low Alloy Steel Grades and arrange Inspectors for monitoring of production weld repair activity followed by visual inspection and final clearance.
• To carry out metallurgical tests for welded structures, decarburization, inclusion rates and grain size to the requirements of TDC and product specifications.
• To organize destructive tests heat wise including hardness testing as per the TDC requirements.
Quality Control and Assurance:
• To monitor process deviations at Steel Melting Shop and to allocate heats suitably based on achieved chemistry.
• To finalize aim chemistry of heats under guidance of Sr. DGM QA based on customer specifications and technical delivery conditions.
• Experience in steel making process metallurgy of the following grades:
(a) Steel Casting grades conforming to IS, DIN, B.S, ASTM/AISI, JIS GAST or any other International / National standards in categories: Stainless Steel, High Mn Steel, Carbon Steel, High Alloy Steel and Blade Steel in As Cast / Proof Machined / Finished Machined.
(b) Forging Quality Ingots: In steel grades EN-24, EN36, EN 353, EN 354, EN355, EN-19, EN-9, EN-8, EN-18, EN-42, AISI 410, 420, 304, 304L, 310, 316, 316L, 321 grades, F Series F1, F5, F9, F11, F12, F22, F91, SAE Series SAE4140, SAE4135, SAE8620, Tool and die steel: H-11, H.13, D-3, S-2, Ball bearing steel: 52100, EN-31 in as cast and heat treated condition.
(c) Forged Rounds for printing Industries, Gear Industries, Power Sector and Special Steel Rolled products for Auto Industry, Power Sector, Chemical and other Industries.
(d) Valve Steel: Martensitic: EN-52 (DIN 1.4718), 21-12N, 21-2N (DIN 1.4875) in hardened and tempered supply condition, Austenitic: 21-12N, 23-8N (DIN 1.4866) in solution annealed condition.
• To organize quality inspection at Rolling Mill, Forge Shop by allocating inspectors and signing off the quality reports.
• To confirm Process Flow Diagrams and Casting requests issued by the Planning department with respect to quality parameters.
• To carry out statistical analysis of diversions/defects and carry out Root Cause Analysis utilizing FMEA, PPAP, MSA, PPQP and SPC methodologies to ensure continual process improvement.
• To monitor calibration status of mechanical instruments and devices.
Advanced Diploma in Welding Engineering and Technology from International Welding Institute
Dual Degree: (1) Metallurgical Engineering (2) Materials Engineering
