Quality Manager
L&T- Mitsubishi Hitachi Power system
Total years of experience :16 years, 2 Months
Japan. The JV Company is manufacturing supercritical thermal power plant at Hazira Factory with having design institute in Japan.
All the raw materials or finished components are procured from china office.
Job Responsibility:
➢ Performed inspection of various raw materials used in Boiler and oil and gas are such as, Tubes, Rifle tube, Pipes, Fittings, Fins, Fin Tubes, Plates of all the grades (P91, P92, P22, P12, P9, P5, T92, T91, T22, T12, CS and SS) and size.
➢ Perform inspection of Pipes and tubes at all the stages like Lab Test (Tensile, Hardness, Microstructure, Bend/Flattening, Flaring, Impact, Chemical Analysis, Nitrogen and oxygen analysis, Simulation Heat Treatment), NDE (UT, ET, MT, if required PT, VT), Dimension and Visual Inspection. Report review of (Billet TC, Heat Treatment Graph and witnessed test report).
➢ Perform inspection of various boiler components such as, valves, safety valve, Fans (PA/ID/FD/Seal Air and it’s all components such as rotor, hubs, blades).
➢ Perform inspection of various non pressure parts such as, dampers, gates, duct, Hopper, Structure.
➢ Perform inspection of various turbine components such as, LP, HP, IP turbine blades, Condenser, Outer Casing, Stage Casing, Diffusers, Rotor, Bearings and bearing pedestal, Lube oil skid, Cooling skid, Baring Gear.
➢ Perform inspection of various turbine auxiliary components such as, BFP turbine, Boiler feed pump, vacuum Pump, Stator cooling water system, Forced draft cooling tower fans.
➢ Performed inspection of various components of ESP such as, Rapper coils, Insulators.
➢ Perform inspection for pipes, tubes and fittings (P91, P92, P22, P12, T92, T91, T22, T12, CS and SS) used in nuclear power plant and used in oil and gas industries.
➢ Prepare the QAP, TDC for different parts of Boilers.
➢ Issue and resolve the NCR and instruction sheets for non-confirming work. Check the CAPA of supplier in order to improve the process and improve the supplier’s internal quality system.
➢ Coordinate with all different suppliers in china/ factory in India/ site at different location in world and complete the inspection of materials depending of its requirement at site and at factory.
➢ Review the documents of all the materials as per specified standards, before providing clearance for dispatch.
➢ Carryout vendor evaluation of different suppliers of all the components used in Boiler, turbine, Hydrocarbon, nuclear plants, Heavy Engineering.
in Project Management / Quality Control and Quality Assurance
Department, Placed at Chengdu, China in the DongFang Electric Company
(Govt. Company of china)
Job Responsibilty:
➢ Prepare the month manufacturing schedule of the boiler pressure parts as well as its auxiliary’s parts material as per the site requirement.
➢ Follow up the movement of the material in the shop floor and record the entire manufacturing schedule on the shop floor. Checking the manufacturing movement of material in the shop floor.
➢ Monitor the manufacturing schedule in different workshops of Dongfang Electric Company as well as its sub-vendors (such as: Wensen:- Headers manufacturer; Chuanrun:- Coils and sling Tube manufacturer; Huaxi Nengyuan:- Waterwall Panels).
➢ Inspection of all the Headers at different stages:-
a) the raw piece enter the shop, b) dimension check of the pipe, c) edge preparation and then do DPT on the edge for checking the surface crackness, d) pre heating and GTAW, e) check the alignment, f) after completion of SMAW and SAW, perform the UT and DPT, g) allow for drilling for subs after marking, h) after stub and other attachment fillet welding, do the random DPT and MT, i) allow for the post weld heat treatment, j) Perform the mechanical test of the sample, k) hydro test and the document inspection, l) painting and packing inspection, m) IBR stamping with the help of inspector.
➢ Inspection of all the coils:-
a) the raw piece enter the shop, b) dimension check of the pipe, c) Pipe bending as per angle provided in drawing d) edge preparation and then do DPT on the edge for checking the surface crackness, d) Thickness checking on the outer surface of the bend angle, e) MT/DPT of attachments, f) RT shots of the joints, g) final painting and packing of material.
➢ Inspection of all the Waterwall panels:-
a) the raw piece enter the shop, b) dimension check of the pipe, c) fillets joints between pipes and fins to prepare the panels, d) RT shots for the pipe butt joints, e) mechanical testing of the sample after post weld heat treatment, f) hydro test and the document inspection, g) painting and packing inspection, h) IBR stamping with the help of inspector.
➢ For the ID/FD/PA fans checking the raw material of the blade, do the finishing and check the hardness and thickness checking, check the thickness after the abrasion coating, final dimension checks.
➢ Attend the meeting with the design, process engineer, quality and project management people of DBC for any manufacturing related issues.
➢ After the completion of butt welding/Fillet Welding of Headers, inspect the sample piece in the mechanical workshop and perform the test (such as: Bend Test, Tensile Test, Impact Test, Hardness Test and Metallographic Test) as per IBR requirement.
➢ Witness the stage inspection of the material such as NDT test (UT, PT, MT and hardness test) of all the pressure as well as non- pressure parts of boiler and it’s auxiliaries.
➢ Review of all the stage inspection documents, WPS and heat treatment graphs of the material before hydro test. Once the certificates are acceptable then inspect the hydro test of the material.
➢ Final dimension checks of all the pressure parts as well as non-pressure parts of the boiler and the packing inspection as per the sea worthy transportation.
➢ Manufacturing and stage quality inspection of the burners, soot blower system, Air preheater, FD, ID, PA, Seal Air, Scanner Air fan of the boiler.
➢ Attend the meeting and try to resolve the site issues related to manufactured material.
➢ Involved in the Project management and quality control activity of (660X2) Lanco Amarkantak stage-2; (660X2) Lanco Bhaband Thermal Power Plant; (660X2) Lanco Vidharba Thermal Power Plant.
➢ All these power plant materials of boiler were manufactured and partly dispatched from china.
Preparing Boiler Auxiliaries (FD Fan, ID Fan, PA Fan, Seal Air Fan, Scanner Air Fan, Coal Feeder, Coal Mill, Boiler Circulation Pump, Air Preheater, Soot Blowers) equipment trial operation procedure.
➢ Preparing Turbine Auxiliaries (CEP, GSC, MDBFP, TDBFP, Vacuum Pump, Turbine Lube Oil Pump, Generator Air/Hydrogen side Sealing Oil Pump, Jacking Oil Pump) equipment trial operation procedure.
➢ Prepare the system procedure such as:- Boiler chemical cleaning, boiler front chemical cleaning, safety valve cold/hot setting, boiler light up, steam blowing, main turbine and BFPT turbine lube oil flushing, Oil firing and turbine rolling procedure, Boiler coal firing and unit full load procedure.
➢ Reviewing the interlocks and protection of Boiler Auxiliaries and Turbine Auxiliaries.
➢ Prepare the punch points after erection completion and make the equipment ready for trial operation.
➢ Check the system readiness for all the individual drives and take the trial operation from DCS for first time as per the provided procedure and record all its related and critical parameters.
➢ Visit the site for every time interval to prepare the punch points and review the system readiness of project.
➢ Coordinate with the project team for any system related issues.
➢ Coordinate with the site engineers for any technical support related to equipment trail and process commissioning.
➢ Involved in the commissioning activity and take the unit to full load and final handover to customer.
➢ Involved in the commissioning activity of (300X2)MW of Lanco Amarkantak Thermal Power Plant; (600X2)MW Lanco Anapara Thermal Power Plant; (600X2)MW of Moser Bear Annupur Thermal Power Plant. All these units are running successfully on the full load.
Worked at different location in Gujrat for installation and commissioning of wind turbines.
➢ Taken initial training in dhaman and bhuj blade manufacturing factory of Suzlon energy, to understand the criticality of blades in the wind turbine.
➢ Project Participated in Inspection, Project Management and Commissioning
➢ MPPGCL- Malwa
➢ NPCIL- Rajasthan Atomic Power Project
➢ MAHAGENCO- Chandrapur
➢ Reliance- Sasan
➢ RRVUNL
➢ NTPC- Tanda
➢ NTPC- Khargone
➢ NUPPL- Ghatampur
➢ IOCL- Haldia Refinery
➢ Central Java Project for MHPS
➢ Rajasthan Atomic Power Project-7 & 8
in