Quality Manager
Bin Quraya Company Limited
Total years of experience :12 years, 6 Months
Vapor Recovery Unit, Dhahran Bulk Plant (BI 10-01036-0002), Upgrade Fire Protection and Industrial Drainage System at KAAB Dhahran (BI 10-01029-0003)
• Liaison with Saudi Aramco Project Management Team (SAPMT) and proponents for project quality issues and escalation as per SAEP-381
• Assign and ensure discipline wise effective inspection coverage as General Inspection Services (GIS) Quality Supervisor for both prime contractors and subcontractors shops and field activities
• Preparation and evaluation of monthly Project Quality Index (PQI) sheet for design, construction & procurement phase projects
• Preparation and evaluation of weekly Project Quality Dashboard (PQD) data and EPM quality status
• Preparation and consolidation of Inspection Unit weekly highlights for all active projects and presenting it during Inspection Section and Division conference call with Project Quality Manager (PQM) and Division Manager - Project Inspection Department
• Review of contractor’s Monthly Quality Management Reports (MQMR) and quality objectives tracking as per approved Project Quality Plan (PQP)
• Preparation and consolidation of senior Vice President and monthly Division Manager Review reports for our Inspection Unit - D&RP P/L PIU.
• Preparation and submission of Project Inspection Index (PII)
• Effective participation in Saudi Aramco internal audits and Contractor/subcontractor full QMS annual internal audits as per project approved Schedule Q
• Conduct Quality Assessments of contractor quality functions and obligations as per Schedule Q, site surveillance and critical focus assessment of special process procedure as per SAEP-1150
• Preparation and submission of Equipment Deficiency Report (EDR) as per SAEP-380
• Ensure implementation of relevant Saudi Aramco Engineering Standards, Procedures and International codes on projects as per project cut off code
• Submission and follow ups of CRM for concrete mix design, third party testing laboratories and batch plants review and approval by BP&CTU as per SAEP-1152 and SAEP-383
• Review and approval of special process and Quality documents as per applicable Saudi Aramco standards and procedures
• Conduct knowledge sharing, lesson learned and quality awareness session with contractors, subcontractors and SAPMT for continuous improvement
• Participation and evaluation of quarterly customer satisfaction surveys as per Schedule Q requirement for contractor
• Review and approval of Contractor’s Project Specific Quality Plan (PQP), tracking of both project management (SAPMT) and contractor quality objectives
• Review and approval of piping and storage tank pressure test packages
• Coordination with GIS team members for Exception Item List (EIL) generation during Partial Mechanical Completion Certificate (PMCC) packages walkthrough and classification of Items as per GI 2.710
• Follow up with SAPMT for consolidation of PMCC EIL items and approval for PMCC Acceptance Committee Chairman as per GI 2.710
• Liaison with SAPMT, Contractor and PID Inspectors for verification and closure of PMCC "YES” and “NO” items as per SA GI 2.710
• Participation in Pre-Commissioning activities with SA Proponents, POD, LPD, FrPD and other stakeholders
• Update E-cabinet as per Inspection Department compliance for project document storage and transmittal log
20” and 24” Inch 350 KM Yanbu - Jeddah Pipelines, Yanbu Tank Farm Package, Yanbu Distribution Hub CMEI Package, North Jeddah Bulk Pant Expansion and Vapor Recovery Unit North Jeddah Bulk Plant
• Effective participation in Saudi Aramco internal audits and Contractor/subcontractor full QMS annual internal audits as per project approved Schedule Q
• Conduct Quality Assessments of contractor quality functions and obligations as per Schedule Q, site surveillance and critical focus assessment of special process procedure as per SAEP-1150
• Review and approval of WPS against ASME Sec IX, API 1104, AWS D1.1 and SAEP-352 guidelines
• Review, comments and approval of method statements and quality control special process procedures as per Schedule Q, Attachment IV
• Review and approval of Welder Job Clearance Card as per SAEP-324 guidelines
• Receiving inspection of incoming welding consumables and construction materials against IFC drawings and as per MTC & ASME II Part C & A
• Witness Request for Inspection (RFI) and maintain Saudi Aramco Application for Inspection of Facilities (SAIF), Quality Management Information System (QMIS) and Enterprise Project Management (EPM) software
• Conduct Visual Inspection of Joint fit-up, In-Progress and Post Welding of piping, tank and structure as per approved WPS, IFC drawings and ASME B31.3, B31.8, B31.4 and AWS D1
• Review and ensure all calibration certificates & tags of weld machine, measuring tools and pressure & temperature gauges as per Aramco specifications
• Perform focus assessment and site surveillance against the project construction activities
• Review and approval the weekly and monthly deliverables i.e. weekly weld production report, welder repair rates, defect analysis report and monthly quality management report.
• Prepare and submit the project quality inspection (PQI) score sheet and project productivity index (PPI)
• Raise Log Book Entries and made follow up of contractor INCR as per SAEP-381
• Monitoring indoor and outdoor construction material preservation, handling and storage in accordance with approved project preservation plan
• Coordinate for Non Destructive examination of welds (RT/UT/MT/PT) acceptance in accordance with ASME Section V, approved quality procedures and ITPs
• Conduct tank in & out of service inspection activities as per API STD 653 & API RP 575 & 00-SAIP-75
• Conduct process piping in service inspection as per API STD 570 & 00-SAIP-75
• Conduct pressure vessel inspection as per API STD 510 & 00-SAIP-75
• Conduct inspection and verify cleaning activity of AC chillers tube as per Carrier operating and maintenance manual
• Selection of Corrosion monitoring locations and monitoring of UT thickness measurement
• Witness Hydro & Pneumatic test as per approved procedure, ASME B31.3 & API 1110
• Review of test package and walk down the line after completion of construction work in accordance with approved IFC drawing
• Inspection of drying, chemical cleaning and service test of lines and stainless steel passivation activity
• Review project quality dossiers and present it to Saudi Aramco
• Liaison with Aramco project quality manager, site management staff and contractors regarding on-going project and in-service inspection activities and expedite the balance work in order to complete piping and pipeline priority systems along with QHSE matters
• Leading a team of 25 inspectors for the erection of 02 Boilers and auxiliaries piping, Coal Shed Erection, Tanks and Silos erection, refractory installation and document completion
• Liaison with FPCL senior management, Hyundai Consultants and Third Party Inspectors regarding on-going project works, expedite the balance work in order to complete piping priority systems alongwith QHSE matters
• Review and approve Inspection Test Plans (ITP)
• Develop master highlighted P & ID sets of all piping test packs along with pressure testing values and types
• QC Documentation and Compiling of piping test packages release for hydro testing
• Prepared and verified punch points A of piping test packages prior to release for hydrotest
• Witnessed pressure testing and re-instatement of piping test packages prior to hand over to commissioning team
• Develop Inspection Test Plans (ITP) of piping, steel structure, insulation, painting, tanks, stationary & rotary equipment erection by assigning checks, extend of inspection & frequency of each activities require quality assurance
• Develop QC protocols of piping, steel structure, painting, insulation stationary and rotary equipment erection
• Review and approved contractor specific working methodologies as per UEPL Specs
• Review and approved brown and greenfield piping test packages
• Develop master highlighted P & ID sets of all piping test packs along with pressure testing values and types
• Review and approved welding procedure specifications against ASME Sec IX
• Coordination with UEPL and contractors for completion, pre commissioning and QA/QC matters
• Punch listing, punch points verification and witnessing of pressure testing of critical system of process, amine and fuel gas system
• Re-instatement of main process area on skid and off skid lines
• Developed the common tracking sheet of piping and equipment erection to monitor the execution and completion works from welding activities to handing over piping priority systems lines, tanks and equipment box-up
• Final review and handing over of 05 work packages quality control dossiers (piping, steel structure and equipment erection) to United Energy Pakistan Limited
• Inspection and supervision of maintenance works of feed gas filter, power generation utilities system lines, hot oil fuel gas system lines, steel structure installations and feed gas cooler packages
• Supervision of pre and shutdown works of 30MMSCFD Amine Trains - 1 & 2 and prepare visual reports of baroscopic inspection, collect samples, inspection of Hydrojetting, Hydro torqueing of manways and equipment box up
• Prepare checklist of equipment and tools prior to deployment at site and ensure QHSE work permit compliances at site
• Work monitoring and site consultation of contractors regarding completion and QA/QC matters of mechanical piping, structure, and equipment erection works
• Directed and supervised the completion team of mechanical site supervisors and QC team for the timely completion of piping priority systems, structures and equipment erection works with all QHSE compliances
• Monitoring day to day activities at all areas, workshops and tanks works for safe work practices and permit to work system compliance
• Developed the common tracking sheet for all six contractors to monitor the execution and completion works of Naimat Phase - 5 from welding activities to handing over piping systems lines, Tank Erections and equipment erections Box up
• Ensure that all operating plants, tools and equipment meet projects HSE standards prior to its deployment at project site
• Developed the common quality inspection test plans for all six contractors of UEPL
• Reviewed and approved the contractors work methods statements as per China Petroleum Engineering (CPE) Specification
• Approval of WPS against ASME SEC IX
• Reviewed and approved the 500 mechanical piping test packages in consultation with design and process engineers of UEPL
• Raised technical queries on issues relating to piping, structure, stationary and rotary equipment
• Prepared and verified punch points A of piping test packages prior to release for hydrotest
• Conduct the HSE meetings with supervisors to mitigate non-compliances
• Witnessed pressure testing and re-instatement of piping test packages prior to hand over to commissioning team
• Assistance of construction & commissioning team in developing of PSSR and its killing
• Assistance of plant operation team in pre commissioning works of equipment and piping priority systems
• Prepared final Punch list of 160 MMSCFD Amine Trains (03) including civil, mechanical & E & I work scope
• Reviewed QC Documentation and Compiling of piping test packages system, steel structure and stationary & rotary equipment erection
• Final review and handing over of 17 work packages quality control dossiers to China Petroleum and United Energy Pakistan
• Directs and supervises a team of mechanical site supervisors for the timely completion of projects with all QHSE compliances
• Liaison with Company’s senior management, Third Party Inspectors and Client regarding on-going project works, expedite the balance work in order to complete piping and pipeline priority systems alongwith QHSE matters
• Develop and review Project Quality Plan (PQP) and Quality Inspection Test Plans (QITPs)
• Progress monitoring of balance work
• Prepare work method statements and Inspection test plans
• Leading a team of QC Inspectors and the sub-contractors (NDT, CP, DCVG and Civil Surveyors, Certified API 570 Inspectors for Hydrotesting) hired by the company
• Coordinate with different labs for the destructive testing of procedure qualification
NDT of weld joints
• Developing and approval of WPS against ASME SEC IX
• Liaison with Company’s senior management, TPI and Client regarding QA/QC matters
• Record review of the Inspection for incoming consumables with MTC
• Witness Welder Qualification Test (WQT) according to ASME IX & API 1104
• Prepare wellhead piping and pipeline weld maps and as builts
• Inspection of welding joints and fitups of piping spools, pipelines, wellhead structures
• Inspection of Heat Shrinkable Sleeves (HSS) application and witness peel testing
• Examination of Painting / Priming by means of Elcometer
• Inspection of Coat wrapping application on piping spools by Holiday Detector
• Inspection of cold bending and Tie-in joints welding
• Witness and record data of pipelines water filling, pigging and Hydrotesting
• Supervision of Cathodic Protection System installation work and DCVG survey of pipeline
• Preparation, compilation and submission of Dossiers (Civil, E & I, Piping and Flowlines)
• Final review of dossiers with client and Punch list killing
• Management Representative (MR) for Integrated Management System and provide pivotal role in IMS certification for Gasco Engineering (Pvt) Limited