Manager QA/QC
Wasco Engineering International Limited
Total years of experience :20 years, 10 Months
1 Currently working as a Management Appointee (MR) and Manager - QHSE for ‘WASCO Engineering International Limited” from 26.04.2018 to Till Date. Currently responsible for QA/QC of below Projects:-
ONGOING PROJECTS:
EPC Installation & Commissioning of MOPU Topside Package for BWE, Gabon
o EPC of 01-Off Gas Booster Compressor Skid
o EPC of 01-Off Production Separator Skid
o EPC of 01-Off Pipe Line Pump Skid
o EPC of 01-Off Fuel Gas Conditioning Skid
o EPC of 01-Off Inlet Manifold Skid
o EPC of 01-Off Flare KO Drum Skid
o EPC of 01-Off Pig launcher Skid
o EPC of 02-Off Power Generation Modules (including 01 with Acoustic Enclosure)
o EPC of 01-Off Produced Water Treatment Package
o EPC of 01-Off N2 Generator Skid & N2 Receiver Vessel
o EPC of 01-Off Chemical Injection Skid
o EPC of 03-Off Pipe Racks
o EPC of 01-Off Wellhead Hydraulic Control Panel (WHCP)
EPC Installation & Commissioning of Gas Lift Compressor Package for BW Energy Gabon S.A.
o EPC Installation & Commissioning of 01-off BW ADOLO 8MMSCFD GLC Package (including all Vessels, Piping, Structural & E&I scope)
Below EPC Packages for Sapele Gas Plant, Nigeria for DGS Integrated Projects Limited \[End User: Seplat Petroleum Development Company:-
o EP & Supply of API 12F Storage Tanks and Skid mounted interconnecting Piping (Project No. C007)
o EPC of Inlet Manifold & Discharge Separator (Project No. C008)
o EPC of Pressure Vessel Modules (08-off) (Project No. C009)
o EPC of Pipe Racks (Project No. C010)
COMPLETED PROJECTS:
Project No. C368 & C369: EPC of North Rumaila New Compressor Station (NCS5) comprising of 04-Off Compressor Package Skids, complete BOP Package and TEG Unit for Shell-BGC, Iraq.
Project No. C370: Refurbishment and EPC of Off-Skid likes for Compressors (04 Trains) for FFCL for hire on Rental Basis.
Project No. L008: Refurbishment and EPC of Off-Skid likes for Compressors (02 Trains) for FFCL for hire on Rental Basis.
Below EPC Packages for Sapele Gas Plant, Nigeria for DGS Integrated Projects Limited \[End User: Seplat Petroleum Development Company:-
o EPC of 07-Off Skid mounted Gas Generator Packages (Project No. P004)
o EPC of GCP, MCP & PMS for Gas Generator Station (Project No. P005)
o EPC of 10-Off Pressure Vessels (Project No. C004)
o EPC of 10-Off Pressure Vessels (Project No. C004)
o EPC of 03-Off Fuel Gas Skids (Project No. C005)
o EP & Supply of Flare Pumps (Project No. C006)
Quality Assurance & HSE:
WASCO IMS (ISO 9001: 2015, ISO 14001: 2015 & OHSAS 18001: 2007 / ISO 45001: 2015) requirements.
Coordinating/Liasening with Certification Body (For ISO 9001: 2015, ISO 14001: 2015 & OHSAS 18001: 2007 / ISO 45001: 2015 Certificates) during Recertification and Periodic Audits.
Preparing & obtaining management approval for Internal Audit Plan/Schedule for internal audit and conduct Internal Audits as per the aforesaid IA Plan.
Bids / Proposals for new Projects (from QA/QC aspects).
2 Worked as Manager - MR & Corporate QHSE Manager for INCO Group of Companies: Responsible for overall QMS implementation in Corporate Office, Dubai & Oman Workshops and Project Sites in Oman, Qatar, UAE & Morocco. Also responsible for Bids / Proposals for new Projects (from QA/QC aspects).
A. Directly handling following Projects (as Project QA/QC Manager):-
(i). “EPC of Storage Tanks” being executed for “Rumaitha / Shanayel Facilities Phase - III Project” (Main Contractor: Consortium of GS E&C and Dodsal / Company: ADCO)
(ii). “EPC of Storage Tanks” being executed for “Al Dabbiya Surface Facilities Phase - III Project” (Main Contractor: Maire Tecnimont / Company: ADCO)
(iii). Jamex Project (Main Contractor: Siemens / Company: DEWA, Dubai)
A. QA Manager (MR and responsible for the following):
- Verification of implementation of Quality Objectives
-Organizing and collating inputs for Management Reviews as per PLL QMS requirements
-Ensuring that processes needed for the QMS are established, implemented and maintained through internal audits
-Reporting to top management/MR on the performance of the quality management system and any need for improvement
-Ensuring the promotion of awareness of customer requirements throughout the organization
-Co-ordinating/Liasening with Certification Body (For ISO 9001: 2008, ISO 14001: 2004 & OHSAS 18001: 2007 Certificates) during Recertification and Periodic Audits.
-Preparing & obtaining management approval for Internal Audit Plan/Schedule for internal audit and conduct Internal Audits as per the aforesaid IA Plan.
B. Bids / Proposals: Responsible for the following:
-Reviewing Invitation to Tender (ITT) documents, understanding, analyzing and accurately assessing ITT QA/QC requirements.
-Involvement in the development of the proposals strategy for the tender.
-Co-ordination, preparation and compilation of complete, compliant and professional proposal documentation (technical part - QA/QC Deliverables like, Project Quality Plans, Project specific Quality Control Procedures, Method Statements, Inspection & Test Plans, Audit Schedules, etc.), for submission to clients in line with client bid documents and tender deadlines.
-Assisting estimation team in calculation the cost of Quality and if required, welding and painting consumables, cost of testing (in labs & at Project Site)
-Liaison with internal departments to ensure that all relevant (QA/QC) input is compliant with ITT requirements.
-Preparation and issue to client of appropriate and concise technical requests for clarification to client during the tender period.
-If required, Liaison with the Procurement Group, Consumable suppliers, equipment vendors and sub-contractors to ensure accurate and timely receipt of quotations.
-Attending and presiding when required, internal tender review meetings.
-Attending client tender clarification meetings / negotiations, including the management and organization of all required client endorsed changes to previously submitted tenders.
-Assisting in the preparation and compilation of contract documents, prior to signature, ensuring that all contract documentation is in line with all previously agreed tender negotiations on QA/QC issues.
-Collating QA/QC related post-contract feedback; obtained from executed projects, for use in future bid efforts.
-Documenting and filing, in an organized manner, of all relevant (pertaining to QA/QC matters) tender correspondence and data.
-Project Start-Up/Kick-Off meetings.
C. Tender Production (Sub-Contracts)
-Review invitation to tender documentation and generate tender/quotation QA/QC compliance checklists.
-Participate in tender kick off meetings
-Establish and agree plans for ITT/RFQ response and effectively manage implementation
-Produce documentation needed to comply with ITT/RFQ submission for technical elements. Comply with submission deadlines identified.
-Prepare project handover packages.
D. QA/QC coordination and other responsibilities
-Overall Co-ordination for various QA/QC activities and assessing Monthly Quality Reports from all Project Sites.
-Preparing Audit Schedules, PQCP, WPS, QA/QC Procedures & Method Statements for Projects (Pre-award and/or initial stages of a newly awarded Project).
-Maintaining QA/QC Database
-Organize/conduct Welding Procedure Qualification (PQR) tests and Welder Performance Qualification Tests for various materials used in the Project viz. CS, LTCS, SS (Austenitic), Alloy Steel, Inconel 825, CRA cladded piping (LTCS + Inconel 625), 22%Cr DSS & 25%Cr SDSS
-Assisting HR in selection & qualification of Welders and QA/QC Personnel for Projects.
- Managing and keeping a record of all Welder Qualification Tests, welders, NDT done at site
- Preparing QAP/FQPs, Project Quality Control Plans, Procedures, site protocols etc.
- Ensuring proper fabrication practices at site
- Preparing Hydro-test Packages for hydro-testing of various piping systems for LBVs, BOS & Compressor Stations
- Reviewing Vendor QA/QC documentation and obtaining client approval for the same
- Preparing MR&IR Packages (Material Receiving & Inspection Report) and obtaining client acceptance/approval for project material.
- Prepare proposed WPS as per project requirements and obtain approval from Client.
- Provide training for welder’s in GTAW & SMAW processes.
- Conduct Welding Procedure Qualification (PQR) tests for various materials used in the Project viz. CS, LTCS, SS (Austenitic) & Alloy Steels.
- Organize & Witness mechanical testing of PQR test specimens.
- Review of non-destructive examination reports.
- Review and modification of existing welding procedure specifications based on field experience and project requirements.
- To ensure that all IM&TE (Inspection Measuring &Test Equipment) under use calibrated within the accuracy requirements of project specifications
- Review and approve vendor's/sub-contractors WPS and procedure-qualification records.
- Coordinate with Purchase department and vendors / suppliers regarding the technical acceptance of welding equipment, welding consumables.
- Review of purchase requisitions for Project Material.
- Organize and schedule Welder Performance tests.
- Inspection & Review of incoming welding consumables & their test certificates before client approval.
- Ensure control of all welding consumables and availability.
- Monitoring duties of welding Inspectors, NDT coordinator, external NDT agency technicians.
- Responsible to monitor the production welders’ performance and suggest improvement.
- Organize or perform the refresher training and certification of the welders.
- Carrying out failure analysis and finding solutions to welding related problems.
- Analyze, document, and implement recommendations for correction of observed Non-Conformities (Process & Product).
- Initiate Technical Queries related to welding and co-ordinate with client representatives for resolving the technical queries
- Provide assistance and technical support to P&E (Plant & Equipment) in the area of welding production and other areas as required.
- Ensuring the implementation of all quality procedures related to welding and other site activities.
- Coordination with construction team & Client inspection team.
- Take care of QA/QC Manager responsibilities during their absence.
- Provide guidance /training /conduct workshop to implement QMS requirements
- QA/QC Manager for the Project. QA/QC Team consisted of (consisting a team of 05 No. GTs & 02 Nos. GETs & 02 Nos. EDHTs, 01 Civil QC Engineer, 04 Civil Inspectors, 02 Civil Lab Technicians)
- Preparing QAP/FQPs, WPS, Site Quality Manuals, Procedures, site protocols etc.
- Ensuring proper fabrication practices at site
- Coordination with construction & Client inspection team.
- Reviewing Vendor QA/QC documentation and obtaining client approval for the same
- Preparing MR&IR Packages (Material Receiving & Inspection Report) and obtaining client acceptance/approval for project material.
- Prepare proposed WPS as per project requirements and obtain approval from Client.
- Provide training for welder’s in GTAW & SMAW processes.
- Managing and keeping a record of all Welder Qualification Tests, welders, NDT done at site & Conduct Welding Procedure Qualification (PQR) tests for various materials used in the Project viz. CS & SS.
- To ensure that all IM&TE (Inspection Measuring &Test Equipment) under use calibrated within the accuracy requirements of project specifications
- Organize and schedule Welder Performance tests.
- Organize & Witness mechanical testing of PQR test specimens & Review of non-destructive examination reports.
- Review and modification of existing welding procedure specifications based on field experience and project requirements.
- Review and approve vendor's/sub-contractors WPS and PQRs
- Coordinate with Purchase department and vendors / suppliers regarding the technical acceptance of welding equipment, welding consumables.
- Inspection & Review of incoming welding consumables & their test certificates before client approval.
- Take care of Fabrication, Erection & Testing of 06 Nos. Tanks (HFO & LFO Storage Tanks as per API 650) and ensure approval of allied QA/QC Documentation.
- Ensure control of all welding consumables and availability.
- Monitoring duties of QA/QC Team & external NDT agency technicians.
- Responsible to monitor the production welders’ performance and suggest improvement.
- Preparing/Review Hydro-test Packages for hydro-testing of various piping systems
- Prepare MCD Packages
- Prepare FTD (Final Turnover Documentation) Index & obtain approval from client
- Compilation of FTD Dossiers & Handover to Client
- Preparing QAP/FQPs, WPS, Site Quality Manuals, Procedures, site protocols etc.
- Ensuring proper fabrication practices at site
- Coordination with construction & Client inspection team.
- Reviewing Vendor QA/QC documentation and obtaining client approval for the same
- Preparing MR&IR Packages (Material Receiving & Inspection Report) and obtaining client acceptance/approval for project material.
- Inspection of incoming Project Material at Vendor Premises during manufacturing & at site after receiving
- Keeping a record of all Welder Qualification Tests, welders, NDT done at site, Conduct Welding Procedure Qualification (PQR) tests & Organize and schedule Welder Performance tests.
- Organize & Witness mechanical testing of PQR test specimens & Review of non-destructive examination reports.
- Inspection & Review of incoming welding consumables & their test certificates before client approval.
- Ensure control of all welding consumables
- Coordination (RFI handling, inspection, witness of various activities) of Nuclear Piping activities (CS, SS, Inconel Piping as per ASME B31.1, ASME Sec. III & ASME Sec. VIII)
- Coordination (RFI handling, inspection, witness of various activities) of three Mega Packages of NP&V Section of R.A.P.P.-5&6 viz. V.R.S., C.A.V.S. & HVAC involving CS, SS, Inconel Piping as per ASME B31.1, ASME Sec. III & ASME Sec. VIII, rolling of pipes (150 to 600 mm dia.) from 3.15 mm thk. IS: 5986 MS plates, Welding of 3.15, 6, 12 mm thk. pipes, Erection of pipe spools and finally testing the piping systems for leakage.
- Review of subcontractor QAP/ITP, WPS, Quality Manuals, Procedures, site protocols etc.
- Inspection of subcontractor fabrication activities at site
- Coordination with subcontractor construction & our (NPCIL) QA/QC, FE (Field Engineering) Teams for Quality & Site Modifications (if any).
- Reviewing Subcontractor’s Vendor QA/QC documentation, MR&IR Packages & Material Inspection with our stores, FE, & QA/QC Teams
- Inspection of incoming Project Material at Vendor Premises during manufacturing & at site after receiving
- Witness, Review & Approve all Procedure Qualification Tests, Welder Performance Qualification Tests & NDT activities
- Witness, Review & Accept/Reject mechanical testing of PQR test specimens & non-destructive examination reports
- Liaise with our Planning department to update S-Curves, Weekly, Monthly & Six Monthly Rolling Plans of all the Packages under NP&V Purview
- Liaise with our Planning department to prepare the Yearly Budgets of NP&V Section
- Monitoring the Progress of all subcontractors under NP&V purview
- Review & Verify the monthly RA Bills (Invoices) raised by subcontractors
- Arranging & Supervising welding activities both C.S. (ASTM A106 Gr. B & IS:1239) and S.S. (ASTM A 213 TP 304 L) pipes by G.T.A.W. process (C.S. to C.S., S.S. to S.S. & C.S. to S.S.) as per approved procedures
- Preparing various fabrication reports viz. WIR (Welding Inspection Reports), Cleaning Reports, NDT Offerings etc.
- Ensuring that all fabrication & Testing is done as per Project Requirements and applicable NPCIL standards (PPE- 549, 550 & 551)
- Arranging & Supervising cleaning of SS Pipes by DM Water followed by Pickling & Passivation
- Arranging & Supervising pipe spool box-up / erection at site as per approved drawings
- Arranging & Supervising hydro-testing of piping systems in-situ