Ashwani Kumar Bhatia

· Prepared project specification for welding of piping, pipeline, structural and vessel as per feed documents, QA/QC requirements brief gist scope of work for welding.

· Supports the Project Manager in dealings with clients regarding Project Quality matters and Contract quality requirements.

· Conducting preproduction quality audit and ensure the approval of subcontractor QC persons, vendors, and workshop/yard facilities.

· Ensuring the Lesson Learnt are captured during project work phase and communicated to project team for improvisation in process.

· Assessment of the Quality suitability of vendors and subcontractors for individual projects & Coordinates for all Quality Control deliverable activities.

· Assesses the Quality Control Plans of subcontractors and identifies any necessary corrective measures.

· Developing and analysis daily, weekly & monthly deliverable reports like weld repair, welders Performance, quality notification status and provide technical solution for meeting the project.

· Prepared the technical deviation request and technical queries to get client concurrence on various specific project spec. such as PWHT criteria for tempered materials, Changing corrosion test method from A923 C to G48 A, Changing consumable lot class and testing schedules, Approval for using FCAW process, Use of previously qualified welding procedures and welders, Using test coupon pipe rolled from plate and changing consumable brand name, Using propane torch for preheat higher thickness and using SAW process in clad 625/825 piping.

· Perform project walk through, identified the punch point & make sure timely completion of the same. Follow up with Design Engineering, production engineering & site construction supervision to effectively close out internal & client punch points on time, in regular manner which helps to achieve zero punch-list

· Working as team with contractor/subcontractors to establish new welding procedure list and other welding deliverable such as Welding control procedure, welding consumable control procedure, welding repair procedure, method statement for purging, method statement for branch welds on clad, furnace and local PWHT procedures, Weld maps and pickling passivation procedure.

· Representing QC issues in various meetings with clients, sub-contractor and vendors.

· Study technical data sheet of vessels, piping classes, MTO’s, client spec., drawings, applicable codes and Standard and contractual specific requirement for the new project. Sharing special technical requirement with QC manager/Proposal team/project manager for costing.

· Planning new welding procedure qualification, welder qualification as per project spec. and standard AWS D1.1, D1.6, EEMUA 158, ASME SEC IX, SEC VIII Div.1 & 2, B31.3, B31.8, API 1104 and DNV OS-C401.

· Estimating NDT quantity & type of NDT required for the entire project.

· Review and modification of existing welding specifications based on field experience and developments taking place in oil and gas industry.

· Prepared welding procedure qualification plan having detailing: Material spec/grade, thick/size, welding process, weld consumables, PWHT, Impact test, production testing, for entire project.

· Prepared weld map for the pressure vessel, tanks, pig traps and critical work (client recommended)

· Prepared project specific procedure: Weld consumable control, general weld repair, weld buildup procedures, inert gas purging and distortion control procedures

· Developed hot-tapping welding procedure in CS-NACE gas pipeline. Proposed welding procedure to check hot tapping possibility by heat dissipation calculation and design calculations.

· Qualified welding procedures/welders for process piping, pressure vessel, offshore and onshore structures, pipelines, pig traps, valve and pump repair/refurbishment involving various chemistries: CS, CS-NACE, LTCS, Low alloy steel, Austenitic SS & stabilized, Duplex and Super duplex SS, High alloy steels, Copper-nickel, Inconel, Monel and hast alloys.

· Review and approve vendors/ contractors proposed welding procedure specifications, construction welding procedure specifications and procedure qualification records.

· Prepared Inconel, Monel, hard facing, Austenitic stainless steel clads, welds buildup procedures and method statement in various repair and refurbishment work in Valve repair, Pump repair, Pig launcher/receiver.

· Involved in welder/ welding foremen recruitment process through reputed agent/consultant and visited various test centers in India.

· Partly shared responsibility of material engineer for incoming project material. Reviewed incoming material test certificate in accordance with test delivery condition, codes, standard and specification.

· Perform receipt material inspection on the site as per PO, applicable standard and client specification requirement. Communicate material/ Certificate related non-conformities to projects/ concerned buyer as applicable.

· Coordinating with Client/ Third Party/ Class Society surveyors for material destructive/ nondestructive testing, material inspection and clearance.

· Giving estimation of various welding and NDT cost for new projects in Bidding.

· Role as welding lead in ASME U/U2/S/R stamp/API 2B/Client specific/ internal/ISO 9001 audit.

· Taking adequate measures to control repair percentage of overall yard. Conducting tool box talk with welders/foremen/supervisor/ production Managers to make aware them on welding requirements and to make ensure the preventive measures in future work properly conveyed to avoid repairs.

· Investigated root cause of welding undercut and porosity problem in 0.5’’/0.75’’/1’’ NPS by using lesser root gap, uniform gas flow rate (gas diffuser) and appropriate torch to work angle in GTAW.

· Developing and implementing new techniques for increasing welding productivity like STT, RMD, various process manipulators etc. Molding different ideas/systems of vendors to suit production sequence.

· Coordinate with sub-contractors for carrying out applicable (NDT).

· Interpret radiographs/ review various test reports upon completion of NDT.

· Arrange for NDT test procedures, operator qualification certificates with sub-contractor.

· Coordinating with NDT operators and concerned personnel to complete the work.

· Update the concerned personnel about NDT completion and status.

· Maintain traceability/ calibration record of NDT equipment’s/ calibration blocks.

· Check sub-contractor invoices as per contact.

· Successfully qualified 150 nos. new welding procedure according to AWS D1.1, EEMUA-158, DNV-OS-401, ABS rules, in different structural steel material: API 2H GR50N, API 2W Gr.50, API 5L Gr. B/ X52, S460NL + Q/M, S355K2+N, S355G7/8 +N/M, S275JR, A36, A106 Gr. B, DNV materials E36, E620, E690 etc. by using different welding processes.

· Qualified approx. 90 nos. new welding procedure according to ASME Sec IX Sec VIII DIv.1, API 1104, B31.3, B31.4, B31.8, NACE MR0175/1SO15156 in different piping, pipeline materials coming under P nos.: - P1(Group1,2), P4, P8, P10H, P34, P42, P43, P44, P45, P1+Clad 625/825 and dissimilar materials by using same Spec/grades/UNS nos. as used in fabrication.

· Documentation of welding procedure: WPS, PWPS, PQR, material/consumable certificate, calibration records, lab test plans of test coupon, generated NDT requests and compiled in the procedure qualification record by taking approval of concerned agencies/client.

· Procedure was qualified in such a way to include requirements of other clients in testing, material selection (having dual certification, NACE requirements), impact temperature and location, hardness indentation etc. so that these can be used without new qualification in other similar projects.

· Participating in the welding audit internally and externally to meet project spec. requirements.

· Prepared failure analysis report of any welding procedure failed to meet client spec. requirements in special test like- Fracture analysis of ferrous steels (CTOD test and CVN impact test), Corrosion tests (G48-A, A262, G28, HIC, SCC, SSC) for corrosion resistance alloys in different heat treatment and supply conditions- quench & tempered, TMCP, normalized, as rolled, forged, cast. Taken approval from client to proceed further- retest or new qualification.

· After finishing/completing procedure qualification, I was involved directly or indirectly to provide solution/way to come out from site/shop problems/issues/NCR/site observations.

· Did site surveillance/spot checks to measure welding parameters, welder performance records, applicable WPS, control distortion, repairs etc. ensuring the quality in production/fabrication.

· Studied various client spec. Tennet, OXY, Qatar petroleum, Shell, Saudi Aramco, Norsek, GL, Petrofac, Zadco, PDO etc. to assist project team for raising technical queries and also in estimation and costing of project for bidding purpose.

· Handled a team of 5 welding inspectors to execute procedure qualification in various projects.

· Provides support to discipline field engineers (piping, component, structural, etc.) with the development of welding documentation (weld data records and weld maps) for their respective construction work packages.

· Prepared technical delivery conditions for consumable procurement, consumable estimation report, planning and scheduling for deliveries at different stages of project.

· Monitoring repair database and taking adequate measures for minimizing repair percentage. Prepared method statements to attend repair in primary and special joints.

· Maintaining regular contact with shop supervisor, welders to provide practical advice, assistance to solution of problems and feedback on welding issues for new learning.

· Helped and guided QA engineer for preparing Quality Control Plan, Non-Destructive Testing Plans, Post weld heat treatment requirements, Distortion control procedure, Ferrite check procedure, hardness check procedure, PMI check procedure etc.

· Delivered training programmed to new joiners briefing ISO procedures, Company quality policy, Quality management system, functional responsibilities, safety procedure, Qualification of WPS, welder, operators.

· Complete understanding of drawings, inspection and test plan and weld maps.

· NDT clearance as per NDT Plan/ ITP (inspection and test plan) requirement.

· Inspection Clearance, slot marking, tie rods, sealing and sliding strips, baffles slot marking, drilling, machining and other related activities.

· Floating head dish and flange setup after machining weld groove on sides, partition plates marking and setup for welding.

· Tube bundle Skelton preparation after standing tube sheet, insertion of tubes Channel flange setup, partition plate marking on channel and setup, channel assembly machining.

· Pneumatic & Hydro test arrangement after complete inspection clearance from TPI.