QA and QC in Pipe Fabrication/Installation

Employer - Dragon Offshore industries LLC, UAE

Position - QA/QC Engineer

Project - Maintenance / Repair of Salman Complex in Persian Gulf - (Short Term)

Experience - From Nov 2012 to Feb 2013

Principal Duties

• Witness and monitor suppliers/contractors work activities, inspection and test in accordance with the approved Quality Plan, ITP, Quality Procedures and etc.
• Issue and follow-up of Non-conformity Report (NCR).
• Ensure testing, measuring equipment is fully calibrated as per specification and has current certification.
• Review of Radiographic films.
• Witnessing tests like Magnetic Particle Testing, Ultrasonic Testing, Dye penetrant testing.
• Witnessing Mechanical Tests for PQR’s and review of Lab reports.
• Preparation of Daily/weekly inspection reports, pre and post-reports, worksheets, noncompliance reports etc.
• In process inspection of pre fabricated items, final inspection and issuing IRN(Inspection Release Note).
• Review daily reports like DWR, PMI report, PWHT report& NDT reports.
• Review Hydro/Pneumatic test packages and witness test.
• Inspection of Gratings, dimensional checks on fabricated structures/modules.
• Review WPS, PQR and welder qualification records.

• Assigned to assist Project Welding Engineer in Procedure Qualification, Welder Qualification and daily welding control activities.
• Conducting Procedure Qualification for Carbon Steel, LTCS & SS materials as per Project scope, Preparation of WPS according with PQR and Project Specification.
• Conducting Welder Qualification Tests, Preparation of Welder ID and maintaining Welder Qualification Records/Renewals.
• Preparation of Welding procedure summary and Weld maps.
• Liaison with Client/TPI on day to day Quality related issues at site and shop.
• Co ordinate with Vendors, Review MTC for Consumables as per Project Spec.
• Welding inspection which includes Fit-up, welding parameters, final Visual Inspection of completed welds
• Review of Radiographic films, PWHT reports, PMI reports, Hardness reports, and Line History sheet
• Witnessing tests like Magnetic Particle Testing, Ultrasonic Testing, Dye penetrant Testing.
• Witnessing Mechanical Tests for PQR’s and review of Lab reports.

• Witnessing welders qualifications and procedure qualification tests for automatic (GMAW), semiautomatic (FCAW) and manual (SMAW) processes.
• Trench inspection and stringing inspection in accordance with Alignment sheets.
• Welding inspection which includes Fit-up, welding parameters, final Visual Inspection of completed welds and weld repair (Partial& through repair)
• Review of Radiographic films
• Witnessing tests like Magnetic Particle Testing, Ultrasonic Testing(Manual & Automatic)
• Inspection of field joint coating( HSS) for surface preparation, Anchor profile, wet film thickness etc as per specification
• Witnessing Adhesion peel strength test.
• Lowering inspection and witnessing holiday test during lowering.
• Hydro testing of U/G, A/G Piping using Dead weight Tester, water filling, thermal stabilization, air volume calculation etc.

• Ensuring implementation of Quality Control Test Plan(QCP), Procedure, Inspection & Test Plan(ITP) and also check the Welders Qualification Test Record, WPS & PQR
• Checking of the Fit-up, Pre-heat, Inter pass temperature etc as per applicable WPS & final Visual Inspection of completed welds for the occurrence of Porosity, Cracks, Undercut, and Spatters prior to Non Destructive Testing
• Review of Radiographic films, PWHT reports, PMI reports, Hardness reports, and Line History sheet
• Witnessing tests like Magnetic Particle Testing, Ultrasonic Testing, Dye penetrant Testing,
• Maintaining material traceability records, Welder Id
• Dimensional checks, Fit-up/ Tolerance checks
• Preparation of Method statements in line with contract/client requirements/Specifications for various works identified during the contract

• Interpretation of P& IDs, Plan drawings & Isometric drawings
• Checking of the Fit-up, Pre-heat, Inter pass temperature etc as per applicable WPS & final Visual Inspection of completed welds for the occurrence of Porosity, Cracks, Undercut, and Spatters prior to Non Destructive Testing
• Inspection of pipe supports, Guides, anchors on the lines installed. Inspection for flexibility, support and anchoring of piping
• Witnessing Hydro test, Pneumatic test, Visual test on completed lines, Flushing and
• Sign off
• Provide technical support in the areas of non destructive examination for welded joints and leading NDT Technicians to perform Radiography, DP, MPI & PMI
• Preparation of test packages and compilation of QA/QC Dossiers
• Review of Radiographic films, PWHT reports, PMI reports, Hardness reports, and Line History sheet

• Prepare & witness Welding Procedure Qualification as per ASME Sec IX & Project Specification.
• Conducting Non destructive inspections on fabrication parts as per client requirements.
• Prepare Bill of Materials from fabrication drawings & ensure that all materials delivery is as per project specifications
• Prepare schedules & ensure that all works are going as per schedule
• Monitor and ensure that all works are in accordance with contract standards and specifications
• Coordinate and supervise technicians and monitor mechanical works such as fabrication and erection piping, steel structure, Equipments & tanks
• Conduct tests like Radiography, Ultrasound Testing, Dye penetrant Testing, Leak testing, and Vacuum Testing & Hydro Testing as per project requirement
• Prepare and submit internal request for inspections
• Daily Visual Inspection of Welds, NDT Inspections

• Micro Structure analysis of iron castings (S.G & Grey)
• Carry out Mechanical Testing of Castings- Tensile, Elongation & Hardness
• Carry out Charpy V Notch (CVN) test for Specific requirements
• Conducting Magnetic particle inspection of castings by Wet Method
• Maintaining Daily inspection reports, NDT related Documents
• Controlling Metal composition by spectro analysis and wet analysis
• Witnessing Ultrasonic inspection of castings- Flaw detection & Nodularity
• Preparation of MTC as per client requirement
• Handling Customer complaints on metallurgical related problems