Posted by on June 10, 19103 at 01:37:28:

27 YEARS OF EXPERIENCE IN INSPECTION ENGINEERING

G. Elumalai
Senior Corrosion & Inspection Engineer
Bahrain Petroleum Company, H-64, Awali, PO Box – 25504, Bahrain
Phone: 00973 9802813 / 294351, Email: elumalai@batelco.com.bh

OBJECTIVE

To attain zenith in professionalism

BRIEF OVERVIEW

• Handled major EPC contracts for construction of refinery, oil / gas producing & gathering centers (upstream). This includes specifying Projects quality requirements in tender documents, Bid evaluations for EPC contracts, etc.
• Handled Pre-tender meetings, Project kick-off meetings, Project Pre-Inspection meetings, Vendor evaluation & pre- inspection meetings etc.
• Handled fabrication of ASME Pressure Vessels, Columns, Heat Exchangers, Piping and API Storage Tanks
• Shutdown/T&I planning, preparation, inspection & reporting of refinery equipment, oil/gas exploration, transmission and storage facilities
• Conducted 200+ external & internal Quality Management System Audits and ensures that non-compliances are identified and closed out effectively
• Involved in R&D welding activities including welding machine development, technology development and training of welders / welding supervisors / engineers
• Imparting training of local nationals in Quality Control & Quality Assurance activities
• Responsible for effective management and completion of assigned projects in line with Division’s guidelines and policies.

WORK EXPERIENCE

Bahrain Petroleum Company (BAPCO)
Senior Corrosion & Inspection Engineer, February 2000 - Present

Roles and responsibilities
• Internal & external inspection of static equipment, valves and the related piping, which includes the activities of on-stream, turnaround & shutdown inspections
• Corrosion monitoring /Control of Gas Dehydration Units, Well Heads, Gas Transmission and Distribution Lines, Gas Lift Lines, Oil Flow /Shipping Lines, Tank Batteries & Well Manifolds
• Carryout material substitutions, upgrading, modifications and failure analysis
• Specify & Review of Tender documents, Purchase requisitions, Material Test certificates including Receipt inspection.
• Review of vendor / subcontractor documents like, welding, heat treatment, NDE, construction / QC procedures and inspection & test plans
• Participate tender/bid meetings, vendor evaluation for pre-qualification

Achievement
• Presented a technical paper in the 5th International conference, exhibition & workshops on Pipeline Rehabilitation & Maintenance held under the patronage of Ministry of Oil, Bahrain during January 19-23, 2002. Paper title “BAPCO Experience on the survey and Repair methods of wear problem on high Pressure Gas Transmission Pipelines”
• Prepared and submitted a technical paper as co-author, for presentation at the Society of Petroleum Engineers (SPE) 13th Middle East Oil Show & Conference (MEOS-2003) to be held in Bahrain during 5-8 April 2003.
• Considerable efforts provided to train Bahraini Engineers to specialize in the field of corrosion, inspection & testing

China Petroleum Engineering Construction Co., Kuwait
Lead QA Engineer, April 1998 – January 2000

Roles and responsibilities
• Responsible for all Quality Assurance activities of the EPC contract for Kuwait Oil Company (KOC) on their new project of production facilities expansion - New Gathering Centers GC27, GC28, Transit Pipeline & Slug Catcher. (300 million U$ Project involving Site fabricated storage tanks, Major Static and Rotating equipment, Structural Steel, Pipe lines, carbon and alloy steel piping , Coating , painting, Fiber glass linings, Gunite lining etc.) with Parsons Engineers Ltd as PMC.
• Preparation, periodic review & revision of Project Co-ordination Manual, Project Quality Plan, Project Quality Manual and preparation of other QA procedures generally in accordance with ISO 9001 quality system and as per contract requirements
• Specify & review of internal documents like contract specification, engineering documents, engineering requisition, procedures & quality plan
• Review of vendor / subcontractor documents like, welding, heat treatment, NDE, construction / QC procedures, inspection & test plans and material test certificates.
• Processing of deviation request
• Performing scheduled Internal Quality Audit, Sub-Contractor / Vendor audit and Quality Surveillance program
• Provide technical guidance to other project personnel on quality-related matters
• Interface with client on Quality Assurance matters
• Participating weekly management review meetings & regular client – contractor - subcontractor review meetings

Achievement
• Imparted training for Chinese Engineers in QA Systems and to qualify few of them as Internal Quality Auditors
• Provided technical guidance as a consultant to other project personnel in China Petroleum on quality-related matters
• Handled several sub-contractors and conducted 200+ external QMS Audits and Internal quality audits in line with ISO 9001

Third Party Inspector for Qatar Petroleum
(Short-term job, through Velosi TUV Inspection Services, Abu Dhabi)

• Inspection activity includes right from the kick off meeting till the final shipment to QP, for the Design & Construction of Truck Mounted Fire Water Tanker constructed @ Alam Steel Industries Co. WLL, Kuwait.
• All inspection coordination with Qatar Petroleum, through Velosi TUV, Abu Dhabi.

Mitsui Engineering & Ship Building Co. Ltd., Kuwait
Sr. QA / QC Engineer, November 1996 – February 1998

Roles and responsibilities
• Responsible for all QA/QC activities of the EPC contract for Kuwait National Petroleum Company (KNPC) on their new MAFP project of PRU, MTBE, ALKYLATION, SSAR & FCC Revamp units till handing over the project to KNPC, with Stone and Webster Engineering Corporation as PMC.
• Performed overall supervision of the QA/QC Engineers, QC Inspectors, NDT Inspectors & Sub Contractors
• Coordination with client / consultant regarding QC related matters
• Review of the QA/QC procedures, method statements, inspection & test plan and WPS submitted by sub-contractors
• Management & execution of Hot Tapping on live lines in accordance with API 2201
• Qualifying PQR tests, approving Field Pressure Testing, Service Test, Steam flushing / blowing, Alloy verification (PMI), Holiday Test on Coating & Wrapping
• Review of Material Test Certificates, Hydro test / Flushing Packages, Vendor QC Dossier, System wise QC Dossier for Piping/Vessel/Static & Rotating Equipment
Achievement
• Field Quality Control Manager resigned and left the company in the middle of the project. At the request of Mitsui management, I assumed that challenging position as Acting Field Quality Control Manager and ensured the project completion with a handover the unit to KNPC little ahead of schedule
• Handled 20+ main subcontractors and 75+ vendors to execute this job and conducted 30+ external QMS Audits and Internal quality audits in line with ISO 9001
• Imparted training for Japanese Engineers to qualify them as Internal Quality Auditors

GULF ENGINEERING COMPANY, SAUDI ARABIA
Sr. QA / QC Engineer, November 1995 – October 1996

Roles and responsibilities
• Managing QA/QC Section by leading a team of QA/QC Engineers, QC/NDT Inspectors and NDT Technicians to perform various inspections & tests for a major ASME code fabrication shop in Saudi Arabia.
• Monitoring the effective implementation of the documented written procedure in line with ISO 9000, ASME Section VIII, Division I, ASME B31.1 and ANSI.
• Responsible for maintaining a good interface with Client’s Representative on all QA/QC matters as per contractual requirements.
• Approval of Welding & Fabrication procedures & the Welder Qualifications tests performed in accordance with ASME Sec. IX
• Familiar on application of Codes & Standards for welded construction.
• Identified the non-compliance & recommended corrective actions.
• Specify & review of contract documents, construction drawing & material test certificates.
• Manpower selection for the fabrication , construction company.
• Served as an active member of the Project Team for Saudi Aramco (Techni Petrol-Italy, ABB Lummus & Japan Gas Corporation), KNPC-Kuwait (Mitsui Plant Engineering Division-Japan), NODC–Qatar, SWCC, Al-Khobar (Mitsui Engineering Services-Japan, Hitachi Zosen Corporation), Saudi Arabian Bechtel Corporation, Petrokemya (John Brown-Houston), Saudi Devi – Jubail, Caustic Soda prilling Plant-Nama, Jubail (Mitsui Plant Engineering Division - Japan), Saudi Aramco Shell Refinery (Re-tubing of Heat Exchangers, Air Coolers), Sadaf, Samad, Kemya – Jubail, SICC, Riydah etc.
• Materials handled: CS, AS, SS (304, 310, 316, 321, 347, 410), Cupro Nickel, Hastalloy, Monel, Inconel, Titanium, and Dissimilar Welding & Cladding etc.

Achievement
• Served as ASME renewal audit review team coordinator for authorization of ‘U’,’PP’ &’R’ stamp certification held in October ‘96. Review and revising the ASME approved GEC quality System Manual and all Quality Control Procedures to accommodate the latest revisions and development in implementation
• As Section Head, directly reported to Chairman and leading a team of QA/QC Engineers, NDT Engineers, QA/QC Inspectors, Inspection Technician, NDT Technicians and involved in selection of man power

KUWAIT SHIP BUILDING & REPAIR YARD COMPANY
Quality Engineer, February 1995 – October 1995

Roles and responsibilities
• Development and implementation of an effective Quality Management System.
• Conducted Internal Quality Audits and external audits.
• Compiled Quality Manuals, Procedures and conducted in-house training courses.
• Inspection coordination and representing the company with Client representatives.
• Specify & review of WPS, supporting PQR, material test certificates and other Quality related documents.

Achievement
• Played a key role in the preparation and subsequent certification to ISO 9001.

SAUDI ARAMCO SHELL REFINERY COMPANY. JUBAIL, SAUDI ARABIA
Inspection Engineer, June 1993 – January 1995

Roles and responsibilities
• Turn around and regular maintenance Inspection of all static equipment includes Pressure Vessels to ASME VIII, Columns, Heat Exchangers, Fin-fan coolers, Furnaces, Storage tanks to API 650, and Safety Relief Valves.
• T&I Scheduling, Shut down Inspection & reporting
• On-stream Inspection of Corrosion & Deposits in Piping.
• Weld inspection to ASME VIII & IX, API 1104, (AWS D.1.1-Structurals) of most of the grades of Carbon Manganese, stainless steels & non ferrous.
• Writing Welding Procedures & conducting WPQ tests.
• Witnessing pressure test on piping systems (Hydraulic & Pneumatic), Leak Test, & Bolt Tensioning)
• Review of material test certificates as part of receipt inspection.
• Well conversant with the refinery-piping layout, Process engineering flow scheme, Line data sheet & Isometric piping drawing.
• Conducted Non-Conformance audit in Refinery to maintain plant integrity.
• Inspection Documentation maintained through EISMAN & PACER (PC network application)

Achievement
• Played a major role as an active member of the Project Team for re-furbishing a Hydro-Cracker Unit of Petrochemical Plant, after a major fire.

BHARAT HEAVY ELECTRICALS LIMITED (BHEL), INDIA
Inspection Engineer, September 1974 – June 1993

HIGH PRESSURE BOILER PLANT (QA/QC DEPARTMENT OF BHEL) (9 YEARS):
Roles and responsibilities
• Inspection of fabricated Pressure Vessels, Heat Exchangers, Boilers, High-pressure Boiler Piping, Power Piping, Storage Tanks, Mixing & Metering Tanks and NDT/Heat Treatment of Welds.
• Raw material inspection of all imported materials at Madras Harbor stores includes review of Material Test Certificates.
• Field Inspection includes the export orders and closely associated with external Inspection agencies including M/s. Lloyds Register, Germanicher Lloyds, EIL, NTPC & IBR.
• Familiar in various codes including ASTM, ASME, API, ANSI, AWS, AWWA, TEMA, BS, BIS & IBR etc.
• Extensive knowledge of Coating/Wrapping Inspection, Rubber lining, Magnetic Coating Thickness Gauges, Holiday detector, Portable hardness tester, Ultrasonic thickness gauge, Sand / Grit Blasting surface inspection, PMI etc.

Achievement
• Obtained Productivity improvement award for Local Stress Relieving for Pipe Welds & for the utilization of site returned materials.

WELDING RESEARCH INSTITUTE OF BHEL (10 YEARS):
Roles and responsibilities
• Involved in R & D work of Welding Machines, Process, Technology and Consumable Development.
• Varied experience gained including hands on practice, in most of the types of Welding Processes, Special Welding / Cutting Processes and NDT Methods.
• Training of Welding Engineers / Supervisors / Inspectors and Welders.
• Conducted PQR tests in accordance with ASME Section IX & Indian Boiler Regulation (IBR).

Achievement
• Suggestion award for the development of Mechanical CO2 Welding set-up for automatic welding of long seams of flapper components in Damper assemblies.
• Obtained National Safety Award for Welding Research Institute during my tenure as Safety Steward for Meritorious performance in industrial safety in achieving largest accident free period. Awarded by Ministry of Labor & Rehabilitation, Govt. of India.
• Appreciated for preventing a major accident & saving a life on an electrical contractor

PROFESSIONAL SKILLS

• Compilation of quality manuals, policies, procedures and inspection & test plans for major EPC Contract Projects for petrochem / oil & gas industry
• Welding fabrication of ASME Coded Pressure Vessels / Heat exchangers, API Storage Tanks & Piping to B31.8, B31.3 & B31.4
• Corrosion monitoring, maintenance and turn around Inspection of static equipment, piping & storage facilities in both Petroleum Refinery and Oil Exploration / Gas Dehydration / Gas Transmission and Cathodic Protection
• Review of Purchase requisitions, Vendor’s quotations, Material Test certificates including Receipt inspection
• Computerized corrosion & inspection monitoring and review of reports / data
• Failure analysis & up-gradation of refinery and oil/gas exploration materials
• Better working knowledge of various industrial standards, international codes/standards
• Thorough knowledge in personal computers for the use of Inspection Software Programs
• Development and implementation of effective quality management System and obtained /maintained the certification to ISO 9001
• Development of Third Party Inspection (TPI) contracts and strategies for new projects
• Perform Vendor / supplier evaluation and pre-qualification
• Participate & review of Tender documents for Quality Management requirement
• Review of subcontractor's quality documents including Project Quality Manual, QA Manual, Method Statement, QC/NDE procedures, ITP & WPS/PQR for many grades of ferrous and non-ferrous material
• Excellent communication & organization relationships with all concerned
• Presented Technical paper in International Conference and participated in numerous conferences & training seminars on welding, NDT and quality systems
• Received several awards & meritorious certificates towards my contribution in Welding Technology

PROFESSIONAL DEVELOPMENT

• IRCA (International Register of Certificated Auditors), UK registered ISO 9001-LEAD QMS Auditor. Certification # A016037. Valid up to January 2006.
• ISO 9000–Lead QMS Auditor Certification by WQM (Worldwide Quality Management Network Ltd.), UK. Certificate # QMI/LAC(Q)/2382 dated 5 March 1999
• ISO 9001–QMS Transition Auditor (ISO 9001-2000) Certification by QMI (Quality Management International), Certificate # QMI/QMS/TAC/O-H/BAN/08 dated 11 June 2001
• ISO 14000–EARA approved Lead EMS Auditor Certification by WQM (Worldwide Quality Management Network Ltd.), UK. Certificate # QMI/EMS-LAC (Q)/233 dated 7 March 2000
• ISO 9000-Internal Auditor Certification by IQM/TUV- Saudi Arabia dated 24 November 1994
• ASNT (American Society for Non-Destructive Testing) certified Level II, NDT Inspector- RT, MT, PT, UT & VT
• Industrial Radiography & Safety Aspects (IRG-1) from BARC-Baba Atomic Research Center, India
• Welding Supervisors Course from Indian Institute of Welding (IIW), India
• Inert Gas Shielded Welding Process from Welding Research Institute (WRI), India
• Engineering Metallurgy Course from Bharat Heavy Electricals Limited (BHEL), India
• Microsoft ‘MS Project 2000’ course, Bahrain
• Industrial Safety Course from BHEL, India
• Refinery Safety Course-S2 from Petromin Shell Refinery Company, Saudi Arabia
EDUCATION

Regional Engineering College, Tamilnadu 1985
BE - Mechanical Engineering

Government Polytechnic 1974
Post Diploma - Welding Technology

Government Polytechnic 1971
Diploma - Mechanical Engineering

PROFESSIONAL MEMBERSHIP

ASME, AWS, NACE, ASM (American Society for Advanced Materials), ASQ (American society for Quality), IQA (Institute of Quality Assurance), AQSA (Association of Quality System Auditors), IIW (Indian Institute of Welding), IWS (Indian Welding Society), ISNT (Indian Society for Non Destructive Testing) & IIM (Indian Institute of Metals)

STRENGTHS

• Hardworking
• Persuasive
• Goal oriented
• Self motivated
• Team work
• Leadership qualities
• Good interpersonal skills
• Excellent communication skills

PERSONAL DETAILS

Date of birth : March 3, 1951
Marital status : Married with two daughters
Languages : English, Hindi & Tamil
Passport no. : V-486197
Validity : October 10, 2005

DRIVING LICENCE

Bahrain : (DL # 510314228 validity 20.05.2005)
Kuwait : (DL # 134273246 validity expired on 28.06.2001 – renewable)
India : (DL # R/TN/045/003192/1998 validity 02.03.2006)