Welding engineer

CURRICULUM VITAE

P MUKUND RAO

Mobile: +91-866*******

E-Mail: *********@*****.*** ; Skype Id: mukundrao

To work in challenge environment, demanding all my skill and efforts to explore and adapt myself in different field, and realize my potential and contribute to the development of organization with impressive performance.

Open to relocation overseas & anywhere in India.

Best time to call: Anytime

PROFILE SUMMERY

A competent professional with 15 years of experience in Heavy Engineering Production Welding, Welding technology, Welding Metallurgy, Welding Inspection, Experienced in structural fabrication welding, API & Plan piping welding, Casting welding of different grades, pressure vessel, duct, gas tube & Destructive & Non-destructive Testing.

Adept with Planning & Project Execution ensuring cost as well as time effectiveness, yield & inventory control.

Well-versed with the process of driving Root Cause Analysis and CAPA (Corrective Action and Preventive Actions).

Expertise in implementing plans & annual turnaround with focus on optimum utilization of manpower and materials.

Hands on experience with Austenitic, Duplex Stainless steels, Inconel, Alloy steels, Carbon Steel, Nickel Alloys & Non-ferrous grades like Al bronze, CuNiAl.

Hands on experience for SMAW/SAW/FCAW/GTAW/ESW etc. welding processes, conducting & leading failure analysis & root cause analysis on welding related issues, weld automation/mechanization.

Strong knowledge and application of ASME, AWS, API, EN/ISO standards like ASME Section IX, AWS D1.1, AWS D17.1, API 650, EN ISO 15614, ASME SECTION II C, ASME B31.1 etc.

Proficiency at grasping new concepts quickly and utilizing it in a productive manner.

A strong communicator with the ability to interact effectively with people at all levels. Possess a flexible learning; detail oriented and positive work ethic.

Planning and Estimation of Welding Consumable like Flux, Electrode, wire and Inventory Control.

Knowledge of special grade electrodes and its composition such as E7018-1, E316L, E2209, E2594, ENiCRMO4, ERNiCuAL, ERCUSiA, 309LMO, UTP 34, E2585 etc.

Qualification of WPS/PQR & WPQ and Mock-up welding for Critical jobs and it’s weld plan.

Conducting first- and second-party AUDITS, controlling non-conforming products, raising & resolving non-conformance reports and ensuring implementation of corrective/preventive actions.

Conducting first- and second-party AUDITS, controlling non-conforming products, raising & resolving non-conformance reports and ensuring implementation of corrective/preventive actions.

Working in coordination with Third Party Inspection Agencies & Client Quality Audits.

Well versed with SAP (systems, applications, products) & ERP (enterprise resource planning) systems.

knowledge of heat-treating processes and properties and structure of metals

ACADEMIC DETAILS:

B-Tech in Mechanical Engineering from J R N Rajasthan Vidhyapeeth University (Udaipur).

Diploma in Mechanical Engineering from Acharya Institute Technology (Bangalore).

ORGANISATIONAL EXPERIENCE:

Since Aug’2018 to continue

Organization: Kirloskar Brothers Ltd.

Designation: Associate Manager (Welding).

Location: Sangli (Maharashtra).

Kirloskar Brothers Limited (KBL) is a world class pump manufacturing company with expertise in engineering and manufacture of systems for fluid management. Established in 1888 KBL, a market leader, provides complete fluid management solutions for large infrastructure projects in the areas of water supply, power plants, irrigation, oil & gas and marine & defense and manufacture industrial, agriculture and domestic pumps, valves and hydro turbines.

April’2010 to Aug’2018

Organization: Welspun Corp Limited.

Designation: As Asst. Manager (Welding Dept.).

Location: Mandya (Karnataka).

Welspun Corp Ltd is the second largest manufacturer of large diameter pipes in the world, all over world completely dominating the sector, in submerged Arc Welded (HSAW/LSAW) pipes, Ductile Iron pipes of Seamless tubes and pipes for Oil, Gas, Petrochemical and Water Line Industries.

Jul’2008 to Mar’2010

Organization: JINDAL SAW LTD. (100% EOU)

Designation: As Shift In-charge (Welding Dept.)

Location: Mundra (Gujarat)

It’s 100% Export Oriented Unit of Large Diameter LSAW Pipes, (by using J C O, Gas Metal Arc Welding, Submerged Arc Welding, Manual Metal Arc Welding), which is ISO 9001:2008, OHSAS 18001 and EMS 14001 certified company.

Dec’2006 to Jul’2008.

Organization: MAN INDUSTRIES LTD.

Designation: Engineer (Welding Dept.)

Location: Gandhi dam (Gujarat).

It’s is a leading manufacturer and exporter of large diameter carbon steel pipes for various high-pressure transmission application for gas, crude oil, petrochemical products and potable water. The company has state of the art manufacturing facilities for LSAW & HSAW line pipes.

KEY RESPONSIBILITIES:

Pre-Fabrication Activities:

Check availability of latest drawings, project specifications. Review of drawings as per standards, Clint specifications & coordinate with design department if any changes require.

Review of Engineering drawings and bill of material to analyze feasibility from welding point of view and converting into welding and Qualification Plan.

Material & consumable Inspection.

Selection of welding consumable as per compatibility & taking care of handling, storage of the same & reviewing the Test Certificates of welding consumables.

Review & approval of supplier/contractor’s procedures, control inspection plans for fabrication.

Specified mechanical testing, chemical analysis and non-destructive testing (NDT/NDE) of materials. and reviewed the results Conduct required tests and check test reports for approval of new consumable brands.

Find out WPS Gap and analyzing the project requirements applicable for the scope of work, before selection of welding processes and establishing the welding procedures required. Familiar with ASME, EN ISO, API, AWS Standards.

Welder/Welding Operator qualification/training & certification as per Project Specification and maintaining their Qualification Records and welder continuity records and also ensuring only qualified welders and operators perform the welding.

Submission of WPS/PQR/WPQ with supporting documents to clients, and getting it approval at the earliest.

Interacts with customer for WPS/PQR/Consumable qualification.

Reviewing and validating the calibration of equipment’s.

Production welding Activities:

Qualification of WPS/PQR & WPQ on different MOC’s (Materials of Constructions), welding process GTAW, SMAW, SAW, FCAW.

Responsible for Prepare WDS (Weld data sheet), Weld Map, Annexure data sheet for all weld joints.

Welding process control activities during fabrication of different grades materials like WCB, LCB, CF8M, CN7M, DUPLEX, CE3MN, SGI, SGN, CI, K Alloys, BRONZE, NIKLE ALUMINIUM BRONZE, INCONEL, INCOLLOY etc. in all stages and ensured the compliances with project specification requirements.

Responsible for ensure all the major welding casting under go through post weld heat treatment for stress relieving.

Continuously involved with client & other departments for part validation process related to welded parts. Responsible for FAIR First Article Inspection Report & PRR Production Readiness Review.

Ensuring proper documentation of welding & process parameters at various stages & assure it is as per Approved WPS & requirements.

Check the correctness of fit-up of joints, Edge preparation, Root Gap, Root Face, Bevel angle, external and internal cleanliness of joints

Check re-baking & holding of electrodes. Preheat, inter-pass temperature as applicable during/before welding, PWHT.

Check & ensure that qualified welder’s/Welding operators are performing welding/tacking within qualified range

Responsible for defects free Pipes and shell welding by SAW process which is used for cement and power plant.

Prepare WPS, PQR, & Production weld plan and weld build-up procedures.

Attain customer complaint and rejection, discussed with team on shop floor and Take customer feedback and suggestion for any scope of improvement.

Completed root-cause analysis reports of non-conforming or field-failure castings. Communicated these results to quality engineers and design engineers, also providing technical support to eliminate re-occurrences.

Preparations of Work instructions and procedures for the Operations According to the type of process and considering the safety aspect and ensuring its implementation

Train & qualifying contract welders on different process/positions & Monitor the qualification requirements of the welding personal, training records and progress report.

Identifying cause of Rework and taking steps to rectify the Defects through analyzing the pattern and occurrences. Conducting repair analysis and failure investigations. Conducting TBT to create awareness among welders to reduce the repair occurrences.

Update the Daily Plant Performance report, Production analysis report, raw material & consumable status report in SAP.

Planning and Estimation of Welding Consumable like Flux, Electrode, wire, shielded gases Consumption control & consumable Handling and reduce inventory and maintain critical spares at store.

To keep progress reports of daily works output and evaluate productivity of work to take necessary action in order to enhance productivity.

Carried out detailed incoming inspection of components to ensure their quality as per the specifications; performed audit inspection on items dispatched through trading warehouse.

Drafted various quality documents such as QAP, and Distributions Lists etc., and sent the same for approval of clients / inspection agencies

Handled proper document storage / Training records / Display on shop floor / plants and uploading on local sites.

Responsible for implementing and maintaining 5s, KAIZEN in the work area.

Maintained the calibration records of various instruments/ equipment’s calibrated internally as well as externally.

Responsible for review mechanical testes such as Tensile, Bend, Impact, Hardness, IGC Test etc. and NDT test like UT, RT, MT, PT defects identification & resolution.

Preparation of Daily production report, defect analysis, CAPA and discussed in meetings.

Responsible for the time study, cycle time and change over time reduction on the shop floor.

Prepare Test piece coupon for welding consumable such as flux, wire etc. & maintain their testing result.

Planning & Monitoring day to day work, same will discussed with all team members and Conduct review meetings, Attended daily production, quality review and labour efficiency meeting.

Distribution of work load to operators in order to achieve daily production target.

To keep progress reports of daily works output and evaluate productivity of work to take necessary action in order to enhance productivity.

Performing Process audits, Identification of NC & Resolution of NC.

Inspection of consumable item like electrodes, shielding gas, grinding wheels etc. For ensuring physical condition, storage, test certificate etc.

Doing continuous development through using various techniques of kaizen.

Arranging certain training programs for workmen to enhance productivity using improvement techniques.

HEALTH & SAFETY:

Responsible for safe working condition in my shift by ensuring all workmen should use their PPE.

Identification/reporting & correction of all unsafe acts & organizing awareness program to avoid the recurrences of similar incident.

Trade validation of welders & welding operators. Carrying out tool box talk to create safety awareness among contractor’s supervisors, welders, helpers.

ACHIEVEMTS:

Financial saving of the Company by reducing the Manpower and rework at the same time.

Lower down the repair percent below the set target.

Appreciated for continual improvement & reduction in cycle time and change over time reduction by modification of welding fixtures and clubbing possible operations in single fixture & eliminated extra movement required earlier.

Developed Weld sequence, and qualified procedures, welders for welding of special grades such as High Nickle alloys and Nickle Aluminum Bronze elements.

Idea for installation of SCADA System on SAW welding for accurate process parameter controlling.

Received Appreciation for controlling inventory during assignment.

TRAINING UNDERGONE:

Attend Internal Auditors Seminar on (ISO 14001: 2004 & OHSAS 18001).

Welding Technologies by LINCOLN ELECTRIC.

Internal Auditor certification by LRQA.

Line pipe welding training by BHEL Trichy.

Attain 5s AUDIT training program.

ASNT LEVEL II Course.

PROFESSIONAL QUALIFICATION:

Welding Inspector Training (CWI) from Welding Research Institute (WRI) BHEL TRICHY.

AUTO CAD & CATIA course.

ITS Skills:

Well versed with MS Office (Word, Excel and PowerPoint) & Internet tools.

Working knowledge of AutoCAD, CATIA

SAP & ERP System knowledge.

PERSONAL DETAILS:

Father Name: P Malleswara Rao.

Date of Birth: 15 Jan 1982.

Passport No: R8555420.

Languages Known: English, Hindi, Telugu, kannada & Tamil.

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