Senior Inspection Engineer (Mumbai)

RAKESH SONGARA

Born : ****

Education Qualification : BE in Mechanical Engineering- 2006

Certification : ASNT Level II in UT,RT,MT,PT

Experience : 18+ Years

Employment History :

Nov 2024 to Till Date : TQCert Service Pvt Ltd (A wholly owned subsidiary of TATA Projects Ltd)

Designation: Sr. Surveyor

Nov’ 2021 to Apr’ 2024 : M/s. DIVINE Engineering & Industrial Solutions Pvt. Ltd, India

Designation: Inspection Engineer

Project: DAK Unit

Client: Hindustan Petroleum Corporation Limited, Mumbai

Sep’ 2021 to Nov’ 2021 : M/s. SGS India Pvt ltd, India

Designation: Inspection Engineer

Project: Plant inspection (Piping and equipment)

Client: Hindustan Petroleum Corporation Limited

Aug’ 2021 to Sep’ 2021 : M/s. Sulzer India Pvt ltd, India

Designation: Inspection Engineer

Project: Shut Down and TA

Client: Bharat Petroleum Corporation Limited, Mumbai

Mar’ 2019 to Mar’ 2021 : M/s. Petrocon Engg. & Inspection Pvt ltd, India

Designation: Inspection Engineer

Project: Plant inspection (Piping and equipment)

Client: Hindustan Petroleum Corporation Limited, Mumbai

Jan’ 2018 to Mar’ 2019 : M/s. Simpage engineering, India

Designation: Inspection Engineer

Project: Plant inspection (Piping and equipment)

Client: Hindustan Petroleum Corporation Limited, Mumbai

Responsibilities:

●Reviewing the documents like Project Specifications, Procedures.

●Conduct all stage-wise Inspection as per approved QCP/ITP with Client, Owner & Third Party.

●To check physical condition (free from Kinks, bend, twist & straightness within limits)

●To check the Material by PMI for Low Alloy Steel (LAS), Stainless Steel (S.S) Materials.

●Weld inspection as per specification and standards.

●Monitoring welding activities before and during fabrication are performed as required by WPS.

●Ensure Preparing welder wise lot registers for covering NDE requirements.

●Monitoring of welder performance every week based on the NDT report

●Check and verify the control of storage of welding consumable.

●Ensure Preheating, Post weld heat treatment is carried out as per approved procedure.

●To witness Welder qualification test and review radiography report.

●Assessment of remaining life of piping based on corrosion allowance and minimum thickness requirement.

●Quality / inspection of refinery storage tank manufacturing.

●Inspection of Statics equipment exchangers, pressure vessel, column, structure, storage tank erection.

●Checking internal / external corrosion, Crevices, Atmospheric corrosion, blistering, Painting & coating, Mechanical damage, vibration and sagging in line etc.

●Inspect lines in accordance with P & ID & isometric drawing for mechanical clearance

●Identification on P & ID’S for pressure test; and prepare Test Packages

●Preparations of as built Isometric drawings referring P & ID.

●Static Equipment Inspection (Shell & Tube heat exchangers, Fin Fan coolers, Columns, vessels, Tanks and pipelines).

●Inspection of rotary equipment pumps, motor, industrial fan.

●Columns Internal Trays inspection (dimensional check, water tightness test).

●Checks of levelness, position, orientation, anchor bolts, conduits, etc. of tanks foundation.

●Performs hydrostatic test Vacuum test of tank and measurement of pad settlement.

●Storages tank internal inspection. Performs punch-listing operations.

●Interpretation and evaluation of PT, UT, RT,MPI and Visual Inspection as per ASME 31.3 & AWS D 1.1 and review of NDT reports.

●Ensure and monitoring Mechanical (welding & NDT) clearance for Hydro Test Packages and review the Loop file for HT.

●Witness Hydro test, Pneumatic testing and Hardness testing with client.

●Monitoring work in progress for compliance with the latest approved revisions of drawings and specifications and verifying that finished work meets acceptance criteria.

●Monitoring calibration status of Welding Machines, Pressure gauges and all instruments.

●Inspection of raw materials for fabrication and clean built of Pipes & Spools.

●Rectifying repairs with qualified workers, re-inspecting in accordance with specifications.

●Inspection of shot Blasting, Painting, As Per Approved Procedure & Standard.

●Report generation and documentation for all the QC works carried out at site.

Jun’ 2011 to Oct’ 2017 : M/s. Eisenmann India Pvt. Ltd, India

Designation: Senior Quality engineer / Inspection

Project: Plant equipment as Process tanks & pre-treatment tunnel of

S.S & M.S, heat exchanger, air heater, Furnace, air supply system

(ASU), cooling coil assembly, Pumps, valves, conveyor system,

conveyor tracks, ERW pipes, Structure, Site Piping, FRP product as

tank, duct & FRP lining, welded pipes, pipe fittings as per applicable

Code / specification / Drawing.

Responsibilities:

●Preparation of process equipment quality plan & ITP, SOP and inspection schedule.

●Supplier development and evaluation with respect production capacity, quality, delivery etc

●Incoming material inspections, thickness verification, Physical condition, Batch number and storage of materials, document verification against Client specification drawings and standards

●Carried-out Inspection at supplier fabrication shop and expediting the multiple project material from PO placement to the material final delivery at project site.

●Perform visual inspection before, during and after welding as well as welding parameters and dimensional aspects.

●Review/ Material Selection of Welding Consumables (AWS/ASME) Electrodes, wires, fillers for different applications

●Witnessed hydro test / NDT & Destructive testing.

●Lab Test witnessed for Physical and chemical testing.

●Maintain all inspection tools, Test equipment’s, Gauges etc are calibrated and all calibration certificates are currently valid.

●Reviewing of WPS, PQR and WPQ test reports and Witnessing welding qualification tests at site.

●Welding application with various processes i.e., SMAW,GTAW,GMAW & SAW

●DFT checking of galvanic coating, Painting of structure and equipment’s as per requirement.

●Painting: Inspection of Surface preparation (Surface Profile, Dust Check), Intermediate & Final Paint inspection for structures.

●Inspection of piping erection as isometric drawing, P&ID, general arrangement drawing

●Maintain the project wise inspection report / documents for final submission.

●ISO 9001: 2015 documentation & implementation.

Aug’ 2008 to Jun’ 2011 : M/s. Tube weld India Limited

Designation: Senior Quality engineer

Project: Inspection & Quality controlling of Pressure vessel, heat

exchanger, boiler pressure parts (Superheated coil, Economizer coil,

Cooling coil, Boiler tube, steam Header, water wall panel, Exchanger

fin tube, Studded bed tube etc.).

Responsibilities:

●Preparation of Quality procedures (inspection test plans / ITP) as per project and client technical requirements and follow-up for its approval and monitor the implementation.

●Incoming material inspections, thickness verification, Physical condition, Batch number and storage of materials, document verification against Client specification drawings and standards.

●Inspection of Seamless, ERW / EFW welded pipe of stainless steel, alloy and carbon steel.

●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.

●PMI verification for Stainless steels (positive material identification)

●Preparing the weld inspection, material traceability certificate & updating the same.

●Review and witnessing of mechanical tests such as tensile, bend, impact, hardness, micro, flattening, flaring, ferrite, IGC and chemical analysis as per the applicable standard And specification

●Welding application with various processes i.e., SMAW,GTAW,GMAW & SAW

●Measurement of Pipe spool dimension and layout checking.

●Involved in various Heat treatment (Stress reliving, annealing, normalizing) for carbon, Alloy steel & stainless steel, Dissimilar pipe spool joint as per code ASME and client specification.

●To conduct and evaluate non-destructive testing (RT, MPT, PT and UT) of weld joints as per ASME Section VIII acceptance standards.

●RT Film Review Interpretation & NDE Report Review.

●Evaluation of pre & post weld heat treatment (PWHT) charts as per ASME Sec V & Sec IX, Sec VIII, IBR and client specification & approved ITP.

●Prepare inspection reports, NCR, technical queries, QA/QC reports and X-Ray and repairing status.

●Involved in Hydrostatic test of pipes, coil & vessel.

●Blasting and Painting Inspection as per approved procedure and project specification.

●Third party witness metallurgical test as ASTM 262 IGC, HIC, Spark test, NACE MR0103, MR0175.

●Coordinate with production, planning and purchase department.

●Analyse production and quality control to detect and correction problems.

●Planning inspection activity and prepare daily inspection reports, job progress card as per ISO, IBR records, TPI records, etc.

●Maintain all inspection tools, Test equipments, Gauges etc are calibrated and all calibration certificates are currently valid.

●Conducting Procedure Qualification for Carbon Steel, alloys, Duplex & 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 / approved the WPS-PQR for prequalification / re-qualification for new material welding As per ASME Sec-IX.

●Conducting the WQT, maintaining the welder’s track record.

●Handling client inspection, demonstrating all activities and documents for approval.

●Liaison, Coordination, communicates extensively with client and Technical Authorities, in dealing with technical issues & External agencies/Third Party (BVIS, TUV, SGS, EIL, TOYO, UHDE, CEIL, NTPC RIO, JACOBS).

●To stick to the ISO system by self and to maintain the same environment throughout the factory.

●Preparing IBR form III B & IV A of manufactured products for IBR approval.

●To maintain identification & traceability of the job under inspection including the status of job as accepted – rejected – rectify – hold using identification tags.

●Monitor & maintain all quality records / documentation as per ISO.9001:2008

Feb’ 2007 to Aug’ 2008 : M/s. Jyoti tech industries P. ltd

Designation: Quality assurance engineer

Project: Fabrication of structure, S.S tank, GI panel, and paint mixing

machine and part processing, testing working for major’s clients of

the company SIEMENS, reliance and L&T and etc

Responsibilities:

●Inspection of MS assembly, machined parts, sheet metal parts, castings and Bought out material with different grade MS and stainless material.

●Ensuring all test reports and verified with grade specification to meet customer’s requirements

●To coordinate with metallurgical testing laboratories for the verification for material

●Maintaining calibration and validation systems for measuring and monitoring devices.

●Achieve and maintain the desired quality of incoming material from vendor.

●Completion of final quality documentation in presentable manner.

●Leading the quality team for timely completion of inspection and quality improvement.

●Control and monitor final product quality.

Inspection experience of Pipe, fittings, flanges, valves:

Client

Vendor/Supplier

Product

Projects

IOCL

Grasim engineering

L&T

MRPL

NTPC

●Remi Engineering.

●MJ Patel India Ltd

●Akash Steel

Pipes

Supply

Static equipment’s Inspection Commodity Experience

Client

Vendor/Supplier

Product

Projects

HPCL refinery Mumbai

IOCL

●Unifab Engg

●Kinam engg

●TEMA engineering

●Raj Engineering

Heat Exchanger

New DAK

NFCCU

SEU-III

DHDS

HPCL refinery Mumbai

●Fabtech Engg Pvt ltd.

●Newton engineering

●Thermax ltd

●Shree Satyanarayana ind.

●Vitech equipment Pvt ltd.

Pressure vessel

New DAK

PDA

EPC project

HPCL refinery Mumbai

●ACME engineering

●Shree Sathyanarayana Industries

Tank

SEU III, NFCCU

HPCL refinery Mumbai

●Crystal engineering

●Unique Chemo plant equipment

Column

New DAK

HPCL refinery Mumbai

●Shree Amba Engineering,

●Perfect engineering

●Rahul Petro tank

Storage tank

Refinery Mumbai

Mercedes Benz

Mahndra Ltd

Eicher motor

●Sunmar Fabrication Pvt ltd

Chimney, Stack

EPC project

Eisenmann India Pvt ltd

●Trans Engineering Pvt ltd

●Summit engineering ltd

Tank, Scrubber, Dosing tank

EPC project

Eisenmann India Pvt ltd

●Sharp thermal engineering

Heater

EPC projects

IOCL

Grasim engineering

L&T

MRPL

NTPC

●Remi Engineering.

●MJ Patel India Ltd

●Akash Steel

Pipes

Supply

Inspection experience of Pumps

Client

Vendor/Supplier

Product

Projects

Eisenmann India Pvt ltd

●Positive metering Pump Pvt Ltd.

●Sulzer

●MultiTech Hydro system

●Price pumps

Dosing Pump, Centrifugal pump,

EPC project

Inspection experience of structure fabrication and galvanized components

Client

Vendor/Supplier

Product

Projects

Mercedes Benz

Volkswagen India,

●Trans Engineering Pvt Ltd

●Rishi laser Ltd

Structure

EPC plant

Mahindra,

Eicher motor

●Asset engineering Pvt Ltd

●Rishi laser Ltd

●Summit Engg Pvt Ltd.

Structure

EPC plant

Inspection in Air Blower Fan

Client

Vendor

Project

Commodity

Eisenmann India

Nadi Air technics Pvt ltd

EPC

Centrifugal Blower, FD fan

Eisenmann India

Airtech Blower Ambernath

EPC

Centrifugal Blower, FD fan

Key Skills:

−Mechanical engineer, work experience Quality / Inspection. Working experience in Oil & Gas Refinery,

−EPC turnkey Project and equipment’s manufacturing industry.

−Team handling, Project coordination, supplier expediting, handle supplier.

−ISO 9001:2015 IMS Documentation and Internal / External Audit, Kaizen, 5S, CAPA.

−Manufacturing and site erection quality control system.

−Inspection of statics equipment and rotary equipment and Process piping, pipe fittings, post weld heat treatment painting, bought out material inspection.

−Structure manufacturing and erection of vessel, heat exchanger, column, tank and column internal.

−On stream inspection of piping and equipment and shut-down inspection.

Familiarity With Codes and Standards:

ASME Sec IX, Sec VIII, Sec II part C, Sec V, ANSI/ ASME B31.3, B31.1, B16.5, B16.11, B36.10, API 570, API 510 India boiler regulations, Engineering Standards and project Client specification.

Soft Skills:

−MS-Office( Word, Excel, Power Point )

−AutoCAD, Catia design V5

−ERP

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