Quality Assurance Manager

Vinay Kumar Bhatt

(Assistant General Manager – Head Welding Technology)

H/No.75 New Paras Nagar, Boh Road, Ambala Cantt (Haryana)133021

e-mail: ********@**********.*** Phone:+918********(Mob.)

***********@*****.**.** +91+171+2670399(Resi.)

Objective: I expect a challenging job that will exploit my technical and interpersonal skills with a reasonably high level of responsibility in an organization with congenial growth opportunities

Personal: b.3rd Dec1978; Indian National; Male; Married(1-Kid);Confident, Enthusiastic, Companionable; Possess good organizational skills and ready to relocate; Hobbies include Organizing events and various group activities, Traveling, Listening songs and Learning new things.

Qualification: M.Tech (Physical Metallurgy) from IIT –Roorkee & B.E from NIT –Raipur

B.E Project: Study of Impact Fatigue Behaviour of Cast Irons.

M.Tech Thesis: Development of Heavy Duty Al-Graphite Based Bearing Materials and Their Characterization.

Technical Paper: Case Study on Face Bend Failure in Dissimilar Joint, presented in Indian Institute of Welding.

Passport Details: Passport No. B 2396456, Place of issue: CHANDIGARH (INDIA)

Six Sigma: Black Belt, Green Belt

Six Sigma Project:

Manufacturing Cycle time Reduction of DNA (Defense, Nuclear & Aviation) projects.

Reduction in cycle time & error in PCR (Plate cutting Request)/PCL(Plate Cutting Layout) .

Professional Experience:

Assistant General Manager - Head Welding Technology in I.S.G.E.C (Indian Sugar & General Engg. Corporation, Yamunanagar) . I am of the core team member for N-stamp (Nuclear) from ASME. I am looking after almost more than 300 Heat exchangers & pressure vessels under fabrication. Two Managers, One Deputy Manager, One Assistant Manager, One Senior Engineer, One Engineer & one supervisor is directly reporting to me for welding planning & execution work.

Company Profile – ISGEC is one of the companies of Saraswati Industrial Syndicate (SIS) formed in 1933. SIS is having Nine sister concerns. ISGEC was established in the year of 1946, it manufactures a variety of heavy engineering equipments for varied application. The products include Pressure vessels, Reactors for refineries, Petrochemicals, Fertilizers & other industries, Hydraulic & Mechanical presses, boiler components, Machinery for cement & steel industries, Chlorine containers. Annual turnover of ISGEC is approx.2400 crore. The company has ISO 9001-2000 certification. ISGEC Quality Assurance manual is approved by ASME authorizing the unit to manufacture U, U2, U3 , N, NPT and S code stamped pressure vessels, columns and heat exchangers including IBR and Repairs and Alterations as per NBBI guidelines under "R" stamp approval.

Covenant Assistant Manager- Welding in Welding Engg. Dept of L&T (Larsen & Toubro Ltd.), Surat (Gujrat) from Feb 2005 to May 2010. I was heading Large Equipment Manufacturing Facility & ship building. I was the core team member for N-stamp (Nuclear) from ASME. Handled 40 projects & 145 equipments.

Company Profile - Larsen & Toubro Limited (L&T) is a technology-driven USD 8.5 Billion company that infuses engineering & imagination. L&T is one of the largest companies in India’s private sector. L&T's Heavy Engineering Division (HED) has established a reputation for quality products in the global market. L&T manufactures and supplies modular precision, custom engineered, critical equipment & system to core sector industries such as Process Plant Industries & Defense, Nuclear Power & Aerospace Sectors.

L&T’s Quality system manual addressing requirements of ISO 9001-2000 (QMS) certification as well as complying with the International Quality Rating System (IQRS) for enterprises. L&T’s Quality Assurance manual is approved by ASME authorising the unit to manufacture U, U2, U3 and S code stamped pressure vessels, columns and heat exchangers and including IBR , Repairs and Alterations as per NBBI guidelines under"R" stamp approval along with PD 5500. L& T is the first company in India (10th in the World) approved by ASME to manufacture “N” code stamp vessels & heat exchangers.

Senior Engineer in Welding Technology Department of ISGEC (Indian Sugar & General Engg.Corporation, Yamunanagar) From July 2003 To Feb2005.

NDT Qualification: PT Level – II under L&T

Auditor: Certified auditor From DNV for ISO 18001 & OSHAS 14000

Welding Qualification:

SMAW : 3G (Vertical Uphill) under L&T

Automatic GTAW: 5F (For Tube # Tube sheet welds, one of the most critical joints of Steam Generator under NPCIL (Nuclear Power Corporation of India Ltd.)

Automatic Pulse GTAW: 1G (For Tube # Tube welds) under NPCIL (Nuclear Power Corporation of India Ltd.)

Automatic Pulse GTAW(Autogenous): 5G(For Ti Tube # Tube welds)

Total Job Profile Includes:

Welding Related Activities:

Handling Enquiry for new projects (Accessing technical feasibility & estimation )

Check manufacturing feasibility at Pre-tendering stage

Support to Product group at Pre-manufacturing stage and identify developmental needs.

Sort-out various technical matters with Customers/Consultants.

Dealing with NPCIL (Nuclear Power Corporation of India Ltd.) , BHAVINI (Bhartiya Vidut Nigam Ltd.-Nuclear) , IGCAR(Indira Gandhi Centre for Atomic Research-Nuclear), LRS (Llyods Shipping Register) , BVIS , IBR(Indian Boiler Regulation), EIL(Engineers India Ltd.) for jobs.

Decide manufacturing processes for various joints (e.g. GTAW, SMAW, SAW, FCAW etc.) and design weld joints accordingly.

Selection, estimation and procurement of various consumables procurement from local/foreign sources.

Development of welding procedures for new materials and procedures to meet requirements of various codes and customer specifications.

Developed Welding Procedures for CS, LAS, SS & Dissimilar joints with ASME codes.

Knowledge of ASME codes : ASME SEC-IX, SEC-VIII DIV.1 & 2 , SEC-II-A,B & C, SEC-III NB , RCC-MR , EN-Std., Indian Std. , BS- Std., B31.3 , API std’s. etc.

Development and implementation of new processes and technology up gradation.

Provide manufacturing technology to shop.

Preparing Inspection Test Plan (ITP) to include all testing requirements of code and customer specification and thereby ensure desired quality.

Training and qualification of welders.

Trouble-shooting on shop floor.

Quality control and surveillance.

Provide support for site problems.

Handling projects like: Gassifiers (Shell & Sasol Technology), Coke Drums (Petrobras, KNPC, IOCL –Baroda, Paradip), ACN Reactors, CDU/VDU, RR package (Reactor, Regenerator), HP Separators, Amine Absorbers, Surface Condenser, Deareators etc.

Handled the most critical jobs of L&T, i.e. Nuclear Jobs (Steam Generator, Roof Slab, Safety Vessel, Main Vessel, Outer Boron Shell Carbide Assembly, Dummy Fuel Assembly etc.)

QA(Quality Assurance) related Activities:

Analysis of NCR’s

Revising the welding related parts of quality manuals

Carrying out Audits (ASME , EHS, WMS, Sub-Contractor)

Conducting training programs for Welding Engineers & supervisors related

to quality and welding aspects

Vendor assessment through Audits

Qualification of fabrication Sub-Contractors

Conducting Quality related meetings for improvements

Handling Customer/Site complaint

Preparing Quality plan(NDE related) for all the projects

QC(Quality Control) related Activities:

Quality control plan related to welding & NDE

Carrying out spot checks to control welding related parameters

Carrying out surprise audits for both production as well as subcontractors

Checking weld visuals

In receipt inspection of welding consumables

Procurement related Activities:

Deciding the welding machines to be procured

Development of vendor for developing new custom made Machines (eg.STT –MIG for Single Sided Full Penetration Welding, Machine for Tube # Tube Welding etc.)

Procurement of Consumables & Developing new brands of consumables

Procurement of Services (eg. Developed a vendor for Brazing )

HR related Activities:

Recruiting Experience Welding Engineers

Recruiting Fresh Engineers Through Campus

Recruiting Experienced Supervisors for Quality & Shop

Recruiting Welders / Welding Operators

Improvements:

Developed Hot wire GTAW for overlay purpose.

Successful development and implementation of Spot Welding (with Micro-TIG M/C) of 0.15mm Stainless Steel strip on 30mm Carbon Steel plate for holding the thermocouples on the surface of roof slab job for Nuclear application. The process has developed for the first time in L&T –HED. The same process was used in Kalpakkam Nuclear Site and in HED Powai also. The process can be used for future jobs.

Face bend tests for Production Test Coupon of Dissimilar joint (CS#SS) were failing while carrying out the test as per conventional bend test method due to non-uniform stretching of CS and SS areas for one of the Nuclear job(Roof Slab). Developed an in- house fixture for wrap-around bend test as suggested in various literatures (provides uniform stretching of sample), which was carried out for the first time in L&T (It was not available in any of the Indian Testing laboratories). By using that fixture, we were able to get satisfactory results for Face Bend test and BHAVINI/ NPC-QS accepted the same. This fixture can be used in future for wrap-around bend test in lieu of guided bend test for dissimilar joints.

Develop a system for PQR's (POWAI+HAZIRA) for Nuclear & Process plant , thus making these PQR's available ON-LINE for Welding Engineering Dept., which would be helpful in Process Time Reduction by avoiding the manual searching of PQR's every time.

Developed and implemented a new methodology to carry out Helium Leak test (Vacuum method) of Tube # Plug welds of PQR/WPS. First time, this type of leak test was carried out for Steam Generator projects (Nuclear application).

While working on a very critical assembly of Steam Generator (Nuclear application) there were very critical joints of cold leg & hot leg shrouds with divider plate. These joints were accessible from one side only & call for full penetration joints that required being ultrasonically tested. To produce defect free joint, we have decide to carry out a full size mock-up for trials as well as confidence built-up of welders. From scrap material we have made a full size mock-up of the joint & welders were trained on the mock-up before they actually welded these joints on the job. Because of this, we could able to weld all these joints without any defect in UT.

Developed of Automatic Pulse GTAW for pipe to pipe SS joints for thousands of seam to weld for (Nuclear application).

Developed of Orbital Automatic Pulse GTAW for pipe to pipe CS/LAS joints for thousands of seam to weld in situ.

Weld visual inspection of piping joint & Tube to Tube sheet Joints apart from normal grove and fillet joints.

LPE inspection of PQR’s (Procedure Qualification Records) , PTC’s(Production Test Coupon) & WPQ’s( Welder Performance Qualifications)

Ti Tube to Tube sheet Welding with Automatic GTAW machine (almost 2 Lacs Holes)

Developed GMAW pulse for Butt welding of coke drums to reduce heat input which in turn result in Bow control problem (prominent in coke drums)

Developed hot Wire GTAW for Non- Ferrous overlay application

Established Vacuum packing of electrodes

Developed & Implemented SAP for online weld plan , welder Deployation , consumable issue & Consumable Inventory Management

Implementing STT-MIG & Pulse on Pulse Technique for Semi-Automatic welding of containers

Exposure:

Nuclear Sector: Manufactured Steam Generators, Roof Slab, Safety Vessel, Main Vessel, Dummy Fuel Assembly, Outer Boron Shell Carbide Assembly, Stainless Steel Sub Assembly etc.

Power Sector : Surface condensers( Ti Tube # Tube sheet Joints) , Deareators , HP- Heaters, Coils , Panels , Headers , tubing , Piping , Drums etc .

Process Plant Sector: Pressure Vessel, Columns (CDU/VDU) , heat Exchangers, Reactors, Gassifiers, ACN Reactors, EO – Reactor , Coke Drums , Containers

Fertilizer Sector: Primary & Secondary Reformer, Waste Heat Exchangers, CO2 Absorber, CO2 Stripper

Ship Building Sector: Cargo Ship

Customers Handled: Exxon Mobil, Flour, UOP, Jacobs, EIL, Technicas, Tecnimont , Technip, Petrobras ,Sasol , KNPC , IOCL , Foster Wheeler , NFL , Adani Power, Tata Power ,Jindal Power, Ansaldo , Alstom, Toyo , L&T , KRIBHCO , NPCIL , BARC, BHAVINI , IGCAR , Lindey , Lurgi, BP –Cherry , Petrofac , Hitachi – Japan etc.

Vocational Training:

Industry: Hindustan Aeronautics Ltd. Lucknow

Duration: Four Weeks

Areas of Training: Heat Treatment, Foundry & Forge, N.D.T

Computer Proficiency:

Languages: C, C++, FORTRAN, BASIC

O.S: Win 95, Win NT 4.0, Win XP

Packages: Oracle 8.0, D2K, BAAN (ERP Module)

Programming Tech: OOPS, PPT

Achievements:

Second Rank in M.Tech.

First Rank in IX and XII

Selected as Master of K.V.No.2

Extracurricular activities:

Secretary of Metallurgical Engg Society in Govt. Engineering College Raipur.

Collected funds for Helpage India.

Participate as the active member of METSO and JESID.

Participate in All India Drawing and Painting Contest and get the merit position

Vinay Kumar Bhatt

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