RISHIKESH KUMAR

• Responsible for Welding procedure qualification, welder qualification, Weld map preparation, Post weld Heat treatment (PWHT) procedure based on technical requirement of project, and approval from client end prior to production.
• Preparation of Technical delivery Condition(TDC) of suitable Material (plates/forgings including simulated Heat treatment requirement) & Consumable based on client specification and ensure procurement accordingly
• Estimation of welding consumables, procurement proposal for welding consumable and raw material with ensure the simulated heat treatment cycle of material as required by ASME and client specification.
• Participate in Technical discussion related to welding/material /consumable with clients, third party, suppliers during product realization and provide the technical solutions
• Co-ordination with team of Welding Inspectors to control welding/quality activities and reporting to engineering Manager.
• Monitoring and controlling of Welding Consumable, shop floor operation manufacturing through welding Inspectors by co-ordination with shop supervisors.
• Resolving issue related welding, material failure due to corrosion, repair practice for maintenance of heat exchangers
• Report for resolution of Non-Compliance, Root cause analysis and corrective and preventive action,
• Ensuring compliance of Quality Management System of Fabrication activities and Audits.
• Responsible for Heat Treatment of Pressure vessels and calibration of recorders, welding machines.
• Process development and Improvement for efficient and effective practice for production.
• Evaluation of Mechanical Testing results and Microstructure of weld metal and Heat Affected zone and parent material.
• Participation in the Upgradation of Quality Manual, Work Instructions, document review while Internal and External Auditing.

Ongoing Project:

• Development of high deposition welding Process with multiple wires through SAW for higher thickness Pressure Vessel
• Analysis of welding consumables consumption and Optimization through welder skill up gradation in different processes

Achievements:

• On job welding Procedure qualification and welding for Replacement of Monel tube with Inconel tube for Repair Maintenance Heat Exchanger job
• Welding Procedure development for higher thickness Carbon steel material in different Heat treatment condition (NT/NACT) with multiple process in same coupon at as welded / different post weld heat treatment condition for sour service & low temperature application.

• Head Quality Assurance and Technical Services, Led team of Quality Engineers to compliance of all Technical documents in-line with project requirement and responsible for project documents QAP, MPS, ITP, RMTS, WPS/PQR for approval
• Develop Risk based Inspection for pipe mills and client requirements as required.
• On-site visit, Testing performed & data Collection and analysis, report Preparation for FIR, RCA, and CAPA
• Participation in daily meeting, Weekly meeting with top management, production plan and target
• Resolving technical issue related to welding, Material, process, quality concerns

Achievement

• Visited steel mill immediately after joining for Vendor quality Improvement at China (International Market- at china [ i) Baosteel Shanghai, ii) Baosteel, Zhanjiang, iii) Xingcheng special steel, Jiangyin and at South Korea[i) POSCO –Gwangyang Works, ii) POSCO –Pohang Works].)
• Reduction of welding defects at F & T end of pipe through enhancement of welding practice
• Proposal for Control of welding bead height for optimization of coating cost by 5%
• Established Impact of copper entrapment during LSAW
• Standard Practice for Mechanical Properties variation record and control at various stages of LSAW for quality Improvement at production and supplier end
• Developed graphical presentation in single page for clear vision for mechanical properties variation in terms of material grade, thickness, suppliers based on data analysis.
• Control of welding defects (gas pocket) formation in LSAW welding
• Upgradation of quality documents and shared with steel suppliers for steel material quality requirement and control mechanism
• Root cause analysis of crack failure of pipe during expansion of pipes
• Controlling of expander operation for optimization of mechanical properties of LSAW pipe

• Preparation/ Participation on Pre-Production Meeting (PPM), Manufacturing Procedure Qualification Test (MPQT), Audit of steel Mills
• Technical discussion with client to resolve issue related to Specifications, MPS and ITP
• Preparation for pipe procedure qualification, testing, welding procedure specification and implementation at plant
• Preparation and approval of project documents QAP, MPS, ITP, RMTS, WPS/PQR etc
• Responsible for Laboratory testing activities control, perform, review and approval during MPQT and regular production of spiral Plant 2.
• On-site visit, data Collection and analysis, report Preparation for FIR, RCA, and CAPA
• Accountable for Steel plant activities and visited several times (china, South Korea, Indian steel Plants) for PPM, MPQT, Material Inspections and Expediting for plates/coils of API Grade line-pipes / IS grades steels

Achievement

• Root cause Analysis and corrective action of Low Impact values (CVN) observed in LSAW pipe
• Root cause analysis and corrective action of failure while expansion
• Root cause analysis and corrective action of DWTT failure in API grade pipe material supplied by M/s Essar Steel, Surat
• Root cause analysis and corrective action of DWTT failure in API grade material supplied by M/s baosteel, Shanghai, China
• Xingcheng special steel, Jiangyin (Vendor) developed by providing necessary quality requirement and production and testing at plant and subsequently pipe formation
• Ovality control in 18” pipe through control of stacking of various rollers and process improvement in ERW
• Impact properties Improvement by control of heating practice in ERW
• Participated in recruitment process on campus interview at various engineering colleges for Metallurgical candidates

Role:

• Heading a team of Welding/Quality Engineers to control welding and quality activities
• Resolving welding*/Quality activities related issues and reporting to the General Manager
• Assisting in manufacturing processes to ensure first time right

Achievements

• Narrow Grove Nozzle developed for welding groove size reduction and better penetration at root run welding through SAW in thicker plates/ parts
• Production process Improvement by increasing the contribution of GMAW and SAW as continual improvement
• PQRs qualified for various grade of material of high-pressure vessels/Heat exchangers as primary role.

Role:

• Lead a team of Welding/Quality Engineers to control welding quality activities
• Resolving welding*/Quality activities related issues and reporting to the General Manager
• Assisting in manufacturing processes to ensure first time right
• Ensuring compliance of Quality Management System of Fabrication activities and Audit
• standardized welding parameters with compressing the various welding processes.
• Developed Double Welder Technique procedure to eliminate the back grinding for reducing the production cycle & cost
• Responsible for manpower optimization for high production output through welding output per shift standardization

Achievement

• Rail Engine block welding fabrication establishment
• Increase of GMAW/SAW process for optimization of welding time and cost reduction
• Root cause analysis and corrective action of shaft failure for hydraulic press
• New vendor development and random visit for compliance check at vendor end.

Role:

• Accountable for welding & quality activities and resolved related all issues
• Preparation/facilitation for plant visits by suppliers/customers/registration bodies/approval of agency

Established:

• Pipe to pipe welding production line through fully automatic orbital Machine
• Hand Held SAW Welding Machine procurement, Installation and production. Payback period calculated – 11 months based on available weld joints of project.
• Pipe Elbow machine establishment and process development

Role:

• Accountable for welding related activities at Plant 15 Heat Exchanger section.
• Lead a team of 6 Welding Engineers to control welding activities on shop for production of Heat Exchangers, Pressure Vessels, Light fabrications etc (Heat Exchanger Group) and reported activities to Senior Manager
• Co-ordination with Mechanical laboratories along with client/TPI and testing performed infront of them and resolving technical Issues.

Major Projects Handled:

• “Energy Efficient Heating- Pre-heating and Post-heating by Burners”- Development by me and Saving 1.35 Crore during Dec’08- Jan’10
• · “Manpower Requirements for PED” for financial year 2009-2010
• “Reduction of Tube to tube-sheet manual welders by using tube to tube-sheet Orbital welding”- saving 40 lakhs during June 2009-Jan 2011 conducted by Boston Consulting Group (BCG)

• Development of American Petroleum Institute (API) grade Line pipe steel plate greater than 12.5mm thickness with collaboration between IIT Bombay & ISPAT Industries for improved Drop weight tear test (DWTT) properties at low temperature
• Through Study of compact strip production of steel Industries
• Analysis mechanical properties of steel plates with respect to various steel making parameters
• Analysis of micro-structural properties across the transvers direction of plate thickness generated by Orientation Imaging Microscopy (OIM)
• Analysis of various mechanical properties Optical Microstructures; Hardness; Tensile Strength; Yield Strength; Impact at low temperature; Chemical Composition etc to optimize the process parameters

• Involved in the production process of Aluminium extruded products, Alloy fabrications, Heat Treatment.
• Associated with Planning and Supply Chain Management (PSCM), Total Productive Maintenance (TPM) and Quality Control (QC) activities.
• Played key role in Installation and Commissioning of Homogenizing Furnace, filler Wire Drawing Machines (new product lines set up).