Kadookkatt Abul Faisal

Dong Yang Corrosion Engineering. Co., Ltd

Bio

RESUME

Name                                        :        K.A Abul Faisal

Contact No                           :       +1(815)981-4576

Email                                 :       abulfaisal@gmail.com

Educational Qualification      :       Bachelor of Technology in Mechanical Engineering

                                                Govt. College of Engineering Trivandrum, India.

                                                Master of Business Administration (MBA)

                                                Specialized in Total Quality Management (TQM)

Professional Qualification     :

v National Association of Corrosion Engineers (NACE) Protective Coating Specialist 2 (PCS-2 Advanced).

v National Association of Corrosion Engineers (NACE) Certified Level 3 Coating Inspector CIP 3 (CIP Cert No 10827)

v NACE Corrosion Technologist (Cert No 68017).

v Certified NACE Internal Corrosion Technologist.

v Certified Welding Inspector-American Welding Society (AWS-CWI) ( Cert No. 03041821)

v Certified ASNT SNT-TC-1A Level II in NDT Methods(Magnetic Particle Testing Ultrasonic Testing, Radiographic Testing)

v ISO 9001:2000 & ISO 14000 Certified Lead Auditor ( Cert No.QMS01-07-11-0089)

v Attended Transition training 9001:2000 to 9001:2008

v Certified Trainer in Clock Spring® Composite Reinforcement System Application.

v Trained in FRP Pipe and Joining Methods from Bond Strand Kuwait.

v Trained in Painting Inspection and Surface Preparation from Hempel Paints Kuwait.

v Trained in Statistical Quality Control, Seven QC tools and Six Sigma.

Work Experience   : Total 20 Years In the field of Protective Coating, Inspection of Static Equipments and Quality Mamagenent in Construction & Maintanance of Plants, Chemical and Oil & Gas Installations on shore and offshore.

Experience Summary:
Core experience includes work with Fusion Bonded Epoxy coating (Single/Dual Layer/ Internal and External),Inorganic zincs, Gunite Lining, epoxies, coal tar epoxy mastics vinyl’s, urethanes, alkyds, acrylics, moisture cure urethanes, vinyl esters, phenolic, polyester linings, FRP linings, glass flake linings and numerous generic types of coating types that include 100percent volume of solids thick film materials. Considerable experience includes surface preparation techniques that includes power tool cleaning, abrasive blasting (open, field, auto-blasting and wheel abrator), and field operations on substrate includes application operations involving airless, conventional and plural component.

Actively involved in QMS activities in coatings work and Inspection on tanks (oil & gas), vessels (DE salters, knock out Drums, Gas oil separators, Scrubbers, oil absorbers, coalesces, Heaters…etc.) under decks, superstructures, above & below ground piping and numerous other structures for various utilities and projects.

Expert in 3layer polypropylene (3LPE), 3layer polyethene, Dual FBE, Heat Shrink Sleeve, HDPE Liner and PUF Insulation jobs.

ü Inspection of Factory application of 3 layer Polypropylene, Polyethylene, Coal tar Enamel, Fusion Bonded Epoxy, Foam Insulation and Internal Coating

ü Modification of Plants for Powder coating. Introduction of new technologies for Robotic Application. Monitoring and Inspection of Coating Jobs.

ü Experienced In Insitu Internal Lining Jobs.

ü Review of coating specifications and attending Pre-Inspection meetings.

ü Monitoring and Application of Casing Filler Application on Short Casing.

ü Inspection and Evaluation of Coatings of Existing Pipe lines, Tanks and Vessels.

ü Selection of abrasives to match the coating specification.

ü Conducting Paining test and qualification of Coating Products and painters.

ü Heat Shrink Sleeve, Clock Spring Application training, Installation.

ü Inspection of WFT & DFT, Peel Strength, and Holiday test of Coatings.

ü Experienced in use of most of the Elcometer paining & Coating Instruments.

ü Locating pipelines and recording locations using Global Positioning Systems.

ü Internationally certified Coating, Painting and Surface Preparation Inspection

ü Inspection of Weld Fit-up and Final weld visual, Film Interpretation, Weld Visual

ü Quality Control & Documentation as per ISO Standards

ü Experienced in Coating Material Selection and Coating Rehabilitation of U/G & A/G Piping, Oil storage tanks and processing Vessels.

ü Assessment, Monitoring and Reporting of Existing condition of Tanks Vessels, Flow Lines, and Transit Lines and in-plant Piping and conducting routine Risk based Inspection.

ü Conducting failure Analysis Investigation, Locating

ü FRP pipe and Fittings Production Monitoring, Inspection and Installation.

ü Internal Auditor as per ISO 9000 &14000 Core Member of ISO Implementation Team

ü Review of Coating Procedures and preparation of Specifications for Painting Jobs.

ü Inspection of Coating for Tanks, Vessels, Flow Lines, Transit Lines and in plant Piping.

ü Inspect problem areas and define root cause, recommend solutions.

ü Corrosion Survey on Pipelines to evaluate the actual extended of corrosion and coordinate with KOC Inspection team to calculate the remaining life, maximum operating pressure and possible repair method.

ü Analyse and report on technical content and feasibility of contractor supplied Coating services.

ü Coating Rehabilitation and application of High performance Maintenance Epoxy Paint Application.

ü CIPS Survey and evaluating condition of Coating and Pipe condition by ECDA.

ü Carry out audits to ensure site supervisors and contractors adhere to the company protective coating procedures. Recommend and follow-up corrective and preventive actions.

ü Evaluate contractor tenders and recommend qualified submissions in conjunction with sites.

ü the root cause, reporting and Implementation of corrective actions. Provide technical advice on protective coating activities for both offshore and onshore plant and equipment.

Detailed Work Experience

Period                                      Designation                               Organisation

Feb –06 – Till Date            Protective Coating Specialist         International Inspection Center,Kuwait
Feb 05- Feb 06             Quality Assurance Manager     CPCL,Dubai, Jabal Ali Free Zone

                              Corrosion Protection

June 03- Feb 05            QA/QC Engineer                   Arabi Enertech KSC, Kuwait

March 99- May 03          Sr. Engineer Quality               Sithara Engineering, Cochin

Nov 97   - March 99       QA Engineer                          Sona Koyo Steering Systems Ltd

                                                                        Chennai

Company            : International Inspection Centre (Intrex). Secondment
Position             : Protective Coating Specialist (In KOC Inspection Corrosion Team)

Period               : Feb –06 – Till Date

Nature Of work:

·    Select the suitable coating, painting and field joint coating materials and systems

·    Perform the detailed design of the coating, field joint coating and painting systems

·    Prepare the technical qualifications related to the coating, painting and field joint coating

·    Prepare the specifications and technical requisitions related to the supply of the coating, painting and field joint coating materials and services.

·    Perform the technical evaluation of the offers received from Vendors related to the supply of the coating, painting and field joint coating materials and services.

·    Review the documentation prepared by painting, coating and field joint coating Subcontractors.

·    Carryout major & Minor Survey of various plants and shutdown maintenance of the Vessels, Tanks, Boilers, chillier and in plant piping.

·    Evaluating condition of Coating and Pipe condition by EDCA.

·    Aiding in Development of Coating Specifications, Contract documents and Feed Packages.

·    Corrosion Survey on Pipelines to evaluate the actual extended of corrosion and coordinate with KOC Inspection team.

·    Material Selection and selection of Coatings for Vessels, Tanks and Pipe Lines.

·    Carrying out failure analysis and related activities.

·    Inspect problem areas and define root cause, recommend alternative solutions.

·    Maintenance, Assessment and Rehabilitation of Crude Oil tanks. Core member Of ISO 9000:2008 & ISO 14000 Internal Audit Team.

·    Raise Non-conformance and Carryout the Implementation of Corrective and preventive actions in case of deviations from the Standards.

·    Review of Painting & Coating procedures and specification.

·    Calibration and Record Keeping of Testing Instruments in the ICT Corrosion LAB.

·    Auditing and Inspection of Internal and External Coating at Pipe manufacturing and Coating Plants.

·    Carrying out Inspection of Coating Jobs in Tanks, Vessels, Above Ground and Underground Piping.

·    Carry out audits to ensure site supervisors and contractors adhere to the company protective coating and procedures. Recommend and follow-up corrective and preventive actions.

·    Qualification of Painting Contractors, Paint materials and Abrasive materials.

·    Inspection of Insitu Internal Lining Jobs.

·    Preparation of Memos and Communicating with Contractors and Paint manufacturers on various coating issues.

·    Analyse and report on technical content and feasibility of contractor supplied Coating services.

·    Team member in Research and develop coating, painting and field joint coating materials and systems

·    Perform the feasibility studies for suitability of the coating, painting and field joint coating systems

·    Review the received documents and elaborate the input data related to the coating, painting and field joint coating works

·    Select the suitable coating, painting and field joint coating materials and systems

·    Prepare the technical qualifications related to the coating, painting and field joint coating

·    Prepare the specifications and technical requisitions related to the coating, painting and field joint coating materials and services

·    Estimate the required man-hours related to the coating, painting and field joint coating engineering works in case of the project award

·    Perform the technical evaluation of the offers received from Vendors related to the supply of the coating, painting and field joint coating materials and services (if any)

·    Review the received documents and elaborate the input data related to the coating, painting and field joint coating works

·    Perform the technical audits of the Subcontractor coating, painting and field joint coating facilities.

·    Witness the Pre-Qualification Test performed by Subcontractors related to the coating, painting and field joint coating.

·    Solve the technical problems related to the coating, painting and field joint coating works.

·    Support Vendor Management for selection of Vendors and for performance of the technical audits.

Major Achievements:

Developed a standard operating procedure for carrying out coating evaluation and issuance of action reports. Our team was able to extract historical data from IDS software for static equipment and use it for effective coating evaluation. We developed a good reporting methodology and to analyse the protective coating effectiveness after each shutdown activity was completed.
Member of a team to presented a paper to NACE International comparing various methods to measure soluble salt on metal surfaces and their effectiveness.
Core Member of team to study factors affecting Cathodic Disbondment Test.
Developed Coating Training Manual for New Kuwaiti Engineers Joining Kuwait Oil Company.
Conducted a study to find factors affecting temperature measurement using Infrared and direct contact thermocouple at various angles and distance of measurement in the application of Fusion Bonded Epoxy process.
Architect and designer of a computerised exam module, reporting module and administration module for the purpose of qualification of Coating Inspectors.
Design of Business Process Management module for automation of QIMS. QIMS stands for Qualification Issuing and Monitoring Software. This computerised module has data entry section which reduces the data entry time by 80% and qualification card delivery time was reduced from over 6 months to less than 2 weeks.
Now in the process of developing a model to integrate the data handling from various departments (Internal Corrosion ,Inspection, Coating and Cathodic Protection).This Corrosion Prediction Model will be able to continuously monitor the effectiveness of coating performance in static equipment and raise alarm in case of excessive corrosion behaviour in static equipment.

Company                  : CPCL,Dubai, Jabal Ali Free Zone

Position             : Quality Assurance Manager Corrosion Protection

Period               : Feb –05 – Feb –06

Work Responsibilities:

à        Establishment of QMS and Implementation of ISO 9001:2000 related activities.

à        Management Representative and Laison of ISO Certification Audit.

à        Development of Quality Circles and Imparting Five S Training.

à        Six Sigma Project Identification and Green Belt Training to Employees.

à        Co-ordination of Six Sigma Activities and Monitering of Project Dash Board.

à        Development of Quality Plan, Sampling Plan and Inspection Activities.

à        Investigating Customer Complaints and Conducting FMEA, DOE , Brainsorming

à        Improving Process Quality by Introducing Pokayoke

à        Conducting Vendor rating and Testing of Raw materials.

à        Leading the Quality Team and Keeping them Motivated and Trained.

à      Estimate the required man-hours related to the coating, painting and field joint coating engineering works in case of the project award

à      Perform the technical evaluation of the offers received from Vendors related to the supply of the coating, painting and field joint coating materials and services (if any)

à      Review the received documents and elaborate the input data related to the coating, painting and field joint coating works

à      Perform the technical audits of the Subcontractor coating, painting and field joint coating facilities.

à      Installation and removal of weight loss corrosion coupons, electric resistance probes and electric polarization probes etc.

à      Servicing of corrosion monitoring fittings at different plant locations using different servicing tools. Conversant with use of tools for online installation and removal of corrosion probes in the refinery.

à      Managing and Interpretation of corrosion data, calculation of corrosion rates.

à      Cathodic protection survey, which include but not limited to structure to electrolyte survey and current measurements of anodes and Transformers/Rectifiers of Refinery and Petrochemical cathodic protection systems.

à      Knowledge of cathodic protection systems for Tank bottoms, Tank Internals, offshore structures and underground piping’s and Vessels. Preparing drawing for new-dedicated cathodic protection system for new storage tanks, attending breakdown and preventive maintenance of cathodic protection systems, installation of new anodes and maintenance of the recorded data’s.

à      Material Identification using spot chemical testing, Nuclear Metal Analyzers & and Optical Emission Analyzers. Preparing Material analysis reports.

à      Metallographic preparation of samples, mounting, polishing and etching the samples and taking photographs of the microstructure.

à      In-situ metallography of stationary equipment at different locations using portable metallographic polishing equipment as well as portable field microscopes.

Company               : Arabi Enertech, Kuwait
Position                 : Quality Control Engineer

Peirod                   : June 03- Feb 06

Experience:

1.    Shut Down & Pipe line replacement and tank maintenance in 8 Oil Gathering Centres of KOC (Transit Lines, Fuel gas lines, Lean gas lines, Dry crude to separator lines Wet crude lines form separators, Engine gas scrubber lines, Flare Lines, Flow lines coming from Wells to GC’s etc)

2.    Pipeline repair Services using Application of Clock Spring On defective Pipelines and conducting Corrosion Survey Replacement of pipe Lines. Painting and Coating Wrapping rehabilitation of underground and above ground pipe lines in Various GC's, attending Shut down jobs in various Oil Gathering Centres/replacement and repair of pipe lines

3.    Installation of FRP Pipe In GC 22

4.    Pipeline Repair and Replacement of 32” BS 150 to GCMB Gas line Installed 428 No of 32” Clock springs.

5.    Pipeline Repair and Replacement of 40” Gas Line From GCMB to MinaAhmadi Refinery.

6.    Repair And Replacement of 16” Crude Line form Wafra To MF/ TB13.

Work Responsibilities:

Corrosion Survey of Pipe and measuring thickness at corroded areas using UT Thickness gauge Meter, Depth gauge etc.

Certification Training and Approval of Clock Spring Trainer form Clock Spring Company and KOC in spool feeder and coil pass methods.

Training of Clock Spring Composite reinforcement Applicators

High performance Epoxy Coating for Pipe Lines using Airless Spray of HEMPADUR Painting System of HEMPEL paints. Inspection of WFT, DFT

Peel of test, Surface profile inspection with Profile gauge as per SA 2 ½ Inspection of Pipes, Fittings, Paints and Coating materials.

Fit up Inspection and Final Weld Visual Inspection of Shop fabricated and Field welded Spools and Maintaining the Welding records.

Radiographic Film Interpretation and DP test for fillet welds.

Evaluation of welders performance and reporting.

Qualification of Welders and Maintaining records as per ISO Standards

Preparation of WPS and PQR for the project.

Inspection of Hydro test & Preparation of the Hydro test Packages

Inspection of Pipe Surface preparation.

Inspection of painting WFT, DFT,Peel of testing etc.

Holiday inspection of wrapping of Underground Piping.

Inspection of Sleeves for Road crossings.

Inspection and monitoring of Welding consumables.

Preparation of records and submitting to the client for approval.

Sand blasting inspection of 32” live line and Installation of Clock spring Composite Sleeve installation.

Inspection of Pipe thickness at corroded areas using D Meter

Certification Training and Approval of Clock Spring Trainer form Clock Spring Company and KOC in spool feeder and coil pass methods.

Training of Clock Spring Composite reinforcement Applicators.

High performance Epoxy Coating for Pipe Lines using Airless Spray of HEMPADUR Painting System of HEMPEL paints. Inspection of WFT,DFT

Peel of test, Surface profile inspection with Profile gauge as per SA 2 ½ or NACE 3

FRP pipe Inspection and Installation in GC-22

Heat Shrink Sleeve Installation and Inspection

June 02-May 03             Surface preparation inspection and coal tar Application Inspection

Inspection of Centrifugal blasted pipes

Helical Pipe Production Plant                        PSL Holdings

                                SAW process by which Sheets are                   Chengalpettu

                                Spirally wound and welded to form

                                Pipes of various Diameters for cross

                                Country pipe lines Job Involves Testing of

                                Produced pipes Hydrostatically and PT and RT

                                Holiday inspection with High voltage coils

                                Inspection Sampling plan RT 20% about 100 shots per day

Sept 02 Dec 02             Review of the coating specification and matching the application according to the specification.

Conducting painter evaluation test.

Liaison with inspection team and application team

High pressure Boiler Line                                NFBC

                                SS Product Water Line SS304L                          Manjapetty

                                Activated Carbon Filter Tanks and Piping

                                Pressure Sand Filter Tank and Connected Piping

                                Iron Removal filter Plant Piping

SS Filling and Micron Filter Lines

                                Compressed Air Line form 40 Bar and 12 Bar

                                Jar filling machine and piping work for that

                                Chillier plant Piping Work

                                Air Conveyer and Support Structure

                                FG carrying Redler Conveyer

                                Product Water Line tank and Supporting Structure.

Work Responsibility:

Inspection of Surface Preparation and Surface Profile Measurement.

        Inspection of Painting Wet Film and Dry Film Thickness.

        Sieve analysis of the abrasive to check the grade.

Coordination with Client Inspection Team.

Inspection of Materials and Verification of MTC.

                                Welding Fit up Inspection, Process Monitoring

                                Final Visual Inspection.

                                Inspection of the CP potential of the tank.

                                Rehabilitating and supplementing the CP System.

                                Verification Of Results for MT and RT

        Verification of As Built Drawings and Isometric Drawings.

                                Preparation of Hydro Test Package.

Jan 02-Aug02

High Pressure Liquid Nitrogen Plant Piping      Saba Powerdex

                                Compressed Air Line

H P Hydro blasting of the water softener             Kakkanad

                                Water Softener Plant Piping (Ion Exchanger)

                                Slurry Mixer Plant Piping

                                Cooling Water line

                                Vacuum Line

                                Chillier Plant Piping

                                ETP Plant Piping and pump installation.

                                Air Receiver tank and vacuum tank Installation.

                                Steam Line to Slurry Heater tank

                                Copper Piping of Co2 Purging Oven

                                Piping for the HAVC Instrumentation

                                HVAC Machine Installation (Cargo Care USA)

                                Lithium Assy Machine Modification

Feb 01- Jan 02              Sulphur Recovery Plant                            Kochi Refinery Limited

Recovery Plant Piping , Structural work ,Storage tank and

                                Evaporator and Condensate removal Pipe line replacement

                                Installation of the impressed current CP system for the tank base

                                Supporting Structure Dia Worked With 3/4 inch to 19 inch                                           Materials used A105, A106 ,API 5L Gr B X52

                                Coating of the Fire Hydrant Line

                                Compressed Air Instrumentation Line

Work Responsibility:

        Inspection of Surface Preparation and Surface Profile Measurement.

        Coating And Wrapping Inspection.

Inspection of Painting Wet Film and Dry Film Thickness.

Conducting HV Holiday test .

Installation and Inspection of Impressed current CP System.

Inspection of Materials and Verification of MTC.

                                Welding Fit Up Inspection , Process Monitoring

Final Visual Inspection. Coordinating with the 3rd Party NDT Inspection Team.

WPS and PQR Verification.

        Welder Qualification and Keeping record of Qualified Welders.

        Preparation of Hydro test Package.

        Verification of As Built Drawings and Isometric Drawings.

        Coordination with Client Inspection Team.

Sept 01-Jan 02              Compressed Air & Vacuum Line for Packing Plant         Chikoos

Fabrication and Modification of Plant –2                     Kakkanad

                                Surface preparation and coating of the Pipe Line Manifold

                                Erection of the RM Conveyer

Conveyer for Product Lines

                                Caser machine Support Modification

Mar 01- Aug 01                  Paining and Coating rehabilitation of the UG pipe lines

                                  Insulation of the heater line.

Heater Water Line Piping                          Sri Sakthi Paper Mill

ETP Plant Piping (FRP)                                     Eloor, Cochin

Modification of Roller Conveyer

                                Paper Roller Conveyer Corrugation Structure

Paper Roll Cutting Machine Modification

                                Pulp Crusher Shaft Holding Structure

                                Pulp Bleacher & Dryer Structure Modification

Paper Unloaded structure.

Aug 99-Mar 01               Coating application monitoring of the plant and

Chlorine Gas Line Piping                           Kunneth Chemicals

                                Bleaching Powder Conveyor                               Eloor Cochin

                                Modification of Blender Piping

                                Assessing the corrosion damage of the existing structure.

                                Finished process Bagging Structure and Conveyer

Mar 99-July 99              Surface preparation and profile inspection

Painting specification details discussion with the client and coating manufacturer

Selection for painters and evaluating the performance for Air less Spray application.

Process Piping of Nitrogen Filling Plant     Sri Padmabalaji Industrial

                                Manifold Piping for CO2 and Liqiud Nitrogen CP Installation.

                                Modification and pipe line replacement in Argon Filling Plant

                                All welding SMAW for Process Piping and Brazing of Copper Piping.

Work Responsibility:

                                Inspection of Raw Materials, Coating materials and Verification of TC.

Coating application Inspection, Welding Fit Up Inspection , Process    Monitoring

Final Visual Inspection, Welder Qualification Verification

                                Coordinating with the 3rd Party NDT Inspection Team.

Nov 97 To March 99            Fully Automated PLC Controlled     SonaKoyo Steering Systems Chennai

                        MIG (GMAW) Machine               Manufacturers of Steering Columns and

                        Lock Ring Welding Machine        R&P Assy for Maruthi Suzuki & Hyundai

                        Lower Column & Bracket Assy Welding m/c      in Gurgaon and Sriperumbathur

                        Upper Column & Bracket Assy Welding m/c        With Collaboration with KOYO

                        Shroud Bracket Assy Welding Machine m/c               Japan and MANDO Korea

                All Machines Adwani-Orlikon SPM's

Work Responsibility:

Surface preparation inspection and Coating application inspection of components.

Conducting salt spray test for the coated parts.

Testing and Inspection of Welded Joints form the above mentioned Welding machines and giving clearance to Production for the start of Mass production, and Recommendation of change in machine settings Like Increase or Decrease of Current , Voltage Gas flow or Torch Position or Fixture Alignment.

Routine Process Monitoring and attending to study of Warrantee Inspection of Ware and Tare of Machine fixtures.

                                Destructive Testing of Weldements using UTM

                                Design Of Fixtures for Fatigue and Reliability Testing and for                                            destructive Testing for new models.

Inspection of Raw Material as Per JIS Standards

Including Magnetic Particle testing (Wet) Method

                                For Heat treated materials and Welding

                                Experienced In GEMBA KAIZEN, QUALITY CIRCLES, Six Sigma

                                POKAYOKE, TPM, ROOT CAUSE ANALISIS

Computer Expertise                       :

§   Proficient in Computerised Report Making Using Microsoft Word, Excel and Power Point.

§   Trained in AutoCAD 2000 Level III and Iron Cad

§   Experienced in Minitab Computerised Statistical Analysis Tool

§   Project Planning Using Microsoft Project and Primavera.

Codes Familiar With

ü API 570,574,510,651

ü ASME 31G, 31.3,31.8

ü ASME Sec. II, V, VIII, IX

ü ASME /ANSI B 31.1, 31.4, 16.5 etc.

ü SSPC STANDARDS

ü API- 5L, 650, 653, 1104

ü KOC STANDARDS

ü NACE, DIN and Canadian Standards

Professional Memberships        : Member of American Welding Society

   Member of SSPC

   Member of National Association of Corrosion Engineers.

   Member of Six Sigma Club Kuwait.

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