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  • Job reference: RMS0147447

Umbilical Manufacturing Inspector

  • Sector: Oil & Gas
  • Location: Alabama - Other
  • Job type: Contract
  • Date posted: 10/09/2014
  • Time left:
    d h m s
    (17/09/14)
This vacancy has now expired.
The Company:
Major Oil and Gas Operator

The Role:
Umbilical Tube Manufacturing Inspector Job Description
Role of Umbilical Tube Manufacturing Inspector:
Primary company representative and technical expert for the manufacture of high yield strength stainless steel tube (Super Duplex Stainless Steel or Zinc-Coated Duplex Steel) located on site.
Ensures all aspects of umbilical tube manufacture is in accordance with the approved manufacturing procedures and is fully documented, and manufacturing record books submitted in accordance with Contract requirements and specifications.
Fully understand the complexity of welding Super Duplex Review and recommend approval of WPS’ s, WPQR’s, welder qualification certificates and maintenance records.
Provide technical support related to qualification of procedures and materials, welding, destructive and non-destructive testing of tubes, factory acceptance testing and preparation for transportation.
Umbilical Tube Manufacturing Inspector key responsibilities:
 Ensure the supplier and sub-suppliers adhere to Company and approved Supplier specification requirements at all times, including any National and International Standards.
 Ensure Suppliers and Sub-Suppliers work in accordance with the approved PQP and ITP’s.
 Monitor materials test reports (MTR) and storage.
 Review Proposed Welding Procedure Specifications (PWPS’s) and Procedure Qualification Testing (PQT) prior to qualification testing.
 Review proposed manufacturing procedures and be fully conversant with the various processes and monitor manufacturing and test parameters.
 Oversee the development of the welding procedure qualification test matrix and the scheduled sequence of the required qualification weld test.
 Oversee qualification testing of welders and procedures.
 Ensure mechanical testing equipment, procedures and quality processes are in alignment with the project specifications for weld procedure and material qualification testing.
 Review and recommend approval of contractor’s WPS’s and WPQR’s after qualification testing.
 Focal point for interpreting specifications and codes related to qualification, testing and production welding.
 Focal point for WPS implementation and application of requirements. Oversee contractor’s development of a WPS selection matrix.
 Ensure compliance with all applicable documentation and regulatory requirements for welding and manufacturing processes.
 Review of QC part of the final documentations.
 Ensure quality of production welding is in accordance with project specifications and WPS’s.
 Notify the Shell Materials and Welding subject matter expert (SME) in the event that consistent welding and NDE problems become apparent.
 Notify the Shell Project Quality Lead and Contract holder in the event Quality issues become apparent during either qualification or manufacturing activities.
 Ensures welding parameter checks are properly executed and documented through training lessons and practical hands on application with contractor.
 Monitor all safety aspects of the inspection and NDT works onsite and participate in HSE program at job site.
 Monitor Zinc-Coating process including parameters of the extrusion process and any in process performance tests
 Monitor the heat treatment process of the tubes/welds and associated parameters.
 Ensure that the Suppliers and Sub-Suppliers provide the requisite level of Quality oversight as determined by the Inspection and Test Plans.
 Confirm that all Supplier and Sub-Supplier QC personnel have the correct level of experience and trade qualifications to provide effective Quality Control over the manufacturing and qualification testing.
 Provide weekly site QC progress and compliance reports using the Quality Inspection and Reporting Management System (QIRMS). Reports to include for photographic evidence.

Qualifications:
Candidates shall have:
 Sound knowledge of small bore super duplex and zinc coated super duplex materials and manufacturing process
 Certification as a welding inspector, according to CSWIP, AWS CWI or equivalent with a minimum of 5 years working experience;
 Qualification level II, according to EN 473, SNT-TC-1A, PCN, CSWIP or equivalent for radiographic interpretation, eddy current and ultrasonic inspection methods with a minimum 5 years working experience
 Good and sound understanding of mechanical testing;
Preference will be given to candidates with an ONC or Associates Degree in metallurgy or personnel with an engineering background.
Individuals shall provide to Company, a concise resume/Curriculum Vitae presented in English, and include reference to qualifications/certification such as EN 473, SNT-TC-1A, PCN, CSWIP, CWI and experience with small bore SDSS and zinc coated SDSS materials.
The successful candidate will be expected to have a good understanding and knowledge of current international standards, as described below. Experience is expected in manufacturing and operational activities for seamless and seam welded tubing manufacturing facilities.
Applicant shall be conversant with the latest Quality and Health and Safety standards, and have working knowledge of inspection methodology, practices and procedures.

Specifications – Knowledge of Manufacturing Standards
The candidate shall have at least 5 years experience of the tube manufacturing standards and be familiar with:
ASTM A240 - Standard Specification for Heat Resisting Chromium and Chromium Nickel Stainless Steel Plate, Sheet and Strip for Pressure Vessels;
ASTM A370 – Standard Test Methods and Definitions for Mechanical Testing of Steel Products;
ASTM A480 - Standard Specification for General Requirements for Flat-Rolled Stainless and Heat Resisting Steel Plate, Sheet and Strip;
ASTM A751 - Standard Test Methods, Practices and Terminology for Chemical Analysis of Steel Products;
ASTM A789 – Standard Specification for Seamless and Welded Ferritic/Austenitic Stainless Steel Tubing for General Service;
ASTM A923 – Standard Test Methods for Detecting Detrimental Intermetallic Phase in Wrought Duplex Austenitic/Ferritic Stainless Steels;
ASTM A1016 - Standard Specification for General Requirements for Ferritic Alloy Steel, Austenitic Alloy Steel, and Stainless Steel Tubes;
ASTM B6 - Standard Specification for Zinc;
ASTM B571 - Standard Practice for Qualitative Adhesion Testing of Metallic Coatings;
ASTM E8 - Standard Test Methods for Tension Testing of Metallic Materials;
ASTM E18 - Standard Test Methods for Rockwell Hardness and Rockwell Superficial Hardness of Metallic Materials;
ASTM E92 – Standard Test Method for Vickers Hardness of Metallic Materials;
ASTM E273 - Standard Practice for Ultrasonic Examination of the Weld Zone of Welded Pipe and Tubing;
ASTM E309 - Standard Practice for Eddy-Current Examination of Steel Tubular Products Using Magnetic Saturation;
ASTM E384 - Standard Test Method for Micro-indentation Hardness of Materials ASTM E543-04 Standard Practice for Agencies Performing Non-destructive Testing;

ASTM E426 - Standard Practice for Electromagnetic (Eddy Current)
Examination of Seamless and Welded tubular Products,
Austenitic Stainless Steels and Similar Alloys
ASTM E562 - Standard Test Method for Determining Volume Fraction by
Systematic Manual Point Count
ASME BPVC Section V – Non-destructive examination
ASME BPVC Section IX – Welding and Brazing Qualifications;
SAE AS4059 – Aerospace Fluid Power - Cleanliness Classification for Hydraulic Fluids;

Work Experience:
Its preferred the individuals shall have a minimum of 5 years manufacturing, inspection and test experience in the manufacturing of Nitronic 19 D, UNS S32750 and UNS S32760 materials. Additionally individuals shall possess some back ground in extruded coatings.
The candidate shall have functioned as an in plant inspector during the manufacture of steel tubing or have been employed as a Company surveillance inspector preferably with knowledge of the fabrication processes of; Seacat Corporation (Houston USA), Gibson Tubes (New Jersey USA). Sandvik Steel (Czech Repubilc, Sweden & Canada) and Sumitomo Metals (Japan), Schoeller Bleckmann Tubacex, Webco Industries, Salem Tube.
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