Throughout my career, I’ve delivered technical leadership across diverse, high-stakes projects where precision and reliability are non-negotiable. Below are examples of the work I’ve contributed to in welding engineering, metallurgical analysis, and quality systems development.
Each project demonstrates problem-solving under pressure, technical depth, and the ability to deliver results that meet or exceed industry standards.
Client: Major Offshore Operator
Role: Welding Engineer
Duration: 2014-2015
Location: Houston, TX & Global Fabrication Sites
Challenge:
No existing U.S. industry standard for reel-lay CRA-lined pipe girth welding created qualification uncertainty and increased project risk for deepwater pipeline installations.
Approach:
Working under the direction of the project’s Principal Welding Engineer, contributed to the development of a comprehensive project-specific welding specification. Participated in defining joint design, consumable requirements, mechanical testing protocols, and inspection acceptance criteria. Collaborated across materials engineering, welding, and QA teams to ensure global supplier and consumable compliance. Supported procedure qualification testing coordination at multiple international facilities.
Result:
The specification filled a critical industry gap and directly influenced revisions to DNVGL-ST-F101, with several clauses now reflecting the original language and approach. This work became the model for subsequent deepwater CRA-lined pipeline projects, improving weld consistency, reducing qualification turnaround time, and ensuring fit-for-purpose performance across the industry.
Technical Details: DNVGL-ST-F101 compliance, API 1104 integration, CRA materials (Inconel 625, 316L SS), mechanized GTAW, qualification testing across multiple global fabrication yards.
Clients: TransCanada (Keystone & Keystone XL), Enbridge, El Paso, BP Americas, Petrobras, Apache Energy, Florida Gas Transmission, Hess, and others
Role: Lead Welding Engineer
Duration: 2008-2012
Company: Serimax NSA, Houston, TX
Challenge:
Major pipeline operators and offshore producers required qualified automated and mechanized welding procedures for high-strength steels (X42-X80) across diverse onshore and offshore applications. Projects ranged from large-diameter onshore transmission pipelines to offshore spoolbase production with demanding specifications and tight schedules.
Approach:
Developed and qualified welding procedures for onshore and offshore pipeline projects spanning North America, South America, and Australia. Led procedure development for TransCanada’s Keystone pipeline system (including Keystone XL), qualifying procedures for diameters ranging from 30″ to 36″ with wall thicknesses up to 15.8mm. Managed automated GMAW, GTAW, and SAW qualification programs for clients including Enbridge (42″ diameter), El Paso (30-42″ diameter), and BP Americas.
Coordinated onshore landline production monitoring and offshore spoolbase production support across multiple projects simultaneously. Developed procedures for challenging applications including sour service environments, fatigue-sensitive designs, and high-production spoolbase operations. Provided technical troubleshooting during production phases, managed welder qualifications, and tracked performance data across domestic and international projects.
Result:
Successfully qualified procedures enabling high-production pipeline fabrication for some of North America’s most significant energy infrastructure projects. Delivered procedures for projects totaling over 150 kilometers of pipeline across multiple operators. Developed expertise in both onshore automated welding (Keystone, Enbridge, El Paso systems) and offshore spoolbase operations (Petrobras, Apache Energy, Hess projects) that proved critical during subsequent post-Deepwater Horizon work under heightened regulatory scrutiny.
Representative Projects:
TransCanada Keystone XL: 36″ diameter, X70 grade steel, 154km onshore transmission
Enbridge Line 42 US: 42″ diameter, X70 grade steel, 50 miles onshore
El Paso Elba Express: 30-42″ diameter, X70 grade steel, onshore transmission
Petrobras Cascade A FSHR: Free standing hybrid riser, offshore spoolbase, sour service
Apache Energy Devils Creek: 16″ diameter, X65 grade, 91km flowline (Australia)
Florida Gas Transmission PHB: 30″ diameter, X70 grade, onshore transmission
Hess Tubular Bells: Offshore spoolbase, fatigue-sensitive and workmanship-critical applications
Technical Details: Automated GMAW (single & dual torch), automated STT GMAW, pulsed GMAW, automated GTAW, SAW processes on X42-X80 grade steels, onshore landline and offshore spoolbase applications, sweet and sour service environments, free standing hybrid risers, SCR (steel catenary risers), fatigue-sensitive and workmanship-critical designs.
Clients: Hess Corporation (Tubular Bells), Deep Gulf Energy (Kodiak)
Roles: Welding Engineer → Spoolbase Site Project Engineer → Spoolbase Site Lead
Duration: 2012-2016
Locations: Houston, TX; Mobile, AL; Global Fabrication Sites
Challenge:
Support welding engineering and site operations for major offshore projects during period of unprecedented regulatory scrutiny following Deepwater Horizon incident. Projects required flawless execution across multiple domestic and international fabrication vendors.
Approach:
Progressed from welding engineer supporting procedure development and vendor oversight to spoolbase project engineering and site leadership roles. Working under senior engineering direction at Hess, developed expertise in offshore welding operations, then applied that foundation at Deep Gulf Energy in increasingly responsible positions. Reviewed and supported approval of procedures, inspection plans, and technical queries across global sites. Managed inspection teams and coordinated with EPC management during spoolbase operations. Provided technical troubleshooting for complex welding qualification challenges.
Result:
Successfully supported delivery of compliant subsea systems under accelerated schedules and heightened regulatory oversight. Contributed to maintaining quality and safety performance while coordinating multiple vendors. Demonstrated rapid learning and progression from engineer to site leadership within 4 years across two major projects.
Client: U.S. Department of Energy
Role: Third-Party Inspector
Duration: 2021-2023
Company: CTLGroup, Skokie, IL
Location: Southwestern United States
Challenge:
Provide independent third-party inspection and verification of stress corrosion cracking repairs on high-temperature thermal energy storage tanks at a Department of Energy facility. Repairs required validation to ensure continued safe operation of critical energy storage infrastructure.
Approach:
Served as independent third-party inspector conducting on-site oversight of repair activities on molten-salt storage systems. Reviewed welding procedures and qualification records, monitored repair execution, and performed fitness-for-service assessments. Coordinated with facility engineers and DOE representatives to ensure compliance with federal facility requirements and project specifications.
Result:
Successfully validated repair integrity and confirmed system readiness for continued service. Demonstrated capability to work within government facility frameworks and handle high-consequence inspection responsibilities. Expanded professional experience into DOE facility support and high-temperature materials applications.
Technical Details: Stress corrosion cracking (SSC) evaluation, molten salt storage systems, high-temperature materials, fit-for-service analysis, DOE facility compliance, repair verification and documentation.
Clients: Industrial, Infrastructure, Legal Sector
Role: Senior Materials Consultant
Duration: 2021-2023
Company: CTLGroup, Skokie, IL
Challenge:
Conduct root cause failure analyses for high-reliability systems supporting litigation, insurance, and warranty claims. Investigations required definitive technical conclusions backed by rigorous testing and analysis.
Approach:
Led forensic investigations of weld failures, corrosion mechanisms, and material degradation using SEM, XRF, FTIR, and metallographic analysis. Evaluated fracture surfaces, identified failure modes, and determined root causes. Produced detailed technical reports for attorneys, insurance adjusters, and engineering firms. Maintained clear communication with clients and legal stakeholders throughout investigation process.
Result:
Successfully managed and executed over $500K in consulting projects during first year, demonstrating capability to deliver complex metallurgical investigations for high-stakes legal and insurance matters. Provided defensible technical analyses that supported resolution of disputes involving weld failures, material defects, and corrosion-related failures across industrial and infrastructure sectors.
Technical Details: SEM/EDS analysis, XRF, FTIR, metallography, microhardness testing, fracture mechanics, corrosion analysis, hydrogen damage evaluation, expert witness support, litigation documentation.
Clients: INTECSEA (Worley), Master Marine
Roles: Client Inspector, Client Representative
Duration: 2017-2018
Locations: International fabrication sites
Challenge:
Provide independent quality oversight for offshore pipeline and structural fabrication across multiple international vendor facilities, ensuring compliance with project specifications and industry codes.
Approach:
Conducted supplier quality audits and welding inspection oversight at global fabrication yards. Monitored production welding, NDE operations, and documentation processes. Identified and escalated nonconformances early to prevent downstream impacts. Coordinated with project QA management and vendors to implement corrective actions and maintain schedule integrity.
Result:
Successfully identified critical welding nonconformance on Sur de Texas pipeline project, preventing significant cost and schedule exposure. Maintained fabrication quality and compliance across multiple international sites while supporting aggressive project timelines. Strengthened vendor accountability through structured inspection and reporting protocols.
Technical Details: DNV and API standards compliance, international fabrication oversight, welding procedure review, NDE coordination, supplier quality audits, corrective action management.
