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Greg Stark Consultancy
       8808 Bradford St., Denton, TX  76207, USA
       (C) +469-231-1285, (H) +940-262-0384

Objective: Contract consulting position supporting Oil and Gas Corporations for Metallurgical and Welding Engineering

Diversified background in Metallurgical and Welding Engineering, and Quality Engineering in:

       Steel Manufacturing and Fabrication                      Oil & Gas (Sour & Sweet) Prod., Transmsn
       Structural Steel & Aluminum Construction             Gas & Refinery Plants & Equipment (S&S)
       Petrochemical Plants & Equipment                        Marine Hardware
       Subsea Pipelines & Equipment                              Offshore Platforms Construction
       Heat treating Alloy Systems                                  All Major Welding & Brazing Processes
       Aerospace Flight & Transport Hardware              Metallurgical Processing and Coating
       Pipe Manufacturing and Mill Survey                      HFI Pipe Sour Gas Qualification Service
       Vessels & Process Piping                                     Failure Analysis & Investigations     
       Forged Flanges, Fittings & Equipment                  Specification Development            
       Fitness for Service (FSS)                                     Statistical Process Control (SPC)       
       NDE Systems–VT, MPT, DPT, UT, RT, ET       Technical Paper Presentation (NACE)

International Specifications: ABS, AMS, API, ASME, ASTM, AWS, BSI, BV, CEN, DIN, DNV, FED, ISO, JIS,


Greg Stark Consultancy                                                                        Metallurgical & Welding Engineering Consultant
Denton, Texas                                                                                                                                        9/07 - Present
Current & Past Projects:
•        ExxonMobil Development Company Consultant (May, 2012 – December, 2014) – Metallurgy and Corrosion Group,
Houston, for welding engineering support to various project locations such as Barzan, Pt. Thomson, Hebron, Banyu Urip,
Marine Well Containment System, ERHA North Phase 2, SubSea Standardization, Odoptu Stage 2, Damar, as well as on site
project support such as Ulsan, South Korea and Scotland.  Guided EPC/Vendor qualification of Super Duplex Stainless Steel
piping, and API 2W grades and ASTM A514 Grade Q structures for offshore platforms.
•        National Pipe Company Saudi Arabia (Mar., 2012) – Performed consultation and third party Quality and Production
Audit of production facility for compliance with API 5L/ISO 3183 for Saudi Aramco Engineering requirements projects.
•        Red Sea Refining Company (Aug, 2011,-Feb, 2012) – PMT Welding Representative for Yanbu Export Refinery
Expansion Project joint venture previously between Saudi Aramco and Chevron.  EPC2, EPC3 and EPC4 packages, as well
as WASIT Gas Project, all in Seoul, S. Korea.
•        Oil States Industries (2011) – Metallurgical engineering consultation for gas carburization of wire rope traction winch
fabrication using ASTM A131, Gr. EH36 for McDermott vessels.
•        National Pipe Company Saudi Arabia (Jan., 2011) – Performed consultation and third party Quality and Production
Audit of production facility for compliance with API 5L/ISO 3183 and Saudi Aramco Engineering requirements projects.
•        Lan Do Development Project by BP (2010 & 2011) – Reviewed subsea pipeline welding specifications and developed
corrosion testing matrix for 13Cr and Inconel 625 clad X65 pipe joints.  Recommendations accepted by BP prior to EPC bid
•        National Pipe Company Saudi Arabia (May, 2010) – Performed third party Technical Capability Audit of production
facility for compliance with API 5L/ISO 3183 and Saudi Aramco Engineering requirements prior to five year tender agreement.
•        Bergrohr GmbH Siegen (2010) – Conducted specifications review and gap analysis for product development of Berg-
Lay CRS lined pipe in accordance with API 5LD
•        Panhandle Energy (2010) – Phase VIII for Florida Gas Transmission; developing Welding Qualification Matrix and Plan,
and welding procedure qualification review.
•        Technip USA (2010) – Metallurgical & Welding engineering for Jubilee Project offshore Ghana  API 1104, Appendix
A, welding procedures for subsea piping and PLET construction.  (API 5L X52 & X65, ASTM A694 F65, ABS EH36,
EN10025 S275 and S355
•        Oil States Industries (2009) – Metallurgical & Welding engineering consulting for marine winches, structures (ASTM
A514 ABS EH36), and ship equipment and hull attachments  (ASTM A514) for Hatlapa (North Sea vessels) and Atlantico
Sul for Petrobras (ASTM A829 Gr 4130, ABS EH36, ASTM A487 Gr 4 Cls B {8630})
•        Turner Industries Group (2009) – Welding inspection surveillance of fabricated carbon steel and stainless steel pipe
spools for BP refinery upgrade to process sour Canadian Crude Tar Sands.  Included PMI verification for all CRA
components and finished spools
•        Rabigh Refining & Petrochemical Company (2008) – Metallurgical & Welding Fitness For Service assessment prior to
start-up for 2.25Cr and 321 piping for refining section and 316L piping for ethylene and propylene service, Rabigh, Saudi
•        Tatsa Mexico (1994) (now Trinity Industries) – Failure analysis and fabrication improvements for Ammonia
transportation truck tanks and chassis fabrication (ASTM A517 cracking)
•        Litton Precision Gear (1991) – Consultancy for Electron Beam Welding (EBW) support contractor for process
improvement and reliability upgrade.  Assisted client during vendor survey for helicopter transmission gear fabrication.


Diversified background includes metallurgical engineering, welding engineering, and quality engineering in steel manufacturing,
fabrication, construction, heat treating, aerospace flight hardware, and oil and gas production and transmission (sour and
sweet), and refining. Very familiar with all major welding and brazing processes including “hands-on” experience with SMAW,
GMAW, FCAW, SAW, & RSW. Experience includes test bed design, metallurgical processing for many alloy systems,
welding metallurgy, welding technology, metallurgical failure analysis, specifications, SPC, DOE, sampling, and extensive failure
analysis using SEM, mechanical testing, and metallographic techniques. Fabrication of ground based structures, pressure
vessels and systems, maintenance and repair, and welding research experience also included aerospace welding of flight
hardware and ground support equipment. Alloy expertise includes familiarity with processing of most steels and stainless steels,
aluminum, and titanium. Limited experience with copper, nickel, and magnesium alloys. Reviewed, and developed, many
welding procedures in accordance with internationally recognized specifications.  Extensive work included ABS, AMS, API,
ASME, ASTM, AWS, military and federal welding codes and specifications, BSI, BV, CEN, DIN, DNV, JIS, ISO, NACE,
welding procedures for pressure vessel, structural, and aerospace applications. Developed first internationally recognized
qualification system for Electric Resistance Welded (ERW) pipe which supports ASME and API.  Familiar with NDT and
inspection techniques (MT, PT, RT & UT) used on castings, forgings, wrought shapes, weldments, and brazements, and
vibration analysis on rotating equipment.

Saudi Aramco Oil Company                                                                                      Metallurgical & Welding Engineer
Dhahran, Eastern Province, Saudi Arabia                                                                                        8/96 to 9/07 (retired)
Member of Consulting Services Dept., Materials Engineering & Corrosion Control Div., Materials Engineering Unit.
•        Responsible Specifying Authority (RSA) for structural commodities, and fasteners, for buildings and alternate
applications such as Space Frames and scaffolding.
•        Surveyed numerous structural and vessel fabrication vendors both in and out of Kingdom
•        Published NACE White Paper, “Qualification of ERW/HFI Manufactured Pipe for Wet, Sour Crude and Gas Services”
•        Surveyed Enventure Global Technologies for expandable downhole tubulars demonstration at Citra Tubino at Batam
Island, Indonesia
•        Evaluated use of Thermal Spray Coatings (TSC) for corrosion and wear resistance for process piping, vessels, and
structures and published Corrosion Technology Item
•        Surveyed vendor pipe mills & forging factories for compliance with Aramco Standards:
o        Arabian Pipes Co.
o        Saudi Steel Pipe
o        National Pipe Co.
o        Precision Forging Factory
o        British Steel (Corus)
o        Ilva Taranto Steel
o        Mannesmann Pipe
o        Corinth Pipe
o        Volzhsky Steel
o        Vyksa Steel Works
o        SeAH Pipe
o        Nippon Steek
o        Kawasaki (JFE) Steel
o        Sumitomo Pipe
o        Lone Star Steel (USS)
•        Reviewed national and international vendor submitted welding procedures to be in compliance with Saudi Aramco
Engineering Standards and Material Specifications based on international specifications such as ASME, API, ASTM and
•        Working member on various Saudi Aramco Standards Committees for drafting and reviewing specifications
•        Developed first internationally recognized specification and rationale for the qualification and process control of Electric
Resistance Welded (ERW) (including High Frequency Induction Welded (HFIW) line pipe, structural pipe, and OCTG casing
and expandable tubing
•        Conducted numerous failure analyses of components (carbon steel, HSLA, 2.25Cr-1.5Mo, 5Cr, 304, 316, 309, 310,
904L, 256SMo, Duplex, IN600, IN625, IN800, AA6061) throughout the company
•        Performed many material selections, and specified processing requirements, in accordance with company specification
and needs at various plant and processing locations (Upstream production, platforms, mooring piles, well head, subsea rigid
and flexible pipe and flanges, onshore pipelines for sour liquid and gas, pumping stations, separators/slug catchers, gas plants,
refineries, bulk plants, and tankage).
•        $50MM was saved by implementing insitu cement lining process for rejuvenation of fire water piping systems rather than
full replacement
•        Served on various Value Engineering committees with approved vendors for improvements to company specifications
(typical savings: $5 - $50MM).
Publications:  Qualification of ERW/HFI Manufactured Pipe for Wet, Sour Crude and Gas Services – NACE MECC10

Raytheon Engineers and Constructors, EBASCO Div.                                                                     Principle Engineer
NASA/JSC Houston, Texas                                                                                                                            3/90 – 8/96

Metallurgical, Welding, and Quality Engineer in Special Processes Group providing technical support to NASA directorates
and contractors.
•        Lead engineer for Safety, Reliability and Quality Assurance Department when required
•        Materials selections, metals processing, heat treating, and welding engineering for:
o        Fabrication of ground support equipment structures,
o        Ground based pressure vessels and pressure systems,
o        Facilities construction,
o        Human-rated training hardware, and
o        Flight and Space hardware
•        Qualified and published several orbital arc tube welding (GTAW) procedures (210 welded joints) using 304L, 316L and
Inconel 718 tubing for the Special Apparatus For EVA Rescue (SAFER) for manned maneuver in space
•        Developed and qualified numerous other welding or brazing procedures and personnel performance tests in support of
MIL-STD-1595A, MIL-STD-2219, MIL-W-6858, ASME Section I, IV, VIII and IX, B31 .1, B31 .3, B31 .5, B31 .9 and
AWS B2.1, and B2.2, Cl .1, C3.4, C3.6, C3.7, Dl .1, Dl .2, Dl .3, and D9.1
•        Earned NASA Manned Flight Awareness Award while member of failure investigation team of leaking Space Shuttle
high pressure helium tanks
•        Specified and directed welding repair of aluminum motion base flight simulator for astronaut training
•        Developed and implemented framework for Space Center-wide welding program formally endorsed by NASA
Engineering for all hardware built by or for Johnson Space Center
•        Performed metallurgical failure analysis and evaluations on ground based assemblies

McDonnell Douglas Helicopter Co. (now Boeing)                                                                Member Technical Staff Ill
Mesa, AZ                                                                                                                                                       12/84 - 2/90

One of several welding engineers responsible for metallurgical and welding engineering and processing technology with special
emphasis on welding – SMAW, GTAW, GMAW, RW, TB, FB, EBW, Friction Welding, electrical soldering for AH-64
Apache Attack Helicopter and MD50 Commercial Helicopter
•        Material selection and regulations for Design, Manufacturing, Product support, and Vendor support – E4130 and
AA6061-T6, AA6063-T6 transportability equipment, 6Al-4V-Ti tubing, Magnesium transmission cases, AA2024 and
AA7075 fuselage, E4340 armor, landing gear, and ballistic tolerant flight hardware, 25mm & 30mm Chain-guns and ordnance
structures, 15-5PH ammo carriers, 17-7PH springs, 13-8PH fasteners,  and MP35N forged rotor blade knuckles
•        Member Conceptual Design Team for MD50 NOTAR (No Tail Rotor) patented design
•        Surveyed many vendors for acceptance to approved vendor list – Welded, Brazed, and Heat Treated subassemblies
•        Optimized Electron Beam Welding (EBW) at approved vendors for fabrication of rotor drive transmission helical gear
(carburized E9310).
•        Performed numerous failure analysis using SEM and metallographic techniques on airframe, drive train, ordnance, and
ground support equipment
•        Demonstrated significant program savings by developing GTAW repair of rejected EB welded and carburized 9310
steel helicopter transmission gears while maintaining optimum metallurgical properties
•        Evaluated fabrication procedures and inspection results for transmission test stand oil piping system built to ASME B31.
1, and recommended vendor corrective action
•        Responsible for supervision of all process procedure qualification (MIL-STD-2219), and personnel performance
qualification (MIL-STD-1595), activities for welding, brazing, and thermal spraying for wear pads

ARMCO, Inc. (now AK Steel)                                                                                              Research Welding Engineer
Middletown, OH                                                                                                                                            5/81 - 11/84

Responsible for process and product development and technical services for many product lines at various corporation plant
locations throughout the country:
Product Support -
•        Technical direction of welding wire product line from melting, rolling, wire drawing and coating, and product qualification
to AWS A5.17 and A5.28
•        Responsible for ASME Section IX welding procedures to qualify each production batch of weld wire to AWS, and
demonstration of weld wire or plate product ability to meet fabrication and heat treatment requirements for ASME vessel and
piping applications
•        Supported numerous corporate products –
o        Steel plate products for storage tanks (API 12D)
o        Vessel fabrication (ASME) and seamless pipe for other ASME and API assemblies
o        Structural construction projects (AWS D1.1, D1.3, D1.6)
o        Line pipe (API 5L) and Well casing (API 5D)
o        GTA welded stainless piping (API 5CRA) for refinery applications
o        Drill through equipment (API 16A) and Well head equipment (API 6A)
Research Activity -
•        Developed a forgeable, heat treatable, NACE accepted (MR0175), high strength, high toughness (-50 F) weld wire
(GTAW, GMAW, SAW) for ASME and API applications such as, vessels, piping, forged and heat treated fittings, and valve
•        Qualified MIL¬100S-1 GMAW and SAW wire for Navy QPL to MIL-E-23765/2 for fabrication of HY-80 plate for
submarine hulls
•        Developed detailed welding procedures for:
o        Specialized FCAW nickel alloy (Udamet 720) overlay of rotary forging dies
o        Wire and strip SAW overlay of plate, vessels, and concast rolls
o        GTAW procedures for tool steel reclamation in machine shops
o        Developed and implemented heat straightening and repair welding procedures for cast iron coke oven doors
o        Overlay welding for reclamation of Eddy Current Brake motors
•        Developed proprietary coated SMAW electrode for repair welding of 3l6L piping for pulp and paper industry
•        Served on various AWS sub-committees and published numerous corporate welding procedures to AWS and ASME
•        Assisted during personnel performance qualifications and welding procedure qualifications at Middletown Works for
new blast furnace construction project

ARMCO, Inc. (now AK Steel)                                                                                                        Product Metallurgist
Kansas City, MO                                                                                                                                            6/69 - 5/81
•        Resident plant welding metallurgist supervised Metallurgical Services Group.
o        Responsible for Structural Steel Bar Joist and Joist Girder Quality Assurance program
o        Incorporated SPC and DOE on in-coming structural materials and production process for improved strength and quality
assurance of final joist and girder product line, which demonstrated real savings and a significant drop in rejections.
o        Joist customer complaints and process quality audits
o        Qualified all structural production welders to AWS D1.1
o        Designed, built, and directed use of testing fixture for steel joist qualification load testing program to demonstrate Steel
Joist Institute compliance of new and existing product designs
o        Maintenance and repair welding engineering support to plant operations machinery components
o        Vibration analysis of operations rotating equipment
o        NDT services (VT, MT, PT, UT) during annual plant maintenance shut downs
o        Directed NDT evaluation and repair of all defective transverse box girder welds in plant overhead cranes
•        Product metallurgist for fabrication and testing of wire rope, concrete post-stressing wire and strand, and spring wire
•        Product metallurgist for hot rolled products: Blooming mill, Merchant bar and structural shapes mills, Rod mill
•        Associate product metallurgist in Electric Furnace steel making and hot rolling facilities for product and process

Professional Engineer (Metallurgical Engineering)   Missouri, No. 15896 (Inactive)
-        Ohio, No. 046577 (Inactive)

ASQC Certified Quality Engineer - No. 31523 (inactive)
AWS Certified Welding Inspector- No. 91040411 (ASME Sec. VIII & API 1104) (inactive)
ASNT - Certified Level II UT inspector per SNT-TC-1A (inactive)

American Society for Metals - Member, Secretary (1976)
American Welding Society - General Member and previous Committee (C7B & D17) member
American Society for Quality Control - General member

1969        Colorado School of Mines; Golden, CO; Prof. Degree (BS), Metallurgical Engineering
1976        Raytown Vocational School, Raytown, MO; Certified Welder in SMAW, GMAW

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