The Senior QA/QC Engineer is responsible for leading and overseeing Quality Assurance and Quality Control activities across the fertilizer complex to ensure that plant assets, materials, equipment, and construction activities comply with applicable international standards, company specifications, and regulatory requirements throughout their lifecycle. The role provides technical assurance for procurement, fabrication, welding, construction, inspection, testing, and material quality, while promoting a proactive "Quality at Source" culture to enhance asset reliability, mechanical integrity, and process safety.
The position also maintains compliance with ISO/IEC 17020 requirements by implementing and continually improving the Inspection Body Management System, supporting accreditation, and ensuring effective quality management practices across the Asset Integrity function.
Lead and manage Quality Assurance and Quality Control (QA/QC) activities across all QAFCO plants and facilities to ensure compliance with company specifications, international standards, and statutory requirements.
Ensure quality assurance throughout the asset lifecycle by participating in vendor qualification, reviewing Inspection and Test Plans (ITPs), quality documentation, manufacturing procedures, and witnessing shop and site inspections.
Manage the qualification of vendors in co-operation with different stake holders like Material management , Mechanical, Electrical , Instrumentation sections etc.
Oversee QA/QC activities for fabrication, construction, installation, repairs, and maintenance of static equipment and piping, ensuring compliance with approved procedures, codes, standards, and contractual requirements.
Manage welding quality assurance by verifying Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), welder qualifications, and non-destructive examination (NDE) requirements for fabrication and repair activities. Review and approve welding book submitted by contractors.
Coordinate and perform inspections with third-party inspection agencies, contractors, and vendors, including factory acceptance tests (FAT), site inspections according to ITP steps and lifting equipment certification.
Ensure effective quality control of incoming materials, equipment, and spare parts by reviewing material certificates, verifying compliance with specifications, maintaining material traceability, and reporting non-conformities.
Expertise needed to take decisions, if any deviations from the specification and Mock test requirement, etc.
Monitor the repair and integrity of pressure equipment, piping, and static equipment in accordance with applicable codes and standards, including ASME PCC-2, to restore and maintain mechanical integrity.
Manage inspection, testing, certification, and performance evaluation of pressure relief devices, and develop optimized inspection scopes using Risk-Based Inspection (RBI) methodologies.
Maintain compliance with statutory and regulatory requirements, including Radiation Protection licensing and other applicable Ministry requirements.
Maintain, calibrate, and control inspection instruments, tools, and equipment to ensure their accuracy, availability, and compliance with quality requirements.
Develop, maintain, and continuously improve QA/QC procedures, inspection documentation, records, and electronic management systems to support effective asset integrity management.
Implement, maintain, and continuously improve the ISO/IEC 17020 Inspection Body Management System, support accreditation activities, conduct internal audits, and ensure effective implementation of all applicable ISO/IEC 17020 requirements.
Collaborate with Operations, Maintenance, Projects, Procurement, Supply Chain, and Asset Integrity teams to promote a "Quality at Source" culture, enhance process safety and mechanical integrity, and drive continuous improvement initiatives.
Provide technical expertise in materials engineering, selection, corrosion, welding, inspection techniques, and damage mechanisms, while supporting engineering studies, troubleshooting, and quality improvement initiatives.
Shall be able to review metallography and preparation of replica.
Participate in Root Cause Analysis for the failures.
Train, mentor, and develop inspection personnel and trainees through on-the-job coaching, knowledge sharing, and technical guidance to strengthen organizational competency.
Ensure full compliance with QAFCO Occupational Health, Safety, Environment and Quality (OHSEQ) requirements, company policies, and all applicable regulatory and process safety standards.