QUALITY CONTROL LEAD

OBJECTIVES:

This position is accountable for ensuring all quality related activities at construction sites conform to the quality control specifications and the procedures/ programs prepared for the Project based on the contract document and Company Standard.

QA/QC Lead Engineer (Civil/ Structural/ Mechanical/ Piping/ Electrical/ Instrumentation)

1.     Responsible for leading the Flawless and QA/QC effort in the CONTRACTOR's area of responsibility.

2.     Must have more than 15 years’ experience in maintenance WORK in the Petrochemical, Petroleum Refining or Power Generation industry.

3.     Minimum 5 years in QA/QC lead position.

4.     Must have a sound understanding of how a QA/QC structure with embedded lessons learnt can provide the foundations of Flawless Turnaround Execution.

5.     Must be able to read, write and speak English.

6.     Must be able to WORK with computers utilizing Microsoft Windows and Office suite of packages.

7.     Must have a diploma or equivalent in QA/QC Management and working knowledge of ISO 9001-2000 and 14001 systems.

8.     Must be capable of managing and executing QA/QC audits & Quality Plan.

9.     Must be capable of developing and interpreting the QA/QC related procedures and guidelines and actively pursue all staff to adhere to the QA/QC standards.

10.  Must be capable of training staff in QA/QC procedures.

11.  Must be able to develop reporting for QA/QC statistics, and KPIs.

12.  Must be familiar with the different welding techniques and their quality requirements and Welding approval procedures.

13.  Working knowledge of NDT requirements for Petrochemical or Power Generation industry.

14.  Must have working knowledge of AWS, ASME and ANSI codes.

15.  Preferably have experience in facilitation of Root Cause Analysis.

MAJOR DUTIES:

1.   Quality Planning & System Implementation

·   Develop and maintain the Project Quality Plan (PQP) in alignment with project requirements.

·   Review and approve subcontractor Quality Control Plans.

·   Establish project-specific Inspection & Test Plans (ITPs) and ensure timely approval.

·   Define quality objectives, KPIs, and acceptance criteria for all construction disciplines.

·   Ensure compliance with ISO 9001, project specifications, and statutory requirements.

2.   Document Review & Technical Approvals

·   Review Method Statements, Work Procedures, WPS/PQR/Welder qualifications, and test procedures.

·   Review weld maps

·   Verify engineering drawings are issued for construction (IFC) and updated revisions are implemented.

·   Approve material submittals, certificates, and supplier quality documentation.

·   Validate control measures for welding, concrete, coating, testing, and installation works.

3.   Inspection Activities

a.       Civil & Structural

·     Inspect excavation, forms, rebar installation, concrete placement, curing, cube test and finishing works.

·     Verify structural steel fabrication, erection, bolt tightening, grouting, and alignment.

b.       Mechanical & Piping

·     Verify fit-up, alignment, welding activities, NDT requirements, PWHT, and dimensional checks.

·     Very correct colour coding and ensure proper segregation and storage of different materials.

·     Conduct material receiving inspections for pipes, valves, supports, and equipment.

·     Oversee hydrotests, pneumatic tests, leak tests, flushing, and reinstatement.

c.       Electrical & Instrumentation

·     Support verification of cable routing, cable pulling, termination, grounding, and panel installation.

·     Support Inspection instrumentation installation, tubing, calibration, and loop checks.

·     Support Confirm testing: insulation resistance, high-pot, continuity, pre-commissioning tests.

d.       Testing & Verification

·     Plan and supervise NDT activities (MT, PT, UT, RT, PMI, hardness test, etc.).

·     Coordinate laboratory testing (soil, concrete cube tests, compaction, weld coupons).

·     Verify calibration status of all measurement and inspection tools.

4.   Nonconformance & Corrective Action Control

·  Issue, track, and close NCRs and any site findings.

·     Lead root cause investigations and implement preventive actions.

·     Prepare NCR trend analysis reports for management review.

5.   Quality Documentation & Handover

·     Maintain RFI logs, test packages, inspection records, and traceability documents.

·  Ensure turnover work packages are complete, accurate, and aligned with client requirements.

·     Manage document control for QC records and ensure proper filing.

·  Compile and handover all work packages in overall handover dossier- Mechanical Completion (MC), Ready-for-Start up (RFSU)

6.   Subcontractor Monitoring

·  Evaluate subcontractor QA/QC performance through site audits and surveillance.

·  Ensure subcontractors follow approved procedures and ITPs.

·  Verify competency of subcontractor inspectors and welders (WQT). Track welder rejection rate and implement consequence management on welders with repeated high rejection rate

·  Enforce timely submission of QC reports and documentation.

·  Conduct/arrange training and maintain training/competency record for workers of all trades, e.g. torquer, welder, fitter, insulator, etc

7.   Coordination & Reporting

·  Conduct daily coordination with construction supervisors and engineering teams.

·  Communicate quality issues to the Project Manager and Client Representatives.

·  Prepare daily, weekly, and monthly quality performance reports.

·  Participate in client and third-party audits and respond to audit findings.

·  Lead weekly QA/QC meetings with contractors, subcontractors, and consultants.

·  Track and prepare re-work report. Report to management on any rework on monthly basis.

8.   Team Management

·     Supervise QC supervisor/inspectors

·     Assign daily tasks and ensure inspectors perform required surveillance and inspections.

·     Conduct quality awareness briefings, toolbox talks, and training sessions.

·  Monitor inspector workloads and adjust staffing to meet project demands, including fatigue management.

9.   Perform other than the above duties entrusted by the Construction Manager, in respect of the Quality Control matter.

KNOWLEDGE AND EXPERIENCE:

·     Familiar with Piping drawings (Plot Plan, Piping Layout, Piping Isometrics and Pipe Spool drawings), P&I diagram, Line index, Specifications and Procedures, etc

·     Experience on welding inspection of the level of CSWIP (Certification Scheme for Welding Inspection Personnel)

·     Familiar with international codes such as ASME, ANSI, ASTM, NFPA, BS, and Shell’s DEP etc

·     Good common of Microsoft office tools

·     Good communication skills and fluent in spoken & written English

EXPERIENCE:

Minimum 5 years’ experience in the actual job execution of Oil/ Gas/ Petrochemical plant construction, preferable with Plant Turnaround involvement as QC Lead role.

EDUCATION:

·     Bachelor’s degree in engineering or above.

Competency Certification such as CSWIP, AWS, NDE, ASME, NACE or equivalent will be an added advantage.