Lead - Quality Assurance Boiler Area

• Role Summary

Manage and execute all Quality Assurance and Control (QA/QC) functions for the Boiler package, covering pressure parts, structural elements, ducting, instrumentations, BOIs and auxiliaries. The role includes planning, implementation, and monitoring of quality activities during engineering reviews, manufacturing at shop/vendor works and site erection phases. The incumbent will interface with engineering, manufacturing, procurement, site and inspection agencies to ensure compliance with QAPs, Manufacturing Quality Plans (MQPs), Field Quality Plans (FQPs), Welding Procedure Specification (WPS) and statutory regulations (such as IBR). Proficient with the Metallurgies utilized in Ultra-Supercritical Technology.

He will function as the single point of contact for all Boiler-related quality matters across project stages and would report to the Head of QA.

• Key Responsibilities:
• QAP/FQP Implementation & Monitoring
• Develop, review and implement QAPs, MQPs, FQPs and WPS for Boiler systems in coordination with Engineering team, OEMs (for auxiliaries and BOIs) and the other members of the central QA team.
• Ensure that all inspections and hold points are adhered to as per the approved plans.
• Identify quality control checkpoints and ensure rigorous compliance at each stage.
• Manufacturing & Vendor Quality Oversight
• Monitor manufacturing quality at in-house facility (for headers, coils, drums, panels, etc.) and vendor facilities (for Structures, BOIs, etc.).
• Coordinate with in-house QC team and third-party inspection agencies to ensure timely inspections and clearances.
• Validate vendor PQRs for welding-related works; ensure welder qualifications are in place.
• Site Quality Management
• Coordinate with Site Quality team for QA/QC activities during erection & assembly of Boiler components.
• Coordinate with erection contractors, site engineers and third-party inspectors for timely inspection and documentation.
• Ensure compliance with IBR, ASME and project-specific requirements during pressure part installation and testing.
• Non-Conformance & Corrective Actions
• Ensure identification and reporting of non-conformities; lead Root Cause Analysis and ensure closure with corrective and preventive actions (CAPA).
• Maintain NCR logs and ensure their timely resolution and documentation.
• Coordination & Interface
• Work closely with Engineering, Procurement and Project Execution teams to resolve quality issues and drive design conformance.
• Attend client/consultant review meetings and support audits pertaining to Boiler quality.
• Documentation & Reporting
• Ensure proper documentation and traceability of all inspection records, material certificates, and test reports.
• Maintain up-to-date quality dossiers for Boiler system.
• Provide support to Head QA and to Project Management team for ensuring Quality Management of Boiler Area.
• Experience & Expertise:
• Strong experience in QA/QC of Boiler systems in large-scale thermal Supercritical and Ultra-supercritical power projects along-with in-depth understanding of QA/QC processes for Manufacturing of Boiler Components and Equipment.
• Hands-on expertise in pressure part fabrication, welding processes and IBR compliance.
• Proficient with Metallurgies utilized in Ultra-Supercritical Technology.
• Familiarity with relevant standards: IBR, ASME, IS, ISO Standards.
• Experience in managing third-party inspection agencies, vendors, and erection contractors.
• Proficiency in preparing and executing QAPs, Welding Procedure Specification (WPS)/PQRs and inspection checklists.
• Strong documentation and reporting skills; experience in quality dashboards/tools is desirable.
• Experience with digital quality tools, inspection software and quality reporting dashboards is desirable.
• Educational Qualifications:
• B.E. / B.Tech in Mechanical Engineering or equivalent from a recognized university.
• IBR Competency
• Postgraduate diploma or certification in Quality Assurance / Welding Technology (desirable).
• Certifications (preferred):
• ISO 9001:2015 Internal Auditor or Lead Auditor
• NDT Level II (RT, UT, PT, MT)
• ASME / NBIC exposure