Senior Engineer, Asset Integrity (QA/QC)

Overview

The Senior QA/QC Engineer is tasked with leading the Quality Assurance and Quality Control functions throughout the fertilizer complex at QAFCO. The primary goal is to confirm that all plant assets, materials, machinery, and construction works meet international standards, organizational specifications, and legal requirements across their entire lifecycle. This role ensures procurement, fabrication, welding, construction, inspection, testing, and material quality processes are technically sound while fostering a "Quality at Source" culture to boost asset dependability, mechanical reliability, and process safety.

This position also upholds adherence to ISO/IEC 17020 standards through the implementation and ongoing enhancement of the Inspection Body Management System, facilitating accreditation and effective quality management within Asset Integrity.

Key Responsibilities

• Direct and supervise QA/QC operations across all QAFCO plants for compliance with company, international, and statutory standards.
• Guarantee lifecycle quality assurance by engaging in vendor qualification, reviewing Inspection and Test Plans and quality documentation, and witnessing inspections at shops and sites.
• Collaborate with various departments including Material Management, Mechanical, Electrical, and Instrumentation for vendor qualifications.
• Oversee QA/QC for fabrication, construction, installation, repair, and maintenance of static equipment and piping, ensuring adherence to procedures, codes, and contracts.
• Manage welding quality by verifying Welding Procedure Specifications, Procedure Qualification Records, welder qualifications, and NDE requirements; approve contractors' welding documentation.
• Coordinate inspections with third-party agencies, contractors, and vendors including factory acceptance tests and site inspections based on ITP protocols.
• Control quality of incoming materials and spare parts by reviewing certifications, verifying specification compliance, maintaining traceability, and reporting discrepancies.
• Exercise judgement on specification deviations and conduct mock tests if necessary.
• Monitor repair and integrity of pressure equipment and piping per applicable standards such as ASME PCC-2, to maintain mechanical integrity.
• Manage inspection, testing, and certification of pressure relief devices, leveraging Risk-Based Inspection strategies to optimize inspection frequency and scope.
• Ensure compliance with regulatory requirements including Radiation Protection licensing and Ministry regulations.
• Maintain and calibrate inspection tools and instruments to assure accuracy and availability.
• Develop and enhance QA/QC procedures, inspection records, and electronic management systems for effective asset integrity oversight.
• Implement and continuously improve ISO/IEC 17020 Inspection Body Management System, conduct internal audits, support accreditation, and ensure compliance.
• Work closely with Operations, Maintenance, Projects, Procurement, Supply Chain, and Asset Integrity teams to promote a culture emphasizing quality, process safety, and mechanical integrity while driving ongoing improvements.
• Provide expertise in materials engineering, corrosion, welding, inspection methodologies, and damage mechanisms; support engineering evaluations and quality improvement initiatives.
• Review metallographic samples and replica preparation.
• Participate in root cause failure analyses.
• Mentor and develop inspection staff and trainees through coaching, knowledge transfer, and technical support to enhance team capabilities.
• Strictly adhere to QAFCO's Occupational Health, Safety, Environment and Quality (OHSEQ) protocols, company policies, and regulatory and safety standards.

Candidate Profile

• Bachelor’s degree in Mechanical or Metallurgical Engineering from an accredited university.
• Extensive experience of 10 to 15 years in a similar functional role within fertilizer, petrochemical or oil and gas sectors.
• Professional certifications such as ASME Authorized Inspector, Welding Inspection Certifications (CSWIP 3.2, AWS, or equivalents), and relevant API certifications including API 510, 570, 653, and 580 In-service inspection.