QAQC Manager

The QAQC Manager is accountable for supervising the quality management processes throughout all project phases, including design, procurement, construction, commissioning, and the handover of Operation and Maintenance manuals. The following outlines the qualifications, roles, and responsibilities for the QAQC Manager for PowerGas pipeline contractors:
Qualifications:
CSWIP 3.1 or AWS-CWI
ASNT Level 2 for RT, UT, MT, PT
Possession of an Engineering degree from a recognized university.
A minimum of 10 years of experience in a QAQC managerial role.
Strong knowledge of ISO standards and project quality plans, with expertise in the preparation of quality control plans.
Experienced in conducting quality assurance audits for both projects and organizations.
Exceptional skills in leading quality meetings and generating comprehensive reports.
Roles and Responsibilities:
Quality Assurance Planning
Develop and implement the Quality Management System (QMS) for the pipeline project.
Define quality policies, objectives, and procedures.
Create a Quality Control Plan (QCP) and Inspection and Test Plans (ITP) for each project phase.
Establish a Document Control System for managing technical documents, drawings, and standards.
Ensure that contractual quality requirements are clear and understood by all stakeholders.
Stakeholder Communication and Coordination
Act as the primary point of contact for all quality-related matters between the client, contractors, subcontractors, and regulatory authorities.
Liaise with the project management team, ensuring that quality is integrated into all aspects of the project.
Represent the QAQC function in project meetings, including progress, design, and safety meetings.
Compliance and Documentation Control
Ensure that all aspects of the project comply with international codes and standards (e.g., ASME, API, ISO, etc.) as well as local regulations.
Ensure that all quality-related documents, including inspection reports, test results, and certificates, are properly archived and accessible.
Design and Engineering Review
Collaborate with the design and engineering teams to ensure that designs adhere to the applicable standards and codes.
Participate in design reviews and ensure that potential quality issues are identified and resolved.
Ensure that design drawings are reviewed and signed off by the QAQC team before construction.
Procurement and Vendor Evaluation
Evaluate vendors and suppliers to ensure they comply with quality standards.
Perform quality audits of suppliers and subcontractors to assess their ability to meet the required specifications.
Review and approve material submittals, ensuring they meet the technical requirements.
Ensure that procurement documentation, such as purchase orders and contracts, include the necessary quality-related clauses.
Manufacturing/Fabrication Quality
Vendor Qualification & Audits:
Review and qualify manufacturers and fabricators to ensure their facilities, processes, and quality systems comply with project requirements.
Conduct supplier audits and assess the capabilities of fabricators to meet quality expectations and standards.
Material Specifications & Approval:
Ensure that all materials used in manufacturing and fabrication conform to project specifications, including pipe materials, fittings, valves, and related components.
Review material certificates and ensure proper documentation of material origin, testing, and compliance with relevant codes (e.g. ASTM, ISO).
Manufacturing/Fabrication Process Control:
Review equipment manufacturing documents especially for primary pressurized containment equipment (e.g. pig launcher/receiver, dry gas filter, metering skids), documents such as design, procurement, material handling, fabrication and testing procedures, inspection and test plan (ITP) to ensure compliance to owners’ quality requirements.
Implement and enforce fabrication quality control procedures for all stages of pipe/equipment manufacturing and welding processes.
Verify that welding procedures are in accordance with approved Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR).
Monitor and approve welding inspections, ensuring that appropriate nondestructive testing (NDT) methods (e.g., radiographic, ultrasonic, or magnetic particle) are applied and results are satisfactory.
Conduct regular audits and inspections of fabrication shops to ensure compliance with quality procedures and safety protocols.
Dimensional Inspections:
Verify dimensional accuracy of fabricated pipes, components, and assemblies to ensure they meet the design and installation tolerances.
Ensure that pipe bending, fittings, and flanges are fabricated according to the drawings and within the specified tolerances.
Coating Quality Control:
Oversee the quality of pipe coating and lining processes (e.g., anti-corrosion coatings, internal lining) during the manufacturing phase to ensure they meet required standards.
Conduct adhesion tests and ensure surface preparation prior to coating complies with the specified standards.
Factory Acceptance Test:
Planning & Coordination: Develop a FAT plan outlining scope, procedures, and testing criteria. Schedule FAT with vendors and ensure alignment with project timelines.
Test Scope: Ensure the test covers performance, safety, dimensional accuracy, and integrity (e.g., pressure, leak tests, function tests).
Documentation Review: Review material certificates, inspection reports, and test procedures for compliance with specifications.
Test Execution: Supervise the FAT process, ensuring tests are carried out according to approved procedures and specifications.
Non-Conformance Handling: Identify and address any non-conformities or issues during the FAT, ensuring corrective actions are taken by the manufacturer.
FAT Results Documentation: Document all test results, ensuring compliance with specifications, and generate FAT reports.
Approval & Shipping: Approve equipment for shipment only after successful completion of FAT and resolution of non-conformities.
Collaboration with Procurement: Ensure procurement is informed of the FAT outcomes to proceed with shipping and project integration.
Fabrication Recordkeeping:
Maintain comprehensive records of fabrication activities, including weld maps, inspection reports, and NDT records for future reference and client handover.
Material Handling and Preservation
Receiving and Inspection of Materials:
Ensure that all incoming materials, including pipes, fittings, valves, and construction equipment, are inspected upon receipt.
Verify that materials are accompanied by proper documentation, such as material test certificates, inspection reports, and supplier certificates.
Conduct visual inspections and measure dimensions to confirm that the materials match the project specifications and design.
Verify that materials are free from damage during transportation and ensure appropriate handling procedures are followed.
Material Storage and Handling:
Ensure that materials are properly stored at the fabrication yard or site to prevent any damage or deterioration.
Implement proper storage methods for pipe spools, fittings, valves, and other materials, considering the environmental conditions (e.g., weather, humidity) that may affect material integrity.
Ensure separation of materials by type, ensuring clear identification and access for installation or fabrication.
Maintain proper inventory management and ensure that all materials are tracked and identified by appropriate tags or labels for easy traceability.
Material Preservation:
Develop and implement a material preservation plan that outlines how materials should be handled, stored, and protected against corrosion, moisture, dirt, and other contaminants.
Ensure that protective coatings, wraps, or preservative treatments are applied to materials when necessary (e.g., pipe ends, flanges, fittings).
Manage the preservation of valves and mechanical equipment during storage and transportation to prevent internal corrosion or damage.
Regularly monitor storage conditions to ensure compliance with preservation requirements (e.g., humidity control, temperature, ventilation).
Transportation and Delivery to Site:
Ensure that materials are safely transported to the project site with minimal risk of damage.
Verify that all necessary packaging and securing techniques are in place to prevent movement, corrosion, or damage during transit.
Inspect material delivery to ensure documentation compliance, including bill of lading, inspection certificates, and delivery logs.
Handling of Non-Conforming Materials:
Implement a Non-Conformance Report (NCR) system to document any issues with the materials, such as discrepancies in quality, damage, or deviations from specifications.
Develop and enforce procedures for the segregation of non-conforming materials to prevent their use in the pipeline installation.
Ensure that corrective actions are implemented for any material handling or preservation issues, including the return of non-conforming items to the supplier or corrective repairs if possible.
Traceability and Documentation:
Ensure that all materials used in the construction process are properly traceable, with records maintained throughout the supply chain.
Develop and maintain material control documentation that includes delivery receipts, inspection reports, and material certificates, which are essential for client acceptance and final project handover.
Track and document any changes in material specifications or deviations from the original plan, ensuring proper approval and record-keeping.
Construction Phase Oversight
Ensure that construction activities are executed in compliance with approved plans, codes, and specifications.
Coordinate inspections including submission of NOI (notice of inspection) to Consultant and Client.
Supervise the testing of pipeline materials (welds, coatings, hydrostatic tests, etc.) according to relevant standards.
Review and approve field inspection reports and ensure non-conformities are addressed.
Monitor the quality of welding, including conducting weld inspections and maintaining records.
Oversee non-destructive testing (NDT) activities, including radiography, ultrasonic testing, and magnetic particle testing, to assess weld quality and material integrity.
Site Acceptance Test:
SAT Planning: Develop a SAT plan detailing the scope, procedures, and responsibilities for on-site testing.
Inspection Upon Arrival: Conduct a thorough inspection of materials or equipment upon arrival to ensure no damage or deviation from specifications.
Operational Testing: Test equipment functionality and performance, including calibration, mechanical, and electrical checks.
Compliance Verification: Confirm that installation and operation meet design specifications and safety standards before acceptance.
Documenting Test Results: Document test results, noting any discrepancies or issues and recording resolutions for non-conformities.
Non-Conformance Resolution: Identify non-conformities and track corrective actions through NCRs, ensuring resolution before final approval.
Final SAT Approval: Grant formal acceptance of equipment or materials after successful testing and resolution of any issues.
Coordination with Project Teams: Ensure clear communication with the project team, including any necessary adjustments or repairs identified during SAT.
SAT Report & Documentation: Provide a detailed SAT report for final project documentation and client handover.
Monitoring and Reporting
Develop quality performance indicators (KPIs) and track the performance of the quality processes.
Conduct regular audits and inspections to ensure compliance with the quality plans.
Provide quality reports and updates to senior management and project stakeholders.
Track and report corrective actions and ensure that they are properly implemented.
Training and Team Development
Provide quality training to project personnel, including site workers, supervisors, and engineers.
Ensure all personnel are aware of and understand the quality control procedures and documentation required for the project.
Promote a culture of quality within the project team by encouraging adherence to best practices and standards.
Non-Conformance and Corrective Action
Identify and document non-conformances and deviations from project specifications.
Investigate and determine the root causes of quality issues, then implement corrective and preventive actions.
Maintain a Non-Conformance Report (NCR) system to track and close out quality issues.
Commissioning and Handover
Oversee the commissioning phase to ensure that the pipeline is completed to the required quality standards.
Ensure that all testing and inspection results are documented and comply with specifications before commissioning.
Ensure all project quality documentation is completed and handed over to the client, including test certificates, as-built drawings, and quality records.
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