Job Summary
We are seeking a highly experienced QA/QC Manager to oversee all quality assurance and quality control activities for a major Combined Cycle Power Plant (CCPP) conversion project in Kirkuk, Iraq.
The project involves converting an existing simple-cycle power plant, comprising two Siemens SGT5-4000F gas turbines, into a combined-cycle facility through the installation of Heat Recovery Steam Generators (HRSGs), a steam turbine, an Air-Cooled Condenser (ACC), and associated balance-of-plant systems.
The successful candidate will be responsible for implementing and managing the Project Quality Management System across construction, installation, pre-commissioning, commissioning, and final handover.
The role requires extensive experience working directly with EPC contractors on power generation projects, particularly combined-cycle power plants, HRSG installation, steam turbine erection, brownfield modifications, and commissioning activities.
The QA/QC Manager will ensure compliance with contractual requirements, international engineering standards, client specifications, and applicable regulatory requirements while managing the quality performance of multiple subcontractors and equipment vendors.
Key Responsibilities
- Quality Management & Compliance
- Develop, implement, and maintain the Project Quality Plan (PQP) and site-specific QA/QC procedures.
- Ensure all construction, installation, testing, and commissioning activities comply with EPC contractual requirements, approved specifications, and applicable international standards.
- Review and approve subcontractor Quality Plans, Inspection and Test Plans (ITPs), method statements, and inspection procedures.
- Establish quality inspection processes, documentation systems, reporting structures, and approval workflows.
- Conduct regular quality audits and ensure effective implementation of ISO 9001 quality management requirements.
- Coordinate with the client, engineering consultants, subcontractors, and third-party inspection agencies.
- Construction & Installation Quality Control
- Supervise and monitor quality activities across civil, structural, mechanical, piping, electrical, and instrumentation works.
- Oversee inspections related to foundations, concrete works, structural steel erection, equipment installation, alignment, and grouting.
- Ensure quality compliance during HRSG erection, steam turbine installation, ACC installation, piping fabrication, and mechanical assembly.
- Monitor welding activities, including Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), welder qualifications, PWHT, NDT, and pressure testing.
- Ensure material identification, traceability, preservation, storage, and inspection requirements are maintained.
- Verify the calibration and certification of inspection, measuring, and testing equipment.
- Brownfield Modifications & Plant Tie-ins
- Manage quality requirements associated with modifications and tie-ins to existing operational power plant facilities.
- Ensure compliance with approved shutdown procedures, permit-to-work systems, isolation requirements, and technical specifications.
- Review inspection and testing requirements for mechanical, electrical, instrumentation, DCS, switchyard, and utility tie-ins.
- Verify completion of quality inspections and testing before systems are returned to operation.
- Maintain proper documentation of existing plant conditions and interface modifications.
- Vendor & Subcontractor Quality Management
- Monitor and evaluate quality performance of construction and commissioning subcontractors.
- Coordinate with international equipment manufacturers and vendor representatives for HRSGs, steam turbines, ACCs, transformers, switchgear, and control systems.
- Ensure vendor installation procedures, technical tolerances, inspection requirements, and acceptance criteria are followed.
- Manage vendor-related quality issues, damaged materials, non-conforming equipment, and corrective actions.
- Coordinate third-party inspections, testing laboratories, factory acceptance testing (FAT), and site acceptance testing (SAT), where applicable.
- Ensure subcontractors maintain adequate QA/QC personnel, inspection resources, and quality documentation.
- Pre-Commissioning, Commissioning & Handover
- Work closely with the Commissioning Manager to ensure quality compliance throughout pre-commissioning and commissioning activities.
- Oversee quality documentation for hydrotesting, flushing, chemical cleaning, steam blowing, loop checking, energisation, and functional testing.
- Verify mechanical completion certificates, inspection check sheets, punch lists, system walkdowns, and turnover packages.
- Ensure all inspection records, testing certificates, and commissioning documentation are complete and traceable.
- Support performance testing, reliability testing, and final system acceptance.
- Coordinate preparation of quality dossiers and documentation required for Initial Acceptance and Final Acceptance.
- Non-Conformance Management & Quality Audits
- Manage Non-Conformance Reports (NCRs), corrective and preventive actions, technical deviations, and concession requests.
- Conduct root cause investigations and ensure timely implementation of corrective actions.
- Plan and execute internal quality audits and subcontractor quality assessments.
- Identify potential quality risks affecting project schedules, costs, safety, and contractual compliance.
- Escalate critical quality concerns to project management and recommend appropriate corrective measures.
- Ensure all NCRs, punch points, and outstanding quality issues are closed before project handover.
- Quality Reporting & Documentation
- Prepare regular quality performance reports, inspection summaries, audit findings, and quality KPIs.
- Maintain complete and auditable project quality documentation in accordance with EPC and client requirements.
- Coordinate with engineering teams on technical queries, field modifications, design deviations, and as-built documentation.
- Ensure inspection records, material certificates, welding documentation, and commissioning reports are properly maintained.
- Support client inspections, external audits, and project acceptance activities.
- Contribute quality-related information to monthly project progress reports and lender reporting requirements.
Qualifications & Experience
Educational Qualifications
- Bachelor's degree in Mechanical, Electrical, or Civil Engineering from a recognised university.
- ISO 9001 Lead Auditor certification – Mandatory.
- Additional inspection certifications such as CSWIP 3.1, CSWIP 3.2, AWS CWI, or equivalent will be an advantage.
