Senior Engineer- Quality Assurance & Quality Control

Position Title: Senior Engineer – Quality Assurance & Quality Control (Fabrication)

Department: Quality Management – Structural & Fabrication

Industry: Heavy Engineering / Transformer Manufacturing

Experience: 4 to 7 Years

Location: Ghaziabad

Education: Diploma/ B.Tech in Mechanical Engineering / Production Engineering

Job Purpose

The Senior Quality Engineer (Fabrication) will be responsible for ensuring the structural integrity, dimensional accuracy, and surface finish of Transformer Tanks, Conservators, Radiators, and Marshalling Boxes for both Distribution and Power/EHV Transformers. This role focuses heavily on welding quality, leak-proof integrity, and anti-corrosive surface coatings to withstand harsh field environments.

Key Responsibilities

1. Welding Quality & NDT (Non-Destructive Testing)

• Oversee and validate all welding processes (MIG/TIG/SAW), ensuring complete adherence to WPS (Welding Procedure Specification) and WPQR (Welding Procedure Qualification Record).
• Conduct and interpret Non-Destructive Testing (NDT) including Dye Penetrant Testing (DPT), Magnetic Particle Testing (MPT), and Radiographic/Ultrasonic Testing on critical load-bearing weld joints.
• Monitor welder performance, maintain qualified welder matrices, and conduct periodic structural audits.

2. Structural Integrity & Leakage Testing

• Establish rigorous inspection protocols for Vacuum Tests and Pressure Tests on finished transformer tanks to guarantee 100% leak-proof performance under extreme EHV conditions.
• Supervise dimensional inspections of complex fabrication assemblies against structural drawings, ensuring strict tolerance control for bush-mounting flanges, turret alignments, and core-holding structures.

3. Surface Preparation & Coating Quality

• Monitor shot-blasting / grit-blasting processes to ensure the required surface roughness profile (e.g., Sa 2.5 standards).
• Audit and validate the chemical pre-treatment and painting/powder-coating processes.
• Ensure precise measurement of Dry Film Thickness (DFT), adhesion tests (Cross-hatch), and holiday testing to guarantee long-term corrosion resistance against environmental weathering and hot transformer oil.

4. Supplier Quality & Defect Resolution (RCA)

• Inspect incoming raw materials including heavy structural steel plates, pipes, gaskets, and outsourced fabricated components (like radiators or conservators).
• Spearhead Root Cause Analysis (RCA) using 8D, 5-Why, and Fishbone diagrams for fabrication defects like oil leakages, weld distortion, blowholes, or paint peeling, and implement effective CAPA.

Technical Requirements & Competencies

• Core Domain Expertise: Deep knowledge of steel fabrication, heavy welding metallurgy, and pressure vessel manufacturing concepts.
• Certifications (Preferred): AWS / CSWIP 3.1 Certified Welding Inspector and ASNT Level II in NDT methods (PT, MT, UT, RT).
• Standards Awareness: Strong familiarity with welding and structural standards such as ASME Section IX, AWS D1.1, and ISO 3834.
• Drawing Literacy: Advanced proficiency in reading and interpreting complex engineering fabrication drawings, GD&T (Geometric Dimensioning and Tolerancing), and welding symbols.