Senior_engineer_QA_QC_Generator_and_Auxiliaries

Job Purpose

To monitor and ensure quality compliance during manufacturing, inspection, and testing of Generator and its auxiliaries (Excitation System, Seal Oil System, Generator Coolers, Bus Ducts, etc.) being supplied by the EPC contractor and OEM vendors, aligning with the Owners technical specifications, quality standards, and codes.

Key Responsibilities

A. Inspection and Compliance Oversight

• Review and ensure implementation of approved:
• Quality Assurance Plans (QAPs)
• Inspection & Test Plans (ITPs)
• Type test and routine test procedures
• Conduct/witness stage-wise inspections for:
• Generator stator and rotor windings
• Core building, bar insertion, brazing, and VPI (Vacuum Pressure Impregnation)
• Generator auxiliaries like seal oil system, hydrogen/air/water coolers, bus ducts, excitation systems

B. Quality Assurance and Documentation

• Review:
• Material Test Certificates (MTCs)
• Welding and brazing qualifications
• NDT reports (especially for rotor shaft and brazed joints)
• Monitor manufacturing quality control processes for bus duct (isolated phase), excitation cubicles, and control panels.
• Validate FAT records, dielectric testing, thermal cycling test, balance testing, etc.

C. Coordination and Vendor Management

• Interface with vendors/OEMs for adherence to Owner's specifications and technical requirements.
• Coordinate with TPI agencies and ensure timely inspection of hold points.
• Support root cause analysis (RCA) for defects or NCRs, and ensure resolution with effective CAPA (Corrective & Preventive Action Plans).
• Review packing, preservation, and dispatch documentation.

D. Support to Engineering and Procurement

• Participate in technical kick-off meetings, vendor audits, and quality reviews.
• Provide inputs to Owner’s engineering team for any deviations or quality-related concerns.
• Ensure proper alignment of manufacturing timelines with the project schedule.

Required Qualifications

• B.E./B.Tech in Electrical or Mechanical Engineering
• 7–12 years of QA/QC experience in large rotating electrical machinery, including generator manufacturing/inspection
• Familiarity with IEC, IEEE, ISO, and ASME codes related to generator quality and testing
• Experience with major OEMs (BHEL, GE, Siemens, Hyundai, Mitsubishi, etc.) is desirable
• NDT Level II (preferred for rotor shaft inspection), knowledge of HV testing, balance tests

Preferred Skills & Tools

• Deep understanding of generator manufacturing and assembly quality controls
• Familiar with testing practices: HV withstand, insulation resistance, impedance, polarization index, and partial discharge tests
• Skilled in document review, inspection reporting, and QA system audits
• Comfortable using digital quality systems and QA databases

Key Competencies

• High attention to technical and quality details
• Independent judgment and effective decision-making
• Strong communication and vendor engagement skills
• Ability to multitask across multiple vendor locations and technical areas