Job Description: QA/QC Engineer – Refractory
Job Title
QA/QC Engineer – Refractory
Department
Quality Assurance / Quality Control
Reports To
QA/QC Manager / Project Manager
Job Summary
The QA/QC Engineer – Refractory is responsible for ensuring that all refractory installation, inspection, testing, and repair activities comply with project specifications, client requirements, applicable codes, and quality standards. The role involves monitoring construction activities, preparing quality documentation, conducting inspections, and coordinating with clients, contractors, and third-party inspectors to ensure high-quality refractory work.
Key Responsibilities
- Develop and implement Project Quality Plans (PQP), Inspection and Test Plans (ITP), and quality procedures for refractory works.
- Review project specifications, drawings, method statements, and quality requirements.
- Inspect refractory materials upon receipt to verify compliance with approved specifications and material certificates.
- Monitor refractory installation activities, including:
- Brick lining
- Castable installation
- Gunning
- Ramming
- Ceramic fiber installation
- Anchoring systems
- Ensure proper surface preparation, mixing, placement, curing, and dry-out procedures are followed.
- Conduct in-process and final inspections in accordance with project quality plans.
- Coordinate inspections with clients, consultants, and third-party inspection agencies.
- Prepare and maintain quality documentation, including:
- Inspection reports
- Material Receiving Inspection Reports (MRIR)
- Request for Inspection (RFI)
- Non-Conformance Reports (NCR)
- Corrective and Preventive Action Reports (CAPA)
- Punch list clearance reports
- Monitor calibration status of inspection and testing equipment.
- Verify material traceability and maintain quality records.
- Identify quality issues and recommend corrective actions.
- Participate in internal and external quality audits.
- Ensure compliance with applicable standards such as ASTM, API, ISO 9001, and client specifications.
- Coordinate with construction, planning, and HSE teams to ensure quality and safety requirements are met.
- Support project completion through final documentation and turnover dossiers.
Required Qualifications
- Bachelor's Degree or Diploma in Mechanical Engineering, Materials Engineering, Metallurgical Engineering, or a related discipline.
- 3–10 years of experience in QA/QC for refractory installation in refineries, petrochemical plants, steel plants, cement plants, power plants, or industrial furnaces.
- Certification in QA/QC or NDT is an advantage.
- ISO 9001 Internal Auditor certification is preferred.
Technical Skills
- Knowledge of refractory materials and installation methods.
- Familiarity with ASTM, API, ISO, and client quality standards.
- Experience in inspection of:
- Dense castables
- Insulating castables
- Fire bricks
- Ceramic fiber modules
- Monolithic refractories
- Ability to interpret engineering drawings and technical specifications.
- Knowledge of dry-out procedures and refractory testing.
- Experience preparing QA/QC documentation.
- Proficiency in Microsoft Office and quality documentation software.
Soft Skills
- Strong attention to detail.
- Excellent communication and reporting skills.
- Problem-solving and analytical abilities.
- Teamwork and coordination skills.
- Ability to work under pressure and meet project deadlines.
Preferred Experience
- Experience in EPC projects.
- Experience with refinery shutdowns/turnarounds.
- Familiarity with international clients such as Saudi Aramco, ADNOC, QatarEnergy, Shell, ExxonMobil, or similar organizations.
- Experience working with third-party inspection agencies.
Key Performance Indicators (KPIs)
- Compliance with project quality requirements.
- Reduction in NCRs and rework.
- Timely completion of inspections and documentation.
- Successful client quality audits.
- Zero quality-related project delays.
- Complete and accurate quality records.
Working Conditions
- Site-based work in refineries, petrochemical plants, steel plants, power plants, cement plants, and industrial furnace projects.
- May require shift work, overtime, shutdown, or turnaround support.
- Compliance with all site HSE and quality requirements.
