Chemical and Mechanical Testing

Perform chemical and mechanical tests to verify material strength and durability in fabricated and FRP components, such as nacelle covers, blade skins, and structural supports. Analyze test results for tensile strength, elasticity, and fatigue resistance, ensuring compliance with specifications for WTG components subjected to high wind and operational loads. Ensure traceability and accuracy of material compositions for critical parts through chemical analysis, identifying any impurities that may impact long-term performance.

Corrosion Protection Systems Inspection

Conduct inspections of corrosion protection applications, ensuring that coatings on fabricated and FRP parts meet standards for offshore and coastal installations. Evaluate coating thickness and adhesion to critical components like tower sections and nacelle frames, confirming their durability in harsh environmental conditions. Document corrosion protection system compliance, focusing on areas where protection ensures the structural integrity of the blades, tower, and hub.

Dynamic Modeling and Simulation Support

Apply insights from dynamic modeling and simulations to assess the performance of fabricated and FRP components under operational stresses and environmental conditions. Assist in analyzing simulated load distributions on nacelle and blade structures, identifying potential stress points and informing quality enhancement practices. Collaborate with engineering teams to ensure simulation results align with real-world performance standards, optimizing component reliability in WTG operations.

Fabrication Process Quality Assurance

Oversee quality checks throughout fabrication processes for components like nacelle frames, blade roots, and tower sections, ensuring structural precision. Conduct inspections to verify dimensions, weld quality, and alignment, preventing defects that could compromise assembly and operation. Collaborate with the production team to identify and address fabrication inconsistencies, providing feedback to improve quality controls for WTG assemblies.

In-Process Quality Control (IPQC) Implementation

Monitor IPQC activities throughout fabrication and FRP processes, ensuring adherence to checkpoints for blade skins, tower segments, and nacelle components. Conduct in-line inspections to detect surface or structural defects early, facilitating timely corrective actions and maintaining quality throughout production.

Machining Process Compliance

Inspect machining quality on fabricated components such as tower flanges, nacelle mounts, and blade attachments to ensure precise tolerances are met. Oversee post-machining inspection processes, addressing any dimensional discrepancies to guarantee compliance with specifications for turbine assemblies. Document machining results and collaborate on process adjustments as needed, ensuring consistency in part quality for the assembly of blades, hubs, and towers.

Manufacturing Processes - Forming Quality Assurance

Conduct quality checks on forming processes for FRP and fabricated parts, such as tower segments and nacelle covers, ensuring materials conform to required shapes and strengths. Verify forming precision in components subjected to dynamic stresses, helping prevent structural failures within turbine assemblies. Work with the manufacturing team to address forming inconsistencies, recommending adjustments to reduce waste and enhance production quality.

Metallurgical Analysis and Material Integrity Verification

Perform metallurgical analysis to inspect grain structure and assess the structural suitability of metals used in fabricated and FRP components. Conduct microstructural evaluations for critical areas like nacelle frames and tower segments, identifying any anomalies like porosity that may compromise component reliability. Provide feedback to suppliers on metallurgical findings, supporting process improvements in material integrity for turbine components.

Non-Destructive Testing (NDT) and Evaluation (NDE) Execution

Carry out non-destructive testing (NDT) methods, such as ultrasonic and radiographic inspections, on FRP and fabricated components to detect internal and surface defects. Analyze NDT results for nacelle shells, tower sections, and blade reinforcements, ensuring that parts meet stringent quality standards for operational reliability.

Metrology and Precision Measurement Practices

Use precision measurement tools to verify dimensional accuracy for fabricated and FRP components, such as nacelle mounts and blade root attachments. Ensure calibration and accurate usage of metrology tools, helping maintain close alignment with design tolerances in parts critical to turbine performance. Document and maintain measurement records, supporting traceability and accountability within the quality assurance process for WTG assemblies.

Process Design and Optimization Assistance

Support initiatives aimed at optimizing fabrication and FRP processes, identifying inefficiencies that impact quality control for nacelle, tower, and blade manufacturing. Assist in implementing lean practices within the QA function to reduce process variability, ensuring production consistency and alignment with industry standards. Participate in cross-functional reviews to refine quality standards, enabling effective adjustments in response to process improvements.

Risk Assessment and Management in Fabrication QA

Assist in conducting risk assessments to identify quality risks within fabrication and FRP processes, prioritizing issues that impact nacelle, tower, and blade quality. Implement preventive actions based on identified risks, minimizing the likelihood of defects and failures in critical turbine assemblies. Contribute to risk management plans specific to fabrication QA, ensuring preventive measures support high product reliability in final assemblies.

Technical Documentation and Reporting

Maintain accurate and detailed documentation for quality inspections on fabricated and FRP parts, including reports on NDT, material compliance, and dimensional checks. Prepare records and reports needed for audits and compliance checks, ensuring that WTG components meet industry and regulatory standards. Ensure proper storage of technical documentation for traceability, supporting transparency and accountability in quality assurance processes.

Welding Techniques and Quality Inspection

Conduct inspections on welded joints in fabricated components such as nacelle frames, tower sections, and blade supports, verifying alignment and strength. Evaluate weld quality using visual and NDT methods, ensuring compliance with standards for structural stability within turbine assemblies. Collaborate with welders to address defects, providing feedback on improvements to meet high-quality welding standards in FRP and fabricated structures.

Key Stakeholders - Internal:

Lead - Fabrication & FRP (QA) Fabrication & FRP Engineer (QA) Executive - Casting, Forging & Fasteners (QA) Engineer - Plant (Mechanical) (QA N&H) Engineer - Moulding (QA Blade) Engineer - Finishing (QA Blade) Production - Nacelle & Hub Team Production - Blade Team Central Planning Team Engineering & Services Team

Key Stakeholders - External:

Fabrication and FRP suppliers Inspection and testing service providers

 

Educational Background:

Diploma or bachelor’s degree in mechanical engineering or Materials Science.

Work Experience:

5+ years of experience in inspection and quality control of fabricated and composite components.

Industry Knowledge:

Proficiency in inspection techniques for welded and FRP components in industrial applications.