QUALITY ASSURANCE & INSPECTION

BEST PRACTICES IN QUALITY ASSURANCE & INSPECTION IN NTPC

QUALITY ASSURANCE & INSPECTION

DEVELOPMENT OF QA&I IN NTPC

1975-1980
THE INFANCY : DEVELOPMENT OF STRONG BASICS

1980-1990
ESTABLISHING MATURE SYSTEM. IMPLEMENTATION OF SAME IN POWER PLANTS

1990-1995
ENTRY INTO BULK O&M PHASE OF PLANTS. STRONG BASE OF FQA

1995-2004
AMBITIOUS GENERATION AND CAPACITY ADDITION PLAN. STRONG BASE OF FQA, RIOs & CQA

QUALITY ASSURANCE & INSPECTION

QUALITY ASSURANCE
CONCEPTS

QUALITY ASSURANCE & INSPECTION

QUALITY
QUALITY

IS

FITNESS
FOR

USE

QUALITY ASSURANCE & INSPECTION

QUALITY
THE TOTALITY OF FEATURES AND CHARACTERISTICS (ATTRIBUTES) OF A PRODUCT OR SERVICE THAT BEAR ON ITS ABILITY TO SATISFY A GIVEN NEED

QUALITY ASSURANCE & INSPECTION

INSPECTION
THE PROCESS OF MEASURING, EXAMINING, TESTING, GAUGING OR OTHERWISE COMPARING ONE MORE CHARACTERISTICS OF A PRODUCT OR SERVICE WITH THE SPECIFIED REQUIREMENTS

QUALITY ASSURANCE & INSPECTION

QUALITY CONTROL
THOSE QUALITY ASSURANCE ACTIONS WHICH PROVIDE A MEAN TO CONTROL AND MEASURE THE CHARACTERISTICS OF AN ITEM, PROCESS OR FACILITY TO ESTABLISHED REQUIREMENTS.

QUALITY ASSURANCE & INSPECTION

QUALITY ASSURANCE
ALL THOSE PLANNED & SYSTEMATIC ACTIONS NECESSARY TO PROVIDE ADEQUATE CONFIDENCE THAT AN ITEM OR A FACILITY WILL PERFORM SATISFACTORILY IN SERVICE.

QUALITY ASSURANCE & INSPECTION

QUALITY SYSTEM

QUALITY ASSURANCE & INSPECTION

DEVELOPMENT OF QUALITY SYSTEM STANDARDS

1975 1977
1979

1981
1982

QA-42 DEVELOPED BY CEGB, UK. QUALITY SYSTEM REQUIREMENTS FOR NTPC CONTRACTS. BRITISH STANDARD 5750 ON QUALITY SYSTEMS. BS:5750 ON QUALITY SYSTEMS REVISED.
FIRST INDIAN STANDARD OF MANUAL ON QUALITY ASSURANCE SYSTEMS WAS PUBLISHED AS IS:10201. ISO-9000 SERIES WAS ISSUED FIRST TIME. REVISED ISO-9000 SERIES ISSUED. CURRENT SERIES OF ISO-9000 ISSUED.

1987 1994 2000

QUALITY ASSURANCE & INSPECTION

QA&I MANAGEMENT SET UP

CORPORATE QUALITY ASSURANCE

FIELD QUALITY ASSURANCE

REGIONAL INSPECTION OFFICES

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CORPORATE QUALITY ASSURANCE

CORPORATE QUALITY ASSURANCE AND INSPECTION IS UNDER ENGINEERING DIVISION LOCATED AT NOIDA , HAVING A STAFF OF 66 ( 53 : QUALITY ASSURANCE + 13 : INSPECTION ). QUALITY ASSURANCE IS HAVING DIFFERENT GROUPS OF MECH., ELECT.+ C&I, CIVIL AND SPECIALIST GROUP.

QUALITY ASSURANCE & INSPECTION

REGIONAL INSPECTION OFFICES

TO FACILITATE PROMPT INSPECTION AT MANUFACTURES WORKS , APPROX. 86 ENGINEERS ARE POSTED AT 10 STRATEGICALLY LOCATED REGIONAL INSPECTION OFFICES SPREAD THROUGHOUT THE COUNTRY. MAJOR EQUIPMENTS FOR POWER PLANTS ARE MANUFACTURED AT BHEL WORKS, HENCE, FIVE OF THESE INSPECTION OFFICES FUNCTION AS RESIDENT INSPECTION OFFICES AT BHELS UNIT AT HARDWAR, TRICHY, RANIPET, HYDERABAD AND BHOPAL. REST OF THE RIOs ARE LOCATED AT KOLKATA, MUMBAI, CHENNAI, BANGLORE, DELHI, THIS ENABLES PROMPT INSPECTION AT MANUFACTURERS WORKS AT DIFFERENT STAGES.

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FIELD QUALITY ASSURANCE

ALL TWENTY THREE PROJECTS OF NTPC (INCLUDING NTPC MANAGED PROJECTS) ARE HAVING FIELD QUALITY ASSURACE GROUPS, EACH HAVING STRENGTH OF THREE TO NINE EXECUTIVES. THIS GROUP IMPLEMENTS QA MANAGEMENT SYSTEM FOR ERECTION AS WELL AS O&M RELATED ACTIVITIES.

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ORGANISATION STRUCTURE OF CQA&I

HEAD (QA&I)
HOD(CQA) MECHANICAL M1 SG & PIPING M2-STST & AUX. HOD(CQA) ELECTRICAL & C&I E1 TURBO GENERATOR & ROTATING MACHINES HOD(CQA) CIVIL HOD(CQA) SPECIALIST GROUP IT SUPPORT STANDARDISATION SUPPORT FOR REFERENCE QUALITY PLANS (RQPs)/ STANDARD QUALITY PLANS (SQPs) MANPOWER PLANNING BUDGETING TRAINING STATUS / PROGRESS REPORTING ISO ACTIVITIES WELDING & NDT CONSULTANCY JOBS AUDITS VENDOR ASSESSMENT VENDOR PRFORMANCE FEEDBACK VENDOR DATA BANK INSPECTION SERVICES CORPORATE INSPECTION OFFICE RIO DELHI RIO HARDWAR REGIONAL INSPN. OFFICES (RIOs) BANGLORE BHOPAL MUMBAI KOLKATTA HYDERABAD CHENNI RANIPET TRICHY FIELD QUALITY ASSURANCE (FQA) GROUPS AT PROJECT SITES/ STATIONS

M2-GT GT/HT ASSO. AUX.

M3-A M3-B MATERIAL HANDLING & Misc. M4 MECHANICAL AUXILLIARIES

E2 TRANSFORMER & SWITCHYARD

E3 SWITCHGEAR & PANELS POWER CABLES E4 C&I PKGS. INST. CABLE CONT. CABLE

QUALITY ASSURANCE & INSPECTION

SUCCESS STORY OF QA&I

QA&I HAS A VERY SPECIAL SIGNIFICANCE IN NTPCs SUCCESS. NTPC ANALYSED THE REASONS OF POOR PERFORMANCE OF POWER PLANTS IN THE COUNTRY AND ENVISAGED MANY STATE OF THE ART MANAGEMENT CONCEPTS.

QUALITY ASSURANCE & INSPECTION

SUCCESS STORY OF QA&I

NTPCS EXPERIENCE OF PLAYING A COMPLEMENTARY ROLE WITH THE EQUIPMENT MANUFACTURER IN ENSURING THE QUALITY OF EQUIPMENT HAS BEEN WELL PROVEN AND DIRECTLY REFLECTS IN THE RELIABILITY AND AVAILABILITY OF THE POWER PLANTS

QUALITY ASSURANCE & INSPECTION

FEATURES THAT MAKE QA&I EFFECTIVE

INVOLVEMENT OF QA&I AT EVERY STAGE AS AN INTEGRATED APPROACH TO ASSURE QUALITY. IN BUILT CHECKS AND EFFECTIVE CONTROLS. BALANCES ENSURE

SOME UNIQUE FEATURES OF NTPC SYSTEM ARE ELABORATED AHEAD.

QA&I

QUALITY ASSURANCE & INSPECTION

ANY CHAIN IS AS STRONG AS THE WEAKEST LINK

LINKS OF THE CHAIN ARE :
RIGHT AND PROVEN TECHNOLOGY RIGHT EQUIPMENT RIGHT SOURCES RIGHT MANUFACTURING PROCESS RIGHT SYSTEMS - MANUFACTURING QUALITY - FIELD QUALITY IN BOTH ERECTION / CONSTRUCTION AND O&M PHASE

RELIBILITY CHAIN

QUALITY ASSURANCE & INSPECTION

ENSURING HEALTHY LINKS

RELIABILITY BY SYSTEM APPROACH ENGINEERING QUALITY SYSTEMS CONTRACTUAL PROVISIONS INSPECTION FIELD QUALITY
- IN ERECTION / CONSTRUCTION - IN OPERATION & MAINTENANCE

QUALITY ASSURANCE & INSPECTION

UNIQUE FEATURES
SYSTEMS APPROACH

PREAWARD TIE -UPS POST AWARD TIE-UPS

QUALITY ASSURANCE & INSPECTION

UNIQUE FEATURES
PRE-AWARD TIE-UPS : QA REQUIREMENTS IN TECHNICAL SPECIFICATION. EVALUATION OF BIDS w.r.t. QA REQUIREMENTS. TIE-UP OF QA REQUIREMENTS DURING PRE-AWARD. FINALISATION OF LIST OF ITEMS REQUIRING QP AND SUB-VENDOR APPROVAL.

QUALITY ASSURANCE & INSPECTION

CQA ROLE IN SPECIFICATION FINALISATION AND PRE-AWARD AGREEMENT

QA REQUIREMENTS IN MODULAR SPECIFICATION BID EVALUATION VALIDATION FOR PACKAGE CONTRACT SPECIFICATION

C Q A

BID EVALUATION REPORT

E N G G

PRE-AWARD AGREEMENT WITH IDENTIFIED VENDORS/ MAIN CONTRACTORS FEEDBACK OF SUBVENDOR PERFORMANCE BY RIO / SITE

(I) LIST OF ITEMS REQUIRING QP AND SUB-VENDOR APPROVAL (II) QA&I CO-ORDINATION PROCEDURE (III) SUB-VENDOR ASSESSMENT PROCEDURE (IV) QUALITY AUDIT REQUIREMENTS TO CS & FORM PART OF LOA

ANALYSIS OF PREVIOUS NON-CONFORMITIES (NCRs)

QUALITY ASSURANCE & INSPECTION

UNIQUE FEATURES
P0ST-AWARD APPROVAL OF QUALITY PLANS.

INSPECTION AND CHP CLEARANCE SYSTEM.

DEVIATION DISPOSITIONING SYSTEM. MDCC LINKED TO RELEASE OF PAYMENT

QUALITY ASSURANCE & INSPECTION

CQA INTERACTION AT POST AWARD STAGE

QUALITY PLAN APPROVAL IDENTIFYING: -ACCEPTABLE VENDORS FOR BOIs -IN-PROCESS CHECKS -FINAL INSPECTION
FIELD QUALITY PLAN APPROVAL IDENTIFYING RECEIPT, STORAGE AND ERECTION CHECKS SUB-VENDOR ASSESSMENT : DETAILS FROM MAIN CONTRACTOR MANUFACTURING DEVIATION DISPOSITIONING ERECTION DEVIATION DISPOSITIONING

C Q A

1. MAIN CONTRACTOR 2. RIOs

1. 2.

MAIN CONTRACTOR FQA

ACCEPTANCE / REJECTION TO MAIN CONTRACTOR

1. 2. 1. 2.

MAIN CONTRACTOR RIO MAIN CONTRACTOR FQA

QUALITY ASSURANCE & INSPECTION

MANUFACTURING QUALITY PLAN

MANUFACTURERS NAME AND ADDRESS MFGR.s LOGO

MANUFACTURING QUALITY PLAN

ITEM : SUB-SYSTEM: QP NO.: REV.NO.: DATE: PAGE: . OF.
QUANTUM OF CHECK 6. M/C N REFERENCE DOCUMENT 7. ACCEPTANCE NORMS 8.

PROJECT PACKAGE

: :

CONTRACT NO. : MAIN-SUPPLIER:

FORMAT OF RECORD 9. D* AGENCY M ** C 10. N 11. REMARKS

SL. NO 1.

COMPONENT & OPERATIONS 2.

CHARACTERISTICS

CLASS

TYPE OF CHECK 5.

3.

4.

DOC. NO.:

REV CAT..

MANUFACTURER/

MAIN-SUPPLIER

MANUFACTURER/ SUB-SUPPLIER

MAIN-SUPPLIER

SIGNATURE FORMAT NO.: QS-01-QAI-P-09/F1-R0

* RECORDS, INDENTIFIED WITH TICK ( ) SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION. ** M: MANUFACTURER/SUB-SUPPLIER C: SUPPLIER/NOMINATED INSPECTION AGENCY, N: NTPC P: PERFORM W: WITNESS AND V: VERIFICATION. AS APPROPRIATE, CHP: NTPC SHALL IDENTIFIED IN COLUM N

LEGEND:

DOC. NO.:

REV CAT..

FOR NTPC USE

REVIEWED BY

APPROVED BY

APPROVAL SEAL

1/1

ENGG. DIV./QA&I

QUALITY ASSURANCE & INSPECTION

FIELD QUALITY PLAN

SUPPLIERS NAME AND ADDRESS

FIELD QUALITY PLAN

ITEM : SUB-SYSTEM : QP NO.: REV.NO.: DATE: PAGE: . OF.
TYPE O F CHEC K 5. QUANTUM O FCHEC K 6. REFER ENC E DOCUMENT 7.

PROJECT PACKAGE

: :

MFGR.s LOGO

CONTRACT NO. : MAIN-SUPPLIER:

ACC EPTANC E NO RMS 8. FO RMAT O F RECO RD 9. D* REMARKS 10.

SL. NO 1.

AC TIVITY AND OPERATIO N 2.

CHARAC TERISTIC S / INSTRUMENTS

C LASS# O F CHEC K 4.

3.

MANUFACTURER/ SUB-SUPPLIER

MAIN-SUPPLIER

SIGNATURE FORMAT NO.: QS-01-QAI-P-09/F2-R0

LEGEND: * RECORDS, INDENTIFIED WITH TICK () SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION. LEGEND TO BE USED: CLASS # : A = CRITICAL, B=MAJOR, C=MINOR; A SHALL BE WITNESSED BY NTPC FQA, B SHALL BE WITNESSED BY NTPC ERECTION / CONSTRUCTION DEPTT. AND C SHALL BE WITNESSED BY ERECTION SUPPLIER (A & B CHECK SHALL BE NTPC CHP STAGE)

DOC. NO.:

REV

FOR NTPC USE

REVIEWED BY

APPROVED BY

APPROVAL SEAL

1/1

ENGG. DIV./QA&I

QUALITY ASSURANCE & INSPECTION

CERTIFICATE OF CONFORMANCE
MAINSUPPLIERS LOGO

(NAM E & ADDRESS OF T HE M AIN SUPPLIER)

M/S.................................................................................................................................... ....... ........................................................................................................................................... .....

Ref. No. : ..................................... ..........................

Date:

CERTIFICATE OF CONFORMANCE Contract Name & Project Contract No./P.O. No. Sub Supplier's Name
Sl. No. Descripti on of item/ Equi pment

: : :

___________________________ ___________________________ ___________________________

Make NTPC DRG. NO. / GFR. DRG. NO. Qty Offe red Bal. Qty BBU Ref. Identi fication Mark

Specification Size/Type/ Rating

It is hereby confirmed that above mentioned component/item/equipment was/were manufactured and tested in accordance with drawings/data sheets as referred above and found acceptable. Signature Name Design : : :

Note:

FORMAT NO. : QS-01-QAI-P-13/ F2-R0

1/1

ENGG. DIV/QAI

QUALITY ASSURANCE & INSPECTION

INSPECTION CALL FORMAT

us'kuy FkeZy ikoj dkiksZjs'ku fy0
NATIONAL THERMAL POWER CORPORATION LTD.

(Hkkjr ljdkj dk midze)

(A Government of India Enterprise)
PROJECT NAME PROJECT NAME :__________________________________ :__________________________________

MAIN-SUPPLIER : M/S____________________________ Address: _________________________________________ ____________________Email________________________ Contact Person : __________________________________ Ph.:_______________Fax(off)________________________ Manufacturer:M/s______________________________________
(Place of Inspection)

INSPECTION CALL FORMAT

(FOR SUBMISSION BY VENDORS)

CONTRACT/PO NO. :__________________________________ DATE PROPOSED :__________________________________

NO. OF DAYS REQUIRED:______________________________ WEEKLY OFF

(For NTPC use) I/C No. Sl. No.

Address: ______________________________________________ _________________________Email________________________ Contact Person : _______________________________________ Ph.:____________________Fax(off)________________________ Mob./Res.:____________________Email____________________

Unit Cat Insp (*) REFERENCE DOCUMENT REMARKS/ UNDERTAKING

:__________________________________
BBU No. ITEM DESCRIPTION / TESTS As in BBU QUANTITY Already Offered Supplied

QP No.

1. 2

Material internally inspected, in line with NTPC QP and found satisfactory. All Reference Documents including latest revisions of NTPC approved QP /Drawing / BBU in original are available and shall be made available during inspection. All stage inspection requirements if applicable has been cleared and relevant CHPs are available. (Applicable for bought out items) Inspection by Main supplier is completed and material is cleared. OR Joint inspection along with Main supplier proposed.

Drg/Data sheet No.

3

4. 5.

Type test Approval from NTPC /Obtained / Pending / Not available.

Engg.

Material shall not be Despatched without Despatch clearance from

SIGNATURE:_____________________ NAME :_____________________ DESIGNATION :__________________ Insp. Cat (*) : Enter 0 for Stage Insp. 1 for Final Physical Insp. 2 for Review of MTCs based on QP 3 for Non-QP cases based on COC.

QUALITY ASSURANCE & INSPECTION

CHP REPORT
RI O --- ---- --

NATIONAL THERMAL POWER CORPORATION LTD

PROJECT_NAME
( A Go v ern men t o f Ind i a Ent erp ri se )

CONTRACTOR

PACKAGE NAM E

C.H.P. CLEARANCE / INTERIM INSPECTION REPORT SOBCONTRACTOR

CONTRACT_NO: CHP_NO: - ---- INSPE CTION DATE I/C NO DESCRI PTI ON OF MATERIAL / QU ANIT IT Y SL OF F ERED TEST NO
Pa g e ---QU ANIT IT Y ACCEPT ED QU ARANTI NE D/R EJECTED QT Y UNITT

PLACE
DISPOS REF ERANCE AL DOCUMENT S CODE REMARKS

MDCC NO:

/ /ANNEXURE

FOR CONTRACT OR/SUBCONTRACTOR

Fo r and beha lf o f NATIONAL T HERMAL POW ER CORP ORAT ION L T D NAME : DESI GNAT ION : FORM AT NO: QS-01 -QAI-P-13 / F3 REV '0'

QUALITY ASSURANCE & INSPECTION

MATERIAL DESPATCH CLEARANCE CERTIFICATE (MDCC)

QUALITY ASSURANCE & INSPECTION

BEST PRACTICES IN QA &I

WELL DEFINED VENDOR ASSESSMENT SYSTEM STANDARDISATION REVIEW & APPROVAL OF QUALITY PLANS THROUGH DREAMS SOFT WARE AND FORWARDING TO CONTRACTORS BY EMAIL. RECIVING INSPECTION CALLS THROUGH INTERNET AND GENERATING CHP AND MDCC THROUGH WINDSOR X SOFT WARE.

BEST PRACTICES IN QA&I

SYSTEM OF FEEDBACK QUALITY SYSTEM AUDITS OF MANUFACTURERS / SUPPLIERS AND PROJECTS SITES. PREPARATION OF TRAINING CALANDER TO CATER NEEDS OF QA,FQA AND INSPECTION EXECUTIVES, ISO 9001-2000 CERTIFICATION TO ALL INSPECTION OFFICES AND CQA

QUALITY ASSURANCE & INSPECTION

BEST PRACTICES
SUB-VENDOR ASSESSMENT SYSTEM
AT NTPC, FOR BOUGHT OUT ITEMS SUB-VENDORS ARE ACCEPTED BASED ON MAIN CONTRACTORS PROPOSAL ON PACKAGE TO PACKAGE BASIS AS PER TECHNICAL SPECIFICATION REQUIREMENTS. AS SUCH, AT PRESENT, THERE IS NO SYSTEM OF SUBVENDOR REGISTRATION OR ENLISTMENT. DETAILS OF EARLIER ASSESSED SUB-VENDOR IS KEPT IN THE FORM OF SUB-VENDOR FILES. VENDOR ASSESSMENT IS CARRIED OUT FOR SUBVENDORS IDENTIFIED IN DR (DETAILS REQUIRED ) CATEGORY DURING PRE-AWARD WITH MAIN CONTRACTOR.

QUALITY ASSURANCE & INSPECTION

BEST PRACTICES
STANDARDISATION
MODULAR AUTOMATED TECHNICAL SPECIFICATION

FINALISATION OF REFERENCE QUALITY PLAN & STANDARD QUALITY PLAN

MODEL LIST OF ITEMS REQUIRING QP APPROVAL AND SUB-VENDOR APPROVAL

INCORPORATION OF QA REQUIREMENTS IN STANDARD CHECK-LISTS PREPARED BY PROJECT ENGINEERING FOR DRAWING & DATA-SHEET APPROVAL

QUALITY ASSURANCE & INSPECTION

BEST PRACTICES
SYSTEM OF FEEDBACK
THE FEEDBACK OF INSPECTION IS USED FOR UPGRADATION OF QA REQUIREMENTS AND TIE-UPS FOR FUTURE PROJECTS
DEVIATION DISPOSITIONING DURING MANUFACTURING / ERECTION AT SITE NOT ONLY ENSURES PROPER RESOLUTION TO THE PROBLEM BUT ALSO PROVIDES FEEDBACK FOR FUTURE WORK.

FEEDBACK FROM OPERATING UNITS IS ALSO ANALYSED AND TAKEN INTO ACCOUNT FOR FUTURE PROJECTS.

QUALITY ASSURANCE & INSPECTION

BEST PRACTICES
QUALITY SYSTEM AUDITS
QUALITY SYSTEM AUDITS OF MANUFACTURING UNITS OF REGULAR SUPPLIERS W.R.T REQUIREMENTS OF ISO & OTHER QUALITY SYSTEM MANUALS IS TAKEN UP . ALSO, QUALITY SYSTEM AUDIT OF NTPC PROJECT SITES W.R.T. NTPC FQA MANUAL & CONSTRUCTION MANUAL IS TAKEN UP. FOLLOW UP FOR NECESSARY CORRECTIVE AND PREVENTIVE ACTION IS MADE BY CQA.

BEST PRACTICES

QUALITY ASSURANCE & INSPECTION