Ntpc Quality Inspection 4h675o

QUALITY ASSURANCE & INSPECTION

BEST PRACTICES IN QUALITY ASSURANCE & INSPECTION IN NTPC


DEVELOPMENT OF QA&I IN NTPC 1975-1980 THE INFANCY : DEVELOPMENT OF STRONG BASICS

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

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

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


QUALITY ASSURANCE CONCEPTS


QUALITY “QUALITY

IS

FITNESS FOR

USE”


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


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


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


QUALITY SYSTEM


DEVELOPMENT OF QUALITY SYSTEM STANDARDS 1975 1977

-

1979

-

1981

-

1982

-

1987 1994 2000

-

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.


QA&I MANAGEMENT SET UP CORPORATE QUALITY ASSURANCE

FIELD QUALITY ASSURANCE

REGIONAL INSPECTION OFFICES


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.


REGIONAL INSPECTION OFFICES TO FACILITATE PROMPT INSPECTION AT MANUFACTURE’S 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 BHEL’S 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 MANUFACTURER’S WORKS AT DIFFERENT STAGES.


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.


ORGANISATION STRUCTURE OF CQA&I HEAD (QA&I)

HOD(CQA) MECHANICAL M1 SG & PIPING M2-STST & AUX.

M2-GT GT/HT ASSO. AUX. M3-A M3-B MATERIAL HANDLING & Misc. M4 MECHANICAL AUXILLIARIES

HOD(CQA) ELECTRICAL & C&I E1 TURBO GENERATOR & ROTATING MACHINES

E2 TRANSFORMER & SWITCHYARD E3 SWITCHGEAR & S POWER CABLES E4 C&I PKGS. INST. CABLE CONT. CABLE

HOD(CQA) CIVIL

HOD(CQA) SPECIALIST GROUP

INSPECTION SERVICES

•IT •STANDARDISATION • 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 •VENDOR DATA BANK

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


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


SUCCESS STORY OF QA&I NTPC’S 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


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


RELIBILITY CHAIN

“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


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


UNIQUE FEATURES SYSTEMS’ APPROACH

–PREAWARD TIE -UPS –POST AWARD TIE-UPS


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.


CQA ROLE IN SPECIFICATION FINALISATION AND PRE-AWARD AGREEMENT QA REQUIREMENTS IN MODULAR SPECIFICATION BID EVALUATION

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

ANALYSIS OF PREVIOUS NON-CONFORMITIES (NCRs)

VALIDATION FOR PACKAGE CONTRACT SPECIFICATION

C Q

BID EVALUATION REPORT

(I) LIST OF ITEMS REQUIRING QP AND SUB-VENDOR APPROVAL (II) QA&I CO-ORDINATION PROCEDURE (III) SUB-VENDOR ASSESSMENT PROCEDURE

A

E N G G

(IV) QUALITY AUDIT REQUIREMENTS

TO CS & FORM PART OF LOA


UNIQUE FEATURES P0ST-AWARD • APPROVAL OF QUALITY PLANS.

• INSPECTION AND CHP CLEARANCE SYSTEM. • DEVIATION DISPOSITIONING SYSTEM. • MDCC LINKED TO RELEASE OF PAYMENT


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

1. MAIN CONTRACTOR 2. RIOs

1. 2.

Q A

MAIN CONTRACTOR FQA

ACCEPTANCE / REJECTION TO MAIN CONTRACTOR

1. 2.

MAIN CONTRACTOR RIO

1. 2.

MAIN CONTRACTOR FQA


MANUFACTURING QUALITY PLAN MANUFACTURER’S NAME AND ADDRESS

MANUFACTURING QUALITY PLAN ITEM :

MFGR.’s LOGO

SL. NO

QP NO.: REV.NO.: DATE: PAGE: …. OF….

SUB-SYSTEM: COMPONENT & OPERATIONS

CHARACTERISTICS

2.

3.

1.

CLASS

4.

TYPE OF CHECK

:

MAIN-SUPPLIER:

REFERENCE DOCUMENT

ACCEPTANCE NORMS

6.

7.

8.

M/C

:

PACKAGE

CONTRACT NO. :

QUANTUM OF CHECK

5.

PROJECT

FORMAT OF RECORD 9.

AGENCY M

D*

C **

11.

REV…… CAT…..

MAIN-SUPPLIER

* 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”

MAIN-SUPPLIER

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

1/1

REV…… CAT…..

DOC. NO.:

LEGEND:

MANUFACTURER/ SUB-SUPPLIER

10.

N

DOC. NO.:

MANUFACTURER/

REMARKS N

FOR NTPC USE

REVIEWED BY

APPROVED BY

APPROVAL SEAL

ENGG. DIV./QA&I


FIELD QUALITY PLAN SUPPLIER’S NAME AND ADDRESS

MFGR.’s LOGO

SL. NO 1.

FIELD QUALITY PLAN ITEM : SUB-SYSTEM :

AC TIVITY AND OPERATIO N

CHARAC TERISTIC S / INSTRUMENTS

2.

3.

MANUFACTURER/ SUB-SUPPLIER

MAIN-SUPPLIER

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

QP NO.: REV.NO.: DATE: PAGE: …. OF….

PROJECT

:

PACKAGE

:

CONTRACT NO. : MAIN-SUPPLIER:

C LASS# O F CHEC K

TYPE O F CHEC K

QUANTUM O FCHEC K

REFER ENC E DOCUMENT

ACC EPTANC E NO RMS

4.

5.

6.

7.

8.

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)

1/1

FO RMAT O F RECO RD 9.

REMARKS D*

REV……

DOC. NO.:

FOR NTPC USE

REVIEWED BY

10.

APPROVED BY

APPROVAL SEAL

ENGG. DIV./QA&I


CERTIFICATE OF CONFORMANCE MAINSUPPLIER’S 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

: : :

___________________________ ___________________________ ___________________________

Specification Size/Type/ Rating

Make

NTPC DRG. NO. / GFR. DRG. NO.

Qty Offe red

Bal. Qty

BBU Ref.

Identi fication Mark

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


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

:__________________________________

CONTRACT/PO NO. :__________________________________ DATE PROPOSED

INSPECTION CALL FORMAT (FOR SUBMISSION BY VENDORS)

:__________________________________

NO. OF DAYS REQUIRED:______________________________ WEEKLY OFF (For NTPC use) I/C No.

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

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

:__________________________________ Sl. No.

BBU No.

ITEM DESCRIPTION / TESTS As in BBU

QUANTITY Already Offered Supplied

Unit

Cat Insp (*)

REFERENCE DOCUMENT

REMARKS/ UNDERTAKING

QP No.

1.

Material internally inspected, in line with NTPC QP and found satisfactory.

2

All Reference Documents including latest revisions of NTPC approved QP /Drawing / BBU in original are available and shall be made available during inspection.

3

All stage inspection requirements if applicable has been cleared and relevant CHP’s are available.

4

(Applicable for bought out items) Inspection by Main supplier is completed and material is cleared.

Drg/Data sheet No.

OR t inspection along with Main supplier proposed. 4.

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

Engg.

5.

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 MTC’s based on QP

3 – for Non-QP cases based on COC.


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

NATIONAL THERMAL POWER CORPORATION LTD PROJECT_NAME

PACKAGE NAME

CONTRACTOR

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

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

MDCC NO:

PLACE

Pa g e ---QU ANIT IT Y ACCEPT ED

QU ARANTI NE D/R EJECTED QT Y

UNITT

DISPOS REF ERANCE AL DOCUMENT S CODE

REMARKS

/ /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'


MATERIAL DESPATCH CLEARANCE CERTIFICATE (MDCC)


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 • 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


BEST PRACTICES • SUB-VENDOR ASSESSMENT SYSTEM AT NTPC, FOR BOUGHT OUT ITEMS SUB-VENDORS ARE ACCEPTED BASED ON MAIN CONTRACTOR’S 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.


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


BEST PRACTICES SYSTEM OF • THE 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 FOR FUTURE WORK.

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


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


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