NTPC Quality Inspection

BEST PRACTICES IN
QUALITY ASSURANCE
&
INSPECTION
IN
NTPC
QUALITY ASSURANCE & INSPECTION
DEVELOPMENT OF QA&I IN NTPC
THE INFANCY :
DEVELOPMENT OF
STRONG BASICS
1980-1990
1990-1995
1995-2004
1975-1980
ESTABLISHING MATURE
SYSTEM.
IMPLEMENTATION OF SAME
IN POWER PLANTS
ENTRY INTO BULK O&M
PHASE OF PLANTS.
STRONG BASE OF FQA

AMBITIOUS GENERATION
AND CAPACITY ADDITION
PLAN.
STRONG BASE OF FQA,
RIOs & CQA
QUALITY ASSURANCE
CONCEPTS

QUALITY
QUALITY
IS
FITNESS
FOR
USE
THE TOTALITY OF FEATURES
AND CHARACTERISTICS
(ATTRIBUTES)
OF A PRODUCT OR SERVICE
THAT BEAR ON ITS ABILITY
TO SATISFY
A GIVEN NEED
QUALITY
THE PROCESS OF MEASURING,
EXAMINING, TESTING,
GAUGING OR OTHERWISE
COMPARING ONE MORE
CHARACTERISTICS OF A
PRODUCT OR SERVICE WITH
THE SPECIFIED
REQUIREMENTS
INSPECTION
THOSE QUALITY ASSURANCE
ACTIONS WHICH PROVIDE A
MEAN TO CONTROL AND
MEASURE THE
CHARACTERISTICS OF AN
ITEM, PROCESS OR FACILITY
TO ESTABLISHED
REQUIREMENTS.
QUALITY CONTROL
ALL THOSE PLANNED &
SYSTEMATIC ACTIONS
NECESSARY TO PROVIDE
ADEQUATE CONFIDENCE THAT
AN ITEM OR A FACILITY WILL
PERFORM SATISFACTORILY IN
SERVICE.

QUALITY ASSURANCE
QUALITY SYSTEM
DEVELOPMENT OF QUALITY SYSTEM
STANDARDS

1975 - QA-42 DEVELOPED BY CEGB, UK.
1977 - QUALITY SYSTEM REQUIREMENTS FOR NTPC
CONTRACTS.
1979 - BRITISH STANDARD 5750 ON QUALITY
SYSTEMS.
1981 - BS:5750 ON QUALITY SYSTEMS REVISED.

1982 - FIRST INDIAN STANDARD OF MANUAL ON
QUALITY ASSURANCE SYSTEMS WAS
PUBLISHED AS IS:10201.
1987 - ISO-9000 SERIES WAS ISSUED FIRST TIME.
1994 - REVISED ISO-9000 SERIES ISSUED.
2000 - CURRENT SERIES OF ISO-9000 ISSUED.
QA&I MANAGEMENT SET UP
CORPORATE
QUALITY
ASSURANCE
REGIONAL
INSPECTION
OFFICES
FIELD
QUALITY
ASSURANCE
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
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.
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
HOD(CQA)
MECHANICAL

M1
SG & PIPING

M2-ST-
ST & 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
& PANELS
POWER CABLES

E4
C&I PKGS.
INST. CABLE
CONT. CABLE
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
ASSURA-
NCE
(FQA)
GROUPS

AT
PROJECT
SITES/
STATIONS
HEAD (QA&I)
HOD(CQA)
CIVIL
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.

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

FEATURES THAT MAKE QA&I
EFFECTIVE
INVOLVEMENT OF QA&I AT EVERY STAGE AS
AN INTEGRATED APPROACH TO ASSURE
QUALITY.

IN BUILT CHECKS AND BALANCES ENSURE
EFFECTIVE CONTROLS.

SOME UNIQUE FEATURES OF NTPC QA&I
SYSTEM ARE ELABORATED AHEAD.
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

C

Q

A
VALIDATION FOR PACKAGE
CONTRACT SPECIFICATION
QA REQUIREMENTS IN
MODULAR SPECIFICATION
BID EVALUATION
BID EVALUATION REPORT
PRE-AWARD AGREEMENT
WITH IDENTIFIED VENDORS/
MAIN CONTRACTORS
(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
FEEDBACK OF SUB-
VENDOR PERFORMANCE
BY RIO / SITE
ANALYSIS OF PREVIOUS
NON-CONFORMITIES (NCRs)
E
N
G
G
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

C

Q

A
1. MAIN CONTRACTOR
2. RIOs
QUALITY PLAN APPROVAL
IDENTIFYING:
-ACCEPTABLE VENDORS
FOR BOIs
-IN-PROCESS CHECKS
-FINAL INSPECTION
FIELD QUALITY PLAN APPROVAL
IDENTIFYING RECEIPT, STORAGE
AND ERECTION CHECKS
1. MAIN CONTRACTOR
2. FQA
SUB-VENDOR ASSESSMENT :
DETAILS FROM MAIN
CONTRACTOR
ACCEPTANCE / REJECTION TO
MAIN CONTRACTOR
MANUFACTURING DEVIATION
DISPOSITIONING
ERECTION DEVIATION
DISPOSITIONING
1. MAIN CONTRACTOR
2. RIO
1. MAIN CONTRACTOR
2. FQA
MANUFACTURING QUALITY PLAN
MANUFACTURING QUALITY PLAN
MFGR.s
LOGO
MANUFACTURERS NAME AND
ADDRESS
ITEM :
SUB-SYSTEM:
QP NO.:
REV.NO.:
DATE:
PAGE: . OF.
PROJECT :
PACKAGE :
CONTRACT NO. :
MAIN-SUPPLIER:
DOC. NO.: REV CAT..
MANUFACTURER/ MAIN-SUPPLIER

AGENCY SL.
NO

COMPONENT &
OPERATIONS

CHARACTERISTICS

CLASS

TYPE OF
CHECK

QUANTUM
OF CHECK

REFERENCE
DOCUMENT

ACCEPTANCE
NORMS

FORMAT OF
RECORD

M C N
REMARKS

1. 2. 3. 4. 5. 6. 7. 8.
9. D* ** 10.
11.
M/C N

DOC. NO.: REV CAT..
MANUFACTURER/
SUB-SUPPLIER
MAIN-SUPPLIER

SIGNATURE
LEGEND: * 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
FOR
NTPC
USE REVIEWED BY APPROVED BY APPROVAL SEAL
FORMAT NO.: QS-01-QAI-P-09/F1-R0 1/1 ENGG. DIV./QA&I
FIELD QUALITY PLAN
FIELD QUALITY PLAN
MFGR.s
LOGO
SUPPLIERS NAME AND ADDRESS
ITEM :
SUB-SYSTEM :
QP NO.:
REV.NO.:
DATE:
PAGE: . OF.
PROJECT :
PACKAGE :
CONTRACT NO. :
MAIN-SUPPLIER:
SL.
NO

ACTIVITY AND
OPERATION

CHARACTERISTICS / INSTRUMENTS

CLASS# OF
CHECK

TYPEOF
CHECK

QUANTUM
OFCHECK

REFERENCE
DOCUMENT

ACCEPTANCE
NORMS

FORMATOF
RECORD

REMARKS
1. 2. 3. 4. 5. 6. 7. 8. 9. D* 10.

DOC. NO.: REV
MANUFACTURER/
SUB-SUPPLIER
MAIN-SUPPLIER
SIGNATURE
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)
FOR
NTPC
USE REVIEWED BY APPROVED BY APPROVAL SEAL
FORMAT NO.: QS-01-QAI-P-09/F2-R0 1/1 ENGG. DIV./QA&I
CERTIFICATE OF CONFORMANCE

FORMAT NO. : QS-01-QAI-P-13/ F2-R0 1/1 ENGG. DIV/QAI
(NAME & ADDRESS OF THE MAIN 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 fi-
cation
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:
MAIN-
SUPPLIERS
LOGO
INSPECTION CALL FORMAT
us'kuy FkeZy ikoj dkiksZjs'ku fy0
NATIONAL THERMAL POWER CORPORATION LTD.
(Hkkjr ljdkj dk midze)
(A Government of India Enterprise)
MAIN-SUPPLIER : M/S____________________________
Address: _________________________________________
____________________Email________________________
Contact Person : __________________________________
Ph.:_______________Fax(off)________________________
PROJECT NAME :__________________________________
PROJECT NAME :__________________________________
CONTRACT/PO NO. :__________________________________
DATE PROPOSED :__________________________________
NO. OF DAYS REQUIRED:______________________________
WEEKLY OFF :__________________________________
INSPECTION CALL FORMAT
(FOR SUBMISSION BY VENDORS)
Manufacturer:M/s______________________________________
(Place of Inspection)
Address: ______________________________________________
_________________________Email________________________
Contact Person : _______________________________________
Ph.:____________________Fax(off)________________________
Mob./Res.:____________________Email____________________
QUANTITY (For NTPC use)
I/C No.
Sl.
No.
BBU No. ITEM DESCRIPTION / TESTS
As in
BBU
Already
Supplied
Offered
Unit Cat
Insp
(*)
REFERENCE
DOCUMENT
REMARKS/ UNDERTAKING
QP No.
Drg/Data sheet
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 CHPs are
available.
4 (Applicable for bought out items) Inspection by
Main supplier is completed and material is
cleared.
OR
Joint inspection along with Main supplier
proposed.
4. Type test Approval from NTPC Engg.
/Obtained / Pending / Not available.
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 MTCs based on QP 3 for Non-QP cases based on COC.
CHP REPORT
NATIONAL THERMAL POWER CORPORATION LTD
( A Government of Indi a Ent erpri se )
C.H.P. CLEARANCE / INTERIM INSPECTION REPORT
PROJECT_NAME
INSPECTION DATE
CONTRACT_NO:
PACKAGE NAME
CHP_NO: ------
PLACE
SOBCONTRACTOR
CONTRACTOR
SL
NO
I/C NO DESCRIPTIONOF MATERIAL /
TEST
QU ANITITY
OFFERED
QU ANITITY
ACCEPTED
QU ARANTI NE
D/R EJECTED
QTY
UNITT DISPOS
AL
CODE
REF ERANCE
DOCUMENTS
REMARKS
FOR CONTRACTOR/SUBCONTRACTOR
For and behalf of NATIONAL THERMAL POWER CORP ORATION LTD
/ /ANNEXURE
RIO ---------
DESI GNATION :
NAME :
MDCC NO:
Page ----
FORMAT 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 E-
MAIL.
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

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 SUB-
VENDOR REGISTRATION OR ENLISTMENT. DETAILS
OF EARLIER ASSESSED SUB-VENDOR IS KEPT IN
THE FORM OF SUB-VENDOR FILES.
VENDOR ASSESSMENT IS CARRIED OUT FOR SUB-
VENDORS 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 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.

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


NTPC Quality Inspection

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