QUALITY ASSURANCE & INSPECTION

BEST PRACTICES IN
QUALITY ASSURANCE
&
INSPECTION
IN
NTPC
 QUALITY ASSURANCE & INSPECTION

DEVELOPMENT OF QA&I IN NTPC

1975-1980 1980-1990

THE INFANCY : ESTABLISHING MATURE

DEVELOPMENT OF SYSTEM.
STRONG BASICS IMPLEMENTATION OF SAME
IN POWER PLANTS

1995-2004
1990-1995
AMBITIOUS GENERATION
ENTRY INTO BULK O&M AND CAPACITY ADDITION
PHASE OF PLANTS. PLAN.
STRONG BASE OF FQA 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 - 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.
 QUALITY ASSURANCE & INSPECTION

QA&I MANAGEMENT SET UP

CORPORATE
QUALITY
ASSURANCE

FIELD REGIONAL
QUALITY INSPECTION
ASSURANCE OFFICES
 QUALITY ASSURANCE & INSPECTION

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

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.
 QUALITY ASSURANCE & INSPECTION

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.
 QUALITY ASSURANCE & INSPECTION

ORGANISATION STRUCTURE OF CQA&I

HEAD (QA&I)

HOD(CQA) HOD(CQA) HOD(CQA) HOD(CQA) INSPECTION REGIONAL FIELD

MECHANICAL ELECTRICAL & CIVIL SPECIALIST GROUP SERVICES INSPN. QUALITY
C&I OFFICES ASSURA-
M1 E1 •IT SUPPORT CORPORATE (RIOs) NCE
SG & PIPING TURBO •STANDARDISATION INSPECTION (FQA)
GENERATOR & • SUPPORT FOR OFFICE BANGLORE GROUPS
M2-ST- ROTATING REFERENCE QUALITY BHOPAL
ST & AUX. MACHINES PLANS (RQPs)/ RIO MUMBAI AT
STANDARD QUALITY DELHI KOLKATTA PROJECT
M2-GT E2 PLANS (SQPs) HYDERABAD SITES/
GT/HT TRANSFORMER • MANPOWER RIO CHENNI STATIONS
ASSO. AUX. & PLANNING HARDWAR RANIPET
SWITCHYARD •BUDGETING TRICHY
M3-A •TRAINING
M3-B E3 •STATUS / PROGRESS
MATERIAL SWITCHGEAR REPORTING
HANDLING & & PANELS •ISO ACTIVITIES
Misc. POWER CABLES •WELDING & NDT
•CONSULTANCY JOBS
M4 E4 •AUDITS
MECHANICAL C&I PKGS. •VENDOR
AUXILLIARIES INST. CABLE ASSESSMENT
CONT. CABLE •VENDOR
PRFORMANCE
FEEDBACK
•VENDOR DATA BANK
 QUALITY ASSURANCE & INSPECTION

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.
 QUALITY ASSURANCE & INSPECTION

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
 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 BALANCES ENSURE

EFFECTIVE CONTROLS.

• SOME UNIQUE FEATURES OF NTPC QA&I

SYSTEM ARE ELABORATED AHEAD.
 QUALITY ASSURANCE & INSPECTION

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
 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 VALIDATION FOR PACKAGE

MODULAR SPECIFICATION CONTRACT SPECIFICATION

BID EVALUATION
C BID EVALUATION REPORT
E
N
G
G
PRE-AWARD AGREEMENT (I) LIST OF ITEMS
WITH IDENTIFIED VENDORS/ REQUIRING QP AND
SUB-VENDOR APPROVAL

Q
MAIN CONTRACTORS
(II) QA&I CO-ORDINATION
PROCEDURE
FEEDBACK OF SUB-
VENDOR PERFORMANCE (III) SUB-VENDOR
BY RIO / SITE ASSESSMENT PROCEDURE TO CS
(IV) QUALITY AUDIT &
REQUIREMENTS FORM
ANALYSIS OF PREVIOUS

A
NON-CONFORMITIES (NCRs) PART
OF
LOA
 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 1. MAIN CONTRACTOR
2. RIOs

C
FOR BOIs
-IN-PROCESS CHECKS
-FINAL INSPECTION

FIELD QUALITY PLAN APPROVAL 1. MAIN CONTRACTOR

IDENTIFYING RECEIPT, STORAGE 2. FQA
AND ERECTION CHECKS

SUB-VENDOR ASSESSMENT :
DETAILS FROM MAIN
Q ACCEPTANCE / REJECTION TO
MAIN CONTRACTOR
CONTRACTOR

MANUFACTURING DEVIATION 1. MAIN CONTRACTOR

DISPOSITIONING 2. RIO

ERECTION DEVIATION
A 1. MAIN CONTRACTOR
DISPOSITIONING 2. FQA
 QUALITY ASSURANCE & INSPECTION

MANUFACTURING QUALITY PLAN

MANUFACTURER’S NAME AND
ADDRESS MANUFACTURING QUALITY PLAN PROJECT :
ITEM : QP NO.: PACKAGE :
MFGR.’s REV.NO.:
LOGO CONTRACT NO. :
SUB-SYSTEM: DATE:
PAGE: …. OF…. MAIN-SUPPLIER:
SL. COMPONENT & CHARACTERISTICS CLASS TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY
REMARKS
NO OPERATIONS CHECK OF CHECK DOCUMENT NORMS RECORD
M C N
1. 2. 3. 4. 5. 6. 7. 8. 9. D* ** 10. 11.

M/C N

DOC. NO.: REV…… CAT…..

MANUFACTURER/ MAIN-SUPPLIER
LEGEND: * RECORDS, INDENTIFIED WITH “TICK” (  ) SHALL BE DOC. NO.: REV…… CAT…..
ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
** M: MANUFACTURER/SUB-SUPPLIER
C: SUPPLIER/NOMINATED INSPECTION AGENCY, N: NTPC
MANUFACTURER/ MAIN-SUPPLIER P: PERFORM W: WITNESS AND V: VERIFICATION. AS APPROPRIATE, FOR
SUB-SUPPLIER CHP: NTPC SHALL IDENTIFIED IN COLUM “N” NTPC
SIGNATURE USE REVIEWED BY APPROVED BY APPROVAL SEAL
FORMAT NO.: QS-01-QAI-P-09/F1-R0 1/1 ENGG. DIV./QA&I
 QUALITY ASSURANCE & INSPECTION

FIELD QUALITY PLAN

SUPPLIER’S NAME AND ADDRESS
FIELD QUALITY PLAN PROJECT :
ITEM : QP NO.: PACKAGE :
MFGR.’s REV.NO.:
LOGO CONTRACT NO. :
SUB-SYSTEM : DATE:
PAGE: …. OF…. MAIN-SUPPLIER:
SL. AC TIVITY AND CHARAC TERISTIC S / INSTRUMENTS C LASS# O F TYPE O F QUANTUM REFER ENC E ACC EPTANC E FO RMAT O F
NO OPERATIO N CHEC K CHEC K O FCHEC K DOCUMENT NO RMS RECO RD REMARKS

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

DOC. NO.: REV……

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;
MANUFACTURER/ MAIN-SUPPLIER ‘A’ SHALL BE WITNESSED BY NTPC FQA, ‘B’ SHALL BE WITNESSED BY FOR
SUB-SUPPLIER NTPC ERECTION / CONSTRUCTION DEPTT. AND ‘C’ SHALL BE WITNESSED NTPC
BY ERECTION SUPPLIER (A & B CHECK SHALL BE NTPC CHP STAGE) USE
SIGNATURE REVIEWED BY APPROVED BY APPROVAL SEAL
FORMAT NO.: QS-01-QAI-P-09/F2-R0 1/1 ENGG. DIV./QA&I
 QUALITY ASSURANCE & INSPECTION

CERTIFICATE OF CONFORMANCE
(NAM E & ADDRESS OF T HE M AIN SUPPLIER)
MAIN-
SUPPLIER’S
M/S....................................................................................................................................
LOGO .......
...........................................................................................................................................
.....

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

..........................

CERTIFICATE OF CONFORMANCE

Contract Name & Project : ___________________________

Contract No./P.O. No. : ___________________________
Sub Supplier's Name : ___________________________

Sl. Descripti on Specification Make NTPC DRG. Qty Bal. BBU Identi fi-
No. of item/ Size/Type/ NO. / GFR. Offe Qty Ref. cation
Equi pment Rating DRG. NO. red 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

 QUALITY ASSURANCE & INSPECTION

INSPECTION CALL FORMAT

MAIN-SUPPLIER : M/S____________________________
us'kuy FkeZy ikoj dkiksZjs'ku fy0 Address: _________________________________________
NATIONAL THERMAL POWER CORPORATION LTD. ____________________Email________________________
(Hkkjr ljdkj dk midze) Contact Person : __________________________________
(A Government of India Enterprise) Ph.:_______________Fax(off)________________________
PROJECT NAME :__________________________________ Manufacturer:M/s______________________________________
INSPECTION CALL FORMAT (Place of Inspection)
PROJECT NAME :__________________________________
(FOR SUBMISSION BY VENDORS) Address: ______________________________________________
CONTRACT/PO NO. :__________________________________ _________________________Email________________________
DATE PROPOSED :__________________________________ Contact Person : _______________________________________
Ph.:____________________Fax(off)________________________
NO. OF DAYS REQUIRED:______________________________
Mob./Res.:____________________Email____________________
WEEKLY OFF :__________________________________

(For NTPC use) Sl. BBU No. ITEM DESCRIPTION / TESTS QUANTITY Unit Cat REFERENCE REMARKS/ UNDERTAKING
I/C No. No. As in Already Offered Insp DOCUMENT
BBU Supplied (*)
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 /
Drg/Data sheet BBU in original are available and shall be
made available during inspection.
No.
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.
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 MTC’s 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 NAME C.H.P. CLEARANCE / INTERIM INSPECTION REPORT

SOBCONTRACTOR

CONTRACT_NO:

Pa g e ---- PLACE
INSPE CTION DATE CHP_NO: - ---- -
I/C NO DESCRI PTI ON OF MATERIAL / QU ANIT IT Y QU ANIT IT Y QU ARANTI NE UNITT DISPOS REF ERANCE REMARKS
SL TEST OF F ERED ACCEPT ED D/R EJECTED AL DOCUMENT S
NO QT Y CODE

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 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
 QUALITY ASSURANCE & INSPECTION

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 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.
 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