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QUALITY ASSURANCE & INSPECTION. BEST PRACTICES IN QUALITY ASSURANCE & INSPECTION IN NTPC. QUALITY ASSURANCE & INSPECTION. DEVELOPMENT OF QA&I IN NTPC. 1980-1990. 1975-1980. ESTABLISHING MATURE SYSTEM. IMPLEMENTATION OF SAME IN POWER PLANTS . THE INFANCY : DEVELOPMENT OF STRONG BASICS.

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development of qa i in ntpc

QUALITY ASSURANCE & INSPECTION

DEVELOPMENT OF QA&I IN NTPC

1980-1990

1975-1980

ESTABLISHING MATURE SYSTEM.

IMPLEMENTATION OF SAME IN POWER PLANTS

THE INFANCY : DEVELOPMENT OF STRONG BASICS

1995-2004

1990-1995

AMBITIOUS GENERATION AND CAPACITY ADDITION PLAN.

STRONG BASE OF FQA, RIOs & CQA

  • ENTRY INTO BULK O&M PHASE OF PLANTS.
  • STRONG BASE OF FQA
quality

QUALITY ASSURANCE & INSPECTION

QUALITY

“QUALITY

IS

FITNESS

FOR

USE”

slide5

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”

slide6

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”

slide7

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.”

slide8

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.”

development of quality system standards

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.

corporate quality assurance

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.

regional inspection offices

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.

field quality assurance

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.

organisation structure of cqa i

QUALITY ASSURANCE & INSPECTION

ORGANISATION STRUCTURE OF CQA&I

HEAD (QA&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)

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 ASSURA- NCE (FQA) GROUPS

AT PROJECTSITES/ STATIONS

success story of qa i

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.

success story of qa i17

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

features that make qa i effective

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 ELABORATEDAHEAD.
relibility chain any chain is as strong as the weakest link

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

ensuring healthy links

QUALITY ASSURANCE & INSPECTION

ENSURING HEALTHY LINKS

RELIABILITY BY SYSTEM APPROACH

  • ENGINEERING
  • QUALITY SYSTEMS
  • CONTRACTUAL PROVISIONS
  • INSPECTION
  • FIELD QUALITY

- IN ERECTION / CONSTRUCTION

- IN OPERATION & MAINTENANCE

unique features

QUALITY ASSURANCE & INSPECTION

UNIQUE FEATURES

SYSTEMS’ APPROACH

  • PREAWARD TIE -UPS
  • POST AWARD TIE-UPS
unique features22

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.
cqa role in specification finalisation and pre award agreement

QUALITY ASSURANCE & INSPECTION

CQA ROLE IN SPECIFICATION FINALISATION AND PRE-AWARD AGREEMENT

QA REQUIREMENTS IN MODULAR SPECIFICATION

VALIDATION FOR PACKAGE CONTRACTSPECIFICATION

C

Q

A

E

N

G

G

BID EVALUATION

BID EVALUATION REPORT

(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

PRE-AWARD AGREEMENT WITH IDENTIFIED VENDORS/ MAIN CONTRACTORS

FEEDBACK OF SUB-VENDOR PERFORMANCE BY RIO / SITE

TO CS

& FORM PART OF LOA

ANALYSIS OF PREVIOUS NON-CONFORMITIES (NCRs)

slide24

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
cqa interaction at post award stage

QUALITY ASSURANCE & INSPECTION

CQA INTERACTION AT POST AWARD STAGE
  • QUALITY PLAN APPROVAL IDENTIFYING:
    • ACCEPTABLE VENDORS FOR BOIs
    • IN-PROCESS CHECKS
    • FINAL INSPECTION

C

Q

A

  • MAIN CONTRACTOR
  • RIOs

FIELD QUALITY PLAN APPROVAL IDENTIFYING RECEIPT, STORAGE AND ERECTION CHECKS

  • MAIN CONTRACTOR
  • FQA

SUB-VENDOR ASSESSMENT : DETAILS FROM MAIN CONTRACTOR

ACCEPTANCE / REJECTION TO MAIN CONTRACTOR

  • MAIN CONTRACTOR
  • RIO

MANUFACTURING DEVIATION DISPOSITIONING

  • MAIN CONTRACTOR
  • FQA

ERECTION DEVIATION DISPOSITIONING

slide32

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
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
slide34

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.

slide35

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
slide36

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.
slide37

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.