BEST PRACTICES IN QUALITY ASSURANCE & INSPECTION IN NTPC

1. QUALITY ASSURANCE & INSPECTION BEST PRACTICES IN QUALITY ASSURANCE & INSPECTIONIN NTPC

2. 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

3. QUALITY ASSURANCE & INSPECTION QUALITY ASSURANCE CONCEPTS

4. QUALITY ASSURANCE & INSPECTION QUALITY “QUALITY IS FITNESS FOR USE”

5. 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”

6. 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”

7. 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.”

8. 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.”

9. QUALITY ASSURANCE & INSPECTION QUALITY SYSTEM

10. 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.

11. QUALITY ASSURANCE & INSPECTION QA&I MANAGEMENT SET UP

12. 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.

13. 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.

14. 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.

15. 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

16. 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.

17. 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

18. 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.

19. 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

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

21. QUALITY ASSURANCE & INSPECTION UNIQUE FEATURES SYSTEMS’ APPROACH • PREAWARD TIE -UPS • POST AWARD TIE-UPS

22. 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.

23. 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)

24. 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

25. 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

26. QUALITY ASSURANCE & INSPECTION MANUFACTURING QUALITY PLAN

27. QUALITY ASSURANCE & INSPECTION FIELD QUALITY PLAN

28. QUALITY ASSURANCE & INSPECTION CERTIFICATE OF CONFORMANCE

29. QUALITY ASSURANCE & INSPECTION INSPECTION CALL FORMAT

30. QUALITY ASSURANCE & INSPECTION CHP REPORT

31. QUALITY ASSURANCE & INSPECTION MATERIAL DESPATCH CLEARANCE CERTIFICATE (MDCC)

32. 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.

33. 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

34. 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.

35. 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

36. 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.

37. 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.

38. BEST PRACTICES

39. QUALITY ASSURANCE & INSPECTION THANK YOU