Presentation on NTPC Inspection Services

8/13/2019 Presentation on NTPC Inspection Services

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Presentation onNTPC Inspection Services


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Introduction

Objectives of Inspection Services

Functions of Inspection Services

Organization Structure

Roles of Inspection Engineer

Customers (External &Internal)

Inspection Process

Summary

PresentationOutline


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Quality Assurance & Inspection

Quality is a relative term and is generally expressed withreference to end use of product

Planned and systematic actions necessary to provideconfidence thereby assure the suitability of product forits intended purpose

Control is a system for measuring and inspecting a

phenomenon

Inspection means checking the acceptability of product

Inspection measure the quality of product


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QUALITY IS DEFINED AS

FITNESSFOR USE

FITNESS IS DEFINED BY CUSTOMER

JOSEPH M. JURAN

CONFORMANCE TO THE REQUIREMENTS

PHILIP B. CROSSBY

DEGREE TO WHICH A SET OF INHERENT

CHARACTERISTICS FULLFILLS REQUIREMENTS

ISO 9000


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THE CHARACTERISTICS OF A PRODUCT OR SERVICE

THAT BEAR ON ITS ABILITY TO SATISFY STATED OR

IMPLIED NEEDS

A PRODUCT OR SERVICE FREE OF DEFICIENCIES

AMERICAN SOCIETY OF QUALITY

QualityBy-design & not By-chance

QUALITY IS DEFINED AS


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QUALITY ASSURANCE INCLUDES

REGULATIONS OF QUALITY OF RAW MATERIAL,

ASSEMBLIES,PRODUCTS AND COMPONENTS,

SERVICES RELATED TO PRODUCTION ANDINSPECTION


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THOSE QUALITY ASSURANCE ACTIONS WHICH PROVIDE MEANS TO

CONTROL AND MEASURE THE CHARACTERISTICS OF AN ITEM,

PROCESS OR FACILITY TO ESTABLISH FITNESS FOR USE

VARIATION IS LAW OF NATURE

FOR EACH PROCESS THE VARIATIONS NEED TO BE IDENTIFIED AND

CONTROL MAINTAINED TO LIMIT THE VARIATIONS WITHIN

SPECIFICATIONS. THIS IS QUALITY CONTROL.

QUALITY CONTROL


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THE PROCESS OF MEASURING , EXAMINING, TESTING ,

GAUGING OR OTHERWISE COMPARING ONE OR MORE

CHARACTERISTICS OF A PRODUCT OR SERVICE WITH

THE SPECIFIED REQUIREMENTS.

A process of segregating good from bad

INSPECTION


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A SET OF POLICIES, PROCESSES AND PROCEDURES

REQUIRED FOR PLANNING AND EXECUTION

(PRODUCTION / DEVELOPMENT / SERVICE) IN THE CORE

BUSINESS AREA OF AN ORGANIZATION.

QUALITY MANAGEMENT SYSTEM


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OBJECTIVES OF INSPECTION SERVICES

TO ENSURE THAT DEFECT FREE PLANT & EQUIPMENTCOMPLIANT WITH TECHNICAL SPECIFICATIONS AND OFSPECIFIED QUALITY.

TO UNDERSTAND INSPECTION REQUIREMENTS OFTECHNICAL SPECIFICATION

ON-LINE PLANNING OF INSPECTION CALLS WITH A VIEWTO IMPROVE TIME SCHEDULE FOR DISPOISITIONING OFINSPECTION CALLS AND TO ATTEND INSPECTION CALLS

IN LINE WITH CUSTOMER REQUIREMENTS.


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Functions of Inspection Services

Verify specified quality level of equipment by carrying outinspection at contractors / sub-Contractors premises, orby review of test certificate in accordance with agreedQuality Plan and contract requirements, for equipment

ordered from Corporate Contract, consultancy assignmentand from project ordered equipment and to carry outinspection activities as per agreed schedule matchingProject Schedule and requirements.

Ensure implementation of agreed documented qualitysystem and programme at contractors / sub- contractorsworks by verifying inspection records, process controlrecords, calibration status during inspection of equipment.


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ORGANIZATIONAL STRUCTURE

DIRECTOR (TECHNICAL)

ED (ENGINEERING)

HEADQA & I

INSPECTION SERVICES

RIO

DELHI

RIO

HWR

RIO

BPL

RIO

BRD

RIO

KOL

RIO

TRY

RIO

RPN

RIO

HYD

RIO

BLR

RIO

TRVN

RIO

MUB

RIO

PUN

RIO

CHN


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Role of Inspection Engineer

Product identification & traceability wherever applicable.

Verification of clearance of earlier inspection stages, whereverapplicable.

Ensure calibration of the measuring equipment used duringinspection.

comprehensive review of the internal quality records of theContractor as per the quality plan ensuring adherence to therequirement and dispositioning of deviations, if any.

Surveillance check on the quality programme of theContractor agreed as per the contract.


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Contd..

Provide feed back on Contractors process control, manufacturing facilities &quality. Reporting Non conformities observed.

Provide regular feedback to Corporate Contracts/ Engg. regarding holdups orlikely delays in Manufacturing Programme. Causes for such hold ups / likely

delays are identified in their reports for speedy redressal.

Monitoring of Inspection Calls, Issue of MDCC for dispatch of equipment aftersatisfactory final inspection and clearance of CHPs & verification ofimplementation of corrective action, as agreed, for dispositioning of Nonconformities.

Association with CQA, as required, for audit of Quality system ofContractors,/Sub Contractors.

Assess the actual manufacturing Progress of the critical items required by theProject Contract Services, identify any hold ups in their manufacturing andsend a report to Project, Engg/CQA Corporate Contracts.


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Calibration of Instruments

Ensures Correct reading

Appropriate reference

Logical approach

Minimum inconsistencies

Better accuracies

Repeatability of measurements

All time confidence Traceability of records

Integrity of reports

Optimum performance


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Customers

External - Contractors/Suppliers

Internal - Projects/Sites


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DOCUMENTS FOR INSPECTION

Quality requirements and testing provisions needs to be the part ofcontract for its effective implementation.

Documents needed for inspection are prepared and submitted bysuppliers and processed and finalized by other groups/div of NTPCand therefore close coordination by inspection services is neededwith all these groups and suppliers

Pre award finalization/commitments include List of agreed make/model/manufacturer of various subcomponents

submitted by supplier and mutually agreed with CQA Finalization of manufacturing quality plan(MQP) containing

a) listing all tests and checks to be done during manufacturing andrecords to be kept for review by inspection engineer duringinspectionb)List all test/checks with sampling plan for test to be witnessed byNTPCThese documents are submitted by supplier and approved by CQA


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Contd..

List of type tests to be done by supplier and to be approvedby NTPC Engg

List of type tests to be done by supplier and to be approvedby NTPC Engg

list of drawing/datasheet requiring approval by NTPC Engg Billing breakup for purpose of on account payments and

issuance of MDCC approved and issued by Contract Div Contract agreements jointly signed by supplier and NTPC Standards such as IS , BIS, ASME, IEC Etc which broadly

specify testing procedures , acceptance norms etc[Checks

identified in MQP are broadly derived from these standards]


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Process of Inspection and Issuance of CHP

and MDCC Complete process is mapped and controlled

through a web based application (known asWINDSORx) accessible through Internet by allinspection offices, suppliers and sub-suppliersand other users of inspection related data

Suppliers submits offer for inspection listingdetails of BBU no , item , total qty , qty alreadysupplied and qty offered for inspection withproposed date for inspection using online portal

The inspection call is scanned for completenessof approved documents


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Contd..

The inspection planning is done through the same portalby the In-charge of inspection office.

Inspection engineers visit the place of manufacture andchecks the following before starting inspection/testing:

Quality plans are approved. Drawing/ Datasheets are approved. Review all internal test records maintained by the

manufacturer.

Check that all the sub-components are ofapproved/agreed make. All the testing equipments are calibrated and are in

working conditions.


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Contd..

After ensuring the above, the preliminary work involves- Verification of availability of complete material for inspection. Identification(stamping)of the offered lot.{to the extent feasible} Performing random sampling of items for testing.{Inline with quality

plan} After selecting sample for testing, witnessing of actual testing starts . Few parameters to check are- Visual Dimensional Conformity.

Functional compatibility checks.examplespressure parts/rotary partsQuality of welds by RT and DPHydro test/pneumatic pr test at 2.0 times working pressureMechanical testing and chemical composition of body materialhardness test

Efficiency test for pumps/blowers/motors


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Contd..

After completion of tests , inspection report(CHP) isgenerated on line using inspection portal from theplace of inspection and MDCC is also issued fromthe portal and handed over to supplier if item is

found acceptable in all respect.

The data thus generated, updated and modifiedby NTPC as well as its suppliers and manufacturers(as a normal course of discharging their functions)

provides comprehensive and customized onlineinformation to various groups and monitoringagencies as well as the clients and suppliers who inturn take immediate corrective actions for ensuringtimely availability of materials and components at

the project site.


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Inspection call entry screen

SNAPSHOTS OF WINDSORx


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A typical list of contracts awarded for NTPC Mauda project


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Inspection Planning sheet


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Inspection weekly grid


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CHP report


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MDCC Reports


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Inspection Planning sheet


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Inspection weekly grid


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QualityBy-design & not By-chance

Quality is not an act .It is a habit


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