quality policy

To attain & maintain a leading position in power

sector through adoption of art of technology,
excellence in engineering & quality management
to international standards towards safe, reliable &
environmental friendly power generation at
optimum cost and time, achieving

Inspection services
objective
To ensure that contractors conform
completely with engineering
specifications and quality plans so that
the Quality equipment/Product is
delivered for Power Generation as a
result tangible & and intangible losses
are kept to a minimum.

INSPECTION DEFINED
Two definitions currently in use are:
A static analysis technique that relies on
visual examination of development
products to detect defects, violations of
development standards, and other
problems.
An inspection is a formal review of a work
product by the work product owner and a
team of peers looking for errors,
omissions, inconsistencies, and areas of
confusion in the work product.

Quality Assurance & Inspection

Project Engineering
Enviromental Engineering
Project Engineering Management
New Projects & Proposal Group
Construction Services
Documentation & Library

Quality Assurance & Inspection Group

CQA

INSPECTION SERVICES
CIS

RIOS

DELHI
MUMBAI
CHENNAI
KOLKOTA
HARDWAR
BANGLORE
HYDERABAD
RANIPET
TRICHY
TRIVANDRUM
BARODA
BHOPAL

RESPONSBILITIES OF INSPECTION SERVICES

1- TO CARRY OUT INSPECTION OF MATERIAL AND EQUIPMENTS ORDERED BY
CORPORATE CONTRACTS OF NTPC.
2- INSPECTION OF O&M SPARES FOR ALL OPERATING UNITS OF NTPC
WHETHER ORDERED FROM CORPORATE CENTRE OR SITES.
3- TO REVIEW RECORDS OF INSPECTION CARRIED OUT BY MANUFACTURERS
Q.C PERSONNEL.
4- TO ENSURE COMPLETENESS OF ITEM BEFORE GIVING DESPATCH
CLEARANCE.
5- TO ISSUE MDCC( MATERIAL DESPATCH CLEARANCE CERTIFICATE) AFTER
SATISFACTORY COMPLETION OF FINAL INSPECTION .

RESPONSBILITIES OF INSPECTION SERVICES

6- TO CARRY OUT PERIODIC CHECKS ON CALIBRATION OF MEASURING &
TESTING INSTRUMENTS USED BY MANUFACTURERS DURING SHOP INSPN
& TESTING.
7- TO CARRY OUT SURVEILLANCE CHECK AT NON-CHP STAGE.
8- TO REVIEW INSPECTION REPORT OF THIRD PARTY INSPN AGENCY& ISSUE
MATERIAL DESPATCH CLEARANCE CERTIFICATE.
9- TO PREVIEW MANUFACTURERS TEST CERTIFICATE AND INSPECTION
REPORT IN RESPECT OF SUCH ITEMS AND STAGES FOR WHICH
INSPECTION BY NTPC HAD BEEN WAIVED OFF.
10- REPORTING OF DEVIATIONS OBSERVED DURING INSPECTION AND
PROMPT DISPOSAL OF SUCH DEVIATIONS.

RESPONSBILITIES OF INSPECTION SERVICES

11- TO KEEP A CONSTANT WATCH ON THE IMPLEMENTATION OF QUALITY
SYSTEMS AT MANUFACTURER WORKS AND TO PROVIDE FEEDBACK TO
CQA GROUP IN THIS REGARD.
12- TO ASSOCIATE DURING SITE PERFORMNACE AND GUARANTEE TESTS ON
VARIOUS EQUIPMENT SYSTEMS.
13- TO ASSOCIATE WITH OTHER GROUPS IN NTPC FOR ANALYSIS OF FAILURE
REPORTS RECEIVED FROM SITES.
14- TO VERIFY COMPELTION OF TESTING & INSPN FOR ALL THE ITEMS
COVERED IN PACKAGE AND TO FURNISH REQUISITE CERTIFICATE DURING
CONTRACT CLOSING STAGE.
15-TO KEEP DOCUMENTATION OF NON-COMPLIANCES .
16- TO PROVIDE THIRD PARTY INSPECTION SERVICES TO OTHER
ORGANISATIONS.

DEFINITIONS:
QUALITY PLAN:
A Document setting out the specific Quality
Practices and Procedures relevant to a
particular item, component or material in
prescribed format.The QP is prepared by the
contractor or subcontractor and subsequently
finalised and approved by Quality Assurance
Department.

CUSTOMER HOLD POINTS(CHP):

Customer Hold points are the stages in process
which are identified in QP beyond which work
will progress only with NTPCs written consent
in respect of the relevant items and materials.

CHP Clearance Report:

A Document prepared at the time of inspection of
materials/items against CHP stages identified in
the finalised QP/Inspection Check List.This
report is jointly signed by NTPC Engineers and
Contractor/Subcontractor for Physical inspections.

MATERIAL DESPATCH CLERANCE CERTIFICATE

(MDCC):
MDCC is a Document issued by Inspection or
Quality assuarance engineer for the
items/materials found in conformance to
contractual requirements after successful
inspection or successful review of test
certificate or certificate of conformance. MDCC
permits the Contractor/Subcontractor for Physical
despatch of the material and also used by the
contractor for purpose of billing and subsequent
payment.

INSPECTION ACTIVITIES
RECEIPT OF INSPECTION CALL
IN INSPECTION CALL FORMAT
Check the availability of
1-QP/CHECK LIST
2-DRAWING/DATASHEET
3-PO Copy if site purchase order

PHYSICAL INSPECTION
-Inspect Material as per approved QP.
-Identify the material.
-Issue CHP report
-Issue MDCC, if no Hold point in CHP.

ENTRY OF INSPECTION CALL IN DATABASE

-A Unique No is assigned to every call

PLAN INSPECTION
-On first Day of Every week, Inspection Call
assigned to inspection Engineer.
-Weekly inspection schedule prepared (GRID).
-Inspection calls Loaded to Floppies of Inspecting
Engineers as per GRID.
-Generation of Various monitoring report.
-Issue of reminder Letters through software.

INPECTION STATUS FEED BACK

-On completion of Inspection, Update the Floppies with server
Database.
-All inspection status with HOLD points & Disposed one are
available in database.Can be viewed on EOC LAN.

INSPECTON CATEGORIES:
CAT 0 - STAGE INSPECTION
CAT-1 - Where as per QP/ICL physical inspection witness by NTPC is
envisaged.

CAT-2. - Where item is covered in QP/ICL but physical inspection

witness by NTPC is not envisaged and material is to be cleared on the
basis of review of Material Test Certificate and/or Inspection reports of
the main contractor or the test reports/Test certificates from the
subcontractor/manufacturer duly disposed & authenticated by Main
Contractor.

CAT-3- Where the item is not covered in QP/ICL but covered in BBU and
inspection is by the Main Contractor/Sub contractor or Manufacturer a
certificate of conformance(COC) should be furnished as per the
prescribed format.

DISPOSAL CODES
DISPOSAL_CODE
DISPOSAL_DISCRIPTION
ACTIONBY
A
ITEM IS NOT READY/ FRESH INSPECTION CALL TO BE GIVEN
B
REWORK /FRESH INSP CALL,WITH COMPLIANCE TO BE GIVEN
VENDOR
CE INSP NOT UNDERTAKEN FOR WANT OF ENGG DOCUMENTS
ENGG
CQ INSP NOT UNDERTAKEN FOR WANT OF QA DOCUMENTS
CQA
D
CALL CANCELLED BY VENDOR
VENDOR
E
MATERIAL IS REJECTED VENDOR
F
INSPECTION CALL INCOMPLETE, RETURNED TO MAIN CONTRACTOR
G
CLOSED IN ABSENCE OF RESPONSE/CLARIFICATION FROM VENDOR/SITE
J
MATERIAL ACCEPTED MDCC ISSUED
JC
ACCEOPTED,CONDITIONAL MDCC,AS ADVISED BY CONTRACTS
CC
JE
ACCEOPTED,CONDITIONAL MDCC,AS ADVISED BY ENGINEERING ENGG
JP
ACCEOPTED,CONDITIONAL MDCC,AS ADVISED BY PROJECT
PROJ
JQ
ACCEOPTED,CONDITIONAL MDCC,AS ADVISED BY CQA
CQA
JX
ACCEPTED CONDITIONAL MDCC ISSUED
K
STAGE INSPECTION ACCEPTED MDCC NOT APPLICABLE
L
ACCEPTED MDCC NOT APPLICABLE
P
CALL PERTAINS TO OTHER RIOS, REDIRECTED
RIO
S
DUPLICATE CALL
RIO
XF ACCEPTED SUBJECT TO APPROVAL OF DEVIATION VENDOR
XG ACCEPTED SUBJECT TO COMPLIANCE VENDOR
XH
MAT INSPECTED, ACCEPTED SUBJECTED TO BBU APPROVAL
CC
XI
ACCEPTED, SUBJECT TO TYPE TEST APPROVAL BY ENGG
ENGG
XM CALL PENDING/NOT DUE
XQ INSPECTION ATTENDED TESTING CONTINUED FOR LONG DURATION TEST
XR ENGINEER DEPUTED REPORT AWAITED
RIO
XT PARTIALY INSPECTED FURTHER INSPECTION REQUIRED
RIO
XX ENGG DOCUMENTS NOT APPROVED IN CAT-I ,MDCC WITHHELD
ENGG
XY ANY CONDITION NOT COVERED ABOVE
XZ AQP / ICL NOT APPROVED IN CAT--I, MDCC WITHHELD
CQA

VENDOR

RIO

DISPOSITION OF NON-CONFORMAITY
NON-CONFORMITY:

Non fulfillment of a specified

requirement.

CORRECTIVE ACTION:

Action taken to eliminate

the cause of an existing non-conformity,defect or
other undesirable situation in order to prevent the
recurrence.

REPAIR:

Action taken on a nonconforming product so

that it will fulfil the intended usage requirement
although it may not conform to the orginaly specified
requirements.

REWORK:

Action taken on a non-conforming

product so that it will fulfill the specified
requirement.

NON-CONFORMITY REPORT:
Formal request from contractor to deviate from a
specified quality requirement in NC-Format.
DISPOSITION OF NC:
Action to be taken to deal
order to resolve NC.

with existing NC in

NC CATOGARIES:
CAT-A: MAJOR NC-Reviewed & Disposed by CQA.
CAT-B: MINOR NC- Disposed by HEAD-RIO.

MONITORING REPORTS
1) EXCEPTION REPORT
2) STATUS REPORT
3)SUMMARY REPORT

DOCUMENT CONTROL
TYPE OF FILES
1) PACKAGE
2) MDCC
3)REFERENCE
4)WEEKLY PLANNING
5)EXCEPTION