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QA&I PROCESS MAPPING

Liaisoning service providers for NDT, PWHT, External Lab on material testing etc.,

Review & approval of QAP for spares & equipments

Providing Technical inputs to end users for spares and material procurement.

To liaison with statutory authority for inspections and Boiler License renewals -IBR

To liaison with statutory authority for RT pit room & source movements -AERB

Reciept inspection of raw materials and goods at site.

All stage & final inspection activities at site and vendor premises.

All fiels inspections during Preventive & Breakdown maintenance.

Welding survelliance & visual inspection

NDT inspections (UT/RT/MT/PT/ECT/PMI/Boroscopic)

Thickness mapping & survey

Hardness inspection

Conducting in situ replica tests

Pneumatic & Hydraulic tests

Corrosion audit & painting inspections

Exploring & Hiring of advanced NDT solutions

Establishing WPS, PQR, WPQ Tests & miscel etc.,

Liasing with laboratories for chemical & Mechanical testing

Survelliance quality checks & cross functional team activities

Review of vendor inspection records for waived off inspection calls.

Inspection records generation and maintenance

To co-ordinate with TPI for outstation inspections within & outside india

Conducting RCA of Boiler tube leaks & recommendation.

Focus on minimizing welding repairs

Participating site level meetings.

Inter-department co-ordination for inspection requirements.

SAP PR generation, PO expediting, service entry & clearance followup etc.,


ANOH - QA CHECK LIST
SL DES LOCATION

1 Visual inspection - Boiler furnace & 2nd pass BOILER

2 Visual inspection - Boiler pent house inside BOILER

3 in situ metallography - Headers & piping BOILER

4 Thickness survey BOILER

5 Hardness survey BOILER

6 PMI Checks BTG

7 Preventive RT BOILER

8 Header stubs - DPT inspection BOILER

9 Welder qualification tests BTG & BOP

10 Welding survelliance inspection BTG & BOP

11 Final welding inspection BTG & BOP

12 NDT of welding BTG & BOP

13 PWHT survelliance inspection BTG

14 Pneumatic test- RH BOILER

15 Hydraulic test - SH BOILER

16 Statutory inspection clearance BOILER

17 PA Fan Blades - DPT inspection BOILER AUX

18 ID Fan impeller- DPT inspection BOILER AUX

19 Bunkers- Visual inspection BOILER AUX

20 TG Bearings- DPT & UT inspection TG

21 Visual inspection - ALP Last stage Blades TG

22 Visual inspection - BLP Last stage Blades TG

23 TDBFP Blades-DPT & MT inspection TG AUX

24 TDBFP Bearings- DPT & UT inspection TG AUX

25 HP Heaters - ECT inspection TG AUX

26 LP Heaters - Pneumatic test TG AUX

27 CW Piping corrocoat - Visual inspection BOP


T
REMARKS
QA&I Process map for procurement activities

END USERS
(PR STAGE)

QA&I providing Technical Purchase order placement


inputs to End user & P&C bypassing QA inputs

P.O Placement

QAP Approval

Reciept of
inspection calls

Physical Inspection Document review &


(TPCIL or TPI) inspection waival

Material reciept &


inspection at site
BTL NOTIFICATION

YES
INTIMATION TO NO
IBR

1. DCIB may issue stop notice under Sec.8(5)(b).


2. Boiler License will get terminated, to be renewed.
3. Inspection of failure location by DCIB.
4. DCIB Recommending repair procedure to DOB. RISK:
5. DOB to issue approval for repair procedure
6. Raw material inspection. 1. Legal compliance violation.
7. Fit-up inspection.
8. Welding & NDT inspection.
9. Boiler hydro test.
CONCLUSION: Above activities may consume 4 to 5 CONCLUSION: Rectification
days after boiler cooling, at the discretion & activities may be completed
availability of Boiler inspector. within 2days after boiler cooling.
lation.

tion
eted
r cooling.