GOOD QUALITY PRACTICES @ NTPC KUDGI

Introduction:
NTPC has been on the path of progress in the form of qualitative and quantitative
capacity addition in our country. With the advent of demand for efficient power
generation and ever increasing growth in the technologies being incorporated into the
concept of power production, we have embraced the supercritical technology. Since
this is just the inception of supercritical technology in our plants, it is only natural to
observe a few practices that are both helpful for progress and in saving time. The
necessity to implement best quality practices is imperative in any Project.

Some the good Quality Practices being followed/implemented at Kudgi STPP, are
described below

Preassembly of Erectable Parts:

One of the major works which is on critical path in any power plant erection is the
completion of the Steam Generator(Boiler). The system, being vast in both tonnage
and activities, requires lot of meticulous planning and implementation to achieve the
required targets. The major concern in any erection process is the number of lifts
required to complete the erection activity. By reducing the number of lifts, one can
reduce the time taken for erection and utilize this time to complete other activities
that follow. It helps in doing activities such as welding and NDE before erection,
which aids in attending to any reworks to be done before lifting the system. This is
where ‘Pre-assembly’ helps in achieving better quality and reduction in time.
A few of the major lifts that have been done, which saved us a lot of time are:

1. Economiser, Pry-Reheater and Rear Arch Wall: Erection of these material is one of
the most important and time taking activity and involve many lifts of erection.
Preassembly reduces the amount of time taken for the erection of the entire
assembly, thus faster clearance is given for further activities.

2. Fin and Seal Welding of Panel to Panel: In the Seal welding of Panel to Panel the
visual inspection of welding and DPT is carried at O Mtr. (Ground) itself. This results
in better quality of welding.
3. Header to Panel and Coils Joints : The welding of major portion of Header to Panel
and Header to Coils is done at boiler Cavity (O Mtr.), so that the welding quality and
repair is reduced and 100 % visual inspection of welding and NDT is Carried.

4. Pre-Assembly of Coal Silo Shells and fixing of SS Linear plates increases the welding
quality and reduces the erection time.

5. SS protection shield and Cassette baffle over the coils in the flue gas path is one of
the most important and time taking work. Preassembly and Shop weld reduces the
amount of time taken for the entire assembly and proper alignment. Mis-alignment
of protection shield may lead to heavy damage to tubes.
 6. Buck Stay and all associated guide beams are welded along with the panel in boiler
cavity (O Mtr.). This facilitates 100% visual inspection of welds and DPT at ground
itself to give further erection clearance after ensuring weld quality.

Other Good practices Adopted to improve Quality of Welding:

1. Pressure Parts Welding Inspection: 100 % visual inspection of welds is carried out
for all Pressure parts welding at site to eliminate the weld defects, gas cutting and
dents..
2. Piping welding Inspection: 100 % root window inspection is carried out for P-91
pipe welding by providing window, from which the whole root is inspected. If any
defects are found the same are rectified/repaired before giving clearance for further
welding. This window inspection results in eliminating the root defects like
oxidation, lack of penetration and root concavity, which inturn minimize the repair
joints.

3. Readiness of DG Set : Availability / readiness of DG set is fully ensured before

starting of critical activities like Welding of P91 or Stress Revelling cycle. Thus, back-
up power from DG set is immediately made available in case of failure of regular
power supply. This reduces sudden temperature drop during the heating and SR
Cycle.
4. Positive Material Identification: 100% PMI is being carried out in boiler tubes and
pipes to rule out any possible mix-up of material and to find out usage of correct
electrode for the material welded. This practice helped us to ensure weld
healthiness.

5. Welder Performance monitor: The performance of each and every welder is

monitored on continuous basis. If the defect ratio of any welder is found increasing
then the welders are trained explaining the causes of defects and remedy actions. If
the defect ratio of any welder continues to be high even after such re-training, the
welder is disqualified and barred from critical welding works.

6. Welding School at Site : M/s DOOSAN, the agency executing SG package at Kudgi
has set up a Welding School for conducting welders’ qualification tests and also for
imparting regular training for qualified welders. Regular training classes to welders
helped in minimizing welding failures at Kudgi.

7. Class room training for welders: Intermittent class room trainings are
conducted to all welders to make them aware of various welding defects
and proper actions to prevent such defects.
8. Welding Rod Control Room : Various consumables used in welding such as
Electrodes, Filler wires..etc are required to be stored at controlled atmosphere to
maintain the required temperature and humidity as well. For this purpose an
exclusive welding rod control room is set up and the temperature and humidity are
monitored continuously.

9. Recognition to good welders: Good performing welders (with least defect

ratio) from each agency are being motivated by presenting a memento
 10. Material Storage:

One of the most important activities required for proper execution of works is the
proper storage of material. Materials in the lay down area are stacked properly
supported with suitable sleepers. Proper codification of the material and location of
storage enabled immediate issue of material. All electrical material and insulations
are stored in proper covered sheds and all valves and motors are stored inside the
warehouses in order to protect them from rain as per storage and preservation
quality plan. This helps in avoiding damage of material and thus reduce any delays
in the succeeding activities.

Conclusion:
Stated above are only some of the good quality practices those have been followed in the
SG- Package of NTPC- Kudgi, which proved to be effective. These are also replicated and
being ensured in other packages as well. Though the practices are not unknown, strict
compliance to quality plan and accepted engineering practices is the key for success. At
Kudgi, it is always our endeavour for continuous improvement and ensure that KUDGI
STPP to become The Best Super Critical Power Plant in the days to come.