POWER LINK CONTRACTING

DUBAI

COMPANY PROFILE

1
 INDEX

1. Brief History, Introduction, Mission statement & The

Pedigree

2. Photographs of Major site activities

3. Company & Activities

4. Organisation chart

5. Work Experience & Capabilities

6. Projects under Execution

7. Key personnel

8. Company Resources/Assets

9. Health, Safety & Environmental Protection System

10. Quality Assurance and Quality Control

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BRIEF HISTORY OF THE COMPANY

Power Link Contracting, Dubai, was set up with the aim of serving the
UAE in building an integrated power network. The company began in
1999 by carrying out the erection of new GSM towers across the UAE and
aviation painting of existing overhead power transmission lines in this
region.

With the strong commitment and dedication of its staff, PLC raised its
profile to take up all type of construction associated with Over Head
Transmission Line (except pile foundation) .PLC is proud to mention its
association in completing all assigned activities in one of the toughest
terrain of double circuit overhead transmission line (D/C OHTL) 400KV
between Fujairah – Dhaid (Northern emirates)

PLC with its strong assets and technical competency also has a sound
financial back-up of the Arab Gulf Pearl Trading Establishment,
Abudhabi, UAE.

INTRODUCTION

Power Link Contracting, DUBAI has made rapid strides in the

construction of overhead transmission lines (OHTL) in U.A.E and has
achieved remarkable growth within a short span of time.

The company is able to execute complete OHTL projects from 33KV to

400KV (except pile foundations) involving survey, construction of access
roads, tower foundation (Pad & Chimney), erection, painting and
stringing. PLC is proud to project progress in foundation, erection and
stringing works have often exceeded client’s expectations.

The manpower strength of the company in UAE stands at about 200

personnel (includes skilled & semi skilled).The company owns latest
technology (operations controlled by remote) tension stringing
equipment (2 sets) from ZECK Germany suitable for both twin and
quadruple conductors including all essential accessories.

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MISSION STATEMENT

To be an innovative company driven by performance, providing the best

value for money and commitment and complete satisfaction to all our
customers/clients with timely completion of project, while pursuing the
path of excellence.

THE PEDIGREE

“Power Link Contracting” bears a strong lineage and draws its strength
from the rich legacy of “Arab Gulf Pearl Trading Est.” The group’s vision
and relentless business excellence ensures total customer satisfaction
.The same zeal and wisdom guides this company too.

The division, with its assets and technical competency and backed by the
financial soundness of the group, is fully geared up for the undertaking of
large projects in Power Transmission Lines and other sectors on Turnkey
basis.

Power Link Contracting, Dubai has its branch office in Abu Dhabi. The
manpower strength in UAE stands about 200 personnel .The company is
involved in number of projects in UAE & OMAN

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PHOTOGRAPHS ON MAJOR ACTIVITIES
Proves our team efforts

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ACCESS ROAD

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 Laying of Access Road in 400KV OHTL Fujairah – Dhaid

Preparation of Access Road in 400KV OHTL Fujairah – Dhaid

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 Access Road in 400KV OHTL Fujairah – Dhaid

Laying of Access Road in 400KV OHTL Fujairah – Dhaid

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FOUNDATIONS

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Preparation of Foundation in 400KV OHTL Fujairah – Dhaid

Excavation in 400KV OHTL Fujairah – Dhaid

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 Reinforcement placed for Foundation in 400KV OHTL Fujairah – Dhaid

Reinforcement placed for Foundation in 400KV OHTL Fujairah – Dhaid

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Preparation for Foundation in 400KV OHTL Fujairah – Dhaid

Stub Setting in 400KV OHTL Fujairah – Dhaid

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 Stub Setting in 400KV OHTL Fujairah – Dhaid

Pouring of Concrete in 400KV OHTL Fujairah – Dhaid

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 Pouring of Concrete in 400KV OHTL Fujairah – Dhaid

Completed Foundation in 400KV OHTL Fujairah – Dhaid

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Foundation with Sub Setting in 400KV OHTL Fujairah – Dhaid

Completed Foundation in 400KV OHTL Fujairah – Dhaid

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Access Road with Completed Foundation in 400KV OHTL Fujairah – Dhaid

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TOWER ERECTION

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Tower Erection with Gin Pole

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Erected Tower in 400KV OHTL Fujairah – Dhaid

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STRINGING

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 Preparation of Roller Hoisting for Stringing

Roller Hoisting for Stringing in 400KV OHTL Fujairah – Dhaid

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 Stringing in 400KV OHTL Fujairah – Dhaid

Stringing in 400KV OHTL Fujairah – Dhaid

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TSE AND TOOLS

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 Socks for Conductor Stringing

Belts for Lifting of Towers Using Crane

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 Spacer Fixing Cradle

Gin Poles for Tower Erection

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Gin Pole for Tower Erection

Pilot Wire Drums

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Single Sheave Pulleys

Three Sheave Pulleys

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Five Sheave Pulleys

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THE COMPANY & ITS ACTIVITIES

The following types of activities are undertaken by

POWER LINK CONTRACTING LLC
(i) Civil Construction and refurbishment
In this sector the civil construction works like survey,
service roads, line transmission and painting of
towers, refurbishment works and electrical work for
the industrial sectors are being covered.
(ii) Transmission system and GSM
In this sector the services are provided to power and
telecom sector. The services includes installation of
transmission line towers, painting, earth work &
laying of service roads, foundations stringing
conductor, OPGW & Cabling, earthing and fixing
aviation lights etc.
(iii) Scaffolding Services
In this sector we provide total solutions for scaffolding
& motorised cradle services. The scaffolding services
include study of required parameters, designing in
accordance with applicable codes & standards and
erection & dismantling work as per our HSE
standards. The services are provided on hire basis,
Turnkey contract basis and as an associate activity
with other construction activities.

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BRANCHES & CONTACT ADDRESS

1. DUBAI
POWER LINK CONTRACTING
P.O.BOX 72351
DUBAI
UNITED ARAB EMIRATES
TEL: 00971 4 – 3365322 / 3365323
FAX: 00971 4 – 3365324
MOB: 0971 – 50- 8116434

2. ABU DHABI
POWER LINK GENERAL CONTRACTING
P.O.BOX 7371
ABU DHABI
UNITED ARAB EMIRATES
TEL: 00971 -2 – 6444575
FAX: 00971 4 – 6443348
MOB: 0971 – 50- 6414980

3. OMAN
POWER LINK CONTRACTING
P.O.BOX 694, P.C 114
MUSCAT
SULTANATE OF OMAN
TEL: 00968 -24875156
MOB: 0968 – 98165-105

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 WORK EXEPERIENCE & CAPABILITIES
Sl. Client Main Contractor Activities of works Executed Quantity
No
1 ADWEA M/s KEC International Supply and painting of 170 No’s
Ltd 400KV/220KV Towers
2 TRANSCO -do- Apply of paint for 400 KV / 220 KV 80,000 SQMTR
towers from Taweelah to Yas
Island
3 SEWA -do- Erection of 220 KV towers from 1000 MT
Altay - Sajja to Sajja - Hamriya

4 ADWEA M/s Larsen & Toubro For 220 KV OHL - Liwa GS to Liwa 2750 MT
Ltd West Erection of
towers
Stringing of conductors / OPGW 45.15 Km
5 ADWEA -do- For 220 KV DC OHL - Sweihan GS 1300 MT
to Al Hayer & Ramah in Al Ain
Erection of towers
Stringing of conductors / OPGW 89.8Km
For 400 KV DC OHL - Jabel Ali to 4500 MT
Merkadh Erection of
towers
6 DEWA M/s Emirates trading Stringing of conductor / OPGW 30km
Agency (ETA) Survey 42 km
Stub setting / Pile Head 175 Nos

7 ADWEA -do- Erection of towers 209 Nos

Stringing of conductors / OPGW 42 km
8 MEW GCC M/s Emirates Trading For 400 KV DC OHL - Dhaid 'S/S' to 4000 MT
Grid Agency (ETA) 'H' S/S Erection of
towers
Stringing of conductor / OPGW 69 km
9 DEWA - do - For 400 KV DC OHL - Diamond 2400 MT
crossings to Bukhiora S/S
Erection of towers
Stringing of conductor / OPGW 9 km
Erection of towers & gantry 50 MT
Construction of access road 0.5 km
10 ADWEA M/s Emirates Star Removal of DC twin bundle Aldrey 5.64 km
International LLC conductor
Removal of OPGW 5.64 km
Removal of DC towers 15 Nos. 358 MT
11 FEWA M/s Civil Contracting For 220 KV / 132 KV DC OHL - 6300 MT
Co. Ltd Northern Emirates Erection of
towers
Stringing of conductor / OPGW 68.5 km
12 SEWA -do- For 220 KV / 132 KV DC OHL - 9 No’s
Northern Emirates
Erection of towers
Stringing of conductor / OPGW 7 km
Construction of access road 131 km
13 MEW M/s Hyundai working platform for 400 KV OHL 293 No’s
(Project MEW/E01/2003-Lot II - 1
14 FEWA M/s National For 220 KV DC OHL – Fujairah 1500 MT

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 Contracting Co. Ltd Erection of towers
Stringing of conductor / OPGW 34 km

15 DEWA M/s National For 400 KV DC OHL - Jabel Ali to 3600 MT

Contracting Co. Ltd Najma Erection of
towers
Stringing of conductors / OPGW 22 km
Dismantling of conductors 22 km
Survey / Profile 9 km
Erection of towers 45 Nos
16 ADCO M/s Ranya Stringing of conductors / OPGW 9 km
Contracting Est. Painting of towers 200 MT
Construction of platform for tower
45 No’s
erection

PROJECTS UNDER EXECUTION

Sl. No Client Main Contractor Activities of Works Executed Qty

For 400 KV DC OHL - Mussafah to

1 TRANSCO M/s Hyundai Madinat (Contract No. N- N-4099) 133 km
Stringing of conductors / OPGW

For 220 KV OHL - Al Ain South West

M/s to Al Oush (Contract No. N-
N-4673) 6000 MT
2 TRANSCO
Kalpataru Erection of towers
Transmission
International Ltd
Stringing of conductors / OPGW 109 km

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 KEY PERSONNEL

DIRECTOR

Mr. Adam Sheikh - Mobile No: 0506414980

DIRECTOR

Mr. M. Umapathy - Mobile No: 919444046106

CHIEF EXECUTIVE OFFICER

Mr. M.Manivannan - Mobile No: 0508116434

HR & ADMIN MANAGER

Mr. Askermon Abu Backer - Mobile No: 0505505361

FINANCE & ACCOUNTS OFFICER

Mr. D.Suresh Jayaseelan - Mobile No: 050 5505364

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COMPANY RESOURCES /ASSETS
A.DETAILED LIST OF TOOLS

S.I. NO. Description Quantity( No's)

1 Pulley lift 6 ton 22
2 Pulley lift 3 ton 29
3 Pulley lift 1.5 ton 34
4 Pilot wire drum stand 6
5 Conductor drum stand 9
6 Conductor clamp (auto) 54
7 OPGW clamp automatic 27
8 Head board OPGW 1
9 Hydraulic cutter 2
10 Hand cutting m/c 2
11 Ground roller 10
12 Single sheave small 54
13 Spacer trolley small 2
14 Spacer trolley medium 3
15 Spacer trolley big 3
16 Swivel connector 27
17 Swivel joint 25
18 Lever Hoist (Turfar) 19
19 Joint protector 40
20 Joint pressing m/c 9
21 Earth discharge cable 14
22 Earth discharge rod 3
23 Double end socks 15
24 Die set 22
25 Conductor clamp liner 173
26 Concrete block 150

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S.I. NO. Description Quantity( No's)
27 Bulta clamp 422
28 Bow shackle 60
29 Block stand 6
30 Aluminium ladder 4
31 Nylon rope 18mm(200mt) 29
32 Nylon rope 20mm(200mt) 16
33 Rachat full drive 6
34 Rachat 1/2 drive 6
35 Reel Winder Zeck 1
36 Rope ladder 2
37 Single end socks 12
38 D" shakle 586
39 Sling 16 x 1 metres 116
40 Sling 16 x 13 metres. 20
41 Sling 16 x 14 metres 15
42 Sling 16 x 2 metres 247
43 Sling 16 x 3 metres 8
44 Sling 16 x 4 metres 12
45 Steel rope 10mm 50
46 Steel rope 12mm 30
47 Steel rope 16mm 46
48 Steel wire cutter 2
49 Template Jack 39
50 Tommy bar (spanner) 147
51 Vibrator m/c 1
52 Walki talki 25
53 Water cooler 2

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B. DETAILED LIST OF EQUIPMENTS

S.I. NO. Description

Description Quantity( No's)
1 Tensioner / Puller (Zeck) 18 Ton 1
2 Tensioner (Tesmec) 12 Ton 1
3 Puller (Tesmec) 8 Ton 1
4 Puller (Tesmec) 3 Ton 1
5 Tensioner (Tesmec_ 3 Ton 1
6 Tensioner / Puller (Zeck) 5 Ton 1
7 Winch m/c 5
8 Sag Bridge set 4
9 Sag scope 2
10 Reel Winder Tesmec 2
11 Roller 3 sheave 135
12 Roller 5 sheave 178
13 Head board conductor 4
14 Gin pole 4
15 Conductor drum jack (Zeck hydralic) 4
16 Pilot wire drum 10mm 13
17 Pilot wire drum 12mm 18
18 Pilot wire drum 18mm 36
19 Pilot wire drum 22mm 23

C.DETAILED VEHICLE LIST

S.I. NO. Description Registration No

1 Toyota Land cruiser 13025
2 Jeep Cherokee 4879
3 Toyota Prado 14751
4 Concorde Cherokee 779
5 3 ton Mitsubishi 41860
6 Toyota pick up 14750

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 7 Hi up 7 Ton 37106
8 Hi up 3 Ton 33756
9 60 seated bus 32811
10 1 ton pick up 33632
11 3 ton Mitsubishi 32813
12 30 Seater Bus 39343

D.MACHINERIES – PAINTING

S.I. NO. Description Registration No

1 Fan for Air compressor 1
2 Magnetic Thermometer & other equip. 1
3 Reverso Tips - 4 1
4 Pneumatic Air Drill-1 1
5 Air Hose 3/4" 1
6 Air Hose 1 1/2" - 40mtr, etc 1
7 A/c Cool Air Tube w/belt-clemco 1
8 Temporary switch for Air Comp 1
9 Sand Blasting Hose & Coupler 1
10 Hose, Reducer joint, Nozzle, etc. 1
11 Mini Blast pot with access. & fright 1
12 Blast Pot with accessories 1
13 Whirling Hygrometer, Gauge, etc 1
14 Graco Airless Spray unit & Elcometer 1
15 Air Compressor 250 & Sand Blasting 1
16 Safety protector 8
17 Sanding m/c 1
18 Screw Tightner 1
19 Sand blasting pot 200 litre 3
20 Sand blasting pot 20 litre small 1
21 Shot gun Hilti DX600N 1

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 22 Shot gun Hilti DXA40 1
23 Painting mixing Machine 1

E.DETAILED LIST OF SCAFFOLDING MATERIAL – 4000 Cubic Metre

F. TESTING INSTRUMENTS & METERS

METERS

S.I. NO. Description Quantity ( No’s)

1 Cable Sensor 1

2 Conductivity meter 3

3 Conductivity meter 1

4 DFT gauge 1

5 Digital low resistance OHM meter 1

6 Digital micro ohm meter 1

7 Dumpy level - S.No.NIKON 606843 1

8 Dumpy level - S.No.Wild 401621 1

9 Dumpy level - S.No.Wild 533746 1

10 Dumpy level - S.No.Wild 556379 1

11 Dumpy level - S.No.Wild 703755 1

12 Dumpy level - S.No.Wild Nak 343817 1

13 Dyna meter 3 ton 2

14 Earth Digital Tester 1

15 Higro meter 1

16 Humidity Calibrator 2

17 Insulation Puncture detecter 1

18 Line Detecter (Mark craft) 1

19 Microprocessor coating thickness gauge 1

20 Ohm meter high current 2

21 Sagging Scope 1

22 Salt level checking meter 1

23 Theodilite T 16 FNR 326013 1

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HEALTH, SAFETY & ENVIRONMENTAL PROTECTION
Common Accidents on Construction sites
1. The Number One accident on Construction sites throughout the world
is falling from a height. To avoid this, you must wear a Safety belt when
working in an area with no edge protection. If you cannot attach the
harness to anything fixed to the tower i.e. life line, Do Not Work in this
area and contact your safety officer. Always connect your Safety Harness
before you enter the danger area. Never reach over Safety barriers or lift
equipment up the side of a tower from one floor to another; you can
easily fall over the edge or drop the equipment, use the hoist instead.
Always wait for hoist behind safety gates. If you are working from a
platform i.e. Scaffold, please check the Scafftag to make sure it is up to
date and safe to use. Do not take risks.

2. The second is workers getting struck by falling materials and work

equipment. Always wear your Safety Helmet and never work directly
underneath the edge of a Tower. Do not enter any areas that has de-
shuttering in progress and if an area is sealed off with warning tape this
is for a reason, Do Not Enter. Never work in the bottom of a lift shaft
where debris is always falling as most construction sites use the lift shaft
as a rubbish chute. Always use pedestrian walkways to commute from
one area to the other.

3. The third is electrical accidents; workers suffer electric shocks and

burns when they use unsafe equipment or when they cut through cables
accidentally. Always check that there is a circuit breaker fitted before
connecting to power supply. Check the condition of cables, if there are any
splits with wires that are mistake, report it to your Foreman
immediately. Do not let cables lie in water, and try to keep cables up on
the wall brackets provided above head height. Ensure cables never lay
across a main walkway where they can cause a tripping hazard.

4. The fourth most common form of accident on a construction site is

being struck by plant vehicles. Never walk behind a reversing vehicle,
wait until it is moving forward. Never squeeze between a vehicle and a

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fixed object. Use all site safe pedestrian walkways to minimize the
amount of time you are in contact with the site plant. Only cross where
there are Flag men and look both ways before crossing.

5. The fifth is ladders and stepladders; if you are working from a

stepladder ensure someone is holding the side; they are extremely
unstable and can topple over very easily. Never stand on the top step. Do
not work near the edge because when you are at working height and you
will be above the edge protection. Ladders are a form of getting to your
workplace, never work from them. They should be 1 meter above the
platform and be at an angle of 1 in 4, i.e. 4 meter high ladder should be 1
meter out at bottom.

Electrical Safety on Construction Sites

Each year, over 20 people die from electric shocks or electric burns while
working on construction sites. There are over 700 serious burns a year,
when electrical arcing occurs, perhaps as a result of accidental short
circuit, the heat generated can be intense and can cause deep, slow
healing burns. Electric shock can also lead to falls from height when
working from a stepladder or platform.

1. Check the electrical equipment you are about to use is

the right colour code for the month, which means it has been
checked by the Safety department and is safe to use.

2. Daily visual inspections of all electrical tools are essential to maintain

safety. Check for any loose wires at socket and for only 1 cable per socket,
check cable for any damage etc.

3. Never let cables lay in water, if there is the smallest cut in the cable
which is hard to detect by eye, it will eventually let in water and could
cause a short circuit.

4. Use wall brackets provided for cables at head height, this prevents
tripping hazards as well as preventing damage to cables from materials
being dropped onto them. Do not place stepladders on top of cables, if the
rubber feet are missing they can cut through the wire and cause
electrocution.
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5. Check the power cable or extension cable back to the source. If it is not
fitted with a Power breaker/Trip switch, do not use and contact your
Foreman.

6. Do not leave extension cables tightly wound when connected to the

power supply, this causes the cables to heat up and can catch fire.

7. If a fellow worker does suffer an electric shock, call the first aid
department and Foreman immediately. If they are suffering from an
electrical shock and are still touching or connected in some way to the
power supply, do not touch them, you will be electrocuted. Turn off all
power before attempting to help.

8. When you have finished working with your electrical power tool
always disconnect it from the power supply in case of accidental start up.

Emergency Evacuation Procedures

1. If you see a fire anywhere inside the Site boundary, immediately find
your nearest Charge hand or Foreman from any contracting company,
who can then raise the alarm.

2. Only tackle the fire with a Fire extinguisher if you feel confident to do
so, do not be a hero and put your life at risk.

3. Use as many Fire extinguishers as you can to put out Fire and always
aim at the base of fire.

4. If the Fire is still raging, leave the well on site alone and go to the
Towers Fire point with all co-workers, do not panic or run, make your
way safely telling all site workers as you go to your nearest assembly
point.

5. When leaving site in an emergency situation due to fire, please

disconnect all power supply if you are in no danger.

6. When you are at the Fire point, do a general head count, see if anyone
is missing, do not under any circumstances go back to the fire.

7. Call your Safety Officer and give details of fire when they arrive.

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8. Inform the First aid representative in your area of any contracting
company about any possible injuries or fatalities. Give number of injured
for Ambulance purposes.

9. If you call for Ambulance ensure you give your exact location and your
telephone number to the emergency services in case they have to phone
back for any other information.

Emergency phone numbers: Fire: 997, Ambulance: 998/999,

Safety Officer 050-3823986 / Safety Inspector: 050-3027822.

10. When the Fire Department arrives, give precise details of any missing
people and any other relevant information.

11. Only go back to your workplace when you have been told to do
by a Charge- hand/Foreman, Fire marshal or Safety officer that it is
safe to do so.

Fire Safety

1. Good Housekeeping is essential to maintain good access and egress

(door) in the event of an emergency, if any work materials or rubbish
are blocking main walkways or exits, move it away immediately.

2. Understanding Fire: there are 3 factors to consider when you think of

Fire: Fuel, Heat and Oxygen. If you remove one of these factors there
will not be a Fire.

3. There are 4 ways that a Fire can spread;

Convection: where fire and smoke rise to the highest point, filling
the area and heating up the materials until they reach their ignition
temperature, and combust.

Radiation: Where objects that are close to the fire heat up and
when reaching ignition temperature will combust.

Conduction: Where objects in direct contact with fire heat up and
then further fire will occur where that objects contact combustible
materials.

Direct Burning: once something is burning, other items in contact
will burn.

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4. Hazards from fire: Heat, Smoke (more people die a year from smoke
inhalation during a fire than any other cause), Toxic flammable fumes,
suffocation, property damage and panic.

5. Top 4 reasons for Fire: Arson, Smoking, Electrical and Cooking.

6. Human behaviour that act as for reasons of fire: Forgetfulness,

Ignorance, Thoughtlessness, Carelessness.

7. Fire drills are important so that you are familiar with where and what
to do in an emergency.

8. Omega has 2 types of Fire Extinguishers on site: Dry Powder and

Carbon Dioxide.

Dry Powder (red) should be used on Class A, B, C and Electricity

Fires.
A = Wood, Paper, Cardboard, textiles and furnishings

B = Petrol, oils, paints, solvents, spirits

C = Natural Gas, Hydrogen, Propane, Butane.

Electrical fires, where a short has occurred.

Carbon Dioxide (black) should be used on B, C and Electrical Fire.

Never touch the horn after use, you will receive frost burn.

9. The Main Contractor has provided Temp Fire Hose Reels in case of a
Fire emergency, this is to be used on class A, B and C fires. Never use
water on Electrical Fires, you will be electrocuted.

10. Fire Extinguisher use; Remove Security tag or pin, Test before use,
Aim hose or horn at base, Squeeze the handle.

Safe Working Procedure of Hand Tools

1. Use the right tool for the right job:

The weight, size, and type of tool should be selected to suit the job
being carried out. Using wrenches as hammers, using screwdrivers as

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 chisels and using knives as screwdrivers is not acceptable and is not
allowed.

2. Using defective or damaged tools:

Tools provided with wooden handles should always be used with the
handles intact. The handles should be tightened with wedges where
necessary. Split or broken handles should be replaced immediately.
Mushroomed chisels are a serious source of hazard and should be
ground down flat again. It is the responsibility of the user to report the
damaged tool to their supervisor and shall be inspected prior to use.

3. Keeping tools in the workplace in loose condition:

Hand tools should not be allowed to lie on work benches, scaffolds, etc,
where they can fall. Sharp tools like chisels should not be kept in
pockets. Hand tools shall not be held in hand while climbing up
ladders, use a tool belt. Tools should never be thrown up or down from
working platforms. While working at critical locations, avoid any
accidental slippage of tools from the users hand, secure it with wire.

4. Using tools in wrong ways:

Wrenches should always be placed on the nut with the jaw opening
facing the direction in which the wrench is to be rotated. Wrenches
should not be pushed but pulled. Chisels being struck by others should
be held by tongs or other holding equipment. While using screwdrivers
the object should not be held in hand. Blades of hacksaws should
always point forward and the stroke should be steady and firm to
avoid jumping of blade.

5. Using cutting tools: Always cut away from your body and hand and
have a firm grip to prevent slipping.

6. When you have finished work for the day, take your tools back to the
stores or your toolbox where they can be stored correctly. Do not
leave hand tools lying around for fellow workers to stand on or trip
over.

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Hot Works Procedures

Hot works permits are designed to prevent fire, property damage and
personal Injury. They are a way of controlling any hot works, with an
inspection of the work area to reduce the risk of fire.

Any Hot works that produces a flame, spark or generates serious

amounts of heat will need a Hot works permit.

1. Before any work with a grinder, welder or Gas cutter has started, you
must speak to your Foreman who can then arrange a Hot works permit
for the task you are about to start. DO NOT START THE WORK WITHOUT
A HOT WORKS PERMIT.

2. The area you are working in will need to be free of all flammable items,
such as, paper, cardboard boxes, wood, any solvents, paints etc. a spark
from a grinder can ignite the vapours of solvents instantly.

3. You will need fire fighting equipment with you such as a fire
extinguisher and water in case of fire start.

4. The permit asks if you have the correct PPE, such as Safety glasses,
gloves, full coverall, dusk mask, etc.

5. The permit is valid for one day and the timing of works will need to be
added i.e. 10am to 2pm.

6. If your work is over a few days you can extend the permit for a
maximum of 3 days before a new permit is needed but speak to your
Foreman at the start of each day to ensure the permit is up to date.

7. Once you have finished the work, report to your Foreman who can
then officially close the permit, it will need signing by a Safety Officer.

8. Any questions regarding Hot Works permits, please speak to your

Safety Officer for the tower you are working on.

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Housekeeping

1. Good housekeeping and site tidiness is essential in an accident

prevention programme and is part of your daily duties with cleanup
being a continuous procedure.

2. It is everyone’s responsibility for an accident free tidy clean site.

3. Once a week there should be extra effort made to tidy the work area
ready for the following week.

4. Work areas, passageways and stairways should be kept clear of all

debris and materials at all time, no excuses.

5. Site Storage areas shall be kept clean and tidy with work materials
neatly stacked or placed.

6. Safe Walkways and other areas where personnel travel should be kept
clear at all times to prevent personnel from using shortcuts and areas
where there is site vehicles.

7. Ensure that all temporary extension leads, wires, electrical cables,

hoses and other equipment shall be kept off all walking surfaces.
Cables, wires, hoses etc shall be elevated above walking surfaces and
other areas where personnel travel and work. Electrical cables shall
not be allowed to lay or rest in water.

8. Spills of oils, grease, cement or any other materials shall be cleaned up

immediately to prevent tripping/slipping and risk of fire.

9. Excess scraps, off-cuts and waste materials shall be collected and

disposed off in the appropriate waste bins.

10. Housekeeping is essential for the safe access/egress in the event of an

emergency situation when all personnel have to be evacuated from
the work area.

~ 47 ~
Supervisors, Foreman& Charge hands Responsibilities towards their
workers

• Assign jobs/tasks to crew and ensure all personnel on site comply

with Company regulation and perform their tasks in accordance with
approved procedures.
• Interact with Customer Representatives at site on all day-to-day
operational matters.
• Safety Focal Point at the site for the operation.
• Bring to the attention of line Management (Managers) potential
hazards to Safety, Health and Environment, which cannot be resolved
by him.
• Ensure that all the crewmembers in the work location are aware of
their responsibility to report immediately any unsafe plan or system
of work and in turn inform the Superintendent accordingly.
• Ensure that all accidents, Near Miss incidents are reported
immediately as per the correct procedures.
• Ensure equipment and associated tools are in good working condition.
• Promote safety awareness in his subordinates.
Employees

• Ensure the work is carried out in accordance with the policy,

procedures and operating practices.
• Manage and maintain the Company equipment / tools and conduct
Pre and Post job maintenance.
• Ensure and follow all the Safety and Operation guidelines specific to
the work location and nature of the job.
• Report any accident/incident to the Site Supervisor immediately.
• Participate in all company organized training programmes and attend
all Safety meetings.
Manual Handling

Manual Handling Accidents account for more than a third of all accidents
reported each year on Construction sites. While fatal manual handling
accidents are rare, accidents resulting in major injury are very common.

~ 48 ~
The most reported manual handling accidents are strains to the back; the
second is injury to fingers and third is injury to the upper limbs.

1. Think before lifting or handling. Plan the lift, ask yourself where am I
taking the load, do I need help, how far have I got to carry it, do I need
gloves, etc.

2. When you pick up load, bend legs and lift in one smooth motion, do not
snatch or jerk load into carrying position. Keep back straight at all times.

3. Think about who is around you when you lift the load is going to hit
anyone when you begin the lift.

4. When lifting, ensure you have a good hold on the load and hug it as
close to the body to support it.

5. The maximum that one person should lift is 25kg but if load is lighter
but very bulky, get help.

6. When carrying a load look ahead, don’t look down, you can easily trip
or fall and injury is often worse when carrying load.

7. Avoid twisting the back, reaching or leaning sideways when carrying

load, this puts pressure on the base of the spine.

8. If you are carrying a long load i.e. conduit, point the front end of the
load up so you don’t carry at head height.

9. Use the lifts or hoist to avoid carrying load up stairs.

10. When lowering the load, once again keep your back straight and bend
the legs to avoid pressure on the spine.

Power Tool Inspection

Always keep power tools in their correct boxes, do not leave them lying
around, they can easily be stood on, tripped over, kicked or damaged
very easily. When issued your power hand tool please follow out these
checks before any work commences.

~ 49 ~
1. Make sure you have the right power hand tool for the job you are about
to execute.

2. Check the condition of any attachments you are using with the power
hand tool, if they are damaged in any way or blunt, report it to your
Foreman.

3. Check condition of Cables, if there are any splits or breaks exposing

wires, report it to your Foreman immediately.

4. Check condition of plug and socket you are about to use, if there are
any cracks or loose wires, report it to your Foreman immediately.

5. Check condition of the Body and Handle of power hand tool. If there
are any cracks or pieces missing including screws, report it to your
Foreman straight away.

6. Check the trigger operation; it should immediately slow down as soon

as you release the trigger, if not, report it to Foreman straight away.

7. Be aware of where your cables are laying i.e. do not let them lie in
water; try to put them above head height if possible.

8. Check that all circuit breakers are in place, if not, report it to your
Foreman immediately, and do not start work without them.

9. Check that you have the right colour code for the month you are in, if it
isn’t report it to your Foreman immediately.

10. Always hold the power tool with 2 hands and hold firmly, do not put
all your weight onto the drill. The handle must be in place.

11. Do not use a drill as a jack hammer, even if it is for a few seconds.

12. Do not lower your power tool to the ground by the electrical cord;
always place it on the ground by holding the body.

13. Always disconnect from the main power source before changing drill
bits or Hilti bits.

~ 50 ~
Wearing Personal Protective Equipment

1. Never go to the site without your basic Personal protective equipment

i.e. Helmet, Safety Shoes and full Coverall and report any defective
equipment immediately.

You should never throw or drop your helmet, if the shell has cracks or
deep scratches, replace it immediately. Do not paint your helmet as
this weakens the plastic.

Safety footwear should be maintained in good condition, checked

regularly and discarded if worn or deteriorated. Laces should be
checked and replaced if necessary. Materials lodged into the tread
should be removed. The stitching should be checked for loose, worn or
cut seams. Boot polish will help preserve your boot and gives extra
protection when wet.

2. When collecting any tool or work equipment from the stores think
about what Personal Protective Equipment you will need to
successfully and safely complete the job.

3. When grinding, disking, chasing and using a jack hammer, always wear
protective eye wear and do not start work until fellow workers have
moved to a safe distance. Make sure the lenses are clean as dirty and
scratched lenses restrict vision. Safety glasses should always be put in
a safe place at the end of the day to protect them.

4. If dust is produced from grinding, chasing, disking or using a jack

hammer, wear a dust mask and replace it regularly.

5. If you have to shout to have a conversation at a 1 meter distance from

the work equipment you should be wearing Ear defenders.

6. If you are using your hands in danger areas, i.e. using a hammer and
chisel, always wears gloves to prevent cuts and abrasions, make sure
they fit well and are not loose so that you can grip tools.

7. Look after your personal protective equipment; it could save your life.

~ 51 ~
Safety Signs

1. Red circle with diagonal line through the middle = Prohibition, You are
not allowed to do.

• No Smoking.
• No Swimming.
• No Authorized access.
2. Yellow triangle with black border = Warning, Risk of Danger ahead.

• De-Shuttering overhead.
• Electricity.
3. Green square with white writing = Safe condition, the safe way.

• Assembly Point.
• Fire Exit.
4. Blue circle with white writing or symbol = Mandatory, You must do.

• Use Filter Mask.

• Wear Safety Goggles.
• Wear Safety Harness.
5. COSHH Information = Symbols and wording.

• Toxic, if swallowed.
• Dangerous to the environment, dispose of correctly when finished.
• Highly Flammable, no naked flames or sparks, fire extinguisher
must be present.
• Irritant, must wear gloves, absorbed through the skin.
Scaffolding - General Access Scaffolds

For any scaffolds make sure:

• It is designed, erected, altered and dismantled by competent

personnel and the work is directed by a competent supervisor.
Scaffloders should always adopt methods of work to prevent falls
during the erection of scaffolding. This will normally mean wearing
harnesses.
• It should never be erected over personnel who are working or
pedestrian areas.

~ 52 ~
 If the work presents a danger to the public, it should be done
during quiet times, e.g. early mornings or the pedestrian area
should be closed with a diversion provided.
• It is based on a firm level foundation. The foundation or ground
should be capable of supporting the weight of the scaffold and any
loads likely to be placed on it. Watch out for voids such as
basements or drains, or patches of soft ground, which could
collapse when loaded, provide extra support if necessary.
• It is braced and tied into a permanent structure or otherwise
stabilized. Rakers only provide stability when they are braced and
secured adequately; single-tube rakers alone do not provide this
and need to be braced to prevent buckling. Put ties in place as the
scaffold is erected and only remove them in stages as it is struck. If
a tie is removed to allow work to proceed, an equivalent tie should
be provided nearby to maintain stability. Always erect and tie
according to the manufacturer’s instructions.
• It is capable of supporting loads likely to be placed on it. Scaffolds
are not normally designed to support heavy loads on their working
platforms. If intending to load out platforms, tell whoever is
providing the scaffold – a special design might be required. Most
work at height falls into 3 categories: light duty, medium duty and
heavy duty; obtain the class of scaffold appropriate to the work you
are doing.
• You never sheet a scaffold without informing the supplier.
• Platforms are fully boarded and wide enough for work and easy
access.
• Scaffold boards are fully supported and not overhanging
excessively.
• There is a tied safe ladder or other easy safe access/egress to the
work platform.
• It is suitable for the task before it is used and checked whenever it
is substantially altered or adversely affected by, for example , high
winds.
Site Safety Rules

1. Use Personal Protective Equipment at all times, Helmet, Shoes,

Coverall, Glasses, Dust mask, gloves and Ear defenders. Do not throw,
drop or paint your safety helmet, keep it in a safe place.

~ 53 ~
2. Use Safety harness on all working platforms or scaffolds. (Regulations
state anything over 2 meters) attach harness as high as possible and
check condition of buckles, clip and rope before you use it. Always
attach the harness before you move into danger area.

3. Do not work in an area where there is no edge protection unless you

can attach a safety harness to a life line or tower.

4. Use correct sockets for power tool connections and cable joints. Check
colour code for month.

5. Always use Safe designated walkways onto site and towers and do not
use short cuts.

6. Report immediately any damaged or defective tools/wires to your

supervisor and return them to the stores.

7. Do not operate any plant vehicles; this also includes personnel

lifts/hoists.

8. Do not attempt to move any ladders or scaffolds without your

supervisor’s permission. Always check Scaff-tags are up to date before
using scaffold.

9. Do not move Mobile scaffold towers with personnel on working

platform, they can easily tip over.

10. Do not attempt to make any electrical repairs, call a qualified person.
Do not remove any safety device e.g. circuit breakers without
permission from supervisor.

11. Use the right hand tool for the right job and in accordance with
manufacturing specifications. Do not use mushroomed chisels or loose
hammer handles.

12. Do not smoke inside the work premises, other than designated
Smoking areas, obey all “No Smoking” signs

13. Do not enter areas where de-shuttering is taking place or areas that
are sealed off with warning tape.

~ 54 ~
14. Never work in the bottom of lift shafts.

15. When using stepladders do not stand on the top step, keep 1m below
the top. You must have another person holding stepladder when
working at height at all times.

16. Do not use a Stepladder next to an edge, once you are at working
height you will be above the edge protection, use mobile tower
scaffold instead with a safety harness.

17. Always hold power tools with both hands and do not put all of your
weight onto drill.

18. Always ensure Grinders have guards fitted and use at arm’s length to
prevent entanglement with coverall and do not use unless handle is
attached.

19. For immediate First aid treatment, contact your Foreman who will
then contact an Omega First aid Rep. If serious injury has occurred do
not move the injured person, the first aid rep will come to you.

20. In the event of an emergency evacuation, please go to your towers

nearest assembly point.

If you are unsure of any site safety rules, please speak to your Tower
Safety Officer.

Stepladder Safety

Stepladder accidents are very common due to errors that can easily be
avoided.

1. Do not work from the top of the stepladder, always keep 1 meter from
top so you can support yourself. Change the height of stepladder if you
cannot reach.

~ 55 ~
2. Always have another person hold the stepladder when working at
height. Never let go of a stepladder when a fellow employee is working at
height, if a tool is needed to be passed to the worker, make them come
down to collect.

3. Never work near an open edge, when you are at working height you
will be above the edge protection. Use a Mobile Tower and a Safety
Harness

4. In open spaces where you can erect a Mobile Tower Scaffold, never use
a stepladder. Mobile towers are a lot safer and can be moved very easily.

5. Do not reach or stretch while working from a stepladder, they are not
designed to accept side loads.

6. No more than 1 person should use a Stepladder at one time.

7. Regular inspection is required; if there are any serious dents or bends

in the frame do not use and always ensure the rubber feet are present.

8. Stepladders should always be used on a level, firm base.

9. Do not sit on the top step while working; you can easily fall over
backwards.

10. Do not climb from one side of stepladder to the other while at height,
you can easily fall.

11. If a fellow employee suffers a fall from height do not move him,
contact your Foreman who can arrange for a First Aid Representative to
come to the injured person. You can cause further injury by moving them.

Summer Safety Alert

With summer already upon us, all of us need a reminder of heat stress
tips for the safety and well being of co-workers and family members.

1. Drink cool water – anyone working in a hot environment should drink

cool water in small amounts frequently – one cup every 20 minutes.
Avoid alcohol, tea, coffee and other caffeinated drinks which will cause
dehydration.

~ 56 ~
2. Dress appropriately – wear lightweight, light colour, loose fitting
clothing and change clothing if it gets completely saturated. Use
sunscreen and wear a hat when working outdoors.

3. Work in well ventilated areas – all work places should have good
general ventilation as well as spot cooling in areas of high heat
production.

4. Work less, rest more – assign a lighter workload and longer rest
periods during the days of intense heat. Short frequent work/rest cycles
are best.

5. Ask how workers are feeling – monitor workplace temperature and

humidity and check workers response to heat. Be alert to early signs of
heat related illnesses and allow workers to stop their work for a rest
break.

6. Know the signs – learn to spot the signs of heat stroke, which can be
fatal. Get emergency medical treatment immediately. First Aid reps will
recognize and treat signs of heat stress, heat cramps and heat stroke.

7. Reduce work for anyone at risk – use common sense when

determining fitness for work in hot environments. Lack of
acclimatization, age, weight, and poor physical condition, and inadequate
rest, previous history of heat illness, certain medical conditions and
medications are just some of the factors that increase susceptibility to
heat stress.

8. Check with your Doctor – anyone with a medical condition should

check with their Doctor before working in hot environments.

9. Eating Habits – eat more frequently ensuring meals are light and
nutritious.

10. Remember – the best defence against heat related illness is

prevention. Staying cool, drink plenty of fluids, wear cool clothing and
monitor outdoor activities are all key factors to staying healthy in hot
environments.

~ 57 ~
Temporary Mobile Tower Scaffolds

Tower scaffolds can be erected easily and quickly and can give good
access. However, they are involved in numerous accidents each year.
These accidents usually happen because the tower has either not been
erected properly or has not been used properly.

If a tower is going to be used:

1. Follow the manufacturer’s instruction for erection, use and

dismantling. Have a copy of the instruction manual available – if the
scaffold has been provided by another contractor they should provide
the information and attached Scafftag.

2. The tower should be vertical and stand on firm, level ground with the
wheels locked.

3. Scaffold equipment should be in good condition, free from twists or

dents.

4. Provide a safe way to get up to and from the work platform, for
example internal ladders. Climbing up the outside of the tower can pull
it over.

5. Provide edge protection (guard rails and toe boards).

6. Tie the tower rigidly to the structure if it is possible or if you are

exposed to high winds.

7. Always check the Scafftag before using Mobile Tower Scaffold, if it is

not up to date speak to your Charge hand or Foreman.

Do not:

1. Use a ladder or stepladder on the working platform or apply other

horizontal loads that could tilt the tower.

2. Overload the working platform.

3. Move the tower by applying force at the platform level.

4. Climb up the outside of the tower to reach the platform.

~ 58 ~
 When moving a mobile tower:

1. Check there are no power lines or overhead obstruction in the

way.

2. Check there are no holes or dips in the ground.

3. Do not allow people or materials to remain on tower as it trips

over very easily when moved.

Using Safety Harnesses

Falls from height are the largest cause of accidental death in the
construction industry. They account for 50% of all fatalities. Most
accidents involving falls could be prevented if personnel were wearing a
safety harness.

1. Health and Safety Regulations state, where work is carried out at

height, every employer shall take suitable and sufficient measures to
prevent any person falling a distance liable to cause personal injury.

2. Never work in areas where there are no safety barriers and no

temporary lifelines or barriers to attach a safety harness to.

3. Before you put a safety harness on, check its condition. Check the
webbing, lanyard and D-ring. If there are any tears, cuts or cracks, do not
use and if harness has had paint or thinners replace it as the chemicals
will weaken the Harness.

4. If you have never worn a safety harness before, check with your charge
hand, Foreman or safety officer for correct fitting.

5. Check the lifeline wire or rail that you are fixing your safety harness to
is secure, if you have any doubt, do not connect, and check with safety
officer.

6. When connecting safety harness, make sure you are in a safe position.
Do not move into danger area until safety harness is fixed.

7. Make sure there is adequate fall height to prevent you from hitting the
ground.

~ 59 ~
8. When connecting safety harness, connect the clip as high up as
possible, thus reducing the fall distance.

9. Remember, a fall with a safety harness will not stop you from getting
injured, most falls with a harness on result in injury from hitting parts of
the building or impact load to the body when the line goes tight.

10. Consider how to recover anyone who does fall.

~ 60 ~
QUALITY ASSURANCE AND QUALITY CONTROL

INDEX

1.TERMS AND DEFINITIONS

2.GENERAL

- Project Summary

- Project Key dates

- Project objective

- Project Scope

3.EPC Quality Management System

- Purpose

- Scope

- Distribution

- Project Quality Statement and Objectives

- Job descriptions

- Management and Quality improvement Reviews

- Quality System

4.Contract Review

5.Design Control

6.Document Control

7.Control of purchased materials and Services

8. Control of customer supplied material

9. Product identification and Traceability

10.Process Control

~ 61 ~
11.Inspection and testing

12.Control of Inspection, Measuring and Test

equipment

13.Inspection and Test Status

14.Non conformance and corrective action

15.Handling storage preservation and Delivery

16.Quality Records

17.Internal Quality Audits

18.Training

1. TERMS AND DEFINITIONS

For the purpose of this Quality Plan and supporting procedures the
following definitions which, in some instances, clarify those contained
within ISO 8402 (Quality Management and Quality Assurance —
vocabulary) shall apply:

TERMS / ABBREVIATIONS DEFINITIONS

Quality The totality of features and characteristics of a

product or service that bear on its ability to
satisfy stated or implied needs.

Quality Management The aspect of the overall management functions

that determines and implements the quality
policy.

Quality Assurance All those planned and systematic activities and

functions necessary to provide adequate
confidence that a product or service shall satisfy
given requirements for quality.

Quality Control The techniques and activities that demonstrate

compliance with specified requirements. This

~ 62 ~
 includes inspection, test, etc.

Project Quality Plan A document derived from the Quality

Management System, modified as necessary to
accommodate particular project requirements.

QC Test and inspection A key document which supports the Project

plans Quality Plan and lists in a logical sequence key
activities such as contract review, engineering,
procurement, construction, installation, and
commissioning activities, etc. It identifies
individual activities, controlling procedures /
standards, verifying documentation, inspection
and test requirements, etc.

Project Control A document which supports the project Quality

procedures plan and describes the procedures for various
activities of Quality system.

Quality Audit A systematic and independent examination to

determine whether quality activities and related
results comply with planned and/or Documented
arrangements and whether these arrangements
are implemented and effective in achieving stated
objectives.

Supplier Refer to “Supplier “includes for subcontractors

TERMS/ABBREVIATIONS DEFINITIONS

Product Result of activities or processes and

encompassed hardware, software, processed
materials and services or any combination of
these.

~ 63 ~
WEP Work Execution Plan

QP Quality Plan

HSE Health, Safety and environment

QA/QC Quality Assurance / Quality Control

EPC Engineering, Procurement & Construction

ISO International Standards Organization

ITP Inspection and Test Plan

WI Work instruction

P0 Purchase order

NDT Non Destructive Testing

S/S Substation

T and D Transmission and Distribution

MRT Management Review Team

OHL Over Head Line

PCP Project Control Procedure

T/L Transmission Line

WSW Water Supply Well

DEP Design Engineering Practice

LCS Local Control Station

CDS Central Degassing Station

For further definitions of Quality or vocabulary refer to BS 4778 Para 1.

~ 64 ~
2. GENERAL
Project Objective::

The main objectives of the OHL Projects are:

-To design and construct a lattice steel tower OHL utilizing, where
possible, double circuit lines for common routes and single circuit lines in
other areas . When fully commissioned, this will be a replacement for the
existing overhead lines on wood poles.

-To provide a suitable Transfer – Bus arrangement for flexibility of

operations of clusters in case of outage of any buffer transformer.
Project Scope::

-Design / Material

-Construction

3. Quality Management System

Purpose:

The purpose of this project Quality plan is to establish specific quality

requirements of customer and ISO 9001 against which the construction
of new Transmission Line and Associated Modifications shall be
organized and managed to ensure the project objectives are achieved and
the PLC Quality Policy is complied with.

The Quality plan is the first level of the overall project quality
management system structure and provides the means by which PLC
management and its customer may gain confidence that the work under
taken for each of the project work phases satisfies the contract and PLC
(T&D) overall requirements for Quality management.
Scope:

The quality plan addresses the requirements of the following

specifications.

Contractual requirements to PLC.

~ 65 ~
PLC Quality Assurance Manual

HSE and Regulatory requirements

ISO 9001:1994.
Distribution:

This Quality plan is issued as an integral part of the WEP and controlled
and issued by Project Manger as per the document & data control
procedure.

Project Manager shall be the custodian of Quality documents and shall be

responsible for amendments and distribution.

It is the responsibility of QC personnel to report any deficiencies or

problems resulting in the use of this Quality plan to Project Manager.
Project Manager is responsible for resolving Quality issues in a timely
manner to the satisfaction of Customer representative.

Project Quality statements and objectives

Quality Policy.

To be the leader in Engineering, Procurement, Installation and

Commissioning of Electrical Substation, Transmission and Distribution
network as per the National / International Standards to meet the
specified Quality requirement.
Quality Objective:

Planning, implementing and monitoring all Quality system activities

during tendering, Designing, Procurement and Project Management.

Planning implementing, Controlling through auditing and continuous

monitoring the Installation, Testing and commissioning activities to meet
customer requirements including safety.

Work for continuous improvement of Quality system and processes

through reviewing their adequacy and effectiveness.

~ 66 ~
Provide and promote Quality awareness at all levels through continuous
training to ensure that the company policy and Quality Requirements are
well understood, implemented and maintained.
Independent Testing Agency

The Third Party Independent Testing Laboratory approved by (i.e. Soil

Compaction Tests / Concrete sampling, Compressive Tests, etc) PLC /
Customer shall be responsible for carrying out all on-site tests, as
directed by the Project Manager and his Inspectors. All tests that fail to
meet the requirement shall be immediately reported to the Project
Manager for corrective action. The testing laboratories to be used in this
project are approved by Customer for all required Civil Testing and non-
destructive examination respectively.

Management and Quality improvement Reviews:

Project reviews shall be undertaken periodically and shall report on

quality related concerns encountered. The causes shall be recorded and
investigated and improvements shall be implemented.

Reviews shall consider the results of audits undertaken on the system,

including references to any significant deficiencies or weakness as
identified in the system.

MRT shall conduct a review at least once in a year by.

Deputy General Manager

Reviews shall normally involve following members,

Project Manager, Procurement Manager

Engineering Manager, Applicable department staff Customer if

necessary and any other person as directed by DGM

Reviews shall be recorded and shall determine action needed to amend

project Execution procedures as require suitable guidance as per
contract shall be followed.

Quality System

~ 67 ~
Project Quality Management Structure.

The Quality Management system documentation for the construction of

Transmission Line and necessary modification project is established in
three levels. General guidance taken from Customer Standards /
Specifications.

FIRST LEVEL DOCUMENT — PROJECT QUALITY PLAN.

The project Quality plan is the First level document of the project Quality
Management system. PLC shall use the Co-ordination procedure &
ITP/QC procedures included in the contract. Specific procedures not
already foreseen in the contract will be prepared by PLC & submitted to
Customer approval before implementation.

The project Quality plan is the guidance document for the site Inspection
and test plans prepared and implemented by PLC (T&D) and reference to
control procedure documents

SECOND LEVEL DOCUMENTS — PROJECT CONTROL PROCEDURES

The project control procedure which is included as Attachment III (for

procedures prepared by PLC) to the Quality plan identifies those control
procedures which shall be followed at various stages of the project in
order to control the specified quality related activities and methods to
ensure compliance.

All project procedures shall fulfil the contract quality requirements.

These procedures and specifications shall have specific project
identification and any changes to these control procedures are indexed in
cover sheet.

THIRD LEVEL DOCUMENTS — INSPECTION.

QC Inspection and Test plans shall be developed to cover the full range of
activities required to cover the contract scope of work during
construction, testing and commissioning stages. The Inspection and test
plans shall identify the Quality activities to be verified, recorded and the
acceptance criteria.

~ 68 ~
The formats shall be developed for all critical activities and shall include
the parameters to be verified during various stages of project and shall
form the evidence for having verified the parameters of specific activity
performed.
Availability:
Availability:

The control and distribution of the documents shall be dealt as per

procedure Document and Data Control.

A copy of all project documents (e.g. Drawings, Scope of work, quality

plan, P.O etc) shall be available at Job Site. The control and distribution of
the quality records shall be as per Quality Records Procedure.

4. Contract Review

During the bid preparation stages and following contract award the
contract documentation shall be reviewed, on an ongoing basis, by
nominated personnel, to enable the specific contract requirements to be
identified and understood and for any queries, ambiguities, errors, etc, to
be clarified, resolved with customer. The capability of the company to
meet the requirements of the contract to be ensured at tenders / contract
stage

5. Design Control

The following describes the general requirements for the control of

design activities and review of engineering information to ensure design
integrity, safety and compatibility with the Contract requirements.
Design Control shall be maintained in accordance with the appropriate
project procedure listed in the project control procedures.

Design interfaces shall be established between interfacing Design Offices

and shall generally be in the form of document transmittals, technical
queries, meetings, reviews and correspondence.

~ 69 ~
Design Input, Development Planning

Design shall be in compliance with Customer Specifications Engineering

Standards Industry Codes, Standards, Legislation and nominated Project
Procedures.

This Contract shall use drawings/documents approved by Customer. PLC

shall examine such documents and identify any areas of conflict or
missing information and establish record or verify data and information
necessary for the design of the Project facilities, for the construction
work at Site.

Design deliverables and associated required by dates shall be identified

and their development progressively monitored.

A key design deliverable at this stage is the Discipline Job Design

Specification prepared by each Engineering discipline and which includes
project specifications and quality procedures.
Design Output

Design output shall be verified by a formal system of

Checking, review and approval to ensure the input

Requirements are met, contain or reference acceptable

Criteria conform to the Contract requirements, and that all

characteristics of the design which are crucial to the safe and proper
functioning of the supplied plant are fully incorporated.
Design Verification

PLC shall use the Customer Specifications and Procedures in addition to

its own Company Procedures and Instructions to control and verify the
design of the plant in order to ensure that the specified requirements are
met.

Design deliverables shall be subjected to a verification check and

approval, by nominated independent function(s).

~ 70 ~
The review of the development of the design shall be carried out by
customers if specified in the contract.

Safety and Environmental reviews shall be scheduled and implemented.

Design Change Controls

Design changes shall be controlled by procedure to ensure that:

Information concerning the design changes is transmitted to all affected

persons in a controlled and timely manner.

The technical impacts of changes are considered and required actions

documented.

All the design changes shall be approved by customer. The design

changes shall be formally agreed technically and contractually with PLC.
As built drawings / Dossier:

As built drawings shall be prepared in sufficient details to present an

accurate record for the customer.

As-built drawings and records are required where the equipment / items,
construction varies from the “Final Certified” drawings approved by
Customer.

The final project completion Dossier in 5 Sets shall include:

-Vendor documents including “Operation and Maintenance Manuals”.

-Final approved “As-Built” Drawings.

-MRB (Manufacturing Record Book).

6. Document Control
Receipt, Issue, Storage of Documents

The receipt, issue, indexing, filing, storage and changes to the Project
documents shall be controlled at all times.

Document Control shall ensure that records of receipt, description,

revision, numbering and distribution are maintained. The distribution
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requirements for each type of document shall ensure the correct edition
of each document is issued to the department or workplace conceded
prior to performance of the activity. Registers of control may be
computer or manually generated.

A transmittal system shall be used for the internal and external

movement of all documents covering Suppliers, Subcontractors and
Customer.

Documents shall be filed and stored for such time as specified and in such
a way as to enable their efficient retrieval and prevent their
deterioration.
Changes and Revisions to Documents

All changes and revisions to documents shall be processed in the same

manner as the original. Revisions shall be clearly identified.

Documents which are subsequently cancelled or superseded shall be

clearly marked as such or shall be removed from the workplace.

The control of drawings / documents issued to Sub-Contractor shall be

controlled in the same manner mentioned above.

7. Control of Purchased Material and Services

General

PLC shall ensure that procurement activities are performed in

accordance with contractual requirements which include;

Customer Specification and Standards.

Project Specifications, Bill of Quantities (BOQ)

All Applicable Codes, Specifications, Standards & drawings.

PLC shall provide & document QA/QC activities in the procurement of

equipment & material to be used or installed during construction.

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Depending on the criticality inspection of the materials, the PLC /
Customer representative or Customer approved 3rd party inspectors
shall perform QA / QC activities at suppliers and sub supplier’s locations.
Purchasing Data

PLC QA/QC Design will review the purchase requisitions and purchased
orders prior to placement for technical, quality requirement.

PLC shall ensure relevant technical and inspection requirement are

passed on to suppliers / sub suppliers.

Customer shall have access to all Purchase Order Inspection Report files.

Procurement Plan shall be prepared including planned and actual dates

for Inquiring P.O., Expected date of Delivery (ETD) and Expected Time of
Arrival at site (ETA).

Review of requisition packages to ensure that Customer requirements

which include but are not limited to standard drawings and project
specifications are in place and accepted at quotation stage.

Selection of Suppliers and Subcontractors.

Suppliers’ selection shall be in accordance with the following points.

- Past experience with PLC.

- Suppliers / sub-contractors approved by Customer on previous

projects.

- Approved vendors

- Verification of Purchased items / Services

PLC shall ensure that the drawings, specifications, inspections

requirements and QA/QC programs are properly transmitted to
suppliers.

The project shall relay on the selected assured suppliers indigenous

quality assurance and quality control activities to deliver equipment and
materials which satisfies the P.O requirements to an extend

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commensurate with the confidence built by each supplier during the
selection process.

The quality assured suppliers selected by PLC for major products must
ensure that their sub-suppliers meet the requirements of established
quality management system and customer approval if any.

Verification by inspection and/or audit that product and service comply

with the purchase order shall be performed to an extent consistent with
the quality level of previous supplies.
Control of Manufacturing Process:

Prior to start of the applicable works PLC shall submit suppliers details to
Customer Representative.

Inspection and testing of purchased materials shall be in line with

applicable project Quality Procedure.

The sub-contractors / suppliers shall submit manufacturing and test

reports for major items. These documents shall be verified and accepted
by PLC before issuing to Customer.

8. Control of Customer Supplied Material

Equipment and materials supplied or assigned to the PROJECT, by or on

behalf of Customer if any, shall be inspected, stored and maintained in
accordance with Customers requirements as appropriate, so as to
establish and preserve the manufactured quality of the item

9. Product Identification and Traceability

The requirements for Materials and Equipment identification and

traceability e.g. Identification tags, equipment number shall be as per
established and related procedures I specification, etc. Measures shall be
taken to ensure that such identification I traceability is maintained
throughout project work stages.

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10. Process Control, Construction & Commissioning
General

PLC shall ensure that all construction activities are performed in

accordance with the requirements of:

-Approved IFC (Issued for Construction Drawings)

-Approved Construction Procedures and Specifications

-PLC Quality Manual, Quality Plan, Inspection, Test Plan and Supporting
Procedures.

-When necessary, Special Quality Procedures & Method Statements

Control during installation

PLC shall define their requirements in engineering specifications and

drawings which require various operations to be performed in
accordance with Drawings and Standards defined work practices and
approved QC inspection and Test plans.

Supplier’s management systems and documents shall be reviewed /

audited, checked to ensure requirements are being followed, and
inspections carried out to confirm compliance as necessary.

Installation of equipment on site shall be performed as per drawings,

work instructions Manufacturer recommendations which define the
activities to be performed, the responsible persons, any special
equipment involved, the essential verifications to be carried out and the
verifying documents to be produced. When critical work processes and
equipments are in use these shall be evaluated by authorized personal
and formally approved.

Where required to define the applicable level workmanship written

standard shall be established.
Special Processes.

Special processes, such as welding, non-destructive testing, protection

coating, Concrete batching, etc, where the results of the processes cannot

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be fully verified by subsequent inspection and testing shall be performed
to approved procedures and the operators qualified in accordance with
applicable standards. Controlled equipment shall be used in special
process like control gauges, measuring equipment etc.

Qualification Tests Records or results for special processes, equipment

and personnel (e.g. welding, non-destructive Testing, etc.) shall be
maintained and available for verification by authorized personnel.

Welders shall be qualified in accordance with AWS D1.1. Qualification

tests shall be monitored by an independent testing agency approved by
Customer.

Welding procedures shall be qualified, prior to implementation, in

accordance with AWS D1.1 by a test laboratory.

Control gauges for special processes, e.g. measuring equipment, shall be

certified and approved and thereafter included in the calibration
programme.

Special working environments (e.g. humidity and temperature control,

clean room, etc.) shall be provided where required.

11. Inspection and Testing

Inspection at Works.

Inspectors shall be qualified and experienced to perform the inspection

functions required and shall meet the minimum requirement for the
project.

Where necessary PLC shall submit details and qualification of their in

house and field Quality Control personnel to Customer for acceptance.
Field resources shall include QC Inspection Agencies

Where specified in the contract PLC shall mandate the inspections and
tests to be performed by the Supplier/Manufacturer on equipment and
materials purchased for the project.

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Inspections shall be performed in accordance with the requirements
detailed in Purchase Order, Quality Control Plans and approved
documents and drawings and procedure.

Customer and nominated third party inspection body, as applicable shall

be invited to witness the inspection. A Release Note issued by the PLC
Inspector based on the third party Inspection certificate / customer
acceptance report shall be the method by which equipment and material
is released ready for shipment to site.
Inspection at Site

Organization Chart in Attachment-2 describes the functional site QC

reporting structure. The PLC QA/QC Manager will manage the provision
of site inspection services to support the construction work.

PLC shall submit details and qualification of QC resources to Customer

for acceptance including agency personnel.

All equipment and material arriving at site shall be inspected or

otherwise verified as conforming to specified requirement in accordance
with documented procedures.

To verify that the Project is constructed to the required standards and

specifications, PLC shall specify and carry out inspections and tests
during and at completion of, construction in accordance the documented
procedures. Each system test activity shall be formally verified by signed
documentation/certification.

Stage wise monitoring shall be done by PLC QC / Customer as per

Inspection and Test Plans.
Commissioning.

Testing and Commissioning shall be done in accordance with approved

procedures and records of Test Reports maintained

Inspection, Test and Commissioning Records

At all stages of the inspection, testing and commissioning process,

records shall be established and maintained which provide clear

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evidence that equipment and materials have passed inspection and/or
test in accordance with defined acceptance criteria.

PLC shall maintain a non-conformance log of any rejections on material

and equipment, and shall investigate the causes of Non-conformance and
indicate corrective action.

Project Records / Documentation shall be submitted as per contractual

requirements.

12. Control of inspection, Measuring and Test Equipment

Control procedures shall be established to ensure that all inspection,

measuring and testing devices used in those activities affecting quality
are properly controlled and calibrated. PLC is not doing any in-house
calibration at present and the calibration shall be done by external
approved test houses and the certificate is maintained as the record of
calibration

Selection of measuring and test equipment shall be controlled to ensure

that such items are of the proper type, range, accuracy and tolerance to
conform to the specified requirements.

Measuring and test equipment shall be properly handled and stored in

order to maintain accuracy.

In the event that equipment is found to be ‘out of calibration’ items

inspected since the last calibration date shall be quarantined and
subjected to reverification as necessary. The instrument is taken out and
recalibrated.

13. Inspection and Test Status

Proper inspection and test status shall be maintained by way of labels,

check lists, inspection log book, and certificates in a logical, systematic
and progressive sequence, to the current inspection and test status of the
construction / installation to be determined at any time

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No material or equipment shall be installed by PLC unless it can be
identified to a particular document that proves the item has been
inspected and has passed that inspection.

Additional Inspection, testing carried out if material to be used in the

Project cannot be identified or reasonable doubt exists about the
authenticity of its identity.

14. Non Conformances / Corrective Action

Project personnel shall have the responsibility for ensuring that any
deficiencies, ambiguities and problems are resolved to the satisfaction of
the project Quality team or QC. Copy of non-conformance / corrective
action report to be transmitted to Customer for information.

Non Conformances regarding the Quality system as identified by quality

assurance audits shall be formally recorded on Audit Finding Sheets and
progressively monitored and closed out by the Project Quality Assurance
Manager

Formal technical and safety audits shall be carried out by PLC personnel
and any non-conformance identified shall be resolved to satisfy the
requirements of Quality Management system.

Deviations to Customer’s contractual requirements shall only be allowed

with their approval. Identified deficiencies which relate to purchased or
subcontracted services shall be subject to rejection, rework or
acceptance with concession approval.

Customer complaints shall be formally addressed to ensure that

appropriate corrective action has been taken and that satisfactory
responses have been made. Non-conformance identified by inspection
and test during any work phase shall be subject to containment and
disposition, including approval by Customer as required.

15. Handling, Storage, Preservation and Delivery

Materials and equipment received shall be subject to receipt inspections

as detailed within the Material Control procedure to verify compliance
with the contract specifications
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Any materials or equipment found to be non-conforming shall be
identified and marked as such and where practical, removed to a
segregated holding area. Materials and equipment shall be to a storage,
handling, maintenance and preservation regime which ensures the
integrity of the manufactured quality. Materials shall be periodically
examined prior to hand over to ensure that the maintenance and
preservation requirements have been carried out in accordance with the
manufacturer’s recommendations.

16. Quality Records

Records that furnish documentary evidence that the quality of items

produced and activities affecting quality are consistent with the contract,
procedures, codes and specification shall be systematically collated,
stored and maintained.

Records shall be indexed, filed and protected to prevent damage,

deterioration of loss. Records can comprise hand written, printed or
typed documents, magnetic tapes, disks, microfilm or other media
acceptable to Customer. Records which are Certificates shall comprise
original documents or authenticated copies.

Records shall be retained for the minimum period specified in the

contract, PLC procedures, or as required by law.

17. Internal Quality Audits

The Project Quality Management system shall be verified by a planned

programme of internal quality system compliance and technical audits
carried out by the Project QA/ QC Manager. The audits shall be conducted
in accordance with the project QA Audit Procedure.

Each project work phase shall be subject to audit the initial horizontal
audit to confirm / facilitate management system establishment and the
second, vertical multi discipline audits to confirm management system

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maintenance. Audit schedules shall be submitted to Customer for review
and acceptance.

Quality Audits are a means of gauging the progress towards the required
objectives and should be seen as assisting the overall activity. Quality
Audits are required to be carried out in order to verify the documented
Quality Management Systems are being complied with.

Quality audits, as well as providing assurances that the activities are

being carried out in accordance with prescribed procedures, shall also be
proactive by identifying and facilitating solutions for any omissions or
deficiencies discovered within the established procedures and working
methods. The PLC QA/QC Manager shall, participate in, or implement, QA
audits of the Project.

Audit findings shall be collated and presented at management reviews to

establish the existence of any adverse trends and initiate any necessary
corrective actions.

18. Training

The Project QA/QC Manager, in conjunction with the senior project team,
shall identify and arrange induction sessions as necessary for key Project
personnel at which time the contents / requirements of this Quality Plan
shall be explained and discussed as well as any changes to the normal
method of working which have been identified for the Project.

Further the project team members shall communicate their work scope
and identify programmes, status and points of interest down below staff.

Training needs of all PLC employees shall be continually assessed to

establish training requirements necessary for their current work scope.
Suitable training shall be arranged as necessary.

Where specialist skills / qualifications are required (i.e. welding / NDT),

the need for such special training shall be reviewed and, if any needs are
identified, appropriate action shall be taken for this to be obtained.

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