Plc-company Profile

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

~ 10 ~

Reinforcement placed for Foundation in 400KV OHTL Fujairah – Dhaid

Reinforcement placed for Foundation in 400KV OHTL Fujairah – Dhaid

~ 11 ~

Preparation for Foundation in 400KV OHTL Fujairah – Dhaid

Stub Setting in 400KV OHTL Fujairah – Dhaid

~ 12 ~

Stub Setting in 400KV OHTL Fujairah – Dhaid

Pouring of Concrete in 400KV OHTL Fujairah – Dhaid

~ 13 ~

Pouring of Concrete in 400KV OHTL Fujairah – Dhaid

Completed Foundation in 400KV OHTL Fujairah – Dhaid

~ 14 ~

Foundation with Sub Setting in 400KV OHTL Fujairah – Dhaid

Completed Foundation in 400KV OHTL Fujairah – Dhaid

~ 15 ~

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

~ 16 ~

TOWER ERECTION

~ 17 ~

Tower Erection with Gin Pole

~ 18 ~

Erected Tower in 400KV OHTL Fujairah – Dhaid

~ 19 ~

STRINGING

~ 20 ~

Preparation of Roller Hoisting for Stringing

Roller Hoisting for Stringing in 400KV OHTL Fujairah – Dhaid

~ 21 ~

Stringing in 400KV OHTL Fujairah – Dhaid

Stringing in 400KV OHTL Fujairah – Dhaid

~ 22 ~

TSE AND TOOLS

~ 23 ~

Socks for Conductor Stringing

Belts for Lifting of Towers Using Crane

~ 24 ~

Spacer Fixing Cradle

Gin Poles for Tower Erection

~ 25 ~

Gin Pole for Tower Erection

Pilot Wire Drums

~ 26 ~

Single Sheave Pulleys

Three Sheave Pulleys

~ 27 ~

Five Sheave Pulleys

~ 28 ~

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. ~ 29 ~

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. No 1

Client

Main Contractor

Activities of works Executed

Quantity

ADWEA TRANSCO

3

SEWA

-do-

Supply and painting of 400KV/220KV Towers Apply of paint for 400 KV / 220 KV towers from Taweelah to Yas Island Erection of 220 KV towers from Altay - Sajja to Sajja - Hamriya

170 No’s

2

M/s KEC International Ltd -do-

4

ADWEA

M/s Larsen & Toubro Ltd

2750 MT

5

ADWEA

-do-

For 220 KV OHL - Liwa GS to Liwa West Erection of towers Stringing of conductors / OPGW For 220 KV DC OHL - Sweihan GS to Al Hayer & Ramah in Al Ain Erection of towers Stringing of conductors / OPGW For 400 KV DC OHL - Jabel Ali to Merkadh Erection of towers Stringing of conductor / OPGW Survey Stub setting / Pile Head Erection of towers Stringing of conductors / OPGW For 400 KV DC OHL - Dhaid 'S/S' to 'H' S/S Erection of towers Stringing of conductor / OPGW For 400 KV DC OHL - Diamond crossings to Bukhiora S/S Erection of towers Stringing of conductor / OPGW Erection of towers & gantry Construction of access road Removal of DC twin bundle Aldrey conductor Removal of OPGW Removal of DC towers 15 Nos. For 220 KV / 132 KV DC OHL Northern Emirates Erection of towers Stringing of conductor / OPGW For 220 KV / 132 KV DC OHL Northern Emirates Erection of towers Stringing of conductor / OPGW Construction of access road working platform for 400 KV OHL (Project MEW/E01/2003-Lot II - 1 For 220 KV DC OHL – Fujairah

209 Nos 42 km 4000 MT

6

DEWA

M/s Emirates trading Agency (ETA)

7

ADWEA

-do-

8

MEW GCC Grid

M/s Emirates Trading Agency (ETA)

9

DEWA

10

ADWEA

- do -

M/s Emirates Star International LLC

11

FEWA

M/s Civil Contracting Co. Ltd

12

SEWA

-do-

13

MEW

M/s Hyundai

14

FEWA

M/s National

~ 32 ~

80,000 SQMTR

1000 MT

45.15 Km 1300 MT

89.8Km 4500 MT

30km 42 km 175 Nos

69 km 2400 MT

9 km 50 MT 0.5 km 5.64 km 5.64 km 358 MT 6300 MT

68.5 km 9 No’s

7 km 131 km 293 No’s 1500 MT

Contracting Co. Ltd

15

16

DEWA

ADCO

M/s National Contracting Co. Ltd

M/s Ranya Contracting Est.

Erection of towers Stringing of conductor / OPGW For 400 KV DC OHL - Jabel Ali to Najma Erection of towers Stringing of conductors / OPGW Dismantling of conductors Survey / Profile Erection of towers Stringing of conductors / OPGW Painting of towers Construction of platform for tower erection

34 km 3600 MT

22 km 22 km 9 km 45 Nos 9 km 200 MT 45 No’s

PROJECTS UNDER EXECUTION

Sl. No

Client

Main Contractor

Activities of Works Executed

Qty

1

TRANSCO

M/s Hyundai

For 400 KV DC OHL - Mussafah to Madinat (Contract No. NN-4099) Stringing of conductors / OPGW

133 km

For 220 KV OHL - Al Ain South West to Al Oush (Contract No. NN-4673) Erection of towers

6000 MT

Stringing of conductors / OPGW

109 km

2

TRANSCO

M/s Kalpataru Transmission International Ltd

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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

~ 35 ~

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

~ 36 ~

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

5

3 ton Mitsubishi

41860

6

Toyota pick up

14750

779

~ 37 ~

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

~ 38 ~

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

~ 39 ~

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 deshuttering 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 ~ 40 ~

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. ~ 41 ~

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. ~ 42 ~

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

998/999,

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. ~ 43 ~

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 ~ 44 ~

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.

~ 45 ~

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.

~ 46 ~

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.

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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.

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•

•

•

• • • •

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 equipment

Inspection,

Measuring

and

Test

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 procedures

A document which supports the project Quality 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

TERMS/ABBREVIATIONS

Product

Refer to “Supplier “includes for subcontractors

DEFINITIONS

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 nondestructive 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 necessary and any other person as directed by DGM

Customer

if

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 ~ 71 ~

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.

~ 72 ~

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 ~ 73 ~

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. ~ 74 ~

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 ~ 75 ~

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 ~ 77 ~

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 ~ 79 ~

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 ~ 80 ~

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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