Project Quality Plan 330 Kv Ohtl………………………….

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PROJECT QUALITY PLAN 330 kV OHTL…………………………..

Revision R0

Date 00/00/2016

Prepared by Ankit Nimbalkar

Document Project Quality Plan Verified By

Name of Project 330 kV OHTL ……………………… Approved By

Client SEC Approval Date /01/2016

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INDEX S.N.

CONTENT

PAGE NO

I

COVER PAGE

1

II

INDEX

III

REVISION CONTROL SHEET

1

PURPOSE

2

SCOPE

3

REFERENCE

4

GENERAL

5

QUALITY POLICY & OBJECTIVES

6

ORGANISATION CHART

7

RESPONSIBILITY & AUTHORITY

8-11

8

RESOURCES

11-15

9

CUSTOMER COMMUNICATION

15-16

10

DESIGN & DEVELOPMENT CONTROL

16-17

11

PROCUREMENT CONTROL

17

12

MONITORING AND MEASUREMENT

18

13

TESTING AND MEASURING EQUIPMENT

19

14

TRAINING PROGRAM

19-20

15

AUDIT

21-22

16

ANNEXURE I (ORGANISATION CHART)

23

17

ANNEXURE II (MANPOWER QUALIFICATION DETAILS)

24

18

ANNEXURE III (DOCUMENTED INFORMATION PROCEDURE)

25

19

ANNEXURE IV (PROCUREMENT CONTROL PROCEDURE)

20

ANNEXURE V (INSPECTION & TESTING CONTROL PROCEDURE)

21

ANNEXURE VI (ITPS)

2-3 4

5-6

7

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ANNEXURE VII (INTERNAL AUDIT PROCEDURE)

23

ANNEXURE VIII (CONTROL OF NONCONFORMANCE PROCEDURE)

24

ANNEXURE IX (CHECKLIST & FORMATS)

25

ANNEXURE X (PROJECT EXECUTION PLAN)

26

ANNEXURE XI (LESSONS LEARNED)

27

ANNEXURE XII (METHOD STATEMENTS)

I

STORE MANAGEMENT

II

SURVEY

III

PIT MARKING & EXCAVTION

IV

FOUNDATION

V

TOWER ERECTION

VI

STRINGING

VII

TESTING & COMMISSIONING

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Revision Control Sheet

S.N.

Date Prepared

Date Issued

Revision

1

29/08/2016

26/08/2016

00

Changes/Remarks

2

3

4

5

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1. Purpose: The purpose of this document is to provide details on the quality system management for the project. To describe organisational structure, functional responsibilities, line of internal and external communication for management and the control systems for quality standard used while executing the project. This will also help in getting insight into opportunities for improvement. 2. Scope: This document applies to all the work executed and all the inspections carried out while completion of the over head transmission line project. 3. Reference: ISO 9001 & ISO 1005-2005. 4. General: This Quality Plan has been produced in accordance with the requirements of the project & ISO 9001 approach for quality management system. It shall be the responsibility of each department and individual persons of that department to adhere to the requirements stated in this plan. 5. Quality Policy & Objectives: Principal Contractor’s Quality Policy Statement Contractor’s Quality Policy Ensures: • To deliver projects on time, within budget and in conformance with the quality standards as detailed by Contractor and the Client. • To implement the works in a safe, healthy and efficient method for staff, sub-contractors and public alike. • To ensure effective management and control quality issues that may impact on the project. • To enhance quality and minimise project cycle time by inculcating “Right First Time” culture. • To undertake the work with minimum of disruption or bad effect upon the corporate goals of Contractor and the Client. • To comply with all applicable statutory & regulatory requirements. • To provide the necessary resources, facilities, competencies, instructions and leadership to achieve the project objectives.

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Quality Policy

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6. Organisation Chart: The organisation structure for the specified project is shown in the attached document (ASKECOC Rev 00 Annexure I). 7. Responsibility & Authority: The following appointments within the Project are to ensure or specifically carry out Quality Management duties to support statutory regulations and/or requirements of the Employer. All of the following personnel are empowered to stop programme works on the grounds of a Quality concern and to give instructions for the immediate situation to be rectified. Other members of the project team are responsible for ensuring compliance with the Quality Plan in accordance with procedures as are applicable to their role. The responsibilities will not be only limited to the below stated, any other requirements and 

Project Manager • Project manager is solely responsible for execution of the project in the required form as stated in this plan. • The provision of the necessary resources, facilities, competencies, instructions and leadership. • Surveillance and monitoring the performance of programme personnel and activities. • Establish site infrastructure. • To comply with all legal and statutory requirements and have proper documentation as per client requirement (permit to work, establishment of site, Contractor approvals, labour approvals etc) • Control Site logistics, material handling and storage. • Manage sub-contractors at site and coordinate with consortium partners. • Control regularly costs, time schedule & critical activities. • Planning, execution & monitoring of the project deliverables. • Monitoring Progress and performance on site. • Supports QA/QC manager in providing essential resources for improving quality standard.



QA/QC Manager • To carry out internal quality audits at regular intervals. • Ensuring compliance of the internal audit observations/NCs in allotted time. • To prepare and maintain the quality related documents (Quality Plans, ITPs, Quality Checklists, Quality reports for client, etc...). • Getting approval of QA/QC documents from client (QA/QC Plan, Checklists, ITPs etc). • Check and review site Quality reports associated with the project together with the development and implementation of Quality controls. • Ensuring the investigation of reported Quality concerns and implementation of identified corrective and preventative actions. • Ensure the availability and implementation of the Inspection & Test Plans. • Ensures provision of Quality required training to the QA/QC engineers by making skill/competency matrix for them and evaluating their knowledge and skills at intervals.

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• Ensure quality requirements of client are met at every level in site and documentation work. • Held monthly quality meets with execution staff along with QA/QC and project manager for discussion about the status of quality at present and issue arising. To advise regarding assurance requirements. Also providing possible solutions and action plan to increase the level of quality standard of project. • Vendors and contractors evaluation in coordination with the project manager.  Site/Construction Manager The Site/Construction Manager shall discharge, on behalf of Contractor, the day to day delegated duties of Principal Contractor for the project and shall also undertake the role of overall Site Person in Charge (SPC) as follows: • To advise the Project Manager and where required check/audit compliance with required technical aspects of the project. • To confirm that the equipment supplied complies with applicable specifications and design standards. • To generate and submit Daily Progress Report. • Ensures that all legal requirements are met as per requirement against manpower and equipment. • To review reports and surveys and advise on action required. • To review compliance with product and product acceptance criteria and standards including components to be used. E.g. Conductors and assembled modules (hardware fittings) plus associated parts and equipment interface assemblies. • Ensures the effective co-operation among all contractors on site. • Manage Engineer’s & contractor’s work programmes, site activities and access to site. • Display notices that are appropriate in respect of the sites. • In liaison with the Project Manager on any necessary information associated with the site. • Ensures provision of site induction and assessment of contractors’ competencies where necessary. • Shall provide input into the Quality Plan and Quality Dossier for during and handover upon project completion to the Quality Manager.  Store In-charge/Material Controller The store in-charge or material controller is responsible for material management and handling. The following stated are the responsibilities of store in-charge/Material Controller. • Ensure that the material received is in full quantity and as per the specifications from the supplier. • Coordinates with QA/QC engineer for carrying out internal inspection of material. • Makes and keeps the list/record of all material and tools and tackles received for the project. • Keeps the track of material to their source in a excel format.

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• Preparation and maintaining of documentation required for receipt, issue and purchase request. • Ensure required material for work activity at site is received within time and securely to the site. • Ensure stacking of material is according to approved layout and complies with the quality & safety requirements of the client and internal. • To inform the QA/QC engineer of any defects or quality issues in material. To segregate non conforming material from other good material and its dispose off according to the instructions of QA/QC engineer. • Maintain the list of shortages and other documents required to trace and communicate the issues. 

Admin Team • To carry out all administrative work such as communications to site office and site store, arrange materials, spares required for office infrastructure, etc. • To coordinate with engineers and store personnel for any documentation delivery and dispatch from or to the third parties, regional offices etc. • More inputs required as per site processes (only those that will be related to quality) • …………………………………. • …………………………………………. • ……………………………………………….



Commercial Team • Ensure the procurement is done according to the client’s & quality requirement. • Making work orders, vendor evaluation, raising purchase orders, all job related to procurement and commercial terms(finance, release of invoices etc) • Clearing of invoices for contractors in coordination with the execution and QA/QC engineers. • Ensure proper control on accounting and material purchases related to quality requirements. • More inputs required as per site processes (only those that will be related to quality) • …………………………………. • …………………………………………. • ……………………………………………….



QA/QC Engineers • To carry out internal quality inspections before raising the request for inspection (RFI) too client’s representatives. • To raise RFIs of specific work to concerned representative after discussing with quality manager prior as per client’s requirement. • To maintain checklists (internal and external), RFIs, Site Instructions, NCRs, other test reports in properly filed manner with log sheet used for tracing.

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• To report biweekly progress and issues to quality manager for making biweekly report for client. • Ensure all inspection and measuring equipment are as per technical requirement and with a valid calibration and test certificates. • To resolve day to day issues (minor) in quality at site and inform the same to quality manager. • To carry out inspections at site and store with consultants. • To make compliance of site instruction, NCRs other major issues in discussion and as confirmed by quality manager at site. • Provide quality awareness training to contract labours at site. • To ensure quality requirements/standards are met at site. • To make method statements in discussion with execution engineers keeping in mind the quality requirements and submit for review to quality manager. 

Execution Engineers • To carry out site work as per the requirement. • To report daily progress to site/construction manager on regular basis. • To solve issue arising in execution at sites. • To make work plans and gang allocation as per requirement to upgrade site progress. • To carry out site inductions and awareness about the process of work to the new gangs. • In coordination with the contractor manage day to day activities at site. • Prepare method statements and checklist by coordinating with QA/QC engineers. • Coordinate with QA/QC engineers and fulfil all test requirements by conducting third party tests wherever applicable. Ensure provision of these to the QA/QC personnel. • Ensure arrangement of equipment/material and other resources availability at site before starting the work. • Raise internal inspection calls to QA/QC engineers after verifying that all requirements for inspection are met. • Resolve issue found during internal inspection in liaison with QA/QC engineers. • To report any quality issues found during work at site to the QA/QC engineers.

 Sub-Contractors Other contractors undertaking site work for the project shall also discharge the role and duties of Contractor but not limited to the following: • • • •

Co-operate with the Principal Contractor to enable them to comply with their duties. Comply with directions of the Principal Contractor. Comply with the applicable rules and requirements in the Quality Plan. Promptly provide information relating to Quality concerns and site incidents or dangerous conditions. • Provide a Contractor's Quality Plan and/or Method Statements that are compatible with this plan.

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• Provide adequate and competent Site Persons in Charge (SPCs) for the areas of their working. • Provide adequate numbers of competent staff to ensure Quality on the project. 8. Resources: The required resources for implementation and improvement of the quality system, and for addressing customer satisfaction, may include any of the following: Suppliers, information, infrastructure, work environment, and financial funds. The principal means for determining and communicating resource requirements are management reviews of the quality system, wherein the detailed discussion over the requirements and available resources along with planning for these is held and action plans made to confer the same.  Responsibilities for Determination of Required Resources The Quality Manager and all management personnel affected by the quality system are responsible for determining resource requirements for the implementation and improvement of the system.  Provision of Resources Top management (Regional) has the responsibility and authority for provision of resources. Resources for designated activities are integrated with the process of defining and initiating the activity. They may take the form of personnel assignments, allocation of space or equipment, training, procurement decisions, budgets, etc. Infrastructure Suitable facilities and work environment are provided as required to assure project quality. This includes planning, provision, and maintenance of employee facilities, workspaces, equipment, software, and associated services. 1) Office facility:  Own Use: • A temporary site office shall be installed prior to mobilization of any construction activity pertaining to the project. • Proposal with layout sketch of the site office shall be submitted to client for approval. If the facilities located outside the Client’s property/premises a written permission of the owner of the land/premises shall be obtained and copy will be furnished to the client for records. • The site office will consist of all IT infrastructure that is necessary to carry out documentation work (Computers, Printers, Internet, Photo copy Machine, etc) in adequate manner so as to avoid queuing for resource availability. • Site office will be provided with necessary illumination facilities and air conditioning systems to maintain comfortable working atmosphere. • Sufficient furniture (working desk, chairs, cupboards, file racks etc…) will be provided depending upon the capacity of staff using the office.

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• All the stationary items will be readily made available before mobilising the staff to office; it will be regularly checked and purchased as per requirement.  Client Representative’s Office: • A temporary site office for client’s representatives will be provided and maintained as per the requirement (Appendix X attachment V in PTS-13CO372- Scope of work & Tech….) in a good condition. All facilities as stated above will be available in this office. • There will be a hall to accommodate Secretary, two Nos. of Engineers and two Nos. of Inspectors. A conference room for meetings will also be provided. • The furniture and other facilities will be as per the requirement and mutual agreement between the client and contractor. • Telephone facility will be provided on demand of the Client, in this case the remittance of telephone rental charges will be redeemed from client. However the contractor shall be allowed to make local calls from this if required.  Store Facility: Store facility will be as per stated in the Store management Procedure (KEC-Q- SOP-0005 Rev 00), any additional requirement will be fulfilled if in contract documents.  Environment: While building the store/office facility proper care will be taken so that there is no harm to the environment. • No trees shall be cut for the construction of the store building or other facility. • Display of hazardous waste storage & collection point will be clearly defined and marked. • Regular housekeeping will be maintained at store and office, all the collected trash will be disposed off in a proper manner on daily basis. • Proper care shall be taken to store hazardous waste and material so that it doesn’t contribute to land, air or water pollution.  Health: A special attention will be given to the health factor of the persons working in the store/office while planning the store /office layout. • Adequate supply of drinking water will be ensured at the facility with availability at required points in the store and office. • Sufficient supply of non drinking water will be provided t required points. • Clean and well maintained sanitary facility will be provided as per the requirements stated in Appendix X attachment V in PTS-13CO372 (Scope of work & Tech….). • A temporary drainage connection from existing system will be provided, to the site office/store. Alternate arrangement will be provided if drainage facility does not exist. • There will be arrangements made for resting of personnel i.e. proper rest rooms to be provided.

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• Adequate first aid facilities will be provided at the store and office in accordance with the requirement. • Arrangement of ambulance shall be there (Tie-up with the nearest hospital & emergency medical facilities), Emergency contact numbers of hospitals, Anti venom centres must be displayed. Emergency exit plan should be displayed at proper location.  Fire Protection: Adequate fire protection will be provided as per the requirement of client and internal company’s plan. • Portable extinguishers shall be provided to all strategic areas by which travel distance to reach the other extinguisher shall not be more than 9.5 meters. • Portable extinguishers shall be a combination of 6 kg.dry powder and 6 kg. CO2 to be well distributed as required. • Wheeled type large capacity extinguisher of CO2 & dry powder shall be provided to all strategic areas as maybe required. • Two zones fire detection and alarm system shall be provided to cover all temporary offices. • Ensure to Identify and prevent heat transfer close to ignitable material within the facility like cable trays and service transformers. • Ensure to isolate the hazard by providing barrier walls within the facility. • Ensure provision and availability of proper protective gears for the personnel involved in the fire fighting. Materials & Equipment: The Materials/Equipment, Engineering and Construction requirements for this project will be in accordance with client’s requirements (i.e. the latest revisions and approved TMSS, TES, and TCS). 1) Materials This covers all type of material required during the project execution stage (Steel structures, Hardware fittings, Re-bars, concrete, etc…) • The steel structure will be provided by the contractor as per the requirements of the properties stated in 20-TMSS 01 Revision 01. • The contractor shall provide certificate of analysis of his product from the client approved Independent test agency at the time of approval and shall be ready to perform the random site sampling test at the client’s approved independent testing agency. • The site sampling test reports shall be forwarded to client directly by the independent testing agency with a copy to the contractor. • The material which is bought by vendor shall be tested and reviewed FAT and test certificates will be submitted to the client for approving the source. • Concrete shall conform to severe exposure condition as per the requirements of 70TMSS-03.

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• In case no ready mix is used, the source of supply of all sand and aggregate shall be sent to the client for approval and fine and course aggregate shall be stored and handled so as to preserve the gradation and cleanliness of the material. Contaminated material will be rejected as per control of non conformance procedure (Annexure VIII). • Reinforcing steel and tie wire shall be per the requirements of SASO/SSA-2/79 and TES-P-122.06. • Welded wire fabric shall conform to ASTM A496 and SASO SSA 224/1981 (cold drawn) wire with minimum yield strength of 240 MPa. • The bonding agent shall be solvent-free epoxy resin, two components, containing pigments and fine fillers. • It shall be ensured that the bonding agent shall be able to provide a bond of far greater strength than the tensile strength of the concrete itself. • The bonding agent shall have the properties as per the PTS-13CO372 (Scope of work & Tech….) and the corresponding ASTM standards. • A two-component (agitate base & curing agent), metallic zinc rich epoxy primer, high performance to give maximum protection against aggressive environments. • The material shall comply with the composition and performance requirements of SSPC and the PTS-13CO372 (Scope of work & Tech….). • Sub-base and Surface course (select fill) materials shall meet all the requirements as per the Surface course material shall be Class C per TCS-Q-113.02. • It shall be free of organic matter, rubbles, cobbles, boulders and other deleterious substances.….). • Repair material above grade surfaces shall confirm to TCS-P-122.05, Section 11.5. • Repair material below grade surfaces shall confirm to TCS-P-122.05, Section 11.5. • All others to be as per the requirement of client and as specified in the TMMS, TCS & TES. • All the hardware items will be given with test certificate and test report to client. • Conductor and structure related hardware shall conform to the requirements of the SEC materials standard specification 12-TMSS-01. • The type of insulators to be used for the shall be in accordance with the requirements of TES-P-122.01, conforming to the requirements of client Materials standard specifications 15-TMSS-02 and 15-TMSS-04 for inland area or as specified by the client. • Copper-clad steel grounding conductors, ground rods, connectors and other materials as per requirement of SEC standards specification 10-TMSS-05 and TES-P-122.10 shall be provided. 2) Equipment: • The equipment required for execution of the project shall conform to the international standards and client specifications. • Equipment used by the sub contractor shall be verified for the conformance to work and a list with the required test certificates will be sent to client.

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• All the measuring and testing equipments will have a valid calibration and testing certificate before being used. Human Resource: ASKEC selects and assigns qualified personnel to ensure that those who have responsibilities defined in the quality system are competent on the basis of applicable education, skills and experience, competence, awareness and training. ASKEC has established and maintains a training process to: • Identify competency needs for personnel who perform tasks affecting quality. • Provide training to address these needs. • Assess the effectiveness of the training provided. • Ensure that personnel are aware of the relevance and importance of their activities and how they contribute to the achievement of the quality objectives • Maintain records of education, experience, training, and qualifications per the control of documented information procedure (Annexure III). • The manpower required for execution of the project shall be adequate to suffice the task and in line with the requirement of client. • Manpower details for this project are shown in the attached organisation chart. • As per consideration of ground staff (e.g. manpower for erection work, foundation work, stringing work etc…) shall be hired from a competent source. • The hired manpower services will be approved by the client, for which all the formalities and requirement (legal, technical & statutory) will be fulfilled by our assistance to the source. • The qualification of the manpower is as given in the Annexure II, upon approval the resource will be utilised for work. 9. Customer Communication: ASKEC communicates all matters regarding the effectiveness of the quality systems to the entire organization. This includes quality requirements, objectives, and achievements as well as product and process performance.  Communication Process • The Quality Manager has the overall responsibility for ensuring that information and data about quality performance and the effectiveness of the quality system are reported to customer. This includes the distribution of all applicable documents, reports, and records to appropriate customer functions. • Formal communication to the Principal Contractor will be via letter or e-mail. Urgent Quality matters override formal methods of communication and the quickest possible method will be used by all parties concerned.

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 Customer Meetings Formal communication/review meetings serve an important role in ensuring proper communication between Client and the Contractor. Weekly or as per Client’s instruction the meetings will be held. Quality issues related to project, material and reviews on support and requirement will be discussed in detail in the meetings.  Communication Records • All the MOMs, emails, site instructions, NCRs etc from customer to contractor and vice versa will be recorded in soft and hardcopy and to be kept for ready reference. • Log sheet for communication record will be maintained to provide ease in traceability.  Customer Complaints • Whenever any complaint is received from customer, it will be logged in the communication log. • Then complaint will be thoroughly scrutinised by the quality manager and enquiry will be put up for the raised issue to the concerned quality engineer. • Corrective and preventive actions according to non conformance procedure will be taken and communicated to client by means of mail. 10. Design & Development Control: The design and development department has a control on the processes to ensure that quality issue are eliminated before reaching to project. The requirements for overall control of drawings and documents for the project are described as below.  Responsibilities • The design manager is responsible for comprehensive control of design documents required for the accomplishment of the projects. He is also responsible for assuring that the appropriate standards and quality requirements are properly translated to the design documents & drawings. • The construction manager is responsible for ensuring that only approved and latest version drawings are used for construction and also for communicating changes to design development team. • The document controller in the design department is responsible for ensuring that the documents are properly controlled and distributed to the required persons thru proper channel.  Design and Development Activities Engineering will translate the needs and expectations from the Client to technical specifications for materials, products, and processes. The design is geared towards meeting customer requirements, while providing a product cost, which will enable ASKEC to have a satisfactory return on investment. Engineering is responsible for providing a design, which is producible, verifiable, and controllable under the specified production, installation, and operational conditions.

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Each design and development activity is planned, divided into phases, and tasks are assigned to qualified personnel equipped with adequate resources. Plans are documented and updated as the design evolves. Organizational and technical interfaces between different functions that contribute to the design and development process are defined and the necessary information documented, transmitted, and regularly reviewed. Designs and design changes are documented, revision controlled, and approved by authorized personnel. Formal, documented design and development reviews are held at appropriate stages of the design and development activity and include representatives from all concerned functions. Design and development verification and validation are performed and approved as appropriate before designs are released to assure each product conforms to all specified design and development requirements. This includes alternative calculations to verify correctness of the original calculations and analysis using design software, and evaluation of sample production model (tower assembly and load testing). Records of verification and validation activities are filed at design department.  Design and Development Changes Design and development input changes may be requested during design and development projects by Client service, Production, or Engineering itself. Once approved by Client, Engineering incorporates the new requirements into the design and adjusts activities and schedules to accommodate the revised design and development input. The design development changes are then incorporated in the final drawings which are sent for approval to the client.  Design and Development Output Design and development output is in the form of documents and provide instructions for manufacturing (i.e., drawings, specifications). All design and development output documentation is reviewed by qualified personnel and approved by the Manager prior to release. After the final approval from Client these are distributed to the manufacturing plant and product is manufactured. These revised drawings are then sent to the project thru proper communication channel for the use. 11. Procurement Control ASKEC ensures that the procurement process is controlled such that purchased products and subcontracted services, which affect product quality, conform to specified requirements. The type and extent of methods to manage the purchasing process depends on the effect on subsequent realization processes and their output. For details, refer to the Procurement Control procedure (Annexure IV)

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12. Monitoring and Measurement Processes that directly affect quality of intermediate and end products are carried out under controlled conditions. To this end ASKEC has established and maintains a process control procedure according to the controlled conditions which is as follows.  The availability of information that specifies the characteristics of the process • Each and every process that is to be done for completion of the particular task is studied in detail with respect to the requirement of client and international standards. • Quality manager ensures that for any activity the technical requirements and requirements according to the international and company standards are completely understood by the execution and quality team. • All the requirements (technical and others) are taken from the client, to ensure nothing is skipped the meeting regarding clarification of the requirement is held between client and ASKEC.  The availability of work instructions/Method Statements • All the major process carried out in the execution will be having a method statement, which will be approved from the client. • Any special work if required will be commenced after developing the method statement of the same. • Internal procedures for audit, procurement control, non conformity control etc, will be made and implemented in the processes.  The use and maintenance of suitable equipment for process • All operating equipment will be maintained as per the company standard. • All necessary equipment required for process shall be ensured are being used to decrease the project cycle time and raise the quality standard of the process. • A maintenance schedule will be prepared for these equipments and regular monitoring for its usability will be ensured before use.  The availability and use of measuring and monitoring devices will be as per the control of monitoring and measuring devices procedure • A procedure to control and monitor the use of measuring devices is established to ensure the accuracy is measurement. • For details refer (Procedure for Control and Monitoring of Measuring Devices) 12.1. Inspection & Testing ASKEC measures and monitors the characteristics of the processes to verify that requirements for the project are met, for which an inspection program is carried out at appropriate stages of the product realization process in accordance with the Inspection and Testing control procedure. (Annexure V, VI for ITPS). The inspection and testing will be controlled as per the inspection and testing control procedure, (refer attached procedure).

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13. Testing and Measuring Equipment ASKEC controls the measuring and testing equipment by regularly monitoring and calibrating the instruments as per the requirement • All the equipment used for measuring and testing are bought from a reputed brand along with the valid test and calibration certificates. • Quality manager will ensure that the equipment used is suitable for the inspection or test that is being performed. • It is the responsibility of the quality manager to prepare a monitoring and track sheet for maintaining the equipment’s present status. • The tracking sheet shall consist of model number, date of purchase, calibration date due date, calibration agency, internal serial number or equipment id for traceability. • It is the responsibility of store in-charge to maintain the list of all equipment along with the current distribution status of it. • The maintenance of the equipment is the responsibility of store in-charge, which can be assisted by the QA/QC engineers. • To maintain the marking and identification of the equipment lies in the responsibility of QA/QC engineers. • All the equipments will be made available to the client’s representative whenever the inspection or testing is carried out. • The equipment if used by construction staff, it is responsible for its maintenance and preservation. • The calibration f the equipment is to be done in presence of QA/QC engineers thru the manufacturer or third party labs. • The equipment to be calibrated shall be made available by the store in-charge and construction engineer on time to the QA/QC engineers. • All the calibrated equipment will be monitored for calibration expiry and maintenance by quality team. 14. Training Program: ASKEC regards employees as its greatest asset. To this end, the company maintains an established employee qualification/training program. All personnel are classified on the basis of appropriate education, training, skills, or experience. Records of all training activities are kept in each employee’s file at the regional or corporate office whichever is applicable.  Training Requirements Review • The responsibility for identifying employee-training requirements lies with each department manager. • The purpose for the review is to identify competency needs for all personnel performing activities affecting quality. • Job requirements, internal audit reports, and corrective action activities determine employee-training needs. In addition, an annual review and midyear review is conducted with each employee, at which time the employee’s training needs, as well as the effectiveness of the previous training is discussed.

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• Each employee is made aware of the relevance and importance of their activities and how they contribute to the achievement of the quality objectives.  Formal and Informal Training • All employees receive an “on-the-job” training by the responsible area supervisor. After a 30-day trial period, all new/transferred employees are evaluated against the position requirements and if performance is found to be satisfactory, qualification for the applicable position is awarded. • New employees receive indoctrination into the quality system from the Quality Manager. • Designated employees may receive formal off-site/on-site training/seminars in various jobrelated disciplines/topics, as determined by the responsible supervisor/manager. This is managed by the central training programs held at regular intervals by the corporate division.  Induction & Training for Sub-Contractors • ASKEC quality team arranges the training program for the key personnel of the sub contractor to induce the awareness about quality till the bottom line. • The quality manager is responsible for the conduction of the training program. • There are various training modules developed for this kind of trainings.  Training and Qualification of Inspectors • ASKEC ensures that the inspectors are having the required qualification to ensure the effectiveness f quality objective. • The competency of the personnel to perform inspections is developed by one of the following methods. - Providing personnel with working knowledge of appropriate contract details, documents, codes, practices followed & standards. - Training or orientation in general and specialised methods of planning and performing inspections. - On the Job training under direct supervision of experienced qualified inspector. • The QA/QC manager regularly evaluates the inspectors for proficiency and skill development.  Qualification/Training Records • The Personnel Manager maintains records of education, skills, experience, training and qualifications for each employee. • A skill and competency matrix is developed and regularly filled based on the evaluation of the personnel. • An online portal is made for maintaining the records at the central corporate HR. 15. Audit: Auditing is the most important phase of any project since it makes us aware about the current condition and what will be the future structure of the project quality. ASKEC has developed a

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procedure for internal auditing (Annexure VII). All the audits carried out by the client are recorded and complied if any non conformance is found. The client will be facilitated with all the necessary requirements for performing the audit. As informed/communicated from client the date of audit will be fixed, however the client is free to do surprise audit of the project at any stage of the project cycle.

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ANNEXURE I Organisation Chart

Page 22 of 35

OVERALL ORGANIZATION CHART Format No: ASKEC-OC

Project CN: 4400007080 - Construction of 380 kV OHTL From Airport Housing (#9050) to PS-3 (#31287)

Rev.No. 00 Dated 26-Jun-2016

Country Manager (Name) Mob.No:

Quality Regional Manager

Safety Regional Manager

(Name) Mob.No:

(Name) Mob.No:

(Name) Mob.No:

Project Co ordinator/ Planning Eng

Commercial Manager

Construction Manager

Quality Manager

Safety Manager

(Name) Mob.No:

(Name) Mob.No:

(Name) Mob.No:

(Name) Mob.No:

(Name) Mob.No:

CAD Coordinator

Store Officer

(Name) Mob.No:

(Name) Mob.No:

Supervisor

Civil/ Mechanical Engineer

(Name) Mob.No:

Electrical Engineer

QA/QC - Civil

QA/QC - Electrical

Safety Engineer

Safety Engineer

(Name) Mob.No:

(Name) Mob.No:

(Name) Mob.No:

(Name) Mob.No.

(Name) Mob.No.

(Name) Mob.No:

Commercial Crew (Name) Mob.No:

Project Manager

Stringing Crew Store Crew Access Road Crew

OPGW Crew

Soil Investigation Crew

Earthing Crew

Admin Crew (Name) Mob.No:

Foundation Crew

Tower Erection Crew

Quality Supervisors

Quality Supervisors

(Name) Mob.No:

(Name) Mob.No:

Safety Supervisors

PROJECT QUALITY PLAN Format No Issue Date

ASKEC-Q/PQP 29/09/2016

Revision No Revision Date

00 20/09/2016

ANNEXURE II Manpower Qualification Details

Page 23 of 35

Manpower Qualification Details Format No: ASKEC-Q/MPQ Project: 380 Kv OHTL B/W PS3 - 9050 S/S

S.N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Name

Rev No 00

Designation

Discipline

Qualification

Experience (yrs)

Remarks

Format No Issue Date

ASKEC-Q/PQP 29/09/2016

Revision No Revision Date

ANNEXURE III Documented Information Procedure

00 20/09/2016

PROCEDURE FOR DOCUMENTED INFORMATION Format No Issue Date

ASKEC-Q/DC 13/09/2016

Revision No Revision Date

00 13/09/2016

PROCEDURE FOR DOCUMENTED INFORMATION WITH GUIDELINES

Prepared By

Reviewed By

Approved By

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PROCEDURE FOR DOCUMENTED INFORMATION Format No Issue Date

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INDEX S.N.

CONTENT

PAGE NO

I

COVER PAGE

1

II

INDEX

2

III

REVISION CONTROL SHEET

3

1

OBJECTIVE

2

PURPOSE

3

SCOPE

4

REFERENCE

5

RESPONSIBBILITY AND AUTHORITY

6

PROCEDURE

6.1

ORIGINATING DOCUMENT

6.2

REVIEWING DOCUMENT

6.3

APPROVING DOCUMENT

6.4

REVISION/MODIFICATION CONTROL

6.5

DOCUMENT DISTRIBUTION CONTROL

6.6

DISPOSAL OF OBSOLETE DOCUMENT

6.7

DOCUMENTATION STORAGE

6.71

FILE NUMBERING SYSTEM

6.72

ELECTRONIC STORAGE

6.73

HARD STORAGE

4

4-5

5-9

7

ANNEXURE I (RASIC MATRIX)

10

8

ANNEXURE II (MASTER DOCUMNETATION LIST FORMAT)

11

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PROCEDURE FOR DOCUMENTED INFORMATION Format No Issue Date

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Revision Control Sheet S.N.

Date Prepared

Date Issued

Revision

1

13/09/2016

13/09/2016

00

Changes/Remarks

2 3 4

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PROCEDURE FOR DOCUMENTED INFORMATION Format No Issue Date

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1. Objective: The objective of control of documentation and records is to ensure that the correct and approved documents are available at every level in the organisation for reference to the employees. 2. Purpose: The purpose of this procedure is to, • Control the documents of Quality Management system. • To ensure that all the documents and data therein are reviewed and approved for adequacy prior to their initial release and the subsequent changes. • To ensure legibility, identification and retrieval of the documents. • It is available and suitable for use, where and when it is needed. • It is adequately protected (e.g. from loss of confidentiality, improper use, or loss of integrity). • Prevent obsolete documents from unintended use. 3. Scope: This procedure applies to all internal and external documentation work carried out in AS-KEC. 4. Reference: ISO 9001: 2015 & Scope of work (PTS- 13CO372) Rev 0. 5. Responsibility & Authority: The responsibilities and authorities of each person, but not limited to, are defined as below. Also a RASIC matrix is defined at Annexure I  Originator • Ensures the need of document that is to be prepared based on the requirement of client, International Standards and Company’s standards and should be having a risk based approach while preparing the document. • Ensures document is properly identified and proper formats are made to identify the revision control. • Ensures that the valid revision is done as per approver’s remark, i.e. task of updating the documents as per requirement.  Reviewer • Ensures the required demand of documentation is met as per the standards, no data in the document contributes to controversy between standards and the mentioned process in document. • Ensures that the document is timely reviewed and sent for updating to the originator. • Ensures through review of document before being sent for approval.

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 Approver • Ensures the valid document is approved. • Ensures provisions of adequate resources financial/time/infrastructural are provided to complete the documentation work. • Ensures evaluation of the originator/reviewer and controller from time to time.  Process Owner • To provide details of work carried out and necessary data for generating a document based on practical situation and the requirements. • Ensures the stark implementation of processes as per documentation at work site (may be office, store or site). • Ensures availability of document at the required place at any point of time while the project is in execution phase. • Give feedback to the originator about any issue in documentation and practical working condition or any change required for any activity.  Cross Functional Team • To provide necessary data, related to the work being affected/ dependent on the documentation of other process, to the originator in coordination with process owner. • To support the originator in providing vital inputs when required.  Expert An expert may be someone with thorough knowledge and a rich experience on the process for which documentation is done may be from same company or hired consultant. • To provide expert comments and validate the document created is appropriate or not as per own knowledge and experience. • To provide data related to good practices and bad practices with their effect related to the documentation being prepared.  Document Controller A document controller may be the quality personnel or the approver, who will also act as issuer. • Ensures that each document is having proper identification & traceability from issue to disposal. • Ensures no duplicity of documents arises. • Ensures obsolete documents are properly disposed off. 6. Procedure: 6.1. Originating Document The need for creating the required document is to be thoroughly accessed and in accordance with the respective departments the documentation creating process will begin. The following considerations and steps t be followed while creating a new document.

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• Document to be generated will be made in consideration of all the requirements of standards and client necessary for the document. • It is to be ensured that no previously created document is present for the same task. • A draft procedure for the required work is to be obtained from the process owners, educating them how to make it, by considering the regular work they are doing while performing the task. • Check with the standard procedure that if certain deviations or misses in the work instructions are present and include those lapses in the prepared document. • Proper document numbering/ format numbering and revision numbering is to be given to the document. • Ensure a standard format is used to create any document that will comply with organisations formats. • Arrange all the required references (standards/client’s technical specs/ company standards etc) and by taking reference prepare the document. • In case of help required from experts, coordinate with the head of department/ approver and arrange the person. • In certain cases also coordinate with the cross functional teams, for the document that is interlinked or depended on the internal other processes. • After the required document is prepared review once for any skipped portions or mistakes, also spellings and grammar. • Send the document for review to the next chain of communication. • Upon receiving the update if any correction is required the same should be done and highlighted before sending for review again. • Ensure no other part in the document is touched rather than the updating portion. 6.2. Reviewing Document The document created needs to be thoroughly reviewed for any mistakes, the process is as follows. • Check the format numbers, template, standards referred in it and proceed checking of each and every point with the reference of the standards and requirement. • All the important parameters of the process to achieve the desired output and with effectiveness are ensured in document. • In certain cases it is required to review the documents with the other departmental heads and get an update on reviewed documents, in such situation the primary reviewer will arrange for the review of required persons and collective feedback of all is checked and given to the originator for updating the document. In no case shall be the document changed by anyone except the originator. • The updated document received from the originator is to be again checked for the required updates are done properly or not. • After ensuring the correctness of the document it is to be sent for approval.

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6.3. Approving Document For the document to be implemented the approval from head of department shall be required for this the following considerations are to be followed. • Check the documentation numbering and format. • In coordination with the reviewer or originator in case reviewer and approver is same, the documentation is to be checked finally for any legal issue, controversy and effectiveness of the process. • The document after that needs to be initialised by the originator, reviewer & approver. • The document should be issued then after the approval by the document controller who shall be the approver. • The documents are to be reviewed on regular basis for any change or revision required for increasing the efficiency & effectiveness of the document. 6.4. Revision/Modification Control All the reports, documents that are prepared may have revisions and modifications, depending upon the adequacy of the document after implementation. The revision or modification control should be as per the following steps. • Upon reviewing the document if any modification is required it shall be sent to the originator. • The required modification to be checked for the necessity for it to be incorporated. • Summarise all the inputs/reasons required for modification. • The required modifications done by the originator is to be checked and ensured done properly by the reviewer. • Upon confirmation the said document is to be sent for approval. • Thus upon approval the document revision details are to be updated in the master list. • The revised document is to be then distributed at respective department. 6.5. Document Distribution Control • Documents hard copies are controlled by respective coordinator by putting “ MASTER COPY” stamp. • All the approved documents are to be stamped with “Control Copy” stamp before distribution. • Ensure the document is distributed to the concerned departments by a centralised process, for soft distribution it should be uploaded the company’s portal, else hard copies with controlled stamped to be sent. • The list of the document is to be kept with details like (date of issue, Document name, number, revision, distribution record etc). • The master list is to be update regularly and available to the concern departmental heads. • All external documents like (drawings, test certificates, etc) are to be checked for the authenticity and then distributed t the respective departments. • The external documents numbering and revision details are to be added in the master list.

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6.6. Disposal of Obsolete Document All the revised documents will leave the copy of documents with older revisions as obsolete and unfit for use. Thus the disposal of such documents is very important, which is to be done as follows. This process applies to all internal and external documents. • Upon receiving the revised document, it is to e checked for the authenticity to the originator. • Upon confirmation of the above the document (drawings, procedures, checklists, formats, etc) are to be traced for older revisions. • The older revisions are to be marked obsolete in case of hard copy stamped with red ink as “OBSOLETE” and in case of soft copy to be removed or isolated from the data base marking obsolete comment. • The hard copies given to each department are to be collected and scrapped, in case if required for reference by the originator it should be marked obsolete and kept at single location for originator to view when required. 6.7. Documentation Storage 6.7.1 File Numbering system • All documents and records shall be entered on the data base files and either given the appropriate existing number or a new number or name to the file. • In case of document is in hard format it should be pinned in individual files having the file number and title of documents kept in it with an index at starting. • Files to be kept at the respective departments with proper communication to the head of department. • The access right to the files is to be decided by the concerned department’s head. 6.7.2 Electronic Storage • All documents and records that are to be stored on electronic media are to be uploaded nowhere else than the company’s portal. • A specific directory is to be made for particular type of documentation. • The master document folder should be accessible to authorised QMS team only. • External documents shall be adequately protected for copy rights and unauthorised distribution to market. • All quotations, Certificates of Destruction and other correspondence produced shall be stored electronically and retained indefinitely. • The diary used for scheduling of all visits made to the document shall be kept electronically for a minimum of two years. • All computer files shall be backed up daily. • The retention period of documents to be a minimum of 10 years or more as per the requirement. • Proper antivirus to be installed in the system so as the files are not hacked or corrupted by any malware. • All the documents like inspection forms, invoices, test certificates and drawings must be kept both in hard and scanned soft copy.

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• All the communication correspondence must be kept in electronic media. 6.7.3 Hard Storage • All documents and records that are to be stored as a hard copy are to be filed and kept in the respective departments. • All external documents are to be filed spate from internal documents and to be labelled as external with the title of content. • Ensure that access to master document is limited to, as said in point 6.7.2. • The hard copies of the documents are to be kept for minimum of 3 years or as per requirement. • Preservation of hard copies from rats/ rodents/ water is to be ensured. In case any document is damaged the same shall be brought into notice of the originator and document controller. • A new copy is to be requested for the same.

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ANNEXURE I RASIC MATRIX

Expert

C

C

Review and approval of documents – New

ASC

I

C

R

3

Review and approval of documents

ASC

I

C

R

4

Modification/ Revising the document

ASC

I

5

Control of documents – Internal

ASC

I

6

Control of documents – External

ASC

6

Document availability at point of use

ASC

1

Origination of documents-New

2

R

I

Process owner

CFT

ASC

Process clause number / description

Document controller

HoD/ Higher Authority

R

S. N.

Reviewer

Originator

Process Owner

C

I

C

I

C

C

R

C

R I

R

Terms:R- Responsible (Those responsible for the task, who ensure that it is done as per the approver) A- Approver (The person/function ultimately answerable for approval) S- Support (Those who support the completion of task by providing necessary resources) I- Informed (Those who are kept up to date of the task usually after completion) C- Consulted (Those who give input for the process to be completed)

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ANNEXURE II Master Documentation List Format

MASTER DOCUMENTATION LIST Format No.

S.N.

ASKEC-Q-MDL

Document Title

Rev. No. 00

Document No

Initial Release Date

Revision No

Issue Date

Master Copy Location

Controlled Copies Location

TOP

Page 11 of 11

PROJECT QUALITY PLAN Format No Issue Date

ASKEC-Q/PQP 29/09/2016

Revision No Revision Date

00 20/09/2016

ANNEXURE IV Procurement Control Procedure

Page 25 of 35

PROCUREMENT CONTROL OF PROCEDURE Format No Issue Date

ASKEC-Q/PC 24/09/2016

Revision No Revision Date

00 24/09/2016

PROCUREMENT CONTROL PROCEDURE WITH GUIDELINES

Page 1 of 11

PROCUREMENT CONTROL OF PROCEDURE Format No Issue Date

ASKEC-Q/PC 24/09/2016

Revision No Revision Date

00 24/09/2016

INDEX S.N.

CONTENT

PAGE NO

I

COVER PAGE

1

II

INDEX

2

III

REVISION CONTROL SHEET

3

1

OBJECTIVE

2

PURPOSE

3

SCOPE

4

REFERENCE

5

RESPONSIBBILITY AND AUTHORITY

6

PROCEDURE

6.1

QUALIFICATION OF SUPPLIERS

6.2

PURCHASING DATA

6.3

VERIFICATION OF PURCHASED PRODUCT/SERVICES

4

4-5

5-7

7

ANNEXURE I (VENDOR EVALUATION REPORT)

8-9

8

ANNEXURE II (VENDOR EVALUATION FORM)

10-11

Page 2 of 11

PROCUREMENT CONTROL OF PROCEDURE Format No Issue Date

ASKEC-Q/PC 24/09/2016

Revision No Revision Date

00 24/09/2016

Revision Control Sheet S.N. 1 2 3 4

Date Prepared 24/09/2016

Date Issued 24/09/2016

Revision 00

Changes/Remarks

Page 3 of 11

PROCUREMENT CONTROL OF PROCEDURE Format No Issue Date

ASKEC-Q/PC 24/09/2016

Revision No Revision Date

00 24/09/2016

1. Objective: The objective of procurement control procedure is to establish a procedure for the control over the process of procurement/purchasing of material required for project completion so that the quality is assured to the max. 2. Purpose: The purpose of this procedure is to define a systematic approach for purchasing, inspection, testing and evaluating the quality of the product. 3. Scope: This procedure applies to all purchases of products and materials within scope of work, whether obtained from vendors or produced in-house. This procedure applies to all procurement activity of the company. This procedure is to provide a framework to: • Identify the correct product/services. • Evaluate the proper source for purchase. • Provide traceability of product quality. 4. Reference: ISO 9001: 2015, ISO 10005-2005. 5. Responsibility & Authority:  Design Manager • Ensures that the required technical specifications are incorporated in the documents sent to the manufacturing & purchase/procurement department for purchase of specific quality and grade of material.  QA/QC Manager • Ensures that the required technical specifications are incorporated in the purchase requisition sent to the purchase/procurement department for purchase of products and services. • Ensures the services which are to be procured are as per the client’s requirement and the source is evaluated for quality rating.  QA/QC Engineer • Ensures the product which is to be purchased is tested and inspected for the quality at the source. • Ensures inspection of receipt material at hub. • In case of any issue to log the records and take appropriate action as per non conformance control procedure.

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 Purchase Manager • Ensures the product/services to be procured confirm the requirements as stated in purchase requisition in coordination with design and quality team. • Ensures vendors are evaluated and sources are filtered as per their level of quality standard. • Ensures in time delivery of the item to project team.  Project Manager • Ensures that in coordination with the quality and purchase manager gets the right product for the project. • Helps the purchasing and quality team to evaluate vendors, sources and inspect quality of material at site and vendor’s plant by providing proper feedback, technical support and facilities to conduct the same. 6. Procedure: 6.1. Qualification of Suppliers • Purchasing and Quality share responsibility for the qualification and monitoring of suppliers. • Suppliers' quality capabilities are evaluated through the use of the supplier evaluation, by reviewing the past experience with other similar companies and where necessary, on-site surveys, before orders for supply of materials and services are placed. The effectiveness of the suppliers' quality system shall be reviewed at intervals consistent with the complexity of the items supplied and the suppliers' performance. ASKEC supplier evaluation is normally the first official contact between ASKEC quality function and a potential supplier. All questions in the evaluation form (Annexure I & II) should be answered as completely as possible, and the form should be returned to ASKEC purchasing within the requested time period. The Supplier evaluation is a necessary prerequisite to any award of business from ASKEC. Quality will review the evaluation findings and determine whether a site survey, described next, is required. • Suppliers who have been supplying ASKEC for past year, and whose performance has proven to be acceptable, their past performance is monitored in the same evaluation form. In case of any degradation in performance necessary action is taken. • Other suppliers are inspected at their location & on the evaluation basis it is decided which suppliers can be sent for client’s approval. • In the evaluation these are required to score a minimum of 60 points to qualify. In certain cases client can predefine the list of approved suppliers for specific material or service, then they are exempted from the requirement for supplier evaluation, and may be classified as “APPROVED”. • The quality manager maintains an approved supplier list, which is authorized by the quality manager and the purchasing manager. This includes all suppliers whose supplies or services affect the quality of the ASKEC products/services, and who have been surveyed/audited and have demonstrated, by performance, their ability to meet the specified quality requirements. • Orders may only be placed with suppliers that are on the list.

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PROCUREMENT CONTROL OF PROCEDURE Format No Issue Date

•

ASKEC-Q/PC 24/09/2016

Revision No Revision Date

00 24/09/2016

An updated approved supplier list is printed or mailed to all personnel who are responsible for preparing and approving the company's purchasing documents.

6.2. Purchasing Data • All purchasing documents are prepared by purchasing department. The documents clearly describe ordered products/services. They include precise identification of the products/services, reference applicable standards and other relevant technical data, and state quality and compliance requirements, quality system requirements; and where appropriate, requirements for qualification of personnel. • All purchasing documents are reviewed and approved by the purchasing manager prior to release. • All the records of the material purchase are kept in proper listed manner to provide easy traceability. 6.3. Verification of Purchased Product/Services Our customers are given the right to verify purchased products at our supplier’s premises. In this case, ASKEC is not relieved of the responsibility for products meeting stated quality requirements.  •

•

• • • • • •

 • • • •

Source Inspection In the event the quality manager or client determines that a verification of purchased products will be required at the supplier’s facility, verification arrangements will be specified on the purchase order. The QC manager and his staff will determine the necessity of source inspection at vendor’s shop in accordance with the contract specifications and intimate project and purchase manager for arrangement of facilities for the same. In case of the services the data of qualification, experience, etc will be vet by the quality and project manager. The QC manager or his staff will carry out inspection according to the inspection test plan (ITP) given by vendor or prepared by quality manager. Upon receiving any non conformance actions according to non conformance procedure will be taken. All inspection and testing records will be maintained by the quality engineers. In case where client requires that inspection is to be conducted by independent agency, the inspection shall be done by the client approved third party. After satisfactory results the material will be cleared for shipment in consultation with the client. Received Material Inspection The material which has been received will be inspected at the store by the quality engineers. Thereafter if the material is found to be satisfactory as per the specifications a request for inspection will be raised for the client’s representative to carry out the inspection. After inspection by client, approved/cleared material then shall be used. In an event of non conformance the action t resolve the issue will be taken as per the non conformance control procedure.

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PROCUREMENT CONTROL OF PROCEDURE Format No Issue Date

• •

ASKEC-Q/PC 24/09/2016

Revision No Revision Date

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The material received will be inspected according to inspection test plan prepared by the quality manager. The checklists will be filled and records maintained by the quality engineers.

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ANNEXURE I Vendor Evaluation Report

Vendor Evaluation Report Format AS-KEC-Q-VER No.

Vendor's Name Vendor's Address

Rev. No. 00

Service/Material S.N.

Evaluation Criteria

1

Organisation

a

Turnover

b

Production Capacity

c d e

2

Available Manpower (Manufacturing) Available Manpower (Services) Infrastructure availability (Includes, machine, equipment, tools etc)

Scoring Criteria

> 20000USD >300% of the requirement*

Vendor's Data

Max Points

Remarks

3 3

>20 >125% of the requirement As per min requirement of ASKEC

6

10

Quality & Competency Level

a

Skilled Manpower

Engineers, ITI Technicians, Certified operators

10

b

Quality Management System

ISO certified

8

System Documentation

System norms, procedures, checklists, etc. Defined Documentation Process, Traceability, record maintenance etc

c

Points Obtained

10

8

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Revision No Revision Date

Delivery Focus

3

Sufficient arrangement of vehicles and means for transport <1% delay in number of delivery data of past

a

Logistics

b

Delivery time

4 a

Past Experience & Record Experience in specific work Total non compliances/customer complaints in past 1 year

b c

00 24/09/2016

Emergency Supply

10

10

>7 years

6

<4 no per customer

10

>60% of quantity demanded

6

Total 100 Score Details of Past companies worked with. Specifying name and key project details

Evaluation Conclusion Category I II III IV

Total Points Scored ≥60 50 to 59 <50

This Vendor falls in the

Decision

Remark

Approved Conditional approval/trail supply Rejected Customer Approved Party

Subjected to compliance of requirement Subjected to compliance of requirement No services/products to be taken No evaluation required

Category of approval

Purchase Manager

Project Manager

Quality Manager

Name

Name

Name

Signature

Signature

Signature

Page 9 of 11

PROCUREMENT CONTROL OF PROCEDURE Format No Issue Date

ASKEC-Q/PC 24/09/2016

Revision No Revision Date

00 24/09/2016

ANNEXURE II Vendor Evaluation Form

Vendor Evaluation Form Vendor's Name Vendor's Address Service/Material

S.N. 1 a b c d e

2 a b

Evaluation Criteria Organisation

3 a b 4

Delivery Focus Logistics Delivery time Past Experience & Record Experience in specific work Total non compliances/customer complaints in past 1 year Emergency Supply

c

Remarks

Quality & Competency Level Skilled Manpower Quality Management System System Documentation

b

Vendor's Data

Turnover Production Capacity Available Manpower (Manufacturing) Available Manpower (Services) Infrastructure availability (Includes, machine, equipment, tools etc)

c

a

Format No. AS-KEC-Q-VEF Rev. No. 00

Page 10 of 11

PROCUREMENT CONTROL OF PROCEDURE Format No Issue Date

ASKEC-Q/PC 24/09/2016

Revision No Revision Date

00 24/09/2016

Details of Past companies worked with. Specifying name and key project details

I hereby declare the above information is true as per my best knowledge and if found false customer is free to reject/blacklist our company. Filled By (Vendor Representative) Date:Name ` Designation Signature

Page 11 of 11

PROJECT QUALITY PLAN Format No Issue Date

ASKEC-Q/PQP 29/09/2016

Revision No Revision Date

00 20/09/2016

ANNEXURE V Inspection & Testing Control Procedure

Page 26 of 35

INSPECTION & TESTING CONTROL PROCEDURE Format No Issue Date

ASKEC‐Q/ITC 26/09/2016

Revision No Revision Date

00 26/09/2016

INSPECTION & TESTING CONTROL PROCEDURE WITH GUIDELINES

Page 1 of 11

INSPECTION & TESTING CONTROL PROCEDURE Format No Issue Date

ASKEC‐Q/ITC 26/09/2016

Revision No Revision Date

00 26/09/2016

INDEX S.N.

CONTENT

PAGE NO

I

COVER PAGE

1

II

INDEX

2

III

REVISION CONTROL SHEET

3

1

OBJECTIVE

2

PURPOSE

3

SCOPE

4

REFERENCE

5

RESPONSIBBILITY AND AUTHORITY

6

PROCEDURE

4

6.1

INSPECTION & TEST PLAN

6.2

MATERIAL INSPECTION

6.3

PROCESS INSPECTION

6.4

INSPECTION AND TEST PROCESS STATUS

6.5

INSPECTION AND TEST RECORDS

4‐5

5‐8

7

ANNEXURE I (MATERIAL ITP)

9

8

ANNEXURE II (PROCESS ITP)

10‐11

Page 2 of 11

INSPECTION & TESTING CONTROL PROCEDURE Format No Issue Date

ASKEC‐Q/ITC 26/09/2016

Revision No Revision Date

00 26/09/2016

Revision Control Sheet S.N. 1 2 3 4

Date Prepared 26/09/2016

Date Issued 26/09/2016

Revision 00

Changes/Remarks

Page 3 of 11

INSPECTION & TESTING CONTROL PROCEDURE Format No Issue Date

ASKEC‐Q/ITC 26/09/2016

Revision No Revision Date

00 26/09/2016

1. Objective: The objective of inspection and testing control procedure is to establish a set of guidelines for the control over the process of inspection and testing of material and processes required for assuring the quality of the process/material. 2. Purpose: The purpose of this procedure is to define a systematic approach for inspection, testing and evaluating the quality of the material/process. 3. Scope: This procedure applies to all processes & materials within scope of work, whether obtained from vendors or produced in‐house. This procedure applies to all in‐process & final inspection & testing activities in the project. This procedure is to provide a framework to:  Identify the non‐conformance in material/processes.  Ensure the quality of product to the optimum by eliminating defects before reaching to client 4. Reference: ISO 9001: 2015 5. Responsibility & Authority:  QA/QC Manager  Ensures that the inspection and test plan for each major process and material is made and approved from client.  Ensures that the ITP received from vendor should be in line with all the technical requirements of client.  Ensures that the inspection and testing of the material or process is carried out according to the plan.  Deputes quality team for optimum output of testing and inspection t vendor’s facility.  Reviews the ITP for modification and improvement from time to time.  QA/QC Engineer  Assists quality manger to prepare ITP in accordance with the requirements.  Does testing and inspection at vendor’s place for material and at the project location for processes.  Ensures any deviation or non conformance observed is reported to the quality manager and corrective actions are taken as per the non conformance procedure.  Maintains all the records of ITP and logs them to a tracking sheet.  In coordination with the execution engineers or vendor’s team all the issues found while inspection or testing are resolved before offering inspection to client.

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INSPECTION & TESTING CONTROL PROCEDURE Format No Issue Date

ASKEC‐Q/ITC 26/09/2016

Revision No Revision Date

00 26/09/2016

 Purchase Manager  Ensures that any non conformance observed and told by the quality manager in a material or process due to material is resolved with the vendor in the given stipulated time.  Ensures that ITPs from vendor are collected and given for verification to quality manager before placing orders or clearing the bills.  Project Manager  Ensures that the facilities for conducting inspection and testing are arranged for the quality personnel.  Ensures all required documents for preparation are available to the quality manager.  Ensures execution work goes as per the recommendations in ITPs.  Ensures the correction process is applied as stated by quality manager within the stipulated time frame. 6. Procedure Incoming, in‐process, and final inspection/testing are conducted to verify that products/ processes conform to specified requirements. Materials, subassemblies, assemblies and finished products are prevented from use until the required inspections are completed. Modified products shall be fully re‐inspected and re‐tested. The required records of inspections/tests are established and maintained. 6.1. Inspection & Test Plan Inspection and test plans contribute t be a controlling document for performing the validation of any material or process.  The inspection and test plan will comprise of all the technical and these will be prepared and verified by the quality manger for its effectiveness.  ITP shall consist but not limited to the followings: ‐ Inspection Activities (combined with P.O. requirement and standard activities). ‐ Vendor/Client details (incl. Third Party inspector witness and hold points, applicable codes, standards, specifications, statutory requirements and acceptance criteria).  Hold point (H): A ‘hold’ point defines a point beyond which work may not proceed without the authorization of a designated customer’s representative/authorized person or it may be of contractor (KEC). ‐ All type test & sample test shall, unless otherwise agreed, be conducted at an independently accredited testing laboratory or agency for material. ‐ All in‐process inspections and tests shall be conducted by the ASKEC competent personnel or independent agency as per the client’s requirement.  Witness Point (W): A ‘witness’ point provides a party (such as the Customer, KEC /TPA, service Provider) with the opportunity to witness the inspection or test or aspect of the work, at their discretion.  Surveillance Point (S): No written notification required but activity is subjected to Engineer's surveillance / monitoring and the records are maintained and produced whenever demanded by client.

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Revision No Revision Date

00 26/09/2016

 Review Point (S): Here the reports will only be reviewed such as mill test report, since these will be performed by independent third party labs or vendors.  The inspection frequency will often be determined by the process requirements or by the type of inspection and/or test under respective IEC / customers’ specification of the process and incorporated in the inspection test plan.  A sample Inspection and test plans is attached (Annexure I & II) 6.2. Material Inspection  Vendor’s Inspection and Test  The material that is being procured will be tested as per the inspection and test plan that is approved by the client.  The inspection and testing may be done by third party or by ASKEC as per the requirement of the client, which may also be witnessed by client if demanded.  All inspection schedules at manufacturing end shall be informed to client as per the contract terms and conditions.  Arrangements for testing and inspections will be made in advance to avoid any delay in the inspection planned.

 Receiving Inspection and Test  All purchased material which influences the project work, or is intended for use as part of, deliverable products is subject to inspection and/or testing by Receiving Inspection. Upon receipt of products, receiving personnel verify the quantity of delivered units, check marking and identification of packages, and inspect all packages for any signs of tampering or damage. If all these checks and inspections are satisfactory, receiving personnel signs the delivery receipt. If not, any shortages or damages are noted on all copies of the delivery receipts.  The received containers are then moved to the designated inspection area, a copy of the purchase order is retrieved, and the packing slips are removed from the containers. Upon opening the containers, the goods are verified against the purchase order and the packing slip, and are examined visually for any signs of damage. The purchase order is stamped “RECEIVED” and is signed and dated by the receiving inspector. All receiving inspections are logged in the checklist.  This will also be offered for inspection to client as per the requirement which will be the “HOLD POINT” in the process. This will be logged in the RFI.  On critical parts and components, as determined by the Quality Manager, a precision inspection/test is performed. This type of inspection includes: ‐ Review of material certificates, supplier inspection records, compliance certificates, and any other relevant documentation delivered with the product ‐ Random sampling based on statistical technique specified ‐ Visual inspection to detect any damage or other visible problems ‐ Performing measurements and testing against specified requirements as required ‐ Recording the sample size, actual measurements, and inspection test results on the Inspection &Test report

Page 6 of 11

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ASKEC‐Q/ITC 26/09/2016

Revision No Revision Date

00 26/09/2016

 Where it is not practical to perform receiving inspection upon receipt, provisions are made to perform source inspection at the supplier’s facility.  The Quality Manager determines the extent and scope of receiving inspection based on the importance of the item and the suppliers’ control methods and performance. The Quality Manager may request that suppliers provide objective evidence of conformance (i.e., material certifications, certificates of conformance, test data, mill test certificates, etc). Objective evidence provided by suppliers may be used as the basis for reducing/waiving receiving and source inspection.  All the inspected material is then properly marked and placed at required place, which is now ready to be used. 6.3. Process Inspection In‐process inspection/testing are conducted to ensure that the process conforms to specified requirements. All the critical processes, thus marked in the requirements are inspected and tested as per the requirement stated in the client’s scope of work and technical manuals.  All the processes which are to be inspected and witnessed by the client’s representative will be undergoing pre‐inspection of ASKEC quality team, which will be recorded in pre‐inspection checklist.  It is the duty of execution engineers to confirm the readiness for inspection to the quality team and rectify the deviations observed.  Upon confirmation from the quality team a request for inspection will be raised 48 hours prior to client’s inspection (except in case of concreting).  The joint inspection will be performed with the consultants and inspection/test report will be signed.  In case of any deviation observed it will be cleared on the spot and inspection/test will be continued.  If the deviation can’t be resolved or inspection/test fails, proper corrective actions will be taken as per the non conformance procedure and the report will contain comments as rejected, prescribing the cause and corrective actions required.  Upon doing the corrective action, the quality engineers will again pre‐inspect it and report to the quality manager, if required the quality manager will also verify the process.  Then after conformation from quality manager the new RFI can be raised for the same inspection again to the client.  The corrective and preventive actions taken will be described in non conformance compliance report. 6.4. Inspection and Test Process Status Inspection/test records, which show clearly whether the product/process has passed or failed the defined acceptance criteria, are established and maintained.

 All personnel authorised to carry out inspections and testing are responsible for identifying the inspection status of product/process and for the release of product/process to the next operation.  A clear log / tracking sheet for RFIs, inspection and testing should be made and maintained by quality engineers, this shall be reviewed by quality manager on weekly basis.

Page 7 of 11

INSPECTION & TESTING CONTROL PROCEDURE Format No Issue Date

ASKEC‐Q/ITC 26/09/2016

Revision No Revision Date

00 26/09/2016

6.5. Inspection and Test Records Inspection/test records, which show clearly whether the product/process has passed or failed the defined acceptance criteria, are established and maintained. The maintenance of the records will be as per documentation control/ documented information control procedure.

Page 8 of 11

INSPECTION & TESTING CONTROL PROCEDURE Format No Issue Date

ASKEC‐Q/ITC 26/09/2016

Revision No Revision Date

00 26/09/2016

ANNEXURE I Material ITP

Page 9 of 11

INSPECTION & TESTING CONTROL PROCEDURE Format No Issue Date

ASKEC‐Q/ITC 26/09/2016

Revision No Revision Date

00 26/09/2016

ANNEXURE II Process ITP

PROJECT NAME

380kV OHTL Between SS 9050 & PS3 BSP

PROJECT CODE

SEC CONTRACT NO:4400007080 M616

DISCIPLINE

TOWER FOUNDATION WORK

NO.

1.0 2.0

4.0

DESCRIPTION OF INSPECTION AND TEST

ISSUANCE OF RFI REQUEST FOR INSPECTION

INSPECTION AND TEST PLAN < INSTALLATION WORK >

REFERENCE < PTS, STANDARD, DRAWING >

ACCEPTANCE CRITERIA

PTS & SEC STANDARD FORM

EXCAVATION WORK ROCK ANCHOR AND / OR ROCK / SOIL PIER FDN REBAR INSTALLATION

AS PER THE APPROVED FOUNDATION DRAWING

INSTALLATION OF REINFORCEMENT BAR

AS PER THE APPROVED FOUNDATION DRAWING

TCS‐Q‐ 11302RO

ITP NO. REV. NO. DATE

ITP NO. REV. NO. DATE

ASKEC‐Q/ITP/IW/TFW 00

26/Jun/16 1 PAGE PAGE of Freq. 1 INSPECTION BY

TPI

ASKEC

SEC

P

H

P

S

P

H

REMARKS

Every Location VERIFYING DOCUMENT/DE MONSTRATED EVIDENCE/REPO RT/CHECKLIST (REFERENCE DOCUMENT) RFI FORM

RFI & PP

RFI & PP Page 10 of 11

INSPECTION & TESTING CONTROL PROCEDURE Format No Issue Date

5.0

ASKEC‐Q/ITC 26/09/2016

Revision No Revision Date

STUB SETTING

CHECKING OF STUB & TEMPLATE SETTING 6.0

7.0

AS PER THE APPROVED FOUNDATION DRAWING

FDN DRAWING & TCS‐P‐ 122.05R0

P

H RFI P2ND

CONCRETE POURING AS PER THE APPROVED DESIGN MIX

DESIGN MIX

7.0

00 26/09/2016

MEASURING, MIXING & PLACING PTS & SPECS CURING PTS COMPRESSIVE STRENGTH TEST OF CONCRETE CYLINDER CRUSHING TEST FOR 3, 7 & 28 DAYS PTS FOUNDATION UPLIFT TEST

UPLIFT TEST R : Document Review,

S : Surveillance Point,

SCOPE OF WORK AND TECH SPEC W : Witness, H: Hold Point, P: Perform

APPROVED DESIGN MIX 70‐TMSS‐03, TCS‐Q‐ 113.03. ACI:318 & ACI:304 70‐TMSS‐03

P

W

H

P

W

W

H

ASTM C 39 / C 39M‐14

P

S

S

PTS‐13C0372 & ASTMD‐ 3689‐90

P

S

S

TPI Report

POURING CARD POURING CARD

TPI Report

TPI Report

Page 11 of 11

PROJECT QUALITY PLAN Format No Issue Date

ASKEC-Q/PQP 29/09/2016

Revision No Revision Date

00 20/09/2016

ANNEXURE VI ITPs

Page 27 of 35

PROJECT NAME PROJECT CODE DISCIPLINE

NO.

380kV OHTL Between SS 9050 & PS3 BSP SEC CONTRACT NO:4400007080 M616 ACCESS ROAD WORK

DESCRIPTION OF INSPECTION AND TEST

1.0 ISSUANCE OF RFI REQUEST FOR INSPECTION 2.0 SOIL QUARRY SOIL SAMPLE TEST CHEMICAL ANALYSIS TEST 3.0 ACCESS ROAD WORK PHYSICAL INSPECTION OF SUB GRADE FIELD DENSITY TEST OF SUB GRADE PHYSICAL INSPECTION OF 1ST LAYER FIELD DENSITY TEST OF 1ST LAYER PHYSICAL INSPECTION OF 2ND LAYER FIELD DENSITY TEST OF 2ND LAYER 4.0 STRUCTURE PAD WORK PHYSICAL INSPECTION OF SUB GRADE FIELD DENSITY TEST OF SUB GRADE PHYSICAL INSPECTION OF 1ST LAYER FIELD DENSITY TEST OF 1ST LAYER PHYSICAL INSPECTION OF 2ND LAYER FIELD DENSITY TEST OF 2ND LAYER R : Document Review, S : Surveillance Point,

INSPECTION AND TEST PLAN < INSTALLATION WORK >

REFERENCE < PTS, STANDARD, DRAWING >

PTS & SEC STANDARD FORM

ACCEPTANCE CRITERIA

W : Witness,

AS PER THE APPROVED FOUNDATION DRAWING AS PER THE APPROVED FOUNDATION DRAWING AS PER THE APPROVED FOUNDATION DRAWING AS PER THE APPROVED FOUNDATION DRAWING AS PER THE APPROVED FOUNDATION DRAWING AS PER THE APPROVED FOUNDATION DRAWING H: Hold Point, P: Perform

TPI

Freq. Every Location VERIFYING DOCUMENT/ DEMONSTRATED REMARKS EVIDENCE/ (REFERENCE DOCUMENT)

ASKEC

SEC

W

H

RFI FORM

P P

S S

S S

TPI Report TPI Report

TCS-Q-11302R0

P

W

H

TPI Report (FDT)

TCS-Q-11302R0

P

W

H

TPI Report (FDT)

TCS-Q-11302R0

P

W

H

TPI Report (FDT)

TCS-Q-11302R0

P

W

H

TPI Report (FDT)

TCS-Q-11302R0

P

W

H

TPI Report (FDT)

TCS-Q-11302R0

P

W

H

TPI Report (FDT)

NA

AS PER THE APPROVED FOUNDATION DRAWING AS PER THE APPROVED FOUNDATION DRAWING AS PER THE APPROVED FOUNDATION DRAWING AS PER THE APPROVED FOUNDATION DRAWING AS PER THE APPROVED FOUNDATION DRAWING AS PER THE APPROVED FOUNDATION DRAWING AS PER THE APPROVED FOUNDATION DRAWING AS PER THE APPROVED FOUNDATION DRAWING

ITP NO. ITP NO. ASKEC-Q/ITP/IW/ARW REV. NO. REV. NO. 00 26/Jun/16 DATE DATE PAGE PAGE 1 of 1 INSPECTION BY

PROJECT NAME PROJECT CODE DISCIPLINE

NO.

380kV OHTL Between SS 9050 & PS3 BSP SEC CONTRACT NO:4400007080 M616 TOWER FOUNDATION WORK

INSPECTION AND TEST PLAN < INSTALLATION WORK >

DESCRIPTION OF INSPECTION AND TEST

1.0 ISSUANCE OF RFI REQUEST FOR INSPECTION 2.0 EXCAVATION WORK ROCK ANCHOR AND / OR ROCK / SOIL PIER FDN 4.0 REBAR INSTALLATION INSTALLATION OF REINFORCEMENT BAR 5.0 STUB SETTING CHECKING OF STUB & TEMPLATE SETTING 6.0 CONCRETE POURING DESIGN MIX

S : Surveillance Point,

AS PER THE APPROVED FOUNDATION DRAWING

TPI

TCS-Q-11302RO

AS PER THE APPROVED FOUNDATION DRAWING

AS PER THE APPROVED DESIGN MIX

W : Witness,

ACCEPTANCE CRITERIA

PTS & SEC STANDARD FORM

AS PER THE APPROVED FOUNDATION DRAWING

MEASURING, MIXING & PLACING CURING 7.0 COMPRESSIVE STRENGTH TEST OF CON'C CYLINDER CRUSHING TEST FOR 3, 7 & 28 DAYS 7.0 FOUNDATION UPLIFT TEST UPLIFT TEST R : Document Review,

REFERENCE < PTS, STANDARD, DRAWING >

ITP NO. ITP NO. ASKEC-Q/ITP/IW/TFW REV. NO. REV. NO. 00 26/Jun/16 DATE DATE PAGE PAGE 1 of 1 INSPECTION BY

FDN DRAWING & TCS-P122.05R0 P

PTS & SPECS PTS

APPROVED DESIGN MIX 70-TMSS-03, TCS-Q-113.03. ACI:318 & ACI:304 70-TMSS-03

PTS

ASTM C 39 / C 39M-14 PTS-13C0372 & ASTMD-368990

SCOPE OF WORK AND TECH SPEC H: Hold Point, P: Perform

REMARKS

Freq. Every Location VERIFYING DOCUMENT/DEMON STRATED EVIDENCE/REPORT/C HECKLIST (REFERENCE DOCUMENT)

ASKEC

SEC

P

H

RFI FORM

P

S

RFI & PP

P

H

RFI & PP

P

H

RFI P2ND

W

H

P

W

TPI Report

W

H

POURING CARD POURING CARD

P

S

S

TPI Report

P

S

S

TPI Report

PROJECT NAME PROJECT CODE DISCIPLINE NO.

380kV OHTL Between SS 9050 & PS3 BSP SEC CONTRACT NO:4400007080 M616 ELECTRICAL WORK (GROUNDING)

DESCRIPTION OF INSPECTION AND TEST

1.0 ISSUANCE OF RFI REQUEST FOR INSPECTION 2.0 GROUNDING TOWER FOOTING RESSISTIVITY SOIL RESSISTIVITY R : Document Review, S : Surveillance Point,

INSPECTION AND TEST PLAN < INSTALLATION WORK > REFERENCE < PTS, STANDARD, DRAWING >

PTS & SEC STANDARD FORM

W : Witness,

H: Hold Point, P: Perform

ACCEPTANCE CRITERIA

ITP NO. ITP NO. ASKEC-Q/ITP/IW/EW REV. NO. REV. NO. 00 26/Jun/16 DATE DATE PAGE PAGE 1 of 1 INSPECTION BY TPI

Freq. Every Location VERIFYING DOCUMENT/DEMON REMARKS STRATED EVIDENCE/REPORT/C

ASKEC

SEC

RFI FORM

W

H

RFI FORM

TES-P122.10 & TCS-P-122.21 TES-P122.10 & TCS-P-122.22

P P

H H

RFI & CHECKLIST RFI & CHECKLIST

PROJECT NAME PROJECT CODE DISCIPLINE NO.

380kV OHTL Between SS 9050 & PS3 BSP SEC CONTRACT NO:4400007080 M616 TOWER ERECTION WORK

DESCRIPTION OF INSPECTION AND TEST

1.0 ISSUANCE OF RFI REQUEST FOR INSPECTION 2.0 GALVANIZING GALVANIZING THICKNESS TEST 3.0 SITE ASSEMBLY WORK VISUAL CHECKING OF MEMBERS AND PLATES BOLT SIZE AND LENGTH INSPECTION 3.0 SITE ERECTION WORK VISUAL CHECKING OF MEMBERS AND PLATES BOLT SIZE AND LENGTH INSPECTION JOINT CHECKING 4.0 TOWER FINAL INSPECTION BOLT TORQUE CHECKING R : Document Review, S : Surveillance Point, W : Witness,

INSPECTION AND TEST PLAN < INSTALLATION WORK > REFERENCE < PTS, STANDARD, DRAWING >

PTS & SEC STANDARD FORM

ACCEPTANCE CRITERIA

NA

TCS-P-122.06

ITP NO. ITP NO. ASKEC-Q/ITP/IW/TEW REV. NO. REV. NO. 00 26/Jun/16 DATE DATE PAGE PAGE 1 of 1 INSPECTION BY TPI

Freq. Every Location VERIFYING DOCUMENT/DEMON REMARKS STRATED EVIDENCE/REPORT/C

ASKEC

SEC

W

H

RFI FORM

W

S

RFI

TCS-P-122.06 TCS-P-122.06

TCS-P-122.06 TCS-P-122.06

P

H

RFI & CHECKLIST

TCS-P-122.06 TCS-P-122.06 TCS-P-122.06

TCS-P-122.06 TCS-P-122.06 TCS-P-122.06

P

H

RFI & CHECKLIST

TCS-P-122.06 H: Hold Point

TCS-P-122.06

P

H

RFI & CHECKLIST

PROJECT NAME PROJECT CODE DISCIPLINE NO.

380kV OHTL Between SS 9050 & PS3 BSP SEC CONTRACT NO:4400007080 M616 CONDUCTOR STRINGING WORK

DESCRIPTION OF INSPECTION AND TEST

1.0 ISSUANCE OF RFI REQUEST FOR INSPECTION 2.0 MESSENGER WIRE PULLING WORK PULLING OF PILOT WIRE 3.0 INSULATOR HOISTING WORK INSTALLATION OF INSULATOR 4.0 CONDUCTOR STRINGING WORK PAYING OUT WORK INSPECTION OF MID-SPAN JOINT SLEEVE 5.0 SAGGING WORK INSPECTION OF SAG INSPECTION OF DEADEND COMPRESSION CLAMP 6.0 MISCELLANEOUS WORK CLAMPING, SPACER DAMPER & JUMPERING R : Document Review, S : Surveillance Point, W : Witness,

INSPECTION AND TEST PLAN < INSTALLATION WORK > REFERENCE < PTS, STANDARD, DRAWING >

ACCEPTANCE CRITERIA

ITP NO. ITP NO. ASKEC-Q/ITP/IW/CSW REV. NO. REV. NO. 00 26/Jun/16 DATE DATE PAGE PAGE 1 of 1 INSPECTION BY REMARKS

VERIFYING DOCUMENT/DEMON STRATED EVIDENCE/REPORT/C

ASKEC

SEC

W

H

TCS-P-122.07 & WP-006

W

S

TCS-P-122.07 & WP-006

W

S

W

S

W

H

WP-006-01 & WP-00602 WP-006-03

W W

H H

WP-006-03 WP-006-03

W

S

PTS & SEC STANDARD FORM

RFI FORM

TCS-P-122.07 & WP-006 TCS-P-122.07 & WP-006

WP-006-01 & WP-006-02 WP-006-03

TCS-P-122.07 & WP-006 TCS-P-122.07 & WP-006

WP-006-03 WP-006-03

TCS-P-122.07 & WP-006 H: Hold Point

TPI

Freq.

RFI FORM

PROJECT NAME PROJECT CODE DISCIPLINE

NO.

380kV OHTL Between SS 9050 & PS3 BSP SEC CONTRACT NO:4400007080 M616 OPGW STRINGING AND SPLICING WORK

DESCRIPTION OF INSPECTION AND TEST

1.0 ISSUANCE OF RFI REQUEST FOR INSPECTION 2.0 PRE-INSTALLATION TEST 3.0 PULLING OF PILLOT WIRE 4.0 PAYING OUT WORK POST INSTALLATION TEST 5.0 SAGGING WORK INSPECTION OF SAG 6.0 MISCELLANEOUS WORK CLAMPING, SPACER DAMPER & JUMPERING 7.0 SPLICE LOSS TEST 8.0 END TO END TEST R : Document Review, S : Surveillance Point,

W : Witness,

INSPECTION AND TEST PLAN < INSTALLATION WORK >

REFERENCE < PTS, STANDARD, DRAWING >

ACCEPTANCE CRITERIA

PTS & SEC STANDARD FORM WP-005 TCS-P-122.08 & WP-005

RFI FORM FORM OPGW-01A

TCS-P-122.08 & WP-005 WP-005 TCS-P-122.08 & WP-005 WP-005

WP-006-01 & WP-006-02 FORM OPGW-02A WP-005-XXX

TCS-P-122.08 & WP-005 WP-005

FORM OPGW - 04A & 05A

WP-005 H: Hold Point

FORM OPGW - 03A & 03B

ITP NO. ITP NO. ASKEC-Q/ITP/IW REV. NO. REV. NO. 00 26/Jun/16 DATE DATE PAGE PAGE 1 of 1 INSPECTION BY

TPI

Freq.

REMARKS

VERIFYING DOCUMENT/DEMON STRATED EVIDENCE/REPORT/C HECKLIST (REFERENCE DOCUMENT)

ASKEC

SEC

W W W

H H S

W

S

W

H

WP-006-01 & WP-00602 FORM OPGW-02A

W

H

WP-005-XXX

W

S

W

H

W

H

RFI FORM FORM OPGW-01A

FORM OPGW - 04A & 05A FORM OPGW - 03A & 03B

PROJECT QUALITY PLAN Format No Issue Date

ASKEC-Q/PQP 29/09/2016

Revision No Revision Date

00 20/09/2016

ANNEXURE VII Internal Audit Procedure

Page 28 of 35

PROCEDURE FOR INTERNAL AUDIT Format No Issue Date

ASKEC-Q/IAP 25/08/2016

Revision No Revision Date

00 25/08/2016

PROCEDURE FOR INTERNAL AUDIT WITH GUIDELINES

Page 1 of 9

PROCEDURE FOR INTERNAL AUDIT Format No Issue Date

ASKEC-Q/IAP 25/08/2016

Revision No Revision Date

00 25/08/2016

INDEX S.N.

CONTENT

PAGE NO

I

COVER PAGE

1

II

INDEX

2

III

REVISION CONTROL SHEET

3

1

OBJECTIVE

2

PURPOSE

3

SCOPE

4

REFERENCE

5

RESPONSIBBILITY AND AUTHORITY

6

PROCEDURE

7

DOCUMENTS

8

AUDIT PLANNING

8.1

METHOD

9

AUDIT PREPARATION

10

CONDUCTION AUDIT

10.1

GENERAL

10.2

DOCUMENT REVIEW

10.3

CONDUCTING OPENING MEETING

10.4

COLLECTION AND VERIFICATION OF INFORMATION

10.5

AUDIT FINDINGS

10.6

AUDIT CONCLUSION

10.7

CONDUCTING THE CLOSING MEETING

11

4

5 5-6

6

6-7 7 8

PREPARING & DISTRIBUTING THE AUDIT REPORT

11.1

PREPARING THE AUDIT REPORT

11.2

DISTRIBUTING THE AUDIT REPORT

11.3

COMPLETING THE AUDIT

8

12

CONDUCTING AUDIT FOLLOW-UP

8

13

QUALITY RECORDS CONCERNING AUDIT

9

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PROCEDURE FOR INTERNAL AUDIT Format No Issue Date

ASKEC-Q/IAP 25/08/2016

Revision No Revision Date

00 25/08/2016

Revision Control Sheet S.N. 1 2 3 4

Date Prepared 25/08/2016

Date Issued 25/08/2016

Revision 00

Changes/Remarks

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PROCEDURE FOR INTERNAL AUDIT Format No Issue Date

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1. Objective: The objective of internal auditing is to ensure that the Quality Management is being operated correctly and effectively, by performing planned and documented checks, designed to ensure that: • The quality system documentation adequately defines the needs of the business • The documented procedures and work instructions are practical, understood and implemented • The customer’s requirement are met • The training of employees is adequate to allow them to do their tasks. Internal audits are the most effective way of continually assessing the effectiveness of the Quality System. 2. Purpose: The purpose of internal audits is not to search for the guilty, or to find fault with individuals' performance, but the system faults. To overcome the loopholes in the system and create an error free system by implementing innovative methods for eliminating the findings observed in internal audit. This procedure defines the way in which our company will perform internal auditing of the quality management system. 3. Scope: This document applies to all the audits being carried out for each work activity of transmission line specified in the contract for this project. It applies to all internal quality audits, which will generally be performed against the requirements of ISO 9001, the company's manual, procedures, process plans and work instructions. 4. Reference: ISO 9001: 2015 & ISO 19011:2011. 5. Responsibility and Authority: QA/QC manager is responsible for planning scheduling and coordinating the internal audits. He may be assisted by other qualified auditors for conducting the audits and preparing reports. Following are the roles & responsibilities of person managing audit. • Establish the extent of the audit programme. • Establish audit responsibilities and procedures. • Ensure necessary resources are provided, including the evaluation of auditors. • Ensure the implementation of the audit programme, such as defining audit objectives, scope and criteria of the individual audits, determining audit methods and selecting the audit team. • Ensure that appropriate audit programme records are managed and maintained. • Monitor, review and improve the audit programme. He will finally compile all the reports and present it to the Project management team along with suggestion for corrective actions. 6. Procedure: Audit Planning Audit Preparation Auditing Writing the audit report Following-up the action Documented Information concerning audits 7. Documents System documents Audit plan and Audit check-list List of Internal documents List of external documents

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8. Audit Planning 7.1 Method : The quality manager is responsible for ensuring that the internal audit programme takes place, for allocation of internal auditors, and for preparing the internal audit schedule. Audit planning consists of preparing the internal audit schedule, which is a controlled document, authorised by the Management Personnel. The schedule should cover all aspects of the QMS at least once a year, although particular activities may be audited more frequently depending on their importance. The schedule should leave room (time) for unscheduled audits in response to: • Anticipated problem areas • Actual problems • Requests from Management • Unforeseen changes in circumstances. The schedule should define for each audit: • The auditor • The auditee (For Audit Schedule refer doc. ASKEC-Q/IAS Revision 00) Performance of an audit involves an interaction among individuals with the management system(s) being audited and the technology used to conduct the audit. Table 1 provides examples of audit methods that can be used, singly or in combination, in order to achieve the audit objectives. Extent of involvement between the auditor and the auditee

Human Interaction

Location of the auditor On Site Conducting interviews.

Via communication means:

Filling checklists and questionnaires with auditee participation

Conducting interviews

Document review with auditee participation Observation of work performed Site visit No Human Interaction

Remote

Filling checklists Sampling (e.g. products) Document review (e.g. records)

Filling checklists and questionnaires Document review with auditee participation Document review Observation of work performed via means of surveillance system

On-site audit activities are performed at the location of the auditee. Remote audit activities are performed at any place other than the location of the auditee, independent of the distance. Interactive audit activities involve interaction between the auditee’s personnel and the audit team. Non-interactive audit activities involve no human interaction with persons being audited but do involve interaction with equipment, facilities and documentation. 9. Audit Preparation The date (at the planning stage the month for the audit will be sufficient: as the time approaches the auditor will set a firm date with the auditee). The auditor will prepare for each audit as follows:

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• By reading through previous audit reports covering the same area (in order that previous problem areas can be examined in more detail, or that areas previously unexamined can be looked at more closely) • By familiarising himself with the requirements of ISO 9001 and the local standards (quality manual, procedures, process plans, work instructions) • By contacting the auditee and confirming the date/time for the audit • By preparing an audit checklist or similar aide-memoir. • By preparing audit checklists formats etc. 10. Conducting Audit 9.1 General During the audit, the auditor will: • Make use of standard auditing techniques to collect objective information concerning the subject being audited • Not respond to rumour and hearsay • Avoid confrontational situations and arguments • Makes notes to aid the writing of the audit report • Collect documentary evidence of conformity or nonconformity • Note where current procedures could be improved • Keep the auditee informed as to the progress of the audit and any findings. 9.2 Document Review As a part of the audit activities the relevant auditee management system documentation will be reviewed to: • Gather information for the preparation of the audit activities. • Get an overview on the extent of the system documentation. • Determine the conformity of the system, as far as documented, with audit criteria. The documentation can include relevant management system documents and records, as well as previous audit reports. The review may be combined with the other audit activities and may continue throughout the audit, if this is not detrimental to the effectiveness of the conduct of the audit. If adequate documentation cannot be provided within the time frame of the audit, depending on the audit scope and objectives a decision should be made as to whether the audit should be continued or suspended until documentation concerns are resolved. 9.3 Conducting Opening Meeting The purpose of the opening meeting is to confirm the audit plan, introduce the audit team and ensure that all planned audit activities are in place. An opening meeting will be held with those responsible for the functions or processes to be audited. In many instances, the opening meeting may simply consist of communicating that an audit is being conducted and explaining the nature of the audit. The meeting will be formal and records of the attendance will be kept. Confirmation of the audit objectives, scope and criteria. Confirmation of the audit plan and other relevant arrangements with the auditee, such as the date and time for the closing meeting, any interim meetings between the audit team and the auditee's management, and any late changes. Presentation of the methods to be used to conduct the audit, including advising the auditee that the audit evidence will be based on a sample of the information available. Confirmation of formal communication channels between the audit team and the auditee. Information on method of reporting audit findings including any grading. Information about conditions under which the audit may be terminated. 9.4 Collection and Verification of Information During the audit, information relevant to the audit objectives, audit scope and audit criteria, including information relating to interfaces between functions, activities and processes will be collected by means of appropriate sampling and will be verified. Only information that is verifiable will be accepted as audit evidence. Audit evidence relevant to the audit findings will be recorded in checklist.

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Fig. Overview of the process from collecting information to reaching audit conclusions

Methods of collecting information include: • Interviews • Observations 9.5 Audit Findings Audit evidence will be evaluated against the audit criteria to identify the audit findings. Audit findings can indicate conformity or nonconformity with audit criteria. When specified by the audit objectives, audit findings must identify opportunities for improvement and provide recommendations for best practice, where this does not compromise independence. The auditor should review the audit findings at appropriate stages during the audit. Conformity with audit criteria will be summarized to indicate locations, functions or processes that were audited. If required, individual audit findings of conformity and their supporting evidence will also be recorded. Nonconformities and their supporting audit evidence will be recorded. Nonconformities may be graded. Those will be reviewed with the auditee to obtain acknowledgement that the audit evidence is accurate, and that the nonconformities are understood. Every attempt will be made to resolve any diverging opinions concerning the audit evidence and/or findings, and unresolved points will be recorded. 9.6 Audit Conclusions The auditor with auditee (only lead representative) will confer prior to the closing meeting to: Review the audit findings, and any other appropriate information collected during the audit, against the audit objectives. Agree on the audit conclusions, taking into account the uncertainty inherent in the audit process. Prepare recommendations. Discuss audit follow-up, as applicable. Audit conclusions can address issues such as: • The extent of conformity of the management system with the audit criteria, including the effectiveness of the management system in meeting the stated objectives. • The effective implementation, maintenance and improvement of a management system. • The capability of the management review process to ensure the continuing suitability, adequacy, effectiveness and improvement of a management system. • Attempt to identify root causes of findings, if stated by the audit objectives. • Consolidate similar findings made in different areas that were audited for the purpose of identifying trends. • Audit conclusions may lead to recommendations regarding improvements, business relationships, or future auditing activities.

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9.7 Conducting The Closing Meeting A closing meeting, facilitated by the auditor, will be held to present the audit findings and conclusions in such a manner that they are understood and acknowledged by the auditee and team. Participants in the closing meeting should include representatives of the auditee, and process owners. The meeting must be formal and minutes including records of attendance, should be kept. As appropriate, the following will be explained in the closing meeting: • Advising the auditee that the audit evidence collected was based on a sample of the information available. • The method of reporting, including any grading. • The process of handling of audit findings and possible consequences. • Presentation of the audit findings in such a manner that they are understood and acknowledged by the auditee any related post audit activities. 11. Preparing & Distributing the Audit Report 10.1 Preparing The Audit Report The audit report will provide a complete, accurate, concise and clear record of the audit, and in accordance with the audit procedures may include or refer to the following: The audit objectives. Identification of the audit client Identification of audit team and auditee´s participants in the audit. The dates and locations where the audit activities were conducted. The audit criteria. The audit findings. The audit conclusions. Any areas within the audit scope not covered with reasons. Opportunities for improvement, if specified in the audit objectives. Strengths and best practices identified. Agreed follow-up action plans, if any. The distribution list for the audit report. 10.2 Distributing The Audit Report The audit report will be issued within an agreed period of time. If it is delayed, the reasons should be communicated to the auditee. The audit report will be distributed to recipients as defined in the audit procedures. 10.3 Completing The Audit The audit is completed when all audit plan activities have been carried out or as otherwise agreed with the person responsible for managing the audit programme. Documents pertaining to the audit should be retained for future reference. Lessons learned from the audit must be entered into the continual improvement process of the management system of the organization needing to conduct audits. 12. Conducting Audit Follow-Up The conclusions of the audit may, depending on the audit objectives, indicate the need for corrections, corrective, preventive or improvement actions. Such actions are usually decided and undertaken by the auditee within an Agreed timeframe. But if an auditee persistently fails to carry out the assigned follow-up actions, the auditor must inform the managing authority (Country head or above), who will take steps to ensure that the follow-up action take place. As appropriate, the auditee should keep the person responsible for managing the audit programme and the audit team informed of the status of these actions. The completion and effectiveness of the actions should be verified. This verification may be part of a subsequent audit.

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13. Quality Records Concerning Audit As the follow-up actions are completed the auditor will record them by up-issuing the original audit report. Once all follow-up actions have been completed, the auditor will sign off the audit report as complete. Completed audit records are stored as quality records and have the following important functions: • Demonstrating that the audit system exists is functioning and effective. • Allowing analysis of types of problems and identifying the most common problems so that preventive actions can be taken. • Analysing response and correction times. • Allowing the auditor to prepare for audits by reviewing the past reports for that area or function. • Providing valuable summary for use in Management Reviews of the Quality System.

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Revision No Revision Date

00 20/09/2016

ANNEXURE VIII Control of Non Conformance Procedure

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PROCEDURE FOR CONTROL OF NON CONFORMANCE WITH GUIDELINES

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INDEX S.N.

CONTENT

PAGE NO

I

COVER PAGE

1

II

INDEX

2

III

REVISION CONTROL SHEET

3

1

OBJECTIVE

2

PURPOSE

3

SCOPE

4

REFERENCE

5

RESPONSIBBILITY AND AUTHORITY

6

PROCEDURE

6.1

IDENTIFYING AND CONTROLLING NONCONFORMING PRODUCT/PROCESS

6.2

REWORK

6.3

SCRAP

4

5

7

CLOSURE OF NCR

5

8

DOCUMENTATION

6

9

ANNEXURE I (NON CONFORMANCE REPORT)

7-8

10

ANNEXURE II (NON CONFORMITY COMPLIANCE REPORT)

9-10

11

ANNEXURE II (HOLD NOTE)

11

12

ANNEXURE II (REJECTION NOTE)

12

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PROCEDURE FOR CONTROL OF NON CONFORMANCE Format No Issue Date

ASKEC-Q/CNC 26/08/2016

Revision No Revision Date

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Revision Control Sheet S.N. 1 2 3 4

Date Prepared 26/08/2016

Date Issued 26/08/2016

Revision 00

Changes/Remarks

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PROCEDURE FOR CONTROL OF NON CONFORMANCE Format No Issue Date

ASKEC-Q/CNC 26/08/2016

Revision No Revision Date

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1. Objective: The objective of control of non conformities is to establish a procedure for the control and disposition of nonconforming products/processes and materials, to prevent unintentional use. To control all Project non-compliant conditions, equipment, processes procedural requirements or incidents by ensuring that all non-compliances are identified and corrected in a formalized and controlled manner. 2. Purpose: The purpose of this procedure is to define a systematic approach to identify, document, evaluate, and request to rectify and close-out non-compliances in the area of quality that might occur during Project construction. 3. Scope: This procedure applies to all nonconforming products/ processes and materials detected within scope of work, whether obtained from vendors or produced in-house. This procedure applies to all COMPANY personnel where they observe situations that do not comply with specified requirements. This procedure is to provide a framework to: • Identify the non compliance. • Document the non compliance. • Determine the required corrective action. • Allow reasonable period to resolve a non-compliant condition by setting “Target [Resolution] dates”. • Prevent recurrence of non compliant issues by performing statistical analysis and developing reports on recurring issues. • Follow up and close out of non compliant issues. • Report status of non-compliant conditions across appropriate levels of organization (internal) and external as deemed appropriate. This will ensure that the root causes of non-compliance are identified and corrective action(s) is taken to prevent recurrence. 4. Reference: ISO 9001: 2015. 5. Responsibility & Authority:  QA/QC Manager • Ensure nonconforming products and services are controlled as defined in documented procedures, obtain customer approval of dispositions if required in customer agreements, and authorize closure of NCR. • Responsible for implementing and maintaining the non-conforming product control system, including maintaining records. • Verifies the corrective and preventive actions.

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• Notes the activities and record it in learning.  Engineers/Store In-charge • Identify and immediately segregate the non conforming material/ process. • Put hold on the on conforming process/ material. • Report the non conformance to QA/QC manager. • To resolve the non conformance by taking corrective and preventive action in discussion with QA/QC manager. • Originates NCR 6. Procedure: 6.1. Identifying and Controlling Nonconforming Product/Process The majority of non compliant conditions will be identified during processes associated with the QA/QC Plan. However, any employee may identify a non compliance situation during their normal working activities. • Non-conforming product/processes may be found at incoming, in-process and/or final inspection. • Immediately upon detection, non-conforming product or process is identified by means of a “HOLD” tag and is segregated from other product/material to prevent inadvertently mixing with good material, in case of non conformity in material. For non conformity in processes immediately stop the process • Issue a “HOLD” tag to the responsible person (supervisor, engineer, etc whichever is applicable) and inform the QA/QC engineer for inspection. • QA/QC engineer will check the process/product if found to not complying with the company or customer’s specifications a detail description (NCR report Compliance Format) about corrective actions and whether it can be used by rework shall be submitted to QA/QC manager. Meanwhile the NCR is to be issued to the responsible person (sub contractor in-charge, Engineer/process owner). Non-conforming product will either be: • Reworked • Accepted by Concession • Scrapped • Returned to supplier/Replaced 6.2. Rework QA/QC manager along with QA/QC engineers will decide whether a corrective action/ rework can be done on the product/process. • The Departmental Manager will review the method of rework with the QA/QC Manager. If it is agreed that the product can be reworked the HOLD tag is joined by a REWORK tag. • The due intimation to check the process/product will be given to client, who then can depute consultant to inspect.

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• Thereafter the corrective measure to be taken will be discussed with consultant and the rework will be done upon agreement/approval. • After the product/process is reworked it will be inspected by the QA/QC team verifying the work is complete and meets the specification. • Then it shall be offered to client for inspection and approval to use. • Upon approval it should be used and records of non conformance compliance to be maintained. 6.3. Scrap • If the product/process can’t be reworked or client doesn’t approve it’s use the product /process outcome is to be tagged”REJECTED”. • The non conformity is to be immediately removed from the place of work and disposed to scrap area. • The data for scrap is to be maintained in the scrap register with the following details  Material ID/Process  Location Details  Quantity material Rejected/ scrap generated from process rejection  Reason for Rejection 7. Closure of NCR: When the NCs are being closed by following the above methods a compliance report for the same is to be generated and handed over to client/consultant. The NCR compliance will consist of the root cause indentified for the NC along with the description of corrective & preventive actions taken. 8. Documentation: All the reports for NCs & its compliance shall be maintained by QA/QC manager.

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Fig. Shows a Flow Chart for Control Non Conformance

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ANNEXURE I Non Conformance Report

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•

Format No Issue Date

•

PROCEDURE FOR CONTROL OF NON CONFORMANCE ASKEC-Q/CNC 26/08/2016

Al SHARlf KEC

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ALSH~f· KEC

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ANNEXURE II Non Conformity Compliance Report

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ANNEXURE III Hold Note

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ANNEXURE IV Rejected Note

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ANNEXURE IX Checklists & Formats

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Insert All Internal & External Checklists RFI formats Track sheet for Calibration All the formats that are made

ANNEXURE X Project Execution Plan

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ANNEXURE X Project Execution Plan

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Insert Project plan/schedule

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ANNEXURE XI LESSONS LEARNED

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Lessons Learned Details of Past Project Project Client

Title of past project

Contract No. Completion Date

Project’s Short Description About project work, contract awarded details, start date completion date, project location etc.

Good Practices What good practices were observed in those projects which lead to may be faster completion time, quality appreciation from client, and description of the activity (good practice with photographs), how was it implemented etc.

Benefit Derived from the Good Practice Describe what benefit it gave to the project and its impact on business and reputation over client.

Major Issues Faced What issues were faced, what went wrong, describing the exact scenario of the issue?

Impact of it on Project Describe what was the impact, how much monetary loss, time loss, rework etc. Difficulties faced at the time of handing over

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Root Cause & Corrections Describe what the root cause of the issue was and what corrective and preventive actions were taken (this to be in detail with pictures)

Implementation in the Present Project Describe how will be the good practice or the corrective/preventive action for issue will be implemented from the start in this project, also the control measure to monitor this critical activity.

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ANNEXURE XII Method Statements

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Insert all Method Statements as stated in index

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