CONTENTS

5.1 FIBER OPTIC CABLE

5.2 FIRE ALARM

5.3 CCTV POLE

5.4 GI CABLE TRAY AND TRUNKING

5.5 LV CABLES

5.6 DB AND FEEDER PILLAR

5.7 LANDSCAPE LIGHTING

5.8 EARTHING MATERIAL

1.0 PURPOSE

To establish a system for ensuring that Incoming items meet the specified contract and Quality requirements. Identify material from receipt through installation, Maintain historical records of the materials, and be able to trace assemblies and selected subassemblies through identification and marking.

Activities such as handling, storage, preservation, of products, systems, components, or installation material on receipt at company sites shall follow this procedure.

2.0 SCOPE

This procedure applies to all systems, components, and/or installation materials purchased, and/or used by the company for fabrication and/or installation within the project.

3.0 DEFINITIONS

This procedure uses definitions in the front of the Quality Plan and ISO 9001 Quality Management and Quality Assurance Vocabulary.

4.0 General

It is the responsibility of Quality Department to ensure the identification and traceability of the item delivered for construction. System, Components and Installation Materials, System, equipment, component or parts shall be traceable to manufacturers’ serial number.

Responsibility

Store-Keeper: The store keeper is responsible for receiving materials and ensure the quantity of the materials delivered comply with the delivery note and Stored in Proper Manner.

QC Inspector: The QC Inspector is responsible for verifying the findings of the store keeper; he is also responsible for final approval of materials/equipment during internal inspection and ensure that the delivered material comply with the approved material submittal.

Site Engineer: For major item, the site engineer will participate in receiving material and inspection.

QA/QC Engineer: The QA/QC Engineer is responsible for maintaining the database, which provides necessary identification and traceability of Materials.

4.2 Material Receipt

The store keeper will receive and verify all materials/equipment against the Purchase Order, count and check for damage, and if in order and acceptable, complete and sign the delivery note.

Store keeper notifies the Quality Team that materials/equipment have arrived and arranges for Inspection the findings should be recorded on the Receiving Inspection Report Form.

The INELT Quality Team will check and verify all materials received and subject them to Goods Receiving inspection. This check will be a physical inspection and it will be noted with the appropriate corresponding documents and MRIR is generated.

This physical inspection will ensure that we have received the correct product that the product is in compliance with the materials description such as: Field tags, stamps, and any marking of identity.

Site QC Inspector will check the objective evidence as provided by a Supplier to determine that adequate quality verification was exercised, for example, review inspection and test reports, MAS's, etc....

The QC Inspector will examine all material for conformity to the Purchase Order and drawings. This examination should cover but not be limited to the following: Dimensions, marking and condition. Name Plate. Quantity and Quality of Product. QC inspector also verifies that the materials delivered are as per material submittal and approval. Uncertified materials will be kept in quarantine and the MRIR will be promptly and accurately filled out.

4.3 Materials Storage and preservation

Tags/labels affixed to the outer box or storage rack identify the contents and physical characteristics of store items.

The store-keeper and the QC personnel shall perform regular monitoring on the material stored to verify their condition.

INELT will store all materials and equipment in such a way as to protect them from damage, deterioration, contamination and loss of identification. Main Contractor will make special provision for sensitive items such as chemical materials, electronics equipment, paints, etc.

INELT will document receipt of materials with their precise location within the lay down area and will ensure that materials of different types, grades and specifications are segregated.

Materials / equipment requiring special storage conditions shall be stored in accordance with manufacturer's instruction.

Heat sensitive items shall be stored under temperature control environment. Materials provided with preservatives during storage shall be verified for proper Packaging and storage.

The QA/QC Engineer, based on the input from the equipment supplier, will prepare and maintain a list of all equipment subject to preservation, including frequency and the type of preservation to be used. Condition of equipment and material in storage will be checked periodically to prevent deterioration and identify non-conforming conditions

The Main Contractor shall provide adequate storage area (Laydown Area) for storing materials and equipment. The Main Contractor shall also provide adequate security for all stored materials within the construction site and laydown areas. Facilities such as electrical power shall also be provided for the internal storage. A well-constructed sun shade shall be provided as well by the Main Contractor for externally stored materials.

4.4 Material release/issue

INELT will use Material Requisition to release materials or items from the Laydown/storage area for fabrication/construction operations. These will be submitted for review and approval by the responsible personnel prior to the subject material being issued from INELT lay down Area or store.

INELT will ensure that the material/equipment is correct for the intended application, that is full and correctly documented and identified and that its issue is recorded.

INELT will then issue the material/item ensuring that no damage or loss of identification is incurred during any loading, off-loading, slinging or other handling operation.

In the case of materials issued and loaded for dispatch to a sub-contractor, INELT will ensure that identification is intact prior to dispatch.

4.5 Handling

Selected employees are instructed, as required, in proper methods of material handling before any actual handling of material occurs.

Site Supervisors/Foremen ensure proper handling, storage and preservation of materials/equipment issued at work sites. Quality personnel monitor the condition of storage and preservation of materials on site.

To prevent damage during material handling the following devices may be used: manual or mechanical lifting equipment, Boom Trucks or Cranes for heavy equipment.

4.6 Packaging and Delivery

Whenever materials are transported from sites, the site supervisor ensures proper packaging and delivery.

The site supervisor also verifies the contents before sealing the package and prepares a Material Transmittal.

4.7 SUPPORTING DOCUMENTATION

Prior to final acceptance of material/equipment, the QC Inspector will verify that supporting documentation has been received and accepted, and the number and specifications from the material is identical to that identified on the Material Catalogue and Test Reports.

MTR's should be verified by the QC Inspector for accuracy of Heat Numbers or Identification numbers, his verification should cover chemical composition, physical and mechanical properties. Approved MTR's should be signed and dated by the QC Inspector and filed in the Quality Records.

Approved MTR's must be annotated with Contract No., P.O. No., P.O. Item No., and Project Name.

4.8 POSITIVE RECALL

Products which are not fully inspected may be released for construction by the QC Inspector, with the Project Manager and Proponent’s concurrence, under the condition that they can be recalled if the complementary Inspection shows that the items do not conform to the specified requirements.

The use of this procedure will be restricted to material/components for which quality documentation from a supplier is not available for review and acceptance by QC Inspector. The supplier will be contacted to confirm that all required inspections/tests have been carried out, accepted and available for submission and review. The affected item will be released from the segregated hold area but hold tags attached will remain until final disposition of the nonconformity.

If the QC Inspector decides to release the material/component on a recall basis, he should inform the Site Project Manager in writing.

The QC Inspector records the identification of the material components to be released, and if necessary makes additional identification either directly on the material/components or on a Tag in such a way that it is possible to trace and to identify, if they should have to be recalled. If the complementary inspection shows that the material/components do not conform to the specified requirements, the QC Inspector will recall the material/component and inform the Project Manager.

The materials/components are brought back to the segregated hold area and processed. Main Contractor will provide a segregated area for storing materials found nonconforming to the project requirements before returning to the supplier.

5.0 Material storage procedure for various electrical components:

· Storage area should be clearly defined.

· Separate areas should be used for different items (For Ease of identification)

· Certain materials and substances should be segregated during storage.

· Areas should be kept Clean and should be routinely inspected.

· Appropriate warning signs should be displayed where necessary( E.g where flammable materials are stored)

5.1 Fiber Optic Cable

Fiber Optic Cable handling and placing

· Cable should never be bent below its minimum bending radius. Doing so can result in bending losses and/or breaks in the cable's fibers.

· The minimum bending radius of a fiber cable under load is 20 × D, where D is the diameter of cable; the minimum bending radius of a fiber cable under no load is 15 × D.

· The cable should never be loaded beyond its maximum tensile strength. Exceeding the cable's placing tension provided in the Cable Data Sheet/Specification, can alter cable and fiber performance and shorten its service lifetime.

· Broken fiber ends created during termination and splicing can be dangerous. These ends are extremely sharp and can easily penetrate the skin. They invariably break off and are very hard to find and remove.

· Be careful while handling the fibers. Dispose of all scraps safely and properly. Do not eat or drink near the installation area.

5.2 Fire Alarm

Materials shall be offloaded and stored in the designated area as per the manufactures instruction.
Storage area shall be barricaded and signed off to prevent unauthorized entry of personnel or moving equipment.
Materials shall be protected from direct sunlight as per the manufacturer’s recommendations.

5.3. CCTV POLE

· CCTV poles lengths as per the Project Requirement are 4 meter & 3.2 meter.

· Boom lift truck in 10 ton lifting capacity (SWL) shall be used for loading, offloading and shifting the pole & components to workplace.

· Boom lift truck shall be inspected by the contractor before starting works.

· Inspection tag/sticker shall be displayed on the truck.

· Equipment shall be with valid registration, insurance and third party test certificate.

· Pre-start inspection shall be carried out by the operator and recorded.

· Faults or malfunctioning shall be immediately reported to the engineer for further actions.

· Operator shall be with valid driving suitable driving license and third party assessment certificate.

· Lifting plan shall be developed by the appointed person for lifting.

· All lifting operation shall be carried out as per the approved lifting plan.

· Lifting supervisor and rigger shall be experienced with valid third party certificates.

· Lifting gears shall be free of damages/defects, colour coded and with valid third party test certificate.

· Poles shall be offloaded and stored in the designated area as per the manufactures instruction.

· Poles shall be stored on compacted and levelled ground surface as per the manufactures instruction.

· Poles shall not be stored above one meter heights and must be properly protected against the movement.

· Storage area shall be barricaded and signed off to prevent unauthorized entry of personnel and moving equipment.

· Manual handling shall be avoided as possible.

· Light weight component below 25 Kg. is only permitted for manual handling at workplace.

· Manual handling techniques shall be discussed in pre-start briefing and followed.

5.4 GI Cable Tray and Trunking:

A. Handling.

· Trays/Trunking shall be packed in bundles using adequate banding and balanced at the center.

· It is recommended that where possible non-metallic banding is used in order to avoid rust stains forming on galvanize products.

· Where products of three meter lengths or above are packed in bundles, they shall be supported with a minimum of three timber bearers which provide sufficient clearance to accommodate the forks of a forklift truck. Bearers shall be spaced evenly along the length of the bundle.

· Where shorter length products are packed in bundles, they shall be supported with a Minimum of two timber bearers which provide sufficient clearance to accommodate the fork of the trolley. Bearers shall be spaced evenly along the length

B. Loading and Off-Loading recommendations.

· Site deliveries should preferably only be made where suitable mechanical handling equipment is available on site.

· The delivered material must be treated with care. Lifting must only be carried out from the sides and the forklift truck tines must pass below a complete bundle, or manually lifted if delivered in singles.

· The tensioned banding used for securing bundles of equipment during transport is not suitable for lifting purposes. When cutting this banding appropriate eye Protection must be worn to avoid injury.

· Sheared steel (particularly pre-galvanized) does have relatively sharp edges and protective gloves must be worn during handling.

C. Storage

In order to store Cable Tray Systems and Cable Trunking Systems safely and maintaining them in their delivered condition, the following guidelines should be considered:-

· Products which are either Hot Dip Galvanized (HDG) after manufacture or non-metallic can be stored outside without cover (excluding boxed items). When stored outside products should be stacked in a method that ensures adequate drainage.

· However outside storage is not recommended for galvanized products due to wet storage stain.

· Ideally, all metallic products should be stored undercover in a dry, unheated environment and be loosely stacked off the ground to ensure adequate ventilation.

· It is important that products that have different finishes are kept apart. Products Pre Galvanized (PG) before manufacture should always be protected and stored in a well ventilated and dry location, and well stacked.

· Any components packaged in degradable bags, boxes, cartons etc. should always be stored in a well-ventilated and dry location.

5.5 LV Cables:

GUIDANCE ON HANDLING, STORING & INSTALLING POWER CABLES

HANDLING:

Damage to cables can occur due to incorrect handling of drums and cables leading to the breakdown of the drum flanges. In exceptional cases, movement of the drum barrel may also take place. Once this breakdown of the drum occurs, the cable is immediately exposed to damage.

For guidance on handling, please refer to the sketches and notes contained in this booklet, which should be followed closely. We have no objection to the use of fork-lift trucks provided that care is exercised not to damage, or remove, the protective battens when pushing the forks under the drum flanges. Unloading can also be safely accomplished by means of ramps and winches.

Under no circumstances should a drum be rolled off a vehicle on to a „cushion of‟ sand, tarpaulin, etc. This action could crumple the flanges and barrel of the drum, driving splinters and/or nails into the cable

STORAGE:

If at any time the drums of cables are required to be stored for reasonably long periods, e.g. prior to shipment or installation, the following points should be noted.

1) The site for storage of drums should be well drained, hard packed soil, or preferably a concrete surface, which will not allow the drums to sink and so give rise to damage due to the extreme difficulty in moving drums when they are sunk into the ground.

2) All drums should be stored with the battens intact, and in such a manner as to leave sufficient space between them for air circulation. Check and tighten tie bolts on the drums at regular intervals.

3) Tier stacking of drums is not recommended. Under no circumstances must the drums be stored „on the flat‟ i.e., with flanges horizontal.

4) All drums, during installation (i.e. when the battens have been removed), should be „scotched‟ so that there is no danger of the flanges of drums coming into accidental contact with unprotected cable on other drums. The cables should not be left unprotected.

5) Cables should be protected from direct rays of the sun by leaving the battens on or covering the cables with thick black polythene sheet.

IMPORTANT: Cable ends must be sealed with end caps during storage and transportation.

5.6 DB and Feeder Pillar:

Storage / Protection: DB, Feeder Pillar and Accessories shall be unloaded with care to avoid any damages. If they are shipped in packs or pallets, each pack of pallet shall be lifted individually with suitable lifting equipment. Every precaution shall be taken to preserve their cleanliness before installation. Store in accordance with manufacturer’s instructions, properly protected from construction activities and weather conditions.

5.7 Landscape Lighting:

· All materials and documentation relevant to this particular section of works shall be checked and verified to ensure correct and approved type.

· Material must be delivered at site in undamaged condition, in manufacturer’s original container or packaging with identification labels intact and legible.

· Lighting fixtures shall be stored on a clean, cool and dry place out of direct sunlight and comply with manufacturer’s recommendation.

· Materials delivered on site shall include Certificate of Country of Origin and factory quality assurance test certificates and reports.

· The site supervisor/ site Engineer will brief the team on the RAMS for the works, COSHH for chemical and explain safe system of work and residual risks related to the works to the work force.

lighting Poles:

Delivery, storage and handling of lighting pole components

· Lighting pole is heavy weight and the length is 12 meter.

· Experienced workers and supervision shall be assigned for the task.

· Bundles of lighting pole shall be offloaded from the trailer truck during the delivery by using mobile crane in 50 ton SWL as per the approved lifting plan.

· Lighting pole and accessories shall be stored in designated storage area provided by the contractor.

· Materials shall be stored as per the instruction manual from the manufacturer.

· Lighting pole bundles and the loose lighting poles shall be protected against movement by using timber blocks and wooden wedges.

· Storage area shall be barricaded and signed to prevent the unauthorized entry of personnel and moving equipment.

· Mobile crane and trailer truck shall be used for shifting light poles from the storage to work place.

· Manual handling shall be avoided as possible.

· Single poles are in light weight shall be manually handled by a team of competent workforce at workplace during the preparation for installation by using mobile crane.

· Wear suitable hand gloves with good grip for manual handling.

· Safe manual handling techniques shall be included in the pre-task briefing.

· Work activities shall be supervised and controlled by the competent supervisor.

· Lifting area shall be barricaded and signed off to prevent unauthorized entry of personnel and moving equipment.

· Approved lifting plan shall be followed.

5.8 Earthing Material:

· Ensure that all materials received are inspected; found acceptable as per approved material submittal and are available to carry out the work.

· Materials enough for a day’s work will only be stored at installation site. Rest of materials will be stored in lay down area or main storage room.

· Materials shall be stored in clean, proper and accessible place.

· Materials shall be stacked and arrange size wise with proper identification.

· Materials shall be protected from direct sunlight and moisture to avoid deterioration.

· Delivery of materials Site Supervisor/Foremen will also check that proper tools and equipment are available to carry out the work.

· Check all the materials before bringing to site if free from any damage through material handling or free from any foreign materials.

PROCEDURE FOR RECEIVING, HANDLING, STORAGE AND ISSUE OF MATERIALS