Departmental Procedure Site Operations DP: · PDF fileDepartmental Procedure Site Operations...

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Departmental Procedure Site Operations DP: SOX (Aligned to Quality Manual and ISO 9001:2008) This manual is to be returned to Head (PROJ) when the individual has no further requirement for it or when he ceases to be an employee of BHEL. Individuals in possession of the Controlled Copies will receive revisions as and when issued. Issue No. 04 Controlled Copy Date of Issue: 16.03.2010 Revision No. 00 Issued to: Effective Date: 16.03.2010 Control Number: Issued by : Head/PROJ Bharat Heavy Electricals Limited Power Sector Western Region Shree Mohini Complex Nagpur 440001

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Departmental Procedure Site Operations

DP: SOX (Aligned to Quality Manual and ISO 9001:2008)

This manual is to be returned to Head (PROJ) when the individual has no further requirement for it or when he ceases to be an employee of BHEL. Individuals in possession of the Controlled Copies will receive revisions as and when issued.

Issue No. 04

Controlled Copy

Date of Issue: 16.03.2010

Revision No. 00

Issued to:

Effective Date: 16.03.2010

Control Number:

Issued by :

Head/PROJ

Bharat Heavy Electricals Limited

Power Sector Western Region Shree Mohini Complex

Nagpur 440001

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DEPARTMENTAL PROCEDURE FOR Issue No. : 04 SITE OPERATIONS Rev. No. : 00 Date : 16/03/10 DP:SOX Page : 01 of 02

Reviewed by Approved by

Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

TABLE OF CONTENTS

Sl

No Chapter

Identification Description No. of

Pages Latest Rev. No.

Effective Date

01 Table of contents

Table of contents 02 00 16/03/10

02 DP : SOX DP for Site Operations 15 00 16/03/10

03 WI : SOX : 01 WI for Site Opening 03 00 16/03/10

04 WI : SOX : 02 WI for Receiving Standards/codes/Regulating Documents & Registration with Statutory Authorities

01 00 16/03/10

05 WI : SOX : 03 WI for Deployment, O&M of CE/T&P/MME

03 00 16/03/10

06 WI : SOX : 04 WI for Receipt, Storage, Preservation, Handling and Issue of Materials.

06 00 16/03/10

07 WI : SOX : 05 WI for Insurance Claims 05 00 16/03/10

08 WI : SOX : 06 WI for Site Purchase 02 00 16/03/10

09 WI : SOX : 07 WI for Purchase of services at site

02 00 16/03/10

10 WI : SOX : 08 WI for Document & Data control

02 00 16/03/10

11 WI : SOX : 09 WI for Review of Mobilisation of subcontractor & Start of work.

01 00 16/03/10

12 WI : SOX : 10 WI for Execution of work. 05 00 16/03/10

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DEPARTMENTAL PROCEDURE FOR Issue No. : 04 SITE OPERATIONS Rev. No. : 00 Date : 16/03/10 DP:SOX Page : 02 of 02

Reviewed by Approved by

Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

TABLE OF CONTENTS

Sl No

Chapter Identification

Description No. Of Pages

Latest Rev. No

Effective Date

13 WI : SOX : 11 WI for Safety of Men & Equipment.

02 00 16/03/10

14 WI : SOX : 12 WI for Inspection & Testing.

02 00 16/03/10

15 WI : SOX : 13 WI for Non-conformity & Corrective action

02 00 16/03/10

16 WI : SOX : 14 WI for Progress Review & Monitoring

03 00 16/03/10

17 WI : SOX : 15 WI for Commissioning

02 00 16/03/10

18 WI : SOX : 16 WI for Final Payment and closing of Sub- contracts.

01 00 16/03/10

19 WI : SOX : 17 WI for Handing over

01 00 16/03/10

20 WI : SOX : 18 WI for Site closing

03 00 16/03/10

21 WI : SOX : 19 WI for Customer Complaints/Feedback

01 00 16/03/10

22 WI : SOX : 20 WI for Quality Assurance Engineer at Site

02 00 16/03/10

23 Summary of Revision

Summary of Revision 02 00 16/03/10

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DEPARTMENTAL PROCEDURE FOR Issue No. : 04 SITE OPERATIONS Rev. No. : 00 Date : 16/03/10 DP:SOX Page : 1 of 15

Reviewed by Approved by

Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE 1.1 This procedure details the site operations for installation of contracted product, systems

and providing related services. 2.0 PRIMARY DOCUMENT 2.1 Quality Manual. 2.2 Standard Procedures. - SP 02 to 13. 3.0 PROCESS MAP

The process map is enclosed. The internal customers for this department are PMX, PUR, TSX, MSX, QLY, FIN, HR, FEX, BOP and COM. There expectations are:

o Timely submission of reports and formats o Adherence to Statutory and Regulatory requirements o Adherence to contract schedules and early warnings o Provision of suitable work environment and upkeep of facilities

4.0 ORGANISATION AND RESPONSIBILITY 4.1 The organisation and responsibility of site operations will be prepared and issued by

site incharge separately as per format PW-004. 4.2 The organisation chart shall be updated whenever any change in organisation set up

takes place. 5.0 ACTIVITIES

Three types of contracts are dealt normally.

(a) Turnkey contracts (T) : Contracts where scope includes total civil works, installation, testing & commissioning responsibilities pertaining to entire project. This also includes contracts on EPC basis.

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DEPARTMENTAL PROCEDURE FOR Issue No. : 04 SITE OPERATIONS Rev. No. : 00 Date : 16/03/10 DP:SOX Page : 2 of 15

Reviewed by Approved by

Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

(b) Erection, Commissioning/ lump sum contracts (E) Contracts where scope includes

installation & commissioning responsibilities. (c) Supervision contracts (S) : Contracts where services are rendered in advisory capacity

for erection and commissioning. This procedure details various work instructions which are used as per contractual commitments. All the work instructions may not be utilised at any given site.

T E S

5.1 Site opening - Establishment of infrastructural facilities as per work instruction No. WI : SOX : 01.

O O O

5.2 Registration with statutory authorities as per work instruction No. WI : SOX : 02

O O *

5.3 Deployment, operation and maintenance of CE/T&P/MME as per work instruction No. WI : SOX : 03.

O O -

5.4 Receipt, storage, preservation, handling and issue of materials as per work instruction No. WI : SOX : 04

O O -

5.5 Insurance claims as per Work Instruction No. WI : SOX : 05.

O O -

5.6 Site purchase as per wok instruction No. WI : SOX : 06 O O -

5.7 Purchase of services at site as per Work Instruction No. WI : SOX : 07

O O -

5.8 Document & Data Control as per work instruction No.WI : SOX:08

O O O

5.9 Review of mobilisation of sub-contractors & start of work as per work instruction No.WI:SOX:09.

O O -

5.10 Execution of work as per work instruction No.WI : SOX : 10.

O O *

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Reviewed by Approved by

Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

T E S

5.11 Safety of men & equipment as per work instruction No. WI : SOX : 11

O O -

5.12 Inspection and testing as per work instruction No. WI : SOX :12

O O O

5.13 Non-conformity and corrective action as per work instruction No. WI : SOX : 13.

O O O

5.14 Progress review and monitoring as per work instruction No.WI:SOX:14.

O O O

5.15 Commissioning as per work instruction No.WI:SOX:15 O O O 5.16 Final payment & closing of subcontracts as per work

instruction No.WI:SOX:16 O O -

5.17 Handing over as per work instruction No.WI:SOX:17. O O O 5.18 Site closing as per work instruction No.WI:SOX:18 O O O

5.19 Customer complaints/feedback as per work instruction No.WI:SOX:19.

O O O

5.20 Quality Assurance Engineer activity on installation as per Work Instruction No.WI:SOX:20

O O O

NOTE : O = Applicable - = Not applicable * = Partially applicable

Responsibility matrix as shown above is applicable generally. However check with

respective contract for change in responsibility, if any.

6.0 DOCUMENT CONTROL

6.1 Preparation and revision of DP:SOX and work instruction shall be carried out as per SP-

02 by a nominee of Head (PROJ)

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Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

6.2 The documents used in the department are controlled as per SP 02.

6.3 Nominee of Site Incharge will maintain a list of documents and control as per SP 02.

6.4 Head (PROJ) shall approve DP:SOX and WIs for Quality Engineer & Commissioning shall be approved by respective Head of Functions.

6.5 On Site Closing, Site Incharge shall return DP:SOX to nominee of HEAD (FEX). 7.0 PLANNING: 7.1 PERFORMANCE PLANNING 7.1.1 Objectives for the site in measurable terms are set in line with QM 5 in April every year. 7.1.2 Annual individual targets are set measured and reviewed as per Performance

Management System. 7.1.3 The list of processes needing pre-qualification is obtained from FEX. Procedures for

qualification of processes, equipment and personnel are obtained from agency concerned.

7.2 RESOURCE MANAGEMENT

7.2.1 Human Resources: Identification of manpower to be deployed is done by PROJ, TSX,

FEX, FIN, HR and QLY. Based on status of execution, resources are mobilised.

7.2.2 Infrastructure : Infrastructure is planned by FEX and executed by Site Operations.

7.2.3 Work Environment: While planning for infrastructure, care is taken for providing

proper work environment depending on the site condition

7.2.4 Safety: Safety of equipment and men is as per WI: SOX: 11

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Reviewed by Approved by

Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

7.3 IDENTIFICATION OF COMPETENCIES

Competencies are identified for personnel at site in consultation with Construction Manager as per Performance Management System.

7.4 IDENTIFICATION OF TRAINING & DEVELOPMENT NEEDS 7.4.1 Training needs of Site staff will be identified by Site In-charge, Commissioning staff by

UCM & Quality staff by Head (QLY) and forwarded to HR Dept. in line with SP 11. 7.4.2 On receipt of acceptance of nomination personnel shall be deputed for training. 7.4.3 On attending training programme, Site In charge, UCM or Head (QLY) shall review

training relevance based on feed backs received from individuals and communicate to HR Dept.

7.4.4 Training records are maintained by HR Dept.

7.5 MEASUREMENT ANALYSIS AND REVIEW 7.5.1 Monthly review is conducted for the following:

o Objectives, plans and targets vis a vis achievements o Audit results o Customer complaints o Product/ Process non conformances o Resources o Improvement activities o Any other point

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DEPARTMENTAL PROCEDURE FOR Issue No. : 04 SITE OPERATIONS Rev. No. : 00 Date : 16/03/10 DP:SOX Page : 6 of 15

Reviewed by Approved by

Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

7.6 IMPROVEMENT ACTIVITIES Based on result of reviews, Non-conformances and QIP / SIP are taken by Head (PROJ) and Head (TSX).Improvement activities are taken up as per SP-13.

8.0 CONTROL OF NON-CONFORMING PRODUCT 8.1 Installation carried out by deviating from Drawing / Document will be dealt as per SP

06. 8.2 Approval of activities, carried out by deviating from documented procedure will be

obtained from authority approving the procedure. 8.3 Approval of competent authority will be obtained for results of activities, which do not

meet requirement. 8.4 Any non-conformance noticed during Qua lity audit will be dealt as per SP 07.

9.0 CORRECTIVE AND PREVENTIVE ACTION 9.1 For Non-conformance in the implementation of system raised as a result of Internal

Quality Audit, Site Incharge shall take corrective and preventive action as per SP 06 & SP 07.

9.2 Site Incharge shall initiate preventive measures to avoid recurrence of such non-

conformance. 9.3 Site Incharge shall communicate to Head (PROJ) and Head (QLY) & MR cases of non-

conformities which require input from other departments. 9.4 Site Incharge shall communicate status of completion of non-conformities to Head

(PROJ) and Head (QLY) & MR. 9.5 Site Incharge or his nominee shall maintain databank of all non-conformities and

corrective action.

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DEPARTMENTAL PROCEDURE FOR Issue No. : 04 SITE OPERATIONS Rev. No. : 00 Date : 16/03/10 DP:SOX Page : 7 of 15

Reviewed by Approved by

Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

10.0 STATUTORY AND REGULATORY REQUIREMENT :

Ensure compliance with Statutory Regulation and Requirement as per WI SOX-01 and WI SOX –02.

11.0 RECORDS AND RETENTION PERIOD 11.1 List of records and retention period

Type of record

Retention period Agency

Welding Heat treatment NDT records

Handing over to customer as applicable or till site closing.

NDT Engr

Preservation records.

Till site closing MM & ERN Log sheets, protocols as per applicable quality plans.

Till site closing On site closing

QAE SER

Calibration records Alongwith instruments transferred

QAE

Construction equipment history cards

Alongwith equipment transferred

MM

Non-conformance reports (MDR, SAR, CAR etc.)

Till site closing QAE

Internal quality audit reports

Till site closing QAE

Performance guarantee test reports

Till site closing TSX

Purchase Documents.

Till site closing MM

After site closing PUR

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DEPARTMENTAL PROCEDURE FOR Issue No. : 04 SITE OPERATIONS Rev. No. : 00 Date : 16/03/10 DP:SOX Page : 8 of 15

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Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

Type of record

Retention period Agency

Insurance Policy, Insurance files & Register

Till site closing MM

Contract related Documents Till site closing PLG

RIV, CRIV, RSV, ISTV Recovery statements

Till subcontract closing MM

Material, T&P, services from Customer.

Till site closing

Till contract closing

MM

PMX

Day Book, RR/LR Register, Stock book.

Till site closing For contract closing (Only Pending issues)

MM PMX

Despatch Schedule Till site closing MM, PLG

MDR Review records Till site closing MM

Site subcontracting Till site closing ERN, MM, PUR

Site subcontracting selection, appraisal records

Till site closing ERN

Process records Till site closing ERN, MM

Guidelines for Purchase Till site closing Return to Head (PUR)

MM

Technical Documents Till site closing On site closing

ALL DEPT,

T&P maintenance schedule, test reports

Till transfer of equipment MM

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Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

Type of record

Retention period Agency

Delegation of Power till site closing Return to Head (Fin)

MM, FIN

13.0 LIST OF SOFTWARE’S DEVELOPED / USED

Software provided by IT is used. 14.0 LIST OF FORMATS USED

Sl..N

o. Description

Format

No. Type

1 Construction equipment History card FEX-F11 I/ O

2 Quarterly statement on Equipment Maintenance

FEX-F12 O

3 Statement of Capital/ fixed Assets Received & Diverted

FEX-F24 O

4 Quarterly Inventory Statement of crane Spares

FEX-F26 O

5 Quarterly Evaluation of Contractor Corporate MM FORMAT

O

6 Purchase Order PUR-F33 I

7 Amendment PUR-F34 I

8 Contract period extension and overrun charges payment proposal PUR –F13

9 Proposal for extension of Insurance Policy PUR-F39

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Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

10 Closing of Contracts PUR-F07 O

11 Summary of Revision PW-006 -

12 Inspection Report of Bought Out Items PW-010 I/O

13 MQR PW-011 O

14 Inside Page for DP. PW-025 -

15 Inside Page for WI. PW-026 -

16 Training needs identification (For Non Executives).

PW-027 O

17 Training evaluation format. PW-030 O

18 Material Reconciliation Statement SOX-F14 O

19 Safety Report (Weekly) SOX-F30 O

20 Safety Report (Accident) SOX-F31 O

21 Safety Report (Quarterly-Fire Safety) SOX-F32 O

22 Safety Report (Monthly – Manpower) SOX-F33 O

23 Weekly status Report (Turnover, billing, Collection, Outstanding)

SOX-F34 O

24 Performance Report – Monthly SOX-F37 O

25 Pending Points Report SOX-F40 O

26 Status / Action Plan for Site Closing SOX-F42 O

27 Site information Report SOX-F43 I

28 MMEs TSX-F13 O

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Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

29 Calibration label TSX-F14 -

30 Withdrawal label TSX-F22 - Note : Site Incharge should obtain relevant formats from concerned issuing authorities as

detailed in SP 02. 15.0 ABBREVIATIONS USED :

ABBREVIATIONS EXPANSION BHEL BHARAT HEAVY ELECTRICALS LTD. C&I CONTROL & INSTRUMENTATION CAR COMMISSIONING ACTION REQUEST CE CONSTRUCTION EQUIPMENT CIV CANNIBALISATION CUM ISSUE VOUCHER CNAN CONSIGNMENT ARRIVAL NOTE COMM COMMISSIONING COM COMMERCIAL CRIV CONTRACTOR’S REQUISITION CUM ISSUE VOUCHER DB DAY BOOK DBR DAY BOOK REGISTER DCR DOCUMENT CONTROL REGISTER DEPT DEPARTMENT DMR DOCUMENT MOVEMENT REGISTER DP DEPARTMENTAL PROCEDURE DRG DRAWING DRIV DEPARTMENTAL REQUISITION CUM ISSUE VOUCHER DTL DOCUMENT TRANSMITTAL COVER LETTER DU DESPATCHABLE UNIT E ERECTION, COMMISSIONING / LUMPSUM CONTRACTS. EC ERECTION & COMMISSIONING

ERN ERECTION FIN FINANCE FIR FIRST INFORMATION REPORT HOD HEAD OF DEPARTMENT HQRS HEAD QUARTERS I INPUT M M E MEASURING AND MONITORING EQUIPMENT

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Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

INST INSTRUMENTS IS INDIAN STANDARDS INSN INSTALLATION ISTV INTER STORE TRANSFER VOUCHER LAS LOADING ADVISE SLIP LF LEDGER FOLIO LOI LETTER OF INTENT LPR LOCAL PURCHASE REGISTER LR LORRY RECEIPT LWR LORRY WAY BILL MDR MATERIAL DISCREPANCY REPORT MFG MANUFACTURING MM MATERIAL MANAGEMENT MOM MINUTES OF MEETING MR MANAGEMENT REPRESENTATIVE MQR MONTHLY QUALITY REPORT MSX MANAGEMENT SERVICES NDT NON DESTRUCTIVE TEST O OUTPUT O&M OPERATION AND MAINTENANCE PEM PROJECT ENGINEERING MANAGEMENT PG PERFORMANCE GUARANTEE PGMA PRODUCT GROUP MAIN ASSEMBLY PLG PLANNING PMX PROJECT MANAGEMENT PRD PRODUCT PS PACKING SLIP PQR PROCEDURE QUALIFICATION REQUIREMENT PUR PURCHASE PW POWER SECTOR - WESTERN REGION QAE QUALITY ASSURANCE ENGINEER QM QUALITY MANUAL QLY QUALITY QTY QUANTITY RIR RECEIPT INSPECTION REPORT RIV REQUISITION CUM ISSUE VOUCHER RR RAILWAY RECEIPT RRIV RETURNABLE REQUISITION CUM ISSUE VOUCHER RSV RETURN STORE VOUCHER S SUPERVISION CONTRACT SAF SAFETY SAR SITE ACTION REQUEST SDR SITE DEVIATION REPORT SER SERVICES

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Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

SFR SITE FAILURE REPORT SRV STORES RECEIPT VOUCHER SMX CONSTRUCTION MANAGEMENT SOX SITE OPERATIONS SP STANDARD PROCEDURE T TURNKEY CONTRACT T.NOTE TRANSPORT NOTE T&P TOOLS AND PLANTS TSX TECHNICAL SERVICES WI WORK INSTRUCTIONS WM WELDING MANUAL WO WORK ORDER WPS WELDING PROCEDURE SPECIFICATION

PROCESS MAP OF SITE OPERATIONS

CU

STO

ME

R R

EQ

UIR

EM

EN

T

CU

STO

ME

R SA

TISF

AC

TIO

N

PMX FEX PUR QLY MSX

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Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

FUNCTIONAL ORGANISATION CHART

SITE OPENING & ESTABLISHING INFRASTRUCTURE

MATERIAL MANAGEMENT

MU / EC

DOCUMENT CONTROL

STATUTORY & REGULATORY REQUIRMENTS

MONITORING VERIFICATION &

CORRECTIVE ACTION

CUSTOMER INPUTS PROPERTY

ERECTION PRE-COMMISSIONING

COMMISSIONING & PG TEST

SITE / CONTRACT CLOSING

PMX

TSX

FEX

COM

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Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

SOX HOD (FEX) HEAD (TSX) HEAD (QLY) PLG PRD MM SAF COMM QAE ERN • Plan and execute site activities for installation to the requirement of contract • Ensure quality checks are carried out as per documented procedures. Identify non-

conformance and implement corrective actions. • Maintain good housekeeping and adherence to Standards/codes & Regulatory requirements • Associate Customer in Implementation of Quality Requirements.

HEAD (PROJ)

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WORK INSTRUCTION FOR Issue No. : 04 SITE OPENING Rev. No. : 00 Date : 16/03/10 Page : 01 OF 03 WI:SOX:01

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE 1.1 This work instruction is for site opening and establishment of infra- structural

facilities 2.0 ACTIVITIES 2.1 Establishment of Infra structural facilities at site 2.1.1 On reaching site, get temporary office space from customer. 2.1.2 Communicate to Project Manager regarding site office opening and mode of

communication. 2.1.3 Receive the following documents: 2.1.3.1 Scope of supply from manufacturing unit/PEM/vendors along with schedules from

PMX. 2.1.3.2 Draft / final contract document, contract co-ordination procedure with customer

from PMX. 2.1.3.3 Contract schedule/L1 network from PMX 2.1.3.4 Contract information sheets from Commercial

2.1.3.5 Schedule of erection & commissioning activities (Net-work/Bar chart) L2 form PMX.

2.1.3.6 LOI/Work order for construction of Site Office/Storage shed from Purchase

Department (as per scope of contract).

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WORK INSTRUCTION FOR Issue No. : 04 SITE OPENING Rev. No. : 00 Date : 16/03/10 Page : 02 OF 03 WI:SOX:01

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.1.4 Obtain following inputs from customer as applicable.

2.1.4.1 Construction Power, Water, Pre-assembly area, approach road for pre-assembly yard, space for material storage/storage shed, space for site office, as per terms of contract.

2.1.4.2 Discuss with customer for staff accommodation and get quarters allotted, alternatively make own arrangements.

2.1.4.3 Get land allotted for labour /supervisor colony, canteen and offices for various subcontractors of BHEL.

2.1.5 Monitor completion of infrastructure/enabling work as per schedule and update progress in SOMS till completion of infrastructure.

2.1.6 Arrange local transport facilities for staff.

2.1.7 Interact with PMX/IT and register for communication facilities for telephone, Internet and fax depending on requirement.

2.1.8 Arrange office furniture items, stationery items, stacking and covering materials through FEX from other sites or procure from time to time depending on requirement.

2.1.9 Survey for hospital facility, ambulance services, fire brigade, schooling, shopping and keep records of address and telephone Nos.

2.1.10 Meet the following local authorities for appraisal of incoming project and site operations.

2.1.10.1 Police.

2.1.10.2 Railways (for siding facilities).

2.1.10.3 Post and Telegraph.

2.1.10.4 Bank.

2.1.10.5 Regional Transport office (for registration / tax etc.) for company vehicles.

2.1.10.6 Local Transporter Office / Godown.

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WORK INSTRUCTION FOR Issue No. : 04 SITE OPENING Rev. No. : 00 Date : 16/03/10 Page : 03 OF 03 WI:SOX:01

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.1.10.7 District Authority.

2.1.10.8 Insurance Company (in case, insurance under BHEL scope, collect the list of surveyors.

2.1.10.9 Local Government bodies as applicable.

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WORK INSTRUCTION FOR Issue No. : 04 RECEIVING STANDARDS / CODES Rev. No. : 00 /REGULATING DOCUMENTS Date : 16/03/10 & Page : 1 OF 1 REGISTRATION WITH STATUTORY AUTHORITIES WI: SOX:02

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE

1.1 This work instruction is for registration with statutory authorities.

2.0 ACTIVITIES

2.1 Receiving Standards / Codes / Regulating Documents.

2.1.1 Identify Standards / Codes / Regulating Documents etc. required for site execution from Drawings / Contract Documents / Quality Plans and / or any other related documents and send requisition to Head (TSX).

2.1.2 Receive related documents as above (point No.2.1.1) for use. In case the requirement is not met within stipulated date, send reminder to Head (TSX).

2.2 Registration with statutory authorities.

2.2.1 To get the clearance from statutory authorities as applicable and progressively as required.

2.2.1.1 Labour Commissioner’s office (Head office & local).

2.2.1.2 Boiler Inspector (Head office & local).

2.2.1.3 Electrical Inspector

2.2.1.4 Sales Tax

2.2.1.5 Income Tax

2.2.1.6 Excise

2.2.1.7 Revenue Department in case of civil works for Royalty payment.

2.2.1.8 Professional Tax

2.2.1.9 Pollution Control Authority

2.2.1.10 Municipal Authority

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WORK INSTRUCTION FOR Issue No. : 04 DEPLOYMENT, O&M OF Rev. No. : 00 CE/T&P/MME Date : 16/03/10 Page : 1 OF 3 WI: SOX:03

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE

1.1 This work instruction is for Deployment, Operation and maintenance of CE, T&P and MME

2.0 ACTIVITIES

2.1 Deployment, Operation and maintenance of CE, T&P and MME.

2.1.1 Review deployment plan of CE, T&P and MME prepared by FEX & TSX Departments and match with site requirement and schedule. Inform FEX/TSX for suitability of deployment (diversion/ procurement).

2.1.1.1 Receive T&P consignment.

2.1.1.2 Check physical condition of consignment and report to FEX and sending site.

2.1.1.3 Call FEX/Equipment supplier representative, if needed.

2.1.1.4 Get the Cranes assembled and tested for their capacity before these are deployed. Refer to FEX guidelines for this.

2.1.2 Receive history card for each construction equipment, from previous site/FEX and further maintain it. Enter all jobs carried out in the history card. If space is not sufficient use additional sheets, Maintain separate file for each T&P.

2.1.2.1 Receive list of spares required for routine/ preventive maintenance of equipment from FEX. Take up for their diversion from other sites or procurement through FEX. Update spares consumed.

2.1.2.2 Check for status of payment of Road Taxes, Registration and validity of Insurance for tyre mounted cranes, trucks and trailers, Licence for HF walkie talkie sets. Ensure prompt payment of statutory dues.

2.1.2.3 Receive capital overhaul schedule from FEX and service contract from PUR.

2.1.2.4 Get the dismantling/assembly or overhauling of cranes done from the contractor/agency arranged/finalised by FEX/PUR.

2.1.2.5 Evaluate work of vendor/sub-contractor after completion of each contract.

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WORK INSTRUCTION FOR Issue No. : 04 DEPLOYMENT, O&M OF Rev. No. : 00 CE/T&P/MME Date : 16/03/10 Page : 2 OF 3 WI: SOX:03

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.1.2.6 Breakdown maintenance, running maintenance, preventive maintenance wherever applicable to be arranged by site, obtain help from FEX, if required.

2.1.2.7 Update status of equipment maintenance for capital T&P .

2.1.2.8 Review T&P to be mobilised by Construction Contractor at different stages of works with reference to schedules and inform Purchase department for any inadequacy/ failure.

2.1.2.9 Review and inform PMX to make available T& P/other utility/inputs in Customer’s scope at appropriate time.

2.1.3 MME

2.1.3.1 Nominate instrument/calibration nominee and inform TSX.

2.1.3.2 Store shall receive instruments with calibration history card from previous site/TSX.

2.1.3.3 Calibration nominee shall generate history cards for all new MMEs.

2.1.3.4 Calibration nominee shall arrange for calibration of instruments in line with Master Instrument Inventory File received from TSX and maintain history card.

2.1.3.5 Calibration nominee shall advise Construction Contractors to ensure calibration of instruments in his scope.

2.1.3.6 Comply with all the requirements and conditions laid down in guidelines for calibration and codification of MME of BHEL and sub-contractors issued by TSX.

2.1.3.7 Update list of instruments in stock twice a year in April/October.

2.1.3.8 Withdrawal of unserviceable MME will be as per guidelines issued by TSX

2.1.4 Withdrawal of CE, T&P & MME.

2.1.4.1 Prepare Induction/Withdrawal plan in April/October every year.

2.1.4.2 Receive instructions from FEX/TSX for diversion as per deployment plan

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WORK INSTRUCTION FOR Issue No. : 04 DEPLOYMENT, O&M OF Rev. No. : 00 CE/T&P/MME Date : 16/03/10 Page : 3 OF 3 WI: SOX:03

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.1.4.3 Despatch CE, T&P, MME along with History Card, Manual, Calibration reports as per deployment plan and update despatch particulars.

2.1.4.4 Raise ISTV for the same.

2.1.4.5 Ensure good working condition of Equipment being diverted before despatch to next site.

2.1.4.6 Update actual utility of Cranes including breakdown details.

2.1.4.7 Update status of capital / fixed assets received and diverted.

2.1.5 Physical Verification

2.1.5.1 Conduct Physical verification of assets and update status

2.1.5.2 Identify unserviceable assets.

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WORK INSTRUCTION FOR Issue No. : 04 RECEIPT, STORAGE, PRESERVATION Rev. No. : 00 HANDLING AND ISSUE OF MATERIAL Date : 16/03/10 Page : 01 OF 05 WI: SOX:04

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE

1.1 This work instruction is for receipt, storage, preservation, handling and issue of materials.

2.0 ACTIVITIES

2.1 Receipt, Inspection, Storage, Preservation, Handling, Issue and Return of materials.

2.2 RECEIPT & INSPECTION

2.2.1 Receipt & Inspection of BHEL manufactured items as well as sub-vendor items on behalf of MUs and ECs.

2.2.1.1 Receive Applicable PGMA list, Shipping List, Model Packing List/ Completion schedule, list of Purchase Orders, despatch schedule, as applicable, from units / PMX. Check the data with SOMS data and take corrective action if any. Receive storage and preservation manual from TSX.

2.2.1.2 Receive from MUs list of BOIs for directly despatched items from Sub-vendors giving PGMA / other identification number, material description, quantity, delivery plan and Vendors’ scope w.r.t. Supply, erection and commissioning.

2.2.1.3 Receive from MUs relevant drawings and documents for manufactured and of Sub-vendors items and link sheet to cover P.O. Numbers and respective supplier’s name to PGMA and other identification system.

2.2.1.4 Receive material and identify by using any of the following documents as applicable.

- RR/LR/LWB/ any other document conveying despatch mode

- Material loading Advice

- Packing list

- Shipping list / completion schedule

- Purchase order copy

- Drawing or any other relevant document.

- Inspection Reports / Test Certificates of Bought out items (BOI) as envisaged in the approved Quality Plan.

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Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.2.1.5 Receive LOI / work order of material handling sub-contractor from Purchase Dept.

2.2.1.6 Review sub-contractor mobilisation regarding readiness to receive material at site/siding/local transporters godown and arrange for required stacking material/ covering material like Tarpaulins, etc.

2.2.1.7 Hand over original RR/LR after authorisation to Material Handling contractor and take acknowledgment.

2.2.1.8 If original RR/LR is not received but only duplicate copy or intimation is received, follow up with Mfg. Units and PMX for receipt of the same.

2.2.1.9 In case consignment is not received in reasonable time after receipt of RR/LR, intimate Manufacturing Units and PMX for the same. Intimate carrier/underwriter as per WI:SOX:05.

2.2.1.10 Maintain record of placement of wagons at Railway siding and release of wagons for all consignment.

2.2.1.11 After receipt of material at site, generate Day Book number and conduct Receipt Inspection of material on the basis of LAS/LWB/RR. Generate material Receipt Inspection Report. Material receipt certificate for manufactured and sub-vendor items shall be sent to respective MUs / ECs within 45 days of the rece ipt of materials. Post locations of material in stock register for identification.

2.2.1.12 Check for shelf life of material, if applicable and ensure prevention of such material from usage in to the product and system wherever shelf life has expired.

2.2.1.13 In case of discrepancy in supplies like shortages, damages and wrong supplies, Material Discrepancy Report (MDR) shall be generated. MDR number shall be marked on the damaged material. MDR shall also be raised for the material supplied by vendors (on behalf of units), which are not accompanied, by purchase order or relevant documents.

2.2.1.14 Construction Manager shall monitor the MDRs and update monthly status of MDRs.

2.2.1.15 Material In charge shall arrange for segregation of damaged/questionable items by inspection with the help of erection engineer/QAE.

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Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.2.1.16 Identify repairable item with blue paint/blue tag and rejected item with red paint/red tag. Rejected items shall be stored separately in areas earmarked for such purpose.

2.2.1.17 If damage/loss is covered under insurance policy, material In charge to raise provisional claims with Insurance Company and also arrange for survey of damaged/lost item (if applicable) as per contract and obtain cost particulars from unit/supplier. For details refer Insurance work instruction No. WI:SOX:05.

2.2.1.18 Material Incharge shall update / generate the material pending list (monthly) which shall include materials against MDRs with MDR reference number and materials required against SAR/CAR/etc. with the help of Erection Engineer/QAE. A separate list of connibalised items, if any, shall be maintained as per clause No. 2.4.12.

2.2.1.19 Site Incharge after review with Erection Engineers shall follow up with Manufacturing Units and send copy to PMX for parallel follow up.

2.2.2 Receipt and Inspection of Items Purchased by Region or Received from Other Sites

2.2.2.1 For material received against purchase orders issued by HOD(Pur), Material Incharge shall raise Stores Receipt voucher with in a week. Material Incharge shall maintain separate stock register for materials received against purchase orders issued by HOD (Pur). In case of discrepancy in supplies like shortages, damages, product not accompanied with documents identifying conformity of product i.e. test certificates, copies of purchase orders, etc., wrong supplies, HOD (PUR) as well as Vendors should be informed for taking corrective action. Wherever payments are released to supplier from site as per PO the relavent Invoice and payment details should be forwarded to Purchase.

2.2.2.2 Material Incharge shall maintain stock register for all other materials, small tools etc., received from other sites. (Condition of the same shall be accertained for utility. Any cost incurred on making them servicable shall be debited to the sending sites. ) Non-moving items shall be identified and disposal action initiated as per procedure.

2.2.3 For materials drawn from customer a separate Control Register shall be maintained.

2.2.4 Updated material availability status shall be maintained to facilitate plan / revise erection programme on 20th of every month.

2.3 STORAGE AND PRESERVATION 2.3.1 Material Incharge shall store material in closed/semi-closed, open storage as per

storage & preservation manual released for different product/equipment by TSX.

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Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.3.2 Where adequate storage conditions as per manuals can not be provided, an alternate suitable storage / coverage shall be provided to avoid deterioration. Engg. Centre / TSX shall be informed suitably.

2.3.3 Material In charge to carry out preservation of material in line with preservation manual released for different product / equipment. Periodicity of preservation shall be decided on site conditions and condition of material. Check for the shelf life of material, such as paints, rubber components, lubricants, oils, chemical, consumables, etc. Do not use material if shelf life of material expired and arrange for replacement where required.

2.3.4 Record of preservation shall be maintained.

2.4 HANDLING AND ISSUE

2.4.1 Material In charge shall issue required material on presentation of authorised Requisition Cum Issue Voucher.

2.4.2 In case of damaged/repairable materials for which MDR has been raised, material shall be issued on Returnable Requisition Cum Issue Voucher.

2.4.3 Erection Engineer / Commissioning Engineer / QAE shall inspect material after repair/rework and close the MDR on satisfactory completion of repair / rework. Erection engineer shall issue RSV and regularising RIV for closing MDR.

2.4.4 When the materials for which MDRs have been raised are received in subsequent supplies / locally arranged in consultation with units/ QAE Nominee, MDRs shall be closed.

2.4.5 Material In charge shall issue T&P / Instrument / cables etc., on presentation of authorised Contractor’s Requisition Cum Issue Voucher.

2.4.6 Material in charge shall issue materials for departmental use on presentation of authorised Departmental Requisition Cum Issue Voucher.

2.4.7 Material after its use, if found in excess, shall be returned to stores.

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Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.4.8 Material In charge along with erection engineers shall reconcile material issue and return. The same shall be submitted with RA Bill / final bill of respective contractors.

2.4.9 Material In charge shall issue / receive material / T&P / Instrument, to / from site as per Inter stores Transfer Voucher.

2.4.10 Material received from other sites should be issued after ascertaining the suitability for use with the consent of site In charge and QAE. Necessary tests, if required, may be carried out for ascertaining suitability.

2.4.11 While preparing ISTV following care shall be taken:

2.4.11.1 Separate ISTV for each capital item shall be prepared. Accessories shall be clearly indicated on ISTV or as annexure. History card and Manuals shall be sent along with ISTV.

2.4.11.2 Separate ISTV for measuring and test equipment shall be prepared. History card and calibration records shall accompany ISTV.

2.4.11.3 Separate ISTV shall be raised for furniture items and other materials (viz. Electrical Construction Power supply Panels, Cables, Acid Cleaning pipes, fittings and valves etc.) shall be prepared.

2.4.12 In case of non-availability of material in one unit but available for other unit, (in store or erected condition) can be cannibalised as per Cannibalisation Cum Issue Voucher after due approval of site In charge.

2.4.13 Once the replacement material received at site the necessary entries are to be made at canniba lization record and reference no. if cannibalization is to be incorporated.

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WORK INSTRUCTION FOR Issue No. : 04 INSURANCE CLAIMS Rev. No. : 00 Date : 16/03/10 Page : 01of 0 5 WI:SOX:05

Reviewed by Approved by Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR PS : WR

1.0 SCOPE

1.1 This work instruction is for lodging insurance claims for contract supplies, BHEL CE and T&P and assistance to customer wherever insurance is in customer scope.

2.0 ACTIVITIES

2.1 General guidelines.

2.1.1 Receive copy of Insurance Policy and related papers from Commercial.

2.1.2 Contact office of underwriters and obtain various formats from them, as applicable.

2.1.3 Obtain names of contact persons for various types of claims.

2.1.4 Study the policy for insurance coverage and identify the types of claims as marine, storage -cum-erection, etc.

2.1.5 Open separate file for each claim and file all relevant papers of claim in the same file.

2.1.6 Open separate despatch register for Insurance Correspondence.

2.1.7 All correspondence for particular claim should carry Insurance Claim reference numbers.

2.1.8 Formats for correspondence with carrier and underwriters are given for guidelines and can be modified suitably as per site requirements.

2.1.9 Preserve the damaged items and make them available for inspection by representative of Insurance Company or appointed surveyor of the company.

2.1.10 Furnish all such information and documentary evidence as the insurance company may require.

2.1.11 Keep the item damaged / not re-usable as the property of insurance company or declare salvage value in claim bill.

2.1.12 Provide necessary assistance in lodging claim by customer as per this work instruction

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WORK INSTRUCTION FOR Issue No. : 04 INSURANCE CLAIMS Rev. No. : 00 Date : 16/03/10 Page : 02of 0 5 WI:SOX:05

Reviewed by Approved by Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

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2.2 LODGING OF INSURANCE CLAIMS

2.2.1 MARINE CLAIMS

2.2.1.1 On receipt of material by rail or road immediate inspection to be carried out for any physical damages to packing or material and any loss of material during transit as per quantity mentioned in LR / RR copy. Prepare the report.

2.2.1.2 Arrange for photographs of damaged components or packing.

2.2.1.3 Make endorsement on the backside of the LR for such damages or loss and obtain Driver’s signature or thumb impression & Driving License Number. In case of material received by Rail, record in Delivery Book/Pilot Book of Railways.

2.2.1.4 Lodge formal claim on carrier for such losses / damages immediately, in any case within 6 months from the date of LR / RR. This claim letter to be sent to carrier by “Registered post with Acknowledgment Due”.

2.2.1.5 Obtain open delivery certificate from carrier. In case Carrier does not issue open delivery certificate (which normally happens in case of Railways) demand the open delivery in writing. Reminders to be sent every week for open delivery and still open delivery is not granted by carrier within three weeks of receipt of material, take the delivery on “Panchanama” in presence of surveyor. In any case, do not forget to make endorsement in “Delivery Book / Pilot Book” as the case may be.

2.2.1.6 In case, material is stolen after taking delivery from carrier but before transporting the same to store yard, lodge FIR with police and obtain copy of FIR, “Panchanama” and Final Investigation Report.

2.2.1.7 Intimate underwriters within 7 days from the date of loss / damage occurred or noticed for registering the claim and deputing the surveyor for carrying out survey.

2.2.1.8 Arrange survey of damaged components and joint inspection by concerned erection group and FQA Engineer. Prepare Material Discrepancy Report.

2.2.1.9 Obtain estimate of loss / damages and other technical details from concerned erection engineer for providing details to surveyor.

2.2.1.10 Obtain survey report from surveyor and bill for survey charges.

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WORK INSTRUCTION FOR Issue No. : 04 INSURANCE CLAIMS Rev. No. : 00 Date : 16/03/10 Page : 03of 0 5 WI:SOX:05

Reviewed by Approved by Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

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2.2.1.11 In case of loss of material or repairs where other agencies like BHEL Manufacturing Units or other suppliers has to replace or repair the material, obtain cost details / proforma invoice from them and arrange for replacement / repairs.

2.2.1.12 Lodge Insurance Claim with underwriters in the prescribed claim form.

2.2.1.13 Submit final Claim Bill with following documents through surveyor by a covering letter.

a) Preliminary inspection report on receipt of consignment.

b) Copy of LR with endorsement of loss / damage in case of road transport.

c) Copy of open delivery certificate/Panchanama /FIR/ Final investigation report as per requirement.

d) Copy of RR in case of Rail Transport.

e) Copy of LAS / Packing slips.

f) Copy of claim lodged on carrier.

g) Copy of post office Receipt as proof of registry or acknowledgment receipt from carrier.

h) Copy of reminders sent to carrier for obtaining open delivery.

i) Copy of correspondence received from carriers.

j) Copy of vouchers for all expenditure as photography charges, survey charges, material cost, labour cost and any other expenditur e incurred, etc.

l) Copy of photographs if any.

m) Copy of intimation of lodging the claim with underwriters.

n) Copy of final claim bill.

o) Copy of claim form.

2.2.1.14 Lodge financial claim on carriers for monetary value within six months of the date of LR/RR for all transit losses/ damages and also for non-delivery.

2.2.1.15 In case of non-delivery of consignment / non-receipt of wagon within 90 days, lodge the claim on carrier. Obtain endorsement of non-receipt of consignment on the

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Reviewed by Approved by Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR PS : WR

reverse of LR / RR from time to time and if even after long period consignment is not received, lodge the final claim on carrier and raise final claim bill on underwriters.

2.2.1.16 Lodge final claim on carrier preferring compensation for loss / damage in case of Road Transport and in case of Railways.

2.2.2 STORAGE AND ERECTION CLAIMS

2.2.2.1 Any loss or damage is occurred or noticed at stores or erection site during erection, pre-commissioning or testing period, obtain immediately the report.

2.2.2.2 Intimate Insurance Company within seven days from the date of incident noticed or occurred.

2.2.2.3 Obtain estimate of loss / damage and other details from concerned Engineer and QAE (Format SOX-F18).

2.2.2.4 In case of theft of any component, obtain copy of FIR lodged with Police and final investigation report from concerned contractor under whose custody the material was kept.

2.2.2.5 Arrange for survey on visit of surveyor along with Concerned engineer and QAE

2.2.2.6 Obtain the cost details of items where replacement is required from manufacturing units or supplier and place demand / Purchase order on them.

2.2.2.7 Lodge the Insurance claim with underwriters in the prescribed claim from.

2.2.2.8 Submit the final claim bill with following documents through surveyor by a covering letter.

a) Copy of FIR, Panchanama, and final investigation report from Police, in case of theft.

b) Copy of photography, in case of damaged items.

c) Copy of vouchers for all expenditures such as photography, material cost, labour cost and any other expenditure incurred.

d) Copy of final claim bill.

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Reviewed by Approved by Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR PS : WR

e) Copy of intimation of lodging the claim with underwriters.

f) Copy of c laim form.

2.3 LODGING OF CLAIM UNDER T&P POLICY

2.3.1 Obtain copy of T&P Policy from PUR indicating the Terms and Conditions.

2.3.2 Intimate underwriters within 7 days from the date of damage / accident for registering the claim and for carrying out survey.

2.3.3 Arrange survey of damaged items and take photographs for future submission.

2.3.4 Carryout repair works or replace components depending on requirement.

2.3.5 Lodge final claim with underwriters in the prescribed claim form with bills of repair / replacement and transport/ Insurance charges and forward the final claim bill copy to Insurance coordinator for follow up.

2.4 CONTROL AND MONITORING OF INSURANCE CLAIMS

2.4.1 Register all the claims.

2.4.2 Send proposal for extension of period at least 30 days before expiry date.

2.4.3 At the time of site closing send the files of pending claims to Commercial.

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WORK INSTRUCTION FOR Issue No. : 04 SITE PURCHASE Rev. No. : 00 Date : 16/03/10 Page : 1OF 2 WI: SOX:06

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE 1.1 This work instruction is for Site Purchase of materials / items to be used as supply

of Product as per contract.

2.0 ACTIVITIES

2.1 Site Purchase - Obtain Purchase Policy & Delegation of powers from HEAD (FIN).

2.1.1 Concerned Engineer shall raise the material Indent for approval of site Incharge keeping in view of the specified requirement with full purchasing data with title or other positive identification, drawings, process requirements, inspection instructions and other relevant technical data, including requirements of approval of qualification of product, procedure, processes, equipment and personnel. For procurement on behalf of units raise indent along with units vendors list, specifications, estimated price as approved by units, acceptance criteria.

2.1.2 On approval of Indent, designated Purchase Official shall allot Registration Number send enquiries to concerned agencies and obtain offers.

2.1.3 Before placing purchase order obtain confirmation from FEX regarding non availability of the item in the region.

2.1.4 For one time/emergency purchases, material can be purchased from nearest vendor and material should be accepted based on inspection requirement specified by the Indentor.

2.1.5 Purchase Official shall prepare comparative statement and get reviewed by Indentor and Site Accounts representative (wherever posted at site).

2.1.6 Site Incharge shall approve the above purchase / issue Purchase order as per delegation of powers.

2.1.7 Site Purchase Official shall make purchase accordingly.

2.1.8 Site Purchase Official shall hand over purchased items to site store and get inspected by Indentor or designated nominee.

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WORK INSTRUCTION FOR Issue No. : 04 SITE PURCHASE Rev. No. : 00 Date : 16/03/10 Page : 2OF 2 WI: SOX:06

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.1.9 Follow work instruction WI:SOX:04 as applicable.

2.1.10 Ensure availing of early payment discount / recovery of penalty as applicable.

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WORK INSTRUCTION FOR Issue No. : 04 PURCHASE OF SERVICE AT SITE Rev. No. : 00 Date : 16/03/10 Page : 01 OF 01 WI: SOX:07

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

0.1 SCOPE

1.1 This work instruction is for purchase of services at site.

2.0 ACTIVITIES

2.1 Purchase of services at site.

2.2 Site Incharge shall identify the area of work to be expedited or work not covered in main contract to meet the requirement of work completion.

2.2.1 Site Incharge shall review the implication of such purchases with reference to contract conditions and obtain necessary approval from competent authority.

2.2.2 Site Incharge shall identify sub-contractor available within project premises / nearby areas who have carried out similar kind of work either with main contractor or other agencies / customer.

2.2.3 Site Incharge / his nominee shall prepare suitable tender specifications including quality plan and checklist, as applicable, in consultation with QAE and issue to such identified sub-contractors.

2.2.4 Site Incharge/ nominee shall receive offers.

2.2.5 Site Incharge shall constitute a committee wherever required to review the offers and prepare proposal for approval.

2.2.6 Site Incharge shall approve the proposal or obtain approval of competent authority depending on the quantum of work and as per delegation of powers.

2.2.7 Site Incharge or his nominee shall issue work order.

2.2.8 Site Incharge or his nominee shall get the work executed as per work instruction WI : SOX : 10.

2.2.9 Maintain record for selection and performance evaluation of sub-contractors.

2.2.10 Inspection and Test records of all such works shall be maintained.

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WORK INSTRUCTION FOR Issue No. : 04 DOCUMENT CONTROL Rev. No. : 01 Date : 16/03/10 Page : 01 OF 02 WI: SOX:08

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE

1.1 This work instruction is for document & data control.

2.0 ACTIVITIES

2.1 DOCUMENT CONTROL

Site in charge shall organize a document control center and nominate persons for controlling various documents from time to time in line with SP 02. Availability of relevant and pertinent documents with task performers shall be ensured.

2.1.1 Check for the availability of the following prior to planning for commencement of work, as applicable.

2.1.1.1 Drawings.

2.1.1.2 Shipping/Package list/Model Packing List.

2.1.1.3 Field Quality Plan/Log Sheets.

2.1.1.4 Storage and Preservation Manual/Instructions.

2.1.1.5 Erection/Installation Manual from Mfg. Units/ Vendors.

2.1.1.6 Commissioning Instructions/Manuals.

2.1.1.7 Welding, NDT, Heat Treatment Manual/Procedures.

2.1.1.8 Field Test Procedures.

2.1.1.9 Operation and Maintenance Manual.

2.1.1.10 Schematics/Schedules of C&I and Electricals.

2.1.1.11 Code for safety management at Power Station Construction site.

2.1.1.12 Code for fire safety

2.1.1.13 IBR

2.1.1.14 Electricity Rules & Act.

2.1.1.15 Labour Laws.

2.1.1.19 Cable Schedules/Termination details

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WORK INSTRUCTION FOR Issue No. : 04 DOCUMENT CONTROL Rev. No. : 01 Date : 16/03/10 Page : 02 OF 02 WI: SOX:08

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.1.1.20 Copies of Purchase Orders by Mfg. Units/PEM on Sub-vendors.

2.1.1.21 Various formats used but originated by other departments as listed in DP : SOX and make arrangements for duplicating

2.1.1.22 Test procedures for construction equipment and calibration guidelines for instruments from FEX and TSX respectively.

2.1.1.23 Ll Schedule & L2 Schedules for installation & dispatches.

2.2 For further requirement, ask Project Management Group / FEX/Manufacturing units for arranging the same for site.

2.2.1 Maintain and establish norms for issue of drawings, documents to BHEL Engineers, Sub-Contractors in line with SP 02.

2.2.2 Obtain drawings/documents issued to sub-contractors back before sub contract closing.

2.2.3 Obtain drawings/documents issued to individuals back on their transfer from site.

2.2.4 Return all the controlled copies of documents / standards/codes to issuing authorities on site closing.

2.3 DATA CONTROL

2.3.1 All data prepared and issued by site will be reviewed & approved prior to issue.

2.3.2 Site Incharge will assign this task on case-to-case basis. Any amendment to data will follow same procedure.

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WORK INSTRUCTION FOR Issue No. : 04 REVIEW OF MOBILISATION OF Rev. No. : 00 SUB-CONTRACTOR & Date : 16/03/10 START OF WORK Page : 01 OF 01 WI:SOX:09

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE

1.1 This work instruction is for review of mobilisation of Sub-contractor and start of work.

2.0 ACTIVITIES

2.1 Receive LOI/Contract agreement for each Sub-contractor from Purchase Dept.

2.2 Intimate sub-contractor to report at site.

2.3 Review mobilisation plan with Sub contractor.

2.4 Facilitate Sub-contractor for obtaining statutory clearances.

2.5 Confirm deployment of adequate manpower, T & P, consumable and other resources for commencement of work at site in line with contract document.

2.6 Finalise work commencement programme.

2.7 Obtain Power of Attorney issued by Contractor in favour of his representative for functions like billing, signing of Measurement Book, issue/receipt of materials and related contractual issues.

2.8 Co-ordinate with customer for making available power supply, water supply to Sub-contractors’ work area / labour colony / site office.

2.9 Hand over work area / foundations / pre-assembly area to contractor after signing protocol.

2.10 Get the work commenced and monitor progress as per WI : SOX :10.

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WORK INSTRUCTION FOR Issue No. : 04 EXECUTION OF WORK Rev. No. : 00 Date : 16/03/10 Page : 01OF 05 WI:SOX:10

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE

1.1 This work instruction is for execution of work.

2.0 ACTIVITIES

2.1 Execution of work.

2.1.1 Sub-contractor to indent the material in Requisition Cum Issue Voucher.

2.1.2 Concerned Erection Engineer/Supervisor to verify RIV with reference to monthly plan and authorise sub-contractor to draw material from stores.

2.1.3 In case, the required material is not available for the particular assembly but available for other unit/product in store or erected condition, Cannibalisation request shall be raised by Erection Engineer and presented to Material Incharge after authorisation by Construction Manager.

2.1.4 Once replacement material received at site stores make the necessary entries.

2.1.5 Erection Engineer shall assist Material Incharge in inspecting incoming material. In case of discrepancy he shall help in highlighting exact nature of discrepancy for raising Material Discrepancy Report.

2.1.4.1 MDRs shall be closed as per disposition received. In case of repair/rework to be carried out, material shall be issued on Returnable Requisition Cum Issue voucher.

2.1.4.2 Erection Engineer / Commissioning Engineer / QAE shall inspect material after rework and assist Material Incharge to close the MDR on satisfactory completion of repair / rework. Erection engineer shall issue RSV and regularising RIV for closing MDR.

2.1.5 Material Incharge shall issue T&P / Instrument / cables etc. on presentation of authorised Contractor’s Requisition Cum Issue Voucher. Erection Engineer shall authorise contractor to draw these materials in line with subcontract agreement.

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WORK INSTRUCTION FOR Issue No. : 04 EXECUTION OF WORK Rev. No. : 00 Date : 16/03/10 Page : 02OF 05 WI:SOX:10

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.1.6 Material Incharge shall issue materials for departmental use on presentation of authorised Departmental Requisition Cum Issue Voucher.

2.1.7 IF STORAGE IN THE SCOPE OF CUSTOMER

2.1.7.1 Erection Engineer shall authorise contractor to draw material in formats provided by customer.

2.1.7.2 On receipt of material at work spot, Erection Engineer shall inspect the material and prepare Receipt Inspection report RIR and inform customer for any damage/deficiencies in product for further necessary action.

2.1.8 Material after its use, if found in excess, shall be returned to stores vide Return Stores Voucher.

2.1.9 Material Incharge along with Erection engineer and subcontractor shall reconcile material issue and return on a monthly basis and forward to finance alongwith RA Bill.

2.2 SAFETY AND QUALITY

2.2.1 Erection Engineer shall ensure safe working conditions and take corrective actions where ever necessary. Use of safety equipment as per contract and safety code shall be observed.

2.2.2 Operation Control Procedures for various activities shall be prepared if necessary and implementation monitored.

2.2.3 Erection Engineer shall ensure availability of trained/qualified personnel for various activities. He shall ascertain that task performers adequately understand quality requirements and subcontractor has provided necessary Quality control and Quality Assurance personnel as per contract.

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WORK INSTRUCTION FOR Issue No. : 04 EXECUTION OF WORK Rev. No. : 00 Date : 16/03/10 Page : 03OF 05 WI:SOX:10

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.3 INSTALLATION :

2.3.1 Verify installation work as per following:

2.3.2 Drawings / Shipping list, Packing list.

2.3.3 Erection Manuals.

2.3.4 Relevant documents required for execution of work - Arranged by PMX from concerned Mfg. Units/ Divisions.

2.3.5 Quality plan and Log sheets - Received from QLY.

2.3.6 Welding activities in line with relevant welding schedules from units and Welding Manual, NDE Manual issued by TSX.

2.3.7 Civil works as per Technical Specification.

2.3.8 Where total installation work is carried out by Sub-vendor on turnkey, concerned engineer shall ensure availability of pertinent document with them at work site.

2.3.9 Log sheets / Protocols will be prepared by Erection Engineer, as required.

2.3.10 Non-conformities during installation shall be resolved in line with SP 06.

2.3.11 For deviations from procedures / instructions, approval of approving authority shall be obtained. (SDR)

2.3.12 MILESTONE AUDIT

2.3.12.1 Obtain list of identified milestones from PSTS Noida .

2.3.12.2 Inform Head (PSTS) for deputing audit team well in advance.

2.3.12.3 Obtain clearance from Head (PSTS) before commencing the milestone activity.

2.3.12.4 Update Site action completion, in case clearance was not given earlier as per SP06.

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WORK INSTRUCTION FOR Issue No. : 04 EXECUTION OF WORK Rev. No. : 00 Date : 16/03/10 Page : 04OF 05 WI:SOX:10

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.4 HANDLING AND PRESERVATION

2.4.1 Erection Engineer shall take adequate precautions during handling and installation to avoid damages to products.

2.4.2 Erection Engineer shall obtain copies of relevant preservation and handling manuals.

2.4.3 Erection Engineer shall instruct sub-contractor to use proper handling methods and avoid damage to equipment during and after installation.

2.4.4 Proper care shall be taken to preserve materials after installation and record of preservation should be maintained.

2.5 DAMAGE/ LOSS REPORTING AND INSURANCE

2.5.1 In case of damage/loss noticed during installation Erection Engineer shall notify Insurance Co-ordinator / Material Incharge immediately.

2.5.2 In case of theft, same shall be notified to police authorities by Material Incharge and FIR obtained . Notify Insurance Co-ordinator for taking up with Underwriters.

2.5.3 If Insurance is with customer, notify the loss or damage to customer.

2.5.4 On erection completion of product/system, prepare protocol and hand over to Commissioning for start up.

2.5.5 Information will be given to Units/PEM for preparation of as-built drawings.

2.6 PAYMENT TO SUB-CONTRACTOR :

2.6.1 Sub-contractor shall fill Daily work log. Erection Engineer shall approve work logs.

2.6.2 Receive RA Bill from subcontractor. Verify with reference to Daily Progress Report. Certify and forward to Finance department alongwith monthly material reconciliation statement, Recovery statement towards T&P, consumables, electricity, etc.

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WORK INSTRUCTION FOR Issue No. : 04 EXECUTION OF WORK Rev. No. : 00 Date : 16/03/10 Page : 05OF 05 WI:SOX:10

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.6.3 Assist Finance to verify bill with reference to contract. Arrange for passing of the bill and ensure payment is released by 7th of succeeding month.

2.6.4 Ensure payment of wages due to the contractors workmen by 10th. Check for recovery of PF and other statutory recoveries.

2.6.5 Send proposals for time extension, ORC etc., at least 30 days prior to expiry of contract term.

2.7 EXTRA WORK CLAIMS

2.7.1 Obtain technical clearance / Debit acceptance from concerned MU through SAR / CAR / FAX.

2.7.2 Prepare departmental estimate wherever the cost of work is high. Obtain administrative approval from competent authority prior to taking up the work.

2.7.3 Maintain daily log sheet for the manpower deployed.

2.7.4 Receive the Extra Work bills from contractor as soon as the work is completed along with signed man-hour sheets send the note for approval in the format to competent authority alongwith enclosures.

2.7.5 Release Payment after receiving the approval.

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WORK INSTRUCTION FOR Issue No. : 04 SAFETY AND SECURITY OF Rev. No. : 00 INFORMATION, MEN & EQUIPMENT Date : 16/03/10 Page : 01OF 01 WI:SOX:11

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGIO N

PS : WR

1.0 SCOPE

1.1 This work instruction is for safety and security of information, men and equipment.

2.0 ACTIVITIES

2.1 Safety

Site Incharge shall nominate a safety coordinator at site who shall have the authority to stop any activity being performed in violation of safety norms and codes as per pertinent documents.

2.1.1 Create safe working environment for safety of men, material and machinery.

2.1.2 Ensure compliance with statutory requirements as per rules and regulations of local, civil, electrical authorities, if any, as identifie d by site, in-charge. A list of such additional requirements shall be maintained by site in charge.

2.1.3 Ensure safety guidelines are followed by BHEL and contractor’s employees and generate periodical reports as below:

2.1.3.1 Weekly Safety Report

2.1.3.2 Accident Report (Whenever accident occurs).

2.1.3.3 Quarterly Fire Safety Report

2.1.3.4 Manpower Safety Report

2.1.4 Constitute safety committee and convene review meeting monthly. Distribute Minutes of Meeting and follow up on corrective actions.

2.2.1 Reports shall be generated from start of work and will continue till installation activities are completed.

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WORK INSTRUCTION FOR Issue No. : 04 INSPECTION & TESTING Rev. No. : 00 Date : 16/03/10 Page : 01 OF 02 WI:SOX:12

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE

1.1 This work instruction is for inspection and testing.

2.0 ACTIVITIES

2.1 INSPECTION AND TESTING

2.1.1 Inspection and Testing activities during site operations shall be in three stages i.e. incoming, in process, final.

2.1.2 INCOMING (Material)

2.1.2.1 Incoming materials shall be inspected as per SP 04 & WI:SOX:04 and following reports shall be generated.

2.1.2.2 Material Receipt Inspection Report on receipt of material and daybook record.

2.1.2.3 Material Discrepancy Report (MDR) for non-conformance during receipt.

2.1.3 IN PROCESS

(Material storage, preservation, issue, erection and commissioning).

2.1.3.1 In process inspection shall be carried out as per drawing, Preservation Manual, Quality Plans, Welding Manual, Erection Manual & Commissioning procedures and following reports shall be generated.

2.1.3.1.1. Preservation status register

2.1.3.1.2 Site Action Request (SAR)

2.1.3.1.3 Commissioning Action Request (CAR)

2.1.3.1.5 Welding Record

2.1.3.1.6 NDT Records

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WORK INSTRUCTION FOR Issue No. : 04 INSPECTION & TESTING Rev. No. : 00 Date : 16/03/10 Page : 02 OF 02 WI:SOX:12

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.1.3.1.7 Heat Treatment Records

2.1.3.1.8 Log sheets/Protocols (matching with progress of work as per Quality Plan).

2.1.4 FINAL

2.1.4.1 Final inspection shall be carried out as per commissioning procedure and O&M manuals. Completion of all checks from the receipt stage up to pre-commissioning will be ensured before conducting final inspection. Following documents/reports sha ll be generated.

2.1.4.2 Completed log sheets/protocol. These completed log sheets should clearly indicate whether the product/inspection/test has passed or failed according to defined acceptance criteria (if required stamp “PASSED/FAILED” may be used).

2.1.4.3 Reliability test report/PG test report (as per contract).

2.1.4.4 Distribute completed log sheets/protocol as given below:

a) Customer as per contract.

b) Engineering Group of Manufacturing Unit - 1 set.

c) On site closing - Service After Sales - 1 set.

d) Project Management Group - 1 set through Head (TSX).

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WORK INSTRUCTION FOR Issue No. : 04 NON-CONFORMITY & CORRECTIVE Rev. No. : 00 ACTION Date : 16/03/10 Page : 01 OF 02 WI:SOX:13

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE

1.1 This work instruction is for Non-conformity and corrective action.

2.0 ACTIVITIES

2.1 NON-CONFORMITY AND CORRECTIVE ACTION

2.2 On noticing product non-conformity/ process deviation generate following reports, as applicable and distribute to the concerned.

a) MDR b) SAR c) CAR d) SDR

2.2.1 Site In charge or his nominee shall review disposition of MDR/SAR/CAR/SDR received and complete action as per SP 04 and SP 06. If as per disposition of SAR/CAR, additional material is required, the same will be intimated to MM for incorporating in pending list. Head (PROJ) shall review status of SAR monthly and take up with concerned.

2.2.2 Site In charge shall review implementation of system/procedure/instructions and take corrective action.

2.2.3 Non-conformities observed during process due to deviation in procedure or otherwise shall be reported to Head (PROJ) and approval obtained for corrective action and deviation from competent authority.

2.2.4 Action on removing non-conformities observed in audits shall be in line with SP 07.

2.2.5 Site In charge shall analyse non-conformities and take preventive action and report to Head (SMX) for review.

2.2.6 For deviations from procedures / instructions, approval of approving authority shall be obtained. (SDR).

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WORK INSTRUCTION FOR Issue No. : 04 NON-CONFORMITY & CORRECTIVE Rev. No. : 00 ACTION Date : 16/03/10 Page : 02 OF 02 WI:SOX:13

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.2.7 For identified milestones by Head (PSTS), inform Head (PSTS) in advance for constituting an audit team for clearing the mile stone activity. Obtain clearance certificate before commencing any mile stone activity .

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WORK INSTRUCTION FOR Issue No. : 04 PROGRESS REVIEW & MONITORING Rev. No. : 00 Date : 16/03/10 Page : 01 OF 03 WI:SOX:14

Reviewed by Approved by

HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE

1.1 This work instruction is for Progress review and Monitoring.

2.0 ACTIVITIES

2.1 PROGRESS REVIEW & MONITORING

2.1.1 All reports shall be generated and reporting shall commence on site opening and continue till all milestones are achieved.

2.1.2 Receive daily progress and manpower report from erection agencies at site through functional engineer after due verification.

2.1.3 Prepare following reports and distribute.

2.1.3.1 Weekly Progress Report to be sent on 1st, 8th, 16th and 24th of every month.

2.1.3.2 Monthly status report

Status of milestone events. Performance Report. Erectable Analysis.

2.1.4 PROCEDURE FOR MACRO PLANNING:

Prepare detail erection plan on monthly basis as per L2 schedule, based on materials availability/expected and customer inputs. Forward to customer through PMX for Approval. Receive approved Plan. Send list of critical requirements to PMX for follow up indicating effect on Turnover with copy to Head (PROJ) every month.

2.1.6 Review with sub-contractors the erection programme, Quality and safety performance and corrective action, with reference to planned targets using SOMS. Send Minutes of Meeting to FEX, PUR and sub-contractor’s Head Quarters indicating corrective action required.

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WORK INSTRUCTION FOR Issue No. : 04 PROGRESS REVIEW & MONITORING Rev. No. : 00 Date : 16/03/10 Page : 02 OF 03 WI:SOX:14

Reviewed by Approved by

HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.1.7 Erection Programme/progress report to be furnished to customer based on mutually agreed format (if applicable).

2.1.8 Any other report agreed with PMX/FEX shall be generated at site and sent to PMX/ISX.

2.1.9 From above reports, Site Incharge to review the progress of erection activities with reference to L2 installation schedule and take corrective action with support of PMX for documents/materials and customer inputs, with FEX for manpower, CE, T & P and with TSX for Commissioning manpower and MME.

2.1.10 Site Incharge to participate in review meetings with PMX to review project progress and initiate corrective action as necessary.

2.1.11 Receive budget formats fromFEX and prepare performance (Revenue) budget and physical budget.

2.1.12 Prepare Induction/withdrawal plan in April/ October ever y year for Manpower) and T&P/MME.

2.1.13 Send SOX F43 site Information report to Head PROJ for necessary follow up.

2.1.14 Review status of pending MDRs and arrange resolution.

2.1.15 Based on work completion, prepare bill on customer as per contract and get it verified by customer and handover to finance for raising Invoice.

Monitor status of Bills/Invoices and send weekly report to Head (Fin), PMX.

2.1.16 Review pending contractual issues, pending points and update status.

2.1.17 Review sub-contractors’ performance and send Annual performance feedback to PUR.

2.1.18 On completion of all milestone activities send report on Status / Action Plan for site closing (Format SOX-F42) every month to PMX.

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WORK INSTRUCTION FOR Issue No. : 04 PROGRESS REVIEW & MONITORING Rev. No. : 00 Date : 16/03/10 Page : 03 OF 03 WI:SOX:14

Reviewed by Approved by

HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.1.19 Review implementation status and scope for improvement in IMS, ISMS and send feedback to MR, ISSO. Take action on communication received from MR, ISSO.

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WORK INSTRUCTION FOR Issue No. : 04 COMMISSIONING Rev. No. : 00 Date : 16/03/10 Page : 01 OF 02 WI:SOX:15

Reviewed by Approved by HEAD (MSX) HEAD (TSX)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE

1.1 This work instruction is for Commissioning.

2.0 ACTIVITIES

2.1 COMMISSIONING

2.1.1 Commissioning Incharge at Site shall prepare Commissioning programme referring to L2 Schedule, availability of customer inputs and system completion.

2.1.2 Commissioning Incharge shall list out activity wise input requirements & keep Site Incharge and Customer informed appropriately.

2.1.3 Check availability of Commissioning procedures, O&M manuals and Checklists / Log-sheets at site documentation section.

2.1.4 Check completion of erection and pre-commissioning log-sheets/protocols and closing of MDRs if any, along with product erection engineers.

2.1.5 Check that personnel provided for commissioning assistance (viz. Electrician, operator) by sub-contractor are qualified for the task assigned and understand quality requirement. Inform site Incharge and sub-contractor for corrective action, if required.

2.1.6 Ensure before initiating any start up of equipment, necessary safety measures and line clearance permits/procedures are adhered to and records maintained.

2.1.7 Carry out Commissioning activities according to authorised procedure. Prepare completion report after successful trial run of the system and send report to Head (TSX), Engineering centres of Units & PEM, as applicable.

2.1.8 Problems/Non-conformities observed during commissioning stage, shall be dealt as per SP 06.

2.1.8.1 In case of failure of product / Equipment / System raise site failure report.

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WORK INSTRUCTION FOR Issue No. : 04 COMMISSIONING Rev. No. : 00 Date : 16/03/10 Page : 02 OF 02 WI:SOX:15

Reviewed by Approved by HEAD (MSX) HEAD (TSX)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.1.9 Generate following reports using SOMS as applicable.

2.1.9.1 Status report of unit in Commissioning

2.1.9.2 Daily status report for commissioned units

2.1.10 Generate a set of all reliability run reports/test reports/trial run reports, unit/area wise and distribute as under :-

a) Customer - As per contract.

b) Engineering Group of Mfg. Unit - 1 set..

c) On site closing - Service After Sales - 1 set.

These reports should clearly indicate whether the product/inspection has passed or failed according to defined acceptance criteria. (If required, stamp “PASSED/ FAILED” may be used).

2.1.11 Generate agreed list of pending points with customer and monitor its liquidation at the earliest.

2.1.12 For deviations from procedures / instructions, approval of approving authority shall be obtained. (SDR)

2.1.13 Obtain clearance certificate before commencing any mile stone activity as per SP -06. For selected milestones inform Head (PSTS) in advance for constituting an audit team for clearing the mile stone activity.

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WORK INSTRUCTION FOR Issue No. : 04 FINAL PAYMENT & CLOSING OF Rev. No. : 00 SUB -CONTRACT Date : 16/03/10 Page : 01 OF 01 WI:SOX:16

Review ed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE

1.1 This work instruction is for final payment and closing of sub-contracts.

2.0 ACTIVITIES

2.1 Final payment and closing of sub-contracts

2.1.1 Check work completion as per contract.

2.1.2 Reconcile the material issued, erected and ensure that balance material is accounted for and returned to stores.

2.1.3 Check all T&Ps are returned in good working condition and all BHEL materials issued on returnable basis are returned to stores in working condition.

2.1.4 Check recovery for services rendered on chargeable basis and material lost / not returned.

2.1.5 Check all drawings/documents issued to sub-contractor are returned to documentation centre.

2.1.6 In case of Material Handling Contractor, settle Demurrage/ wharfage claims with customer and then release final bill.

2.1.7 For deviations from contracts, where rates are not available in contract, get approval of competent authority for rates agreed with sub-contractor.

2.1.8 Fill checklist (Format PUR-F07) and send certified Final bill alongwith it to PUR.

2.1.9 Enclose copy of approvals for time extension, diversion in quantity and CRIV reconciliation statement along with final bill.

2.1.10 Take corrective actions, if any, as advised by PUR.

2.1.11 Obtain clearances of statutory authorities like labour department from sub-contractor.

2.1.12 Get no claim certificate from sub-contractor and then release his balance payments.

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WORK INSTRUCTION FOR Issue No. : 04 HANDING OVER Rev. No. : 00 Date : 16/03/10 Page : 01OF 01 WI:SOX:17

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE

1.1 This work instruction is for handing over.

2.0 ACTIVITIES

2.1 HANDING OVER

2.1.1 On completion of commissioning/reliability trial run, prepare the list of pending works/points/ issues to be resolved.

2.1.2 Commissioning and Site Incharge to arrange handing over protocol.

2.1.3 Send handing over protocol copies to customer and PMX.

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WORK INSTRUCTION FOR Issue No. : 04 SITE CLOSING Rev. No. : 01 Date : 16/03/10 Page : 01 OF 03 WI:SOX:18

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE

1.1 This work instruction is for site closing.

2.0 ACTIVITIES

2.1 SITE CLOSING

2.1.1 Completion/preparation of agreed action plan with customer on following issues related to contract.

2.1.1.1 Prepare list of jointly agreed pending points. Take up with concerned agency and monitor completion using SOMS. Send copy to project Manager.

2.1.1.2 Replacement under warranty/rectification in consultation with Mfg. Units/PEM/Vendors.

2.1.1.3 Hand over materials, T&P to customer as agreed under the contract. Reconcile material receipt, erection and return of balance materials.

2.1.1.4 Facilitate PG test completion in co-ordination with TSX and obtain completion certificates from customer, as applicable. In case PG test is planned for later date, prepare list of works to be completed prior to PG test and hand over to TSX and PMX for follow up.

2.1.1.5 Settle recoveries regarding material/services, T&P arranged/hired from customer. Prepare protocol/MOM and send to PMX.

2.1.1.6 Expedite settlement of pending invoices and realisation of final payment. Send status to PMX/COM for settlement.

2.1.1.7 Hand over erection/commissioning protocols/log sheets.

2.1.1.8 Hand over the quarters allotted by customer and settle related issues, if applicable.

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WORK INSTRUCTION FOR Issue No. : 04 SITE CLOSING Rev. No. : 01 Date : 16/03/10 Page : 02 OF 03 WI:SOX:18

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.1.1.9 Send the project Completion Report to Head MSX

2.1.1.10 Handing over initial / O & M spares, wherever received / applicable, as per contract.

2.1.1.11 Hand over packing material to customer, if applicable, as per contract.

2.1.2 Closing of erection, commissioning and service contracts.

2.1.2.1 Settle final bills.

2.1.2.2 Stores clearance by contractor.

2.1.2.3 Settle balance extra works claims / additional claims in consultation with PUR Department.

2.1.2.4 Settle recovery/claim of BHEL on contractor.

2.1.3 Settle balance insurance claims by co-ordinating/obtaining details from concerned units / vendors / surveyors /insurance agencies, wherever applicable. Send files of pending claims to Purchase for settlement along with required details.

2.1.4 Divert / dispose off materials in consultation with FEX/TSX/Mfg. Units.

2.1.4.1 Identify diversion / disposal of capital T&P after due approval of competent authority and take action as per WI :SOX: 03.

2.1.4.2 Identify diversion / disposal of items other than capital T&P and take action in consultation with FEX.

2.1.4.3 Identify for diversion or disposal of balance lubricants, chemicals, paints and other sundry items in consultation with FEX and take action.

2.1.4.4 Identify for diversion or disposal of office equipment and furniture in consultation with FEX and take action.

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WORK INSTRUCTION FOR Issue No. : 04 SITE CLOSING Rev. No. : 01 Date : 16/03/10 Page : 03 OF 03 WI:SOX:18

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

2.1.4.5 Identify for diversion or disposal of surplus materials / damaged components in consultation with FEX to units or other sites.

2.1.4.6 Dispose off scrap and unserviceable T&P after due approval of competent authority.

2.1.5 Diversion / disposal of records as per respective work instruction or as given in record and retention.

2.1.6 Release balance manpower.

2.1.7 Clearance from local statutory authorities (wherever applicable including refund of deposits, if any).

2.1.8 Dismantling/diversion/return of Communication equipment ie.FAX, TELEPHONE, INTERCOM etc as per advise of IT/PMX.

2.1.9 Hand over stores/office sheds to customer or dispose off depending on contractual obligation.

2.1.10 Clear off areas allotted by customer for storage yard, office shed & storage sheds.

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WORK INSTRUCTION FOR Issue No. : 04 CUSTOMER COMPLAINTS Rev. No. : 00 & FEED BACK Date : 16/03/10 Page : 01 OF 01 WI:SOX:19

Reviewed by Approved by HEAD (MSX) HEAD (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0 SCOPE

1.1 This work instruction is for customer complaints/ feed back

2.0 ACTIVITIES

2.1 CUSTOMER COMPLAINTS / FEEDBACK.

2.1.1 Receive Customer complaints/feedback. Forward the same to registering agency as per SP-08.

2.1.2 Register Customer complaints pertaining to site workin g including violation of safety norms and performance of sub-contractors. In addition send the same to registering agency as per SP –08.

2.1.3 Customer complaints pertaining to site working shall be resolved by Site Incharge and feed back given as per SP-08.

2.1.4 Review customer complaints and remind concerned for early disposition.

2.1.5 On receipt of disposition, convey it to customer.

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WORK INSTRUCTION FOR Issue No. : 04 QUALITY ASSURANCE Rev. No. : 00 ENGINEER AT SITE Date : 16/03/10 Page : 01 OF 01 WI:SOX:20

Reviewed by Approved by HEAD (MSX) HEAD (QLY)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

1.0. SCOPE

1.1. This work instruction is for Quality Assurance Engineer at site.

2.0 ACTIVITY

2.1 Quality Assurance Engineer/nominee shall be identified by Head (QLY)/Construction Manager.

2.2 Verify availability of quality plans prior to start of work for BHEL manufactured items and under Installation at site. For vendor items under installation at site obtain Quality Plan / Documented work instruction /Instruction Manual from supplier with assistance of PMX.

2.3 Take up with Head (QLY) for additional requirement.

2.4 Associate in stage inspection as per quality plans requirement

2.5 Any deviation noticed during stage inspection, take up with concerned task performer for correction. Where disposition is required from other agencies, generate formats as per SP 06.

2.6 Conduct audit on storage and preservation in line with SP 04, and audit on process of installation as per Quality Plans, drawings, technical instruction and report in Site Deviation Report (SDR) using SOMS.

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DEPARTMENTAL PROCEDURE FOR Issue No. : 04 SITE OPERATIONS Rev. No. : 00 Date : 16/03/10 SUMMARY OF REVISION Page : 01 of 02

Reviewed by Approved by

Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

SL. NO. CLAUSE/ PAGE/ FORMAT NO.

REV. NO DATE NATURE OF CHANGE

1. TABLE OF CONTENTS 00 16/03/10 Revised in line with QM

issue 05 and SP Issue 04

2

DP:SOX

00

16/03/10

Revised in line with QM issue 05 and SP Issue 04

3 WI : SOX : 01 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

4 WI : SOX : 02 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

5 WI : SOX : 03 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

6 WI : SOX : 04 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

7 WI : SOX : 05 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

8 WI : SOX : 06 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

9 WI : SOX : 07 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

10 WI : SOX : 08 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

11 WI : SOX : 09 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

12 WI : SOX : 10 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

13 WI : SOX : 11 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

14 WI : SOX : 12 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

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DEPARTMENTAL PROCEDURE FOR Issue No. : 04 SITE OPERATIONS Rev. No. : 00 Date : 16/03/10 SUMMARY OF REVISION Page : 02 of 02

Reviewed by Approved by

Head (MSX) Head (PROJ)

BHARAT HEAVY ELECTRICALS LIMITED, POWER SECTOR WESTERN REGION

PS : WR

15 WI : SOX : 13 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

16 WI : SOX : 14 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

17 WI : SOX : 15 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

18 WI : SOX : 16 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

19 WI : SOX : 17 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

20 WI : SOX : 18 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

21 WI : SOX : 19 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

22 WI : SOX : 20 00 16/03/10 Revised in line with QM issue 05 and SP Issue 04

23 Summary of Revision

00 16/03/10 Revised in line with QM issue 05 and SP Issue 04