PSS - Site operations Methodology, System & Processes

Civil Works, Installation & Commissioning Processes Safety

Objectives & Goals Overview of the Site Works Processes Roles and Responsibilities of Site Manager Comply to all legal / statutory requirements.
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nObjective: Overall responsible for all the activities on site.
n Follow MI & Code of Practice(COP)for safety.
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n Raise site personnel’s competency, skills & Establish site infrastructure.
n Comply to safety manual, project Safety plan, hazard &
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knowledge level to achieve excellence in site Control Site logistics, material handling and
n Risk Assessment.
Review
operations. Site
Site storage. 100% compliance to following safety priority areas of
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Management
n Ensure enhanced uniform Site execution Activities
Ensure compliance to safety, QA system,
n “Energizing Safety.”
Methodologies implementation across all PSS environment & Statutory compliance. n Electricity – 7 step procedure.
project business. Civil Works
Interface to the customer on site.
n n Use of Harnesses, Lanyards and Temporary Lifelines.
n "Stop Hurting People". Zero injuries. Deliver Safely, on activities
Output Manage sub-contractors at site and coordinate
n n First aid and Emergency Medical response.
Budget, on Time, in Full, and to the right Quality. Input
doc’s Prepare Site Installation Complete doc’s with consortium partners. n Material handling.
nGoal: planned Site Start up activities Site Activities Data
n Improve operational results in the projects business. sheets
Planning, execution & Monitoring project
n Conduct regular safety reviews & monitor performance of
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activities
n Obtain full compensation for extra works,delays and Commissioning
progress and performance on site. contractors against agreed standards.
hindrances from the customer both in terms of time activities Billing & claim of project (Customer &
n Recording, reporting, and investigating fatal and serious
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and money. Contractor). incidents, lost time injuries, medical treatment injuries,
n Ensure fulfillment of subcontractor obligations for the Material Control regularly costs, time schedule & critical
n first aid, near misses, and occupational diseases.
specified time, quality, cost and safety agreed upon. Handling issues and report to the project manager Communicate safety alerts & share lessons learnt.
n Continual improvement of site team competencies. Receive, Control & Reconcile site fund.
n Impart awareness & train all ours & contractor’s site
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n Improve customer satisfaction. Handing over & site closing.
n personal to carry out task in safe & responsible manner.

Preparation for Site, Site Startup & Store Management

Prepare for Site
Documentation.
n Collect site survey report.
n Contract copy & schedule.
n Contractor’s PO
n Site Manual & FQP
n Statutory, drawing & store
registers.
n Insurance policy -
Our/contractor
n Safety Manuals, checklists
& forms.
n Product Manuals
n Form-V & license.
n RACI chart
Formal Site taking over
n Office furniture
n Coordinates & benchmarks
n Leveling, obstacles
n Soil strata & compaction
n Space for office & stores
Construction water / power
n verification.
n Adequately sized DB with proper
earthing & rain protection.
n Overhead cabling in yard for
power distribution
n Backup DG, as required.
n Planned
water
distribution.
n Curing
pond.
n Sufficient illumination at site for
night work.
n Construction & drinking water
arrangement
Site Start up Material Handling Planning & Reporting
Inward
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n Arrangement of transport,
n Follow product manuals for storage &
n Availability of overall project schedule with requirements
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(Receipt)
/filing racks. accommodation, Drinking method of handling/lifting of equipment. 4 weeks look ahead schedule for civil & erection work, with material
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Register
water, sanitation facilities, Do not roll / drag packing cases.
n & manpower planning.
Establishment
n Security, labour camp out Receipt
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Report Conduct material Inspection & LR
n Maintain daily report register. Weekly review records with all the
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communication side work premises
(MRR) Endorsement on receipt & physical contractors including resource planning.
system - PC, Good condition calibrated
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Monthly report covering the Site Works progress:-
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printer, scanner, Internet facilities & tools & tackle.
Inspection Report (MIR)
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Statutory & Safety displays at
n Report transshipments.
n Executive summary with Milestones planned & achieved.
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Mobiles Requisition / Issue form
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office & sites. Structure material receipt tracking for
n Critical issues, hold points – Internal & with customer.
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Indoor store with racks.
n Local
n Consumption Report
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each type, total qty. Status report - total work requirement, planned completion,
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facilities, Reconciliation Statement
n & for each receipt.
Outdoor fenced store with brick
n cumulative work done & Plan for next 4 weeks.
material / Non conformance Report
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bedding. Measure weight of
n Recovery plan for backlog.
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machiney Material Return Note.
n steel material on
Cement store.
n availability Stock Transfer Note /
n Availability & requirement of machinery, manpower & drg.
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receipt.
. Challan Claim, risk & opportunities with Customer & Contractors.
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Unloading arrangement.
n Understanding of Customer
n FIR for theft registration at police station
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Stock Register
n Non-conformance report for work done & material supplied.
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Establish Approach to site &
n organisation, quality, & communication / assessment by
certification billing & Assets Register.
n insurance surveyor. Safety and security issues.
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temporary drainage .
reporting requirements. Damage reports.
n Separate Scrap storage & tracking.
n Invoicing / collection details.
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Fabrication & scrap yard.
n Local purchase register
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Arrangement of rain cover for material
n Formal record of hold points & front clearances given by customer
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Joint verification report
n protection. & hindrance register.

Setting out & Earth Work Foundation work

Civil Works
Civil work activities involved In Substation work
Complete survey, pillar making, traverse closing
n ( PCC / RCC - Concreting ) Buildings & facilities work Tower / Gantry & Equipment
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and cross check it. Document it with Customer.
Check bed level of pit for firm compacted soil ,
n Correct layout and diagonal setout before foundation
n foundation.
Rerouting service lines and cables etc.
n design depth & size clearance all around. RCC work to ensure right angle & correct of all the Transformer foundations including
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Cut & fill the area up to required level & compact it.
n Proper tested materials to be mixed for PCC and
n buildings. NGR foundation, oil catch pit, burnt
laid in level for required size by protecting Foundation / plinth filling to be compacted properly
n oil pit & associate rail track.
Planning for approaches for movement, materials
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formwork around. below grade slab / plinth PCC, so as to avoid the floor
stock yard, fabrication yard and machineries settlement. Cable trenches, cover slab including cable pipe & pit work.
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Place correct dia and length of bars as per drawing with two binding
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placement area.
wires. Plan for best utilisation of cut pieces . Ensure Straight and finished column& masonry work at
n Road crossing works for cable Trench & Drain.
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Planning for soil disposal area, stacking of
n Shuttering materials to be straight, face finished, rigid, along with firm
n superstructure. Provide chicken mesh at the junction of brick &
Road with berm, Drain work, fence / boundary wall work.
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backfilling soil (no soil around the pit) for concrete before plaster work to avoid crack.
steel support. Ensure curing for all cement work.
backfilling before excavation. Check the cable entry points, pipe sleeves, Panel base
n Removal of surplus soil, leveling, anti
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Maintain records for cube tests, Sieve analysis
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fixing, cut out at slab & wall as per drawing to avoid weed & Micro grading.
Establish test procedures & record the
n for sand & aggregate, slump cone, compaction
rework.
quality compliance. test for backfilling work. Yard PCC & gravelling.
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Ensure the completion of Plumbing, sanitary works,
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Pour card to be signed by customer before all
n Grouting for structures, support work for
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Testing of sand, aggregate, brick, cement ,
n Septic tank ,soak pit, plinth protection, succor drain, rainwater pipe etc.
concrete work ( preferable Design mix to be before starting up the tile fixing & painting. firefighting pipes, Earth pit, Sealing of
rebar etc.
used for RCC work). cable entries like erection related work.
Layered back filling to be done with
n Proper grading in drain & cable trench to be provided.
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Steel template to be used for the positioning of bolt/stub.
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compaction and conduct corecutter Ensure Cable route crossings through road , Drain crossings the road
n Buildings work – Control Bldg, Bay control room, Pump house,
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Reconfirmation from structural drawing for orientation of foundation
n & below trench should be as per drawing and meeting all the electrical
compaction test as per FQP. water tank , security room, car parking etc.
,Size & Position of bolt before concrete work. requirement.

Earthing Structure erection & Stringing

Installation Work Cable laying & termination
Outdoor/Indoor Equipment erection
Ensure compliance to approved drawing of main
n Follow approved drawing for erection. Maintain
n Prepare cable cutting schedule, based on
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mat, equipment earthing & earthing notes. anchor bolt top as per drawing, using templates for
& Interconnection actual route length measurement & drum
Comply welding procedure & welder
n bolt fixing. Ensure orientation, leveling & alignment as per
n length availability.
prequalification. Don’t miss bolts in any connections, joints or
n approved drawings & product manuals Cable ends to be capped to avoid water
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bracings. Comply to welding procedure & welder pre
n entry.
Lay mat below trenches, road, culverts, drain etc.
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Ensure orientation, leveling & alignment as per
n qualification. Neat dressing with adequate bending
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before starting civil work.
approved drawing. Measure pad height & adjust nut of foundation
n radius & clamping.
Record joint measurements in line with site manual &
n Use torque wrench for bolt tightening & keep
n bolt before bus work to maintain uniform bus No Loose glanding. Seale all pipe
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FQP for laying & welding with customer. (Helps in record. height. Follow cutting schedule. Ensure electrical openings.
reconciliation, billing & taking over.) Prepare & follow conductor / tube cutting schedule.
n clearance. Use grommet to close all openings of
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Neat bends/fabrication of riser for quality &
n Record joint measurements in line with site manual
n Follow Contact surface preparation guidelines.
n gland plates.
aesthetics. Avoid sharp bends. & FQP for laying of conductor / shield wire & Use torque wrench & maintain record. No excess Trays, pipe bends, tees, elbows are to be
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Back filling & proper compaction is critical.
n a c c e s s o r i e s , w i t h c u s t o m e r. ( H e l p s i n loading on terminal pad. used, as required.
reconciliation, billing & taking over.) Use binding wire for holding conductor, after
n Record joint measurements as per site
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Ensure isolator auxiliary mat laying on compacted
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Follow sag tension charts while conductor / shield
n cutting. manual & FQP for cable laying,
soil.
wire stringing. Ensure adequate electrical clearance. Record joint measurements as per site manual &
n termination, glanding tagging & ferruling
All bolted connections to have plain & spring
n Maintain record for acceptance by customer. FQP for erection & bus work with customer. w o r k w i t h c u s t o m e r. ( H e l p s i n
washers. Record use of torque wrench with torque No long string projections in conductor to avoid
n (Helps in reconciliation, billing & taking over.) reconciliation, billing & taking over.)
values for tightening.

Commissioning
Commissioning & Close Out Site Management - Competency Areas
Check readiness for access, completeness of installation including
n Complete Site Activities Review Site Activities Planning and Plan, schedule, monitor and control activities with
Scheduling efficient utilization of available resources.
safety etc. With Customer
n Internal with project office /
n Review all site activities
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Inspect / Test equipment and installation.
n Physical completion of all work.
n contractor Customer Satisfaction Customer Satisfaction by providing value in
Review the processes and tools.
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n Settle claim & NCR issues. Management accordance with the contract.
Use calibrated testing instruments.
n Certification of hindrances &
n Review NCRs.
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n Conduct material
Check correctness of safety
n obtain time extension. reconciliation. Project Financial and Monitor and control project financials to maintain or
Inform about best practices
n Cost Management
interlocks & conduct integrated Obtain & attend all punch list
n n Conduct financial improve contract margins & cash flow.
test. points & acceptance by customer. reconciliation Inform about “Caution” areas
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Legal and Contract Understands legal and contractual requirements to
Ensure availability of statutory
n Settle claim & NCR issues.
n n Reconcile / Selling of scrap Inform about changes on site
n Managementa manage projects within given borders.
clearance of drawings & as per MI.
Red mark site corrections in all
n Submit site closing report with
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installation. (Electricity board, n Obtain no due & royalty Project Reporting Communication to customer and other stakeholders
drawings for as built corrections. lessons learned, improvement areas,
CEIG, CEA or any other authority, certificates from contractors. timely for desired understanding.
contractor performance etc. Scope and Change manage scope / collection and all project issues, by
as applicable) Handover client signed checklist,
n n Information to statutory
bodies about site closing. Management negotiations and approvals.
Check readiness for start up
n FQP, commissioning documents..
n Filing of PF returns. Executing Risk and Opportunity
Get the permission to begin hot
n Conduct all material reconciliation
n Timely generation, collection , dissemination , storage
n Account settlement with PM. Planning Processes Management
commissioning. Conduct financial reconciliation.
n Processes Closing by disposition of site information.
n Transfer asset & surplus Processes
Controlling
Test all equipment operations in accordance with the function
n Contractual spares handing over
n material / equipment to other Processes Procurement obtain necessary services, materials and equipment
description and design description. sites, as advised by PM, Management from external and internal suppliers.
Identify warranty issues & actions.
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Conduct performance test as per contract.
n n Clean up site Inititiating
Conduct satisfaction survey.
n Site Management Effectively monitor and control site for predictable
n Demobilize the site office, Processes Time
Record customer’s witness for all above.
n store. fulfillment of activities with available resources.

Power System Project :

Substation Compliance Owners :
Site Team