Key elements of QMS &

Check points during various OSP works

Contents

Confidential Reliance Industries Limited 2

Our Quality Policy

Q
Our commitment is to ensure
highest quality delivery to
delight our customer and
encourage the culture of FTR
(First Time Right) which is
effectively done with
initiation, innovation and
sharing through the following
3 Tier Quality Control Methodology
Key Elements of QMS
Key Elements of QMS
Key Elements of QMS - ITP & Measurement plans

Process Step Inspection check sheet ITP Format No

Before start of work Site Inspection Report FMT CL 029

Trenching completion Inspection Report (Trenching

FMT CL 030
Work)

Ducting Completion Inspection Report HDD Duct

FMT CL 031
Laying

Back filling Completion Trench / Foundation Backfilling FMT CL 032

MH / HH installation Inspection Report Construction of

FMT CL 033
Splice Joint Chambers

Duct Crossings (Rail and Road) Inspection Report Crossings FMT CL 034

Ready for OFC blowing Ducting History Sheet FMT CL 035

Inspection Report Crossing at FMT CL 036

Duct Crossing at Bridges
Bridges
Key Elements of QMS - ITP & Measurement Plans
 Trenching Work
• Availability of IFC/SLD at site & whether execution is in concurrence to released IFC/SLD

• ROW permission from concerned authorities and completion of ITP 29

• Actual Offset Taken is as same as given in the IFC.

• Trenching is done inside the ROW Limits & as per ROW permission.

• Lime Marking is done & cross-pit is taken at every 200M prior to trenching.

• Trench Dimension is 450X300MM.

• Trench is straight and No horizontal/vertical undulations are there.

• Trench Bottom is Uniform & free from sharp edge stones.

• Depth of the trench is minimum 1.65M in case of Normal Soil.

• Depth of Trench is minimum 1.25M in case of Rocky Area.

• Depth of trench is such that it is 0.5M below the other utilities.

• 50MM bedding is done at Trench bottom in case of Rocky Area.

• Completion of ITP 30 and sign off

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Ducting
• Availability of Non-FIM (Coupler / end plug etc) are ensured prior to ducting.

• Duct Roll is checked for any Physical Damage.

• De-coiler is used for opening the duct.

• Duct is free from twists & kinks.

• No Water/mud is present in trench while laying the ducts.

• DWC is installed prior to ducting required as per the specifications.

• Duct is in sequence as per specs & do not overlap each other.

• Ducts is joined with Couplers using proper coupling tools ( Duct cutter / chamfering tool) & is

tightened properly. Respective Lat/Long to be recorded with the GPS.

• End Plugs is installed in free duct ends during laying.

• Completion of ITP 31 and sign off

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Back filling
• Ensure Soft Material padding is done prior to the backfilling of the excavated material.

• Red Stone (1000X300X25)mm is installed at all coupler locations prior to backfilling.

• Ensure additional protection such as PCC, tile protection has been done as per requirement prior to

backfilling.

• Backfilling is done in layer of 500mm with excavated material & compaction is done up to the NGL.

• Crowning of 250mm is done at the top of the backfilled trench from NGL.

• Warning Tape of 0.2mm thickness of HDPE is used & is placed at depth of 650mm from NGL in case

of Normal soil & 200mm padding from the bed in case of Rocky Area.

• Completion of ITP 32 and sign off

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HDD Execution
• Availability of IFC/SLD at site & whether execution is in concurrence to released IFC/SLD.
• Availability of SUE Survey report wherever applicable & Bore path plan
• ROW permission from concerned authorities and completion of work permit form
• Lime Powder marking done, that too in straight line using nylon rope or not.
• Marking to be done using spade/Yellow paint as  applicable at every rod.
• Documentation/ITP’s ( HDD 01 & HDD graph 18) availability & validation for work executed
• Preparation of Rough ABD’s for previous shot .
• Compliances to Safety PPE’s i.e reflective jackets, helmets, safety shoes are being used by labours,
supervisors, trackers etc.
• Availability of Caution Tapes, Barricading Cones, Caution Boards in adequate quantity.
• Availability of First Aid Box at deployed HDD m/c.
• Depth is as per specification at entry & exit point and intermediate points.
• Usage of Duct cutter/Chamfering tool for coupler installation for & handling of ducts at site.
• End plugs at duct ends and Red stone in coupler location
• Pilot is running on Lime powder marking & Offsets from Road Center
• Utilities if any at HDD pits to analyze possible consequences foreseen for MH/HH installation and to
ensure proper vertical / horizontal distance from existing utilities
• Crowing at pits where backfilling has been done.
• Bentonite usage and Mud Sucking Pump/Mud disposal Van availability
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Crossing Culverts / Bridges / Railways

• Need permission letter from the concerned authorities

• Authority Contact details (PWI engineer, Signalling, Station manager & Emergency contacts).
• Track details for railway crossing
• Signalling cables details
• ROW Boundary details for staring & ending,
• Before starting  need Joint survey with Authorities and vendor team.
• Crossing trains details with schedule timings.
• Entry/Exit pit for HDD excavation need to be done by manually as per survey plan.
• Soil strata(Normal/Hard) and depth as per Specification
• Water levelling with bed depth
• Before starting  need Joint survey with Authorities and vendor team
• Planning for HH/MH installation
• If clamping, based on bridge/culvert conduction need planning.

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MH HH Installation – Intracity
• Start off with visual inspection for cracks, honey combing, air bubbles at rings, Cover & collar.
• Before PCC , ground is well compacted to avoid tilting of MH under it any circumstances.
• PCC bed is laid over compacted layer of ground at bottom portion  ,this needs to be 200mm as per
specs.
• Ducts should not be arrested in PCC at bottom neither there is any residual left behind of PCC at
duct body.
• Duct entries is from center of MH rather aligning towards either direction.
• Duct sequence needs to maintained.
• Finishing of PCC bed is smooth with uniform base.
• Duct entries at bottom most ring are properly sealed.
• Subsequently holes left on rings(4nos.) to be sealed properly post installation.
• No gap is foreseen b/w rings on MH.
• Engraving of Client’s name along with batch no. , manufacturer name in case of MH cover & date of
casting to be added for rings.
• Total no. of rings installed 5/4 with zero tolerance .

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MH HH Installation – Intracity
• MH cover diameter needs to 760 mm or as per approved specifications
• Ensure MH is not encroaching beyond ROW limits/any other utilities to avoid any future anomalies.
• Duct entries inside MH is smooth & at floor level avoiding passage through sharp turns/edges.
• Joints b/w inner & outer rings needs to be sealed properly such that to avoid any seepage.
• MH cover height is 100 mm or as per specifications
• MH installed should flush in symmetry to NGL, in no case it should supersede NGL.
• Post installation any extra debris needs to be removed from site .
• ITP CL-33 along with ABD is filled  by FE.
• Post installation any additional remarks other than above are mentioned in ITP CL-33 under remarks
category.
• MH/HH location GPS & Three points ref to be maintain in ITP as well as in SLD

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 MH HH Installation – Intercity
• Start off with visual inspection for cracks, honey combing, air bubbles at rings, Cover & collar.
• Before PCC , ground is well compacted to avoid tilting of MH under it any circumstances.
• PCC bed is laid over compacted layer of ground at bottom portion  ,this needs to be 200mm as per
specs.
• HH to be Installed at the distance of 985 Mtrs from other HH or MH i.e. distance to be checked
• MH to MH Distance to be 4 km.
• Prior to Install HH/MH its to be check for any Physical damage and as dimensions per specs
• Prior to Install PCC of M10 to be done and thickness of 125 mm and 50 mm outer area to be checked as
per specs.
• Requirement of any Additional HH to be checked in between to MH
• MH HH dimensions are as per specification.
• To check Duct Placing in cable entry slot (25 MM above from the bottom) or as per specification
• Depth from NGL (600 mm ) and Sequence of Entry , Exit of ducts to be checked
• ROW and Existing Utilities to be checked
• Encloser hanger and any Bushes in encloser hangers to be checked
• IBSL and OFC Engrave Marking on the MH HH cover to be checked
• Lifting hooks in cover, Sealing and Cleaning to be Checked
• Any Exposed steel surface exists
• Related ITP 33 is filled in MH/HH location GPS & Three points ref to be maintain in ITP as well as in SLD
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 DIT & Blowing
• Availability of Proper Safety equipment and PPEs is used during DIT.
• Availability of Approved Compressor Machine.
• Calibration certificate for Compressor and Gage Meter.
• DIT is from the HH to MH.
• Three Step procedure is followed before execution of DIT as (1-Air Test.2-Sponge Test.3-Shuttle
Test.)
• Sponge Test-Sponge is with sponge 150% higher than of duct internal diameter
• Shuttle Test- Shuttle is done with shuttle of 80% of duct ID*150mm length and passed through duct.
• Pressure Test-Pressure to be maintained : 07-10 bar for 30 minute and is not dropped  3bar in half
hrs. ( 0.1bar/1 minute is allowed).
• Approved blowing Machine is used.( Plumtaz,C BS, Condux), if any other blowing machine is used it
should tested and certified by RJIL
• Plastic Tirpal is used for making 8 figure prior to OFC blowing
• Jack should is or drum  Uncoiling.
• Usage of Duct cleaner

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 DIT & Blowing
• Blowing Air pressure checked and is not exceeding 7-10 bar during blowing.
• HH and MH is cleaned and closer hanging rod is installed.
• Duct is straight inside HH and duct entry is from entry point.
• Height of HH and MH from NGL.
• Duct entry is sealed.
• ITP-41 and ITP-42.
• In blowing cable loop plan is on paper.
• ITP-13 and ITP-11,ITP-06 are filled in
• Drum Test report of  OFC drum is completed
• Eight figure for OFC Loop inside chamber
• Machine temperature is not exceed 55 degree.
• Coupler pits are closed before DIT and blowing.
• Simplex caps are installed at the end of ducts through which fibre has been blown

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 Splicing
• Splicing is done using a good quality fusion splicing machine in air conditioned vehicle
• Splicing machine make, model & calibration certificate to be checked
• Cable armor earthing is done
• The splice loss per joint is minimal and is not be more than 0.10 dB & average Splice loss for a min
of 3 splices are not be more than 0.06 dB per splice when measured with OTDR
• Specified Joint Closures suitable for underground, buried installation is used at each OFC joint
• At least 0.6 m to 0.8 m neatly coiled without kinks fibre is stored in the fibre tray of joint closure
• Joint closure assembly is done as per instructions of manufacturer & sealed properly before it is
taken out of splicing van
• Proper fiber routing, numbering & Route indication label to be maintained in closer, Cable reading
to be verify with ITP11
• After assembly joint closure is tied to the supports inside the man-hole with the help of plastic
cable & all bolts clamps and other fixing devices used is of corrosion proof
• Before clamping the joint closure, the joint closure is filled with air pressure of 1.0 kg/cm 2 (g) &
the fall in pressure shall not be more than 0.1 kg/cm2 after 1 hour
• With the joint closure pressurized, it can be dipped in a water bucket and checked for any air
leakages. Records of all such test is maintained against each splice joint with number
• Completion of ITP 09 on line
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 Earthing
• A Copper rod of around 20mm diameter and 1 m long is buried along with good quality of Charcoal
and salt at a min 2.5 m depth from NGL or as required so that the resistance in normal soil is less
than or equal to 2 ohm
• GI strip flat of 50 mm wide and 6 mm thick after bolting and welding with rod is brought to the
surface for bonding with the optic fibre armor
• Specially made clamp, made of steel is used for bonding the GI strip with the copper rod and with
cable armor for avoiding corrosion and galvanic currents
• Multiple earthing rods may be required in some of the locations where soil resistivity is high
• For Intercity routes earthing is done at the joint pit closest to the interval of 8 Kms (Normally at
every alternate joint) & at end facilities such as AG3/AG2/AG1/ILA.
• For Intracity routes earthing is done at the end facilities such as AG3/AG2/AG1/e-NodeB
• Care is taken to ensure that armor is made continuous at the joint closures

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 Route Marker Installation
• Route markers made of RCC (1:2:4) are provided at a distance of every 250 meters or wherever
there are crossings or major deviation in the route from being straight
• Additional route markers are installed on both sides of the crossing, duct coupler locations and
man-hole / hand-hole locations
• Markers are of 1250 mm length with base of 100 x 250 mm tapering to 100 x 200 mm and name/logo
of owner is engraved on the surface and painted with white fluorescent color
• Markers are installed at 0.5 M from the trench and away from the road centre in a manner that 500
mm length is below ground and 750 mm is exposed
• Above ground surface of route marker is painted in Blue, Route Markers placed at coupler locations
is painted in Yellow and at the man-holes is painted in Red color
• For intra-city routes Electronic Route Markers are placed inside each man-hole/hand-hole
• Electronic Markers are located with electronic locator after tuning at specified frequency
• Location of Electronic Markers with GPS coordinates are recorded and incorporated in “As-built”
drawing
• Normal route marker is falling within 50m of any Man-hole/Hand-hole/ Duct coupler marker then
the normal route marker is not used.

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 ABD
• Location (LAT/LONG coordinates) of each man-hole/hand-hole with route distance, segment distance
and cumulative distance
• Drawing of each Man-hole/Hand-hole showing the relative position of the HDPE duct entering and
exiting from the Man-hole/Hand-hole
• Route plans duly marked with as-built information regarding depth of ducts, sequence (using color
code), turning points, special protections provided, if any
• Location of duct couplers, Man-hole/Hand-holes, intermediate facilities (Inline Amplifiers, ROADM,
FOADM/branch-off) if any
• All inspection reports & test reports for all the materials procured by Contractor
• Duct Integrity Test Report
• Offset & Depth at every 50 m and Deviations from designated route where applicable
• 3 point reference for all Man-holes / hand-holes their GPS coordinates (LAT/LONG)
• Locations of other facilities (ILA/ROADM/FOADM etc. if any) along the route
• HDD profile (as recorded by HDD machines guidance system or through separate tracking system such
as DigiTrack)
• Route marker locations and coordinates
• Duct coupler locations and coordinates Crossing location, length and duct position w.r.t. facility
being crossed
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 ILA / AG2 Civil Works
• Site Lay out and Marking as per IFC

• Excavation depth as per IFC for DG, Shelter foundations, MH, Earthing, Compound wall .

• Material : Make / Mfg date of cement and sand, aggregate, bricks, steel , GI pipe and strip, charcoal,

Sault , Pipe for Gate , Chain link mesh , ISA, ISMC, MS plates , MS rods and Barbed wire and any

embedded item, HMPS door etc.

• Dimensions of PCC, bar bending as per design, Shuttering / formwork / support and application of

lubricant

• Mixing of Concrete as per specifications and compaction with Vibrator

• Samples of concrete in cubes to be taken for checking compressive strength of 7 days and 28 days

curing concrete as per the design / specs

• Post concrete Curing for 10 -15 days as per cement type and grade

• Assembly of Earthing electrode, burying depth and Backfilling of Earth pit and Chamber construction

as per IFC

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 ILA / AG2 Civil Works
• Brick work, fixing of Rungs, cut out for cable entry and plastering of MH from both sides and

Precast covers for MH and Earthing chambers as per IFC

• Gate Inspection at Fabrication yard as per IFC.

• Brick work dimensions and plastering , fixing of Angle posts, Barbed wire, turn buckles with I bolt,

chain link mesh as per IFC

• Back filling of plot, slope, drainage and levelling as per IFC.

• Shelter Installation as per scope and specs.

• Brick work, plastering, painting, water proofing, sealing of existing room as per IFC in AG2.

• Documentation : Inspection reports for DG, Shelter foundation , MH, Compound wall/Barbed wire,

Earthing

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 ILA / AG2 Electrical Works
• Material : Cables, GI strip, Lugs, tools and tackles, SMPS, DG Set, Battery Bank, EFC ( Emergency

force cooling ), PAC , IPMS, Power distribution boards, Bus bars , EB Meter , Cable Trays , fire

extinguisher, surveillance camera, smoke detectors, door sensor etc as per IFC and specifications

• Shelter / Indoor : Cut outs and Installation of EFC / PAC, SMPS, Battery Bank, IPMS, Power

distribution board, Lighting , cable tray, Power distribution board, MCB , Fuse rating , door sensor,

Smoke detector , surveillance camera, fire extinguisher , wiring – primary / secondary point, Bus bars

etc. PVC conduit pipe , sealing of cable entry holes, Cable routing on tray as per IFC

• Outdoor : Excavation depth for Power & Alarm cable / Earthing strip, clamps, bolts and cable laying,

Cable color codes, cable sizes and routing, No sharp bend in Power cable, Installation of DG Set, Bus

bar, Termination Power cables with proper sizes of lugs and crimping, proper sizes of Cable glands

used for cable entry in DG, Shelter, terminations of Alarm cable, Fabrication of cable tray, steel work

etc as per IFC.

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 ILA / AG2 Electrical Works
• Earthing : Earthing value of Individual earth pit, network Earth grid formation and value by

calibrated Digital Earth tester, GI strip routing and welding , Cable laying etc. Earthing Termination

for Antistatic Mat of Shelter flooring, SMPS body , +ve Bus bar of SMPS, IPMS Body, Neutral, BUS bar,

Cable tray, ISMB of Shelter, Gate and fencing, DG Body , DG Neutral, EFC body, Battery Bank Rack

etc as per

• EB Supply : Excavation depth for cable size and cable routing, Installation of EB Meter box, Fuses,

MCB rating, EB pole and transformer, clamps, bolts, lugs, Termination and color code of Power cable

as per IFC and specs.

• Statutory : Current Transformer/ Power Transformer calibration, EB Meter calibration, load sanction

letter, NOC from state EB for DG running etc as per IFC.

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