UKBA have today refused my husband's residence card. We applied with me (Irish citizen) as self-sufficient.
We sent everything they needed with first batch of documents, EXCEPT my CHI policy document, which we didn't yet have. We explained that we would send it asap.
It arrived a few days later. I forwarded it, along with a request (in the same envelope) for the return of my passport because a family member in Ireland was very unwell and I expected that I might need to travel.
They sent BOTH passports back about a week later.
Today then letter arrived to explain that they have refused on the basis of my not having CHI. The list of documents considered does not include the policy document that was sent along with the request for the passport.
I called them. The lady I spoke to said that she could see from the case record that they do have the CHI policy in question (they didn't return it, they returned my husband's CHI policy and everything else). So they received it, it's on their records, and for some reason they chose not to consider it, and refused the application on that basis.

They've sent me an appeal form that is 'Appeal to the first-tier tribunal'. Is this the right form? Do I need to fill this out or should I just write a letter pointing out their mistake and saying that we will pursue judicial review if they do not rectify it?