Working Plan Procedure For GCB and Generator Accessory Installation

Revised as
DH3E-L-A3-
C 05-Aug-16 A. Benoni S. Suresh R. Prakash R. Subramaniam SC-E-160802-
0324
Revised as
DH3E-L-A3-
B 20-Jun-16 A. Benoni S. Suresh R. Prakash R. Subramaniam
SC-E-160609-
0174
A 06-Apr-16 A.Benoni SSA.Suresh R.Prakash R Subramaniam First issue
REV. DATE PREPARED BY CHECKED BY REVIEWED BY APPROVED BY DESCRIPTION
OWNER:
POWER GENERATION CORPORATION 1
THERMAL POWER PROJECT MANAGEMENT BOARD 3
CONSULTANT:
POWER ENGINEERING CONSULTING JOINT STOCK
COMPANY 2
CONTRACTOR:
SUMITOMO CORPORATION
SUB-CONTRACTOR:
JURONG ENGINEERING LIMITTED (JEL)
Ref.:
CONTRACT
DUYEN HAI 3 EXTENTION THERMAL POWER No.:
PROJECT:
PLANT PROJECT DH3EXT-
25112014
DOCUMENT STATUS: FOR APPROVAL
Document Title:
WORK PLAN PROCEDURE FOR GCB AND GENERATOR

ACCESSORY INSTALLATION
Project Document No.:
REV: C
DH3E-BAA-E-JEL-0070
Contractor Document No.:

REV: C
DH3E-BAA-E-JEL-0070
JURONG ENGINEERING LIMITTED.
Work Plan Procedure for GCB and Generator Accessory
Installation REV : C
DUYEN HAI 3 EXTENSION THERMAL POWER PLANT PROJECT, VIETNAM
Table of contents:
NO. DESCRIPTIONS PAGE
COVER PAGE
TABLE OF CONTENT 1
1 GENERAL 2
1.1. PURPOSE 3
1.2. SCOPE OF WORK 3
1.3. MAN POWER LIST 3
1.4. SITE ORGANIZATION CHART 4
1.3. REFERENCE DOCUMENTS 5
2 INSTALLATION SEQUENCE – FLOW CHART 6
3 INSTALLATION PROCEDURE 8
3.1. PREPARATION 9
3.2. TOOLS AND EQUIPMENT 9
3.3. TRANSPORTATION, LOADING/UNLOADING, PRESERVATION 10
3.4. INSTALLATION DETAIL 11
4 QUALITY INSPECTION 19
5 SAFETY PLAN 21
5.1. PLAN TOOLS AND EQUIPMENT SAFETY 22
5.2. STORAGE SAFETY 22
5.3. CRANE AND RIGGING 23
5.4. PERSONAL SAFETY 25
5.5. HOUSE KEEPING 26
5.6. WASTE INDUSTRIAL MATERIAL 27
5.7. GENERAL HOUSE KEEPING 27
5.8. CONFINED SPACE WORK 27
5.9. EMERGENCY PROCEDURE AND EMERGENCY FLOW CHART 28
5.10. TEMPLETE PERMIT TO WORK 29
6 JOB SAFETY ANALYSIS AND RISK ASSESSMENT 30-37
1
1. INTRODUCTION
1.GENERAL
1.GENERAL.
2
1.1 Introduction
This document contains the above mentioned installation works Method of Statement
for the GCB and Generator Accessory at the Duyen Hai 3 Extension Thermal power
plan project, Vietnam.
The purpose of procedure is to describe all the activities to be performed for the GCB
and Generator Accessory installation. The general sequencing of activities are intended
to ensure that all the works are properly planned and executed in accordance with the
contract document. Rev C
1.2. Scope of Work
This procedure covers the general process, methods, equipment, tools materials
preparation for GCB and Generator Accessory installation.
This document does not contain pre-commissioning and commissioning procedures

which shall be submitted separately by SC/Vendor later.
1.3 Man Power List
No. of
Man power person
1 Electrical Engineer 1
2 Electrical Supervisor 1
3 Foreman 1
4 Welder 1
5 Electrical Fitter 15
6 Crane operator 1
7 Signal man 1
8 Helper 2
3
1.4. Site Organization Chart
JEL (M&E Erection Works) Organization

Date: 06-Apr-16 S. Veeramani E
Project Director
HEAD OFFICE
SITE
Ramanathan Subramanian E
Site Project Manager Ngo van Son L
+84-169-591-9534 Site Secretary
+84-972-540-353
Ramachandran Prakash E
Site Manager
+84-164-862-4839
Ngai Sek Kee E Loo Hock Chye E Gurusamy Jeyamohan E

Overall Site Construction
Site Admin Manager Site Finance Manager
Manager
+84-163-616-4145 +84-96-189-6083 +84-941-859-594
Sivaprakasam
Bueza Dennis Silvestre Nguyen Thi Oanh L Le Thi Mong Thu L Lucio Medallo Louie Rosales E Benoni B Arricivita E Mangasi Lumbanbatu E Thiru Moorthy E
E Muruganandam E
HSE Manager Admin Co-ordinator Sr.Accountant Material Controller QA/QC Sr. Engineer Mech Chief Engineer Electrical Engineer Project Controller
+84-165-548-7705 +84-904-542-630 +84-943-222-308 +84-1689-087-911 +84-169-585-9626 +84-121-226-2298 +84-163-513-0019 +84-122-694-0344
Peter Tamondong E Tran Thi Huyen Tran L Phan Thị Ngọc Qúi L Chandrakanth Ravuth E Murugesh Rathinam E Sookragsa Eknarin E Tran Minh Loc L P. Ganesh E
Safety Coordinator Admin Asst(HR) Accountant Deputy Material Controller QA/QC Sr. Engineer CW Piping Engineer (MIS) Planning Engineer
+84-120-569-4386 +84-165-274-0848 +84-168-317-1757 +84-1699 609 592 +84-169-585-9626 +84-165-429-2793 +84-163-839-9260 +84-166-667-7535
Le Minh Trung L Ramasamy Sakthivel E Iilayaraja E Document Controler Muniyandi Subbu E Dinesh Babu E
Safety officer Camp Controller Material Asst-1 Mohan Vignesh E Steel Strcutre Engineer Planning Engineer
+84-937-046-349 +84-164-520-6864 +84-1693-713-96 +84-1673-20-448 +84-169-222-3541 +84-165-548-7705
Tran Minh Tien L Nguyen Thi Ngoc Dung L Truong Thi Oanh L Trinh Phuong Dung L
Admin Asst(Safety) Material Clerk +84-976-364-700 +84-1203-576-566
+84-968-063-009 +84-964-009-646
Tran Thao Uyen L Vo Thi Ngoc Hien L

Admin Asst (Safety) Material Clerk
+84-902-891-701 +84-982-253-430
Lifting Supervisor -1
LILAMA - 18 LILAMA - 69.1
Nguyen Trong Tuan Tran Manh Hung Ngo Quang Hung

Mech Site Manager E&I Site Manager Site Manager
0969.376.081 0907.232.682 0983 339 880
Pham Truong Giang

Deputy Mech Site Manager Doan Dinh Dai To Viet Cuong
0979.922.348 Deputy Site Manager Deputy Site Manager
0915 248 199 094 331 8811
Huynh Ngoc Long To Dac Kien Dang Van Hai Dong Thanh Tinh
HSE Manager Construction Manager QA/QC Manager Construction Manager Nguyễn Văn Quân Nguyen Thi Thu Ngan
01649.770.244 01656.535.253 0963.823.724 0904.406.254 Material & Machinery Accountance Manager
0984 594 325 01655 385 622
Nguyen Van Chien Do truong Gang

QA/QC Manager Admin Manager
0979 949 336
Pham Hong Trong Ngo Văn Minh

HSE Manager Contract Control, DCC,
0943 551 553 0984 522 637
ORGANIZATION CHART: DUYEN HAI 3 EXTENTION PROJECT

Notes: Construction Team
Prepared By M. Thiru
E - Expatriate Staff
Checked By R. Subramanian
L - Local Staff
Approved By S. Veeramani
Date 06-Apr-16
Page 4
Rev C
1.5. Reference Documents
 Drawing:
- DH3E-MKA-E-TSB-0001 : Single line of steam turbine generator main circuit
- DH3E-BAC-E-B&V-0006 : Generator Circuit Breaker schematic drawing.
- DH3E-BAC-E-B&V-9001 : Generator Circuit Breaker Outline drawing.
- DH3E-BAA-E-B&V-9001 : IPB General Arrangement – Plan view.
- DH3E-BAA-E-B&V-9002 : IPB General Arrangement – Section view.
- DH3E-BAA-E-B&V-9003 : IPB General Layout.
- Erection Manual of GCB’s Manufacturer, VT cubicle and generator NGR
- Technical Specification of GCB, VT cubicle and generator NGR.
- VT cubicle & generator NGR outline and detail drawing
…
 Standards:
- IEEE C37.013 : AC High-Voltage Generator Circuit Breakers
Rated on a Symmetrical Current Basis.
- IEC 60298 Ed. 3.0 A.C. : Metal-enclosed switchgear and control gear for
rated voltages above 1 kV and up to and including 52 kV.
5
2. ERECTION SEQUENCE – FLOW

CHART
6
2. ERECTION SEQUENCE – FLOW CHART
Preparation Works
(Include platform / Scaffolding Installation if
necessary)
Centreline/Marking
Support, Structure Assembly and

Installation
Lift up and Install NGR Lift up and Install GCB Install VT cubicle, Excitation
XFMR on the right position
Connect NGR to IPB Connect GCB to IPB Connect VT cubicle, Excitation

XFMR to IPB
Finishing Work (Touch up paint,

grounding, pressurization system,
cleaning, testing, internal check)
Official Inspection
Final Sealing
7
3. INSTALLATION PROCEDURE
8
3. Installation
3.1. Preparation
 Before installing, consult all drawings.
 Arrange, analyze drawings and typical documents clearly before the site
execution.
 Receiving floor plan drawings for each installation from vendor.
 Ensure the affected areas are well coordinated with all other related party.
 Install barricade and caution board around working area.
 Confirm elevation as per drawing.
 Cleaning of installation area and mark adjustment according to layout
drawing.
 Ensure tools and equipment are well maintained. Usage of handmade
strictly prohibited.
 Installation scaffolding:
- Concentrate scaffold and accessories to site.
- Verify scaffold to ensure nothing damage.
- Ensure wearing full PPE properly and prepare tools be fastened by
lanyards.
- Execute erecting scaffold and tag yellow card during erection.
- Ensure scaffold after erecting steady enough and supply proper
handrails, toe planks.
- Remove obstructions and tag green card prior to use.
- Scaffold can only be verified and certified tagged by a suitably qualified
scaffolds inspector
3.2. Tools and equipment (with illustration)
1. Portable hand tools for the work ( Angle grinder, hacksaw, hammer)
9
2. Chain block, crane
3. Lifting beam, shackle bow, wire sling
3.3. Transportation, loading/unloading, preservation

3.3.1. Transportation
In principle, suitable transport such as hub crane is preferred. Road survey
should be conducted in order for smooth trek of materials/equipment to job
site. During transportation inside the site, driver must keep slowly speed less
than 10km/h. In each corner, cross way, it’s necessary to provide banks man to
10
keep the vehicle turning safely.

3.3.2 Loading/Unloading
Before start any loading/unloading work, make sure all machinery, lifting
equipment, tools are inspected and tagged with color code. Around
loading/unloading area, barricade and sign board should be provided. Only
rigger can do the rigging work and un-authority personnel must not be
allowed to entry the area.
Care shall be observed to prevent damage of the materials during
loading/unloading. Upon receipt, examine the shipment for damage or loss.
Check the contents against the packing list before discarding any packing
material. Documents should be available as per material receiving
procedures.
3.3.3 Preservation
The equipment should be kept indoor and stored at a well-ventilated and
dry location as manufacture recommend.
If indoor storage is not available, the equipment may be kept outdoor with
undertaken manufacture instruction and following recommendations.
Equipment stored outdoors should be placed above ground (more than
150 mm high) and covered at 2 extremities to avoid dampness / rain or
canvass to prevent damage,
Periodical inspection or inventory of the materials should be performed
randomly.
Use the special tool for lifting as provided.
3.4. Installation details.

3.4.1 GCB installation to the supporting structures.
 Installation of Generator Circuit Breaker starts after all foundations and

main equipment are on base (main generator, step-up transformer, auxiliary
transformer and the excitation transformer).
11
 Civil hand over report with full signature to be taken over prior start work.
 Make the basic centerline marking according to the foundation drawing.
 The position of supporting steel structure shall be longitudinally located
according to the allowable tolerance.
 Install each supporting structure, following the type of support given at the
drawing.
 Check alignment and level of each element.
 Fixing bolt of supporting structures.
12
13
14
GCB connection with IPB

 Check elevation and alignment of GCB bus bar to the IPB elements.
 Level tolerance for GCB bus bar to the IPB element should not be greater
than 2mm.
 Clean IPB elements and GCB bus bar with dry cloth or rag
 Install and connect braids in GCB bus bar to IPB element
Connect to GCB:
15
For illustration
3.4.2 NGR installation to the supporting structures.
 Consult approved layout and outline drawing.

 Get civil elevation and handover report.
 Make the basic centerline marking according to the foundation drawing
 The position of NGR cubicle shall be located according to the allowable
tolerance with IPB.
 Check alignment and leveling NGR cubicle.
16
 Fix NGR to supporting structures
3.4.3 VT cubicle installation to the concrete foundation.
 Installation of VT cubicle starts after all foundations IPB installation.

 The position of VT shall be located according layout drawing and
allowable tolerance (compare with IPB).
 Make the basic centerline marking according to the foundation drawing.
 Install VT cubicle on anchor bolts or embedded parts as per drawing.
 Check alignment, leveling and adjustment (if necessary)
 Tighten bolt and marking.
17
18
4. QUALITY INSPECTION
19
4. QUALITY INSPECTION
Upon approval of Inspection Test Plan and Inspection forms, these documents
will be included later:
Title: “Site Inspection and Test of GCB and Generator Accessory System
ITP ref No: “DH3E-BAA-E-JEL-0125”
Those applicable test plan & forms will be implemented during inspection and
erection, and keep records for final documentation in which to be submitted later to
TPMB3/PECC2. SC/JEL will do internal check before submit request for official
inspection.
20
5. SAFETY PLAN AND EMERGENCY

PROCEDURE
21
5. Safety plan and Emergency procedure.

5.1. Plan Tools and Equipment Safety
The following four basic principles shall be applied to and govern the safe use
of hand power tools, and which principles are:
- To choose the right tools for the job
- To use only tools in a good condition
- To use the tools correctly, and only for the purpose they were intended
- To maintains and store tools properly
All power tools shall be inspected and monitored monthly with color
coding/tagging. Electrical tools shall be checked to ensure the supplied voltage is
comparable to the machines design.
Electrical leads and connections shall be connected to a single power plug.
Where required for electrical tools shall be properly earthed.
Hoses supplying air to pneumatic tools shall be inspected for signs of wear or
damage, and connecting clamps proved secure.
High speed rotating equipment, such as grinder, shall be fitted with protective
guards.
Grinding discs are rated by the speed at which the discs rotate, and this must be
compatible with the rotational speed of the grinder itself.
Power tools shall never be left operating unattended.
Spark arrestor shall be fitted to all equipment exhausts where a risk of
combustible gases in the atmosphere exists.
5.2. Storage Safety
Gas cylinders used in cutting and welding shall:
- Be stored separately, depending on the type of gas contained, and whether
empty or full.
- Be storage upright, and shielded from direct sunlight or other head source.
- Be storage in a good ventilated area.
- Be fitted with a safety caps when not in used.
- Be properly secured during transportation
- Not be lifted by the nozzle, rolled, or used as rollers themselves.
When handling cylinders, ensure hands, clothes, gloves, etc., are free from oil,
dirt, grit and grease. Under no circumstance shall oil be allowed to contaminate a
cylinder containing oxygen. Joint fitting on acetylene cylinders must not be made
of copper or silver, as when in contact with the gas, these metals form explosive
compounds.
22
All gas and oxygen regulators shall be fitted whit flashback arrestors, being
flashback arrestors valves designed to prevent an explosive mix developing in
either cylinder such that explosive mixes can occur due to loose connections,
leaking hoses, etc.
Prior to use, all equipment shall be thoroughly checked to ensure:
a) All connection is tight
b) All fitting such as gauges, flashback arrestors, etc., are functioning
correctly
c) Hoses are in good condition and free from sign of cracking or perish in
d) Checking for leaks shall be by means of soapy liquid to each joint.
UNDER NO CIRCUMSTANCE SHALL A NAKED FLAME BE APPLIED TO
ANY PART OF THE CYLINDER OR HOSE ARRANGEMENT TO DETECT
LEAKS
The cutting and welding of certain metals or metal coatings such as zinc
galvanized surfaces give off harmful fumes, and such works must, where possible
be carried out in a well-ventilated area. When working at height, do not place
cylinders directly beneath the work area, as molten metal may fall onto hoses,
causing leaks, and possibly igniting the gases.
5.3. Crane and Rigging

All works involving the use of a crane shall be properly planned in advance,
and in the case of complex, over dimension of very heavy load above 41 ton of
material, use tandem crane lift and over 75% crane capacity than the rigging
study (lifting plan to be submitted separately document) shall be carried to ensure
that:
- The crane is capable of lifting the load by given the known working radius,
boom length, detail weight of the load, etc.
- The condition of the ground at the crane location is the satisfactory to
support the crane and the load.
- The rotation of the cabin and boom are not to be restricted by any means.
- Suitable matting or plates are available to protect under grounds services
and paving.
- All lifting gears such as sling, shackles, hooks, etc., of the correct rating are
Available, in good condition and monthly inspection and monitoring by color
coding/tagging
- Chain block shall be certified as Viet Nam construction regulation
Rigger is required a suitably qualified and experienced person to be appoint
23
and responsibilities will include the preparation of rigger training course and
safe rigging and lifting of the load at the location.
Crane and lifting equipment must be inspected and carry a valid test certificate
issued by as accredited testing agency, designated by the government of the
country, monthly color coding and inspection (by DH3E Project HSE).
Crane hooks are to be fitted with properly functioning safety clips to prevent
the displacement of the sling from the hooks during the lifting.
Loads must always be slung with the center of gravity directly beneath the
crane hooks, to prevent uneven tensions being applied to the sling legs.
The angle between sling legs shall not, under any circumstances exceed 120
degree, as this doubles the tension on each leg, thereby reducing the lifting
capacity of the sling 50%.
For wheeled cranes, outriggers shall be used for each lift, regardless of the size,
and shall always be fully extended. One person only, shall give instruction to the
crane operator (signalman).
A’ trial’ lift shall be carried out, raising the load a short distance above its pick-
up points, to check the stability of the crane, and efficiency of the brakes.
The loads shall, at all times be kept as close to the ground as possible.
Whenever possible, and after lifting the load from its pick-up point, the radius
of the lift should be shortened to increase the crane’s lifting capacity and stability.
Wire sling and the chains under direct tension during the lift shall not be
extended artificially, nor be knotted.
Wire sling which show signs of excessive wear, kinking, or broken wires shall
be discarded and not used further.
At no time while the load is suspended shall personnel perform any works
directly beneath.
Particular consideration to the presence of low-level structures such as pipe
bridges shall be given, where crane is to move about the site.
Consideration shall be given to prevailing weather conditions, and where a
greater than normal risk exists, the lift shall be postponed until more favorable
conditions developed.
Retain a fire extinguisher at the location of fabrication or welding works at all
time. All the works carrying out at a height greater than 2 meters above the
24
ground level must be performed a properly constructed & maintain working

platform.
5.4. Personal Safety

- Head Protection
All personnel shall be issued with safety helmets, which shall be used at all
times those personnel, are on site. Safety helmets shall be checked periodically
for signs of wear, and in particular for cracks in the shell, and damage to the chin
traps. Any evidence of such wear shall result in helmets being discarded, and a
replacement issued. Aluminum helmets shall not be allowed on site. Helmets shall
not be painted, as this may result in embrittlement of the shell.
- Hand Protection
Gloves shall be used by personnel involved in works for possibility of the
following hazards:
+ Risk of abrasion
+ Risk of cutting
+ Risk of tearing
+ Risk of chemical, or other, burn
+ Risk of infection
The wearing of gloves should be avoided if possible, when works are being
carried out on, immediately next to rotating or moving equipment.
- Foot Protection
Suitable safety footwear shall be worn by personnel, considering the nature of
works and such hazards as:
+ Risk of crushing by heavy objects.
+ Penetration by sharp objects
+ Penetration by chemical or harmful liquids.
+ Weld spatter
- Hearing Protection:
Hearing protection shall be worn by personnel involved in works in areas of
high noise levels (>100dBA), or when working with equipment that generate high
noise levels.
Hearing protection is available in 2 basic types, being an external Cup type
defender which fits over the outside of the ear, and an internal plug-type, usually
made of compressible foam, which fits inside the ear.
Selection of the correct type shall depend upon:
+ The nature and source of the noise
+ The assumed, or known, level of the noise
25
+ The pitch or frequency of the noise

+ The attenuation, (or protection factor), offered by the defender
- Eye Protection
All personnel shall be provided with suitable eye protection wherever there is a
risk from:
+ Flying particles
+ High speed flying particles
+ Dust ingress
+ Chemical splash
+ Radiation glare
+ Hot sparks or material spatter
+ Harmful vapors
The correct selection of eye protection shall depend on the assessment of the
risk, or combination of risks, based on the foregoing.
Eye protection with scratched, of fogged lenses shall be discarded, and
replacements issued.
Respiratory equipment whether static bottle-type or self-contained breathing
apparatus shall only be worn by trained and qualified personnel.
Self-contained breathing apparatus shall generally be used in emergency
situation, while scheduled work shall utilize the static bottle-type.
Regular inspections are required to ensure:
- Cylinders are full and gauges function correctly
- All connection are proven tight
- Face masks show no sign of damage or possible leakage
All operatives shall be fitted with life –lines when entering hazardous areas.
Operation shall be rotated at regular intervals, depending upon the nature of the
works being performed.
Safety harness shall be worn by all personnel working height greater than 2 m
above the ground level, where properly construction working platforms are
neither available, not practical. Safety harness will be used with double lanyards.
5.5. House Keeping

- During the execution of erection works, all time keep the working area &
storage area used should be free from accumulation of waste or rubbish.
- All temporary & surplus material shall be removed to the designated
disposal area selected by the contractor & dumped in suitable.
- To provide construction personal with policies and procedure, which pertain
to housekeeping during construction operations in order to eliminate accidents,
26
improve efficiency and reduce cost.

- Housekeeping is very fundamental and necessary activity on any project
and is the responsibility of every person working on the project.
5.6. Waste Industrial Material

- Every day on the completion of work the steel scrap & Rubbish shall be
removed or disposed in a satisfactory manner & leave the premises in a condition
satisfactory to the client representative.
- All the steel scrap & wooden packing cases should be removed to the
designated scrap yard only.
- Electrode bits, grinding wheel residue & steel scraps should be disposed in
separate places.
5.7. General House Keeping
- Works area, passageways and stairways and all other areas shall be kept free
of debris and materials.
- Trash containers/drums shall be used for disposal of scrap material and
other construction generated debris.
- Storage areas shall be kept clean and material neatly stacked or place.
- Walkways and other areas where personal travel shall be maintained free of
equipment, obstruction, and other materials, which may cause an accident or
injury.
- Construction material shall be storage or placed in an orderly manner.
- Electrical cables, cords, wires and other such temporary system shall be
keeping of the walking surface in an elevated position where they pose no
potential danger to personnel or damage by construction activities or
equipment.
- Lunch and eating area, rest shed area shall be kept clean and free of all food
scraps, wrappers, cups and other disposable items.
5.8. Confined space work

- Only employees who have been properly trained on the hazards associated
with confined space work shall be allowed to enter a confined space.
- Before entering a confined space, employees shall obtain a Confined Space
Entry Permit.
- Before any entrance cover to a confined space is removed, it shall be
determined that there are no temperature or pressure differences, or other hazardous
conditions that may injure the employees removing the cover.
- When covers are removed from confined spaces, the opening shall be guarded
27
by a railing, temporary cover, or other temporary barrier.

- Before entering a confined space, employees shall test all levels of the
confined space for the presence of flammable or toxic gases and vapors or an oxygen
deficient atmosphere.
- If flammable or toxic gases or vapors are detected or if an oxygen deficiency
is found, forced ventilation shall be used to maintain oxygen at a safe level and to
prevent a hazardous concentration of flammable or toxic gases and vapors.
- While work is being performed in the confined space, a person with basic
first aid training shall be immediately available to render emergency assistance if
there is reason to believe that a hazard may exist in the space or if a hazard exists.
- Entry into a confined space with an unsafe atmosphere shall be avoided if at
all possible. Employees required to enter a confined space with an unsafe
atmosphere shall be equipped with a fresh air breathing apparatus, body harness, and
attended lifeline.
- Electric welding, gas welding, cutting, or any other hot work shall not be
performed on the interior or exterior, or near the openings of any confined space
which may contain flammable or explosive gases or vapors until the space has been
properly cleared.
- Compressed gas bottles shall not be taken into a confined space.
- Safe access to the confined space shall be maintained at all times. If
possible, all cords, hoses, leads, etc., shall be routed through an entrance other than
the employee access into the confined space.
- Before employees are allowed to enter a confined space, all electrical and
mechanical energy sources that could affect the employees working in the space shall
be physically rendered inoperative, locked out, and tagged. If required, the space
shall be drained, vented, and cleaned.
The confined space permit to work and Confined Space Entry Procedure is
mentioned in DH3E-ZEN-G-SC-0047.
5.9. Emergency Procedure and Emergency Flow Chart

Emergency procedure and Emergency flow chart has submitted separately
to TPMB3/PECC2 via document no. DH3E-ZEN-G-SC-0047 (Section 2). Please
refer above mentioned document for your reference.
28
5.10 Template Permit to Work
29
6. JOB SAFETY ANALYSIS AND RISK

ASSESSMENT
30
JURONG ENGINEERING LTD.
Work Plan Procedure for GCB and Generator Accessories Installation
REV : C
JOB SAFETY ANALYSIS / RISK ASSESSMENT
Project Reference: JOB SAFETY ANALYSIS / RISK ASSESSMENT Contract No.:

DH-3 Ext. Power Plant Project Construction Control Number: DH3E - JSA - E - JEL -………
Project
Discipline Owner:
Job being analyzed: GCB and Generator accessories Installation
Electrical Construction
Initial date: …./…./ 2016 Last revision date: Initial Revision number: 00 Number of pages: …
JSA / RA performing Name Signature
Date Check PPE and Controls Required: must be approved
Sitemembers:
supervisor/Engineer S.Muruganandam …./…../2016 PPE for the task.
Originator / EHSS Officer Le Minh Trung …./…../2016 Safety Helmet X PTW Fire Blanket x
Approval: Designation Name Signature Date Hand Gloves X LO/TO Life Rings/Vest
Site Manager: R.Prakash …./…../2016 Safety Glass X Leather Gloves X Others;
JEL Chief Engineer: S.Suresh …./…../2016 Full Face X Ear Protection X
EHSS Manager: …./…../2016 Mono
Shield Goggles Respirator X
Safety Shoes X Fire X
All controls must be valid; if it can only be verified by a document Cotton Gloves Extinguisher
Barricades X
NOTE: then it must be available with the JSA / RA.
If safe system of work plan cannot be followed or changes in conditions, If job involves industrial waste, chemical, biohazards, or
STOP and RE-ASSESS. health hazards
New risks and hazards constitute a review of this JSA /TORA.
IMPACT COMPANY Industrial Hygienist approval required.
ASPECT
IMPACT
ENVIRONMENT
Prob x Cons = RR
Prob x Cons = RR
CODE
CODE
JOB STEPS /
RERSONNEL
REPUTATION
RISK AS
ASSET
cause effect
Use the same language or dialect of the

Language barrier x 1x1=1 NA NA
1. Conduct safety tool box talk Miscommunication x

Give verbal communication in quite non noisy
1x1=1 NA NA
and task instructions. Potential accident .environment. Get feedback. Ask problems.
Selection of task performer x
Assigned task to most competent, senior or
2x1=2 NA NA
Potential accident with knowledgeable experience.
31
REV : C
Incorrect tools for the

task. Defective tools. Check condition of tools and equipment on a
X 3x2=6 regular basis. Monthly colour coded. 2x1=2 NA NA
Potential accident
2. Preparation of
Equipment, tools for the Worker/ Supervisor must ensure safe operability of
tasks. Defective Heavy Equipment heavy equipment valid with certificate and
X 2x3=6 inspection sticker. 2x1=2 NA
Potential accident NA
Daily inspection checklist acceptable.
Material shall be stored in proper way. Storage
Collision
5x3=15 area shall be clean and free from hazards. 2x2=4
Injuries due to collision X X Material shall be stored separately to avoid NA
3x3=9 2x2=4 NA
Property damage collision.
Fork lift Operators and Job Supervisor shall

3. Material handling Materials falling. ensure that the vehicle is not overloaded.
X X 5x2=12 All trucks shall be equipped with covering with 2x1=2 NA
Risk of skid and slip NA
ropes for easy (un)covering. 2x1=2
Property damage
Area of operation suitably barricaded.
Dust Water spraying of dust prone roadway.
Eye irritation X 4x2=8 2x1=2 NA
NA
Respiratory illness 3x2=6 2x1=2
X
Severe/Adverse weather 3x2=6 Pre-planning weather tracking. Maintain 1x1=1 NA

X X communication with base. NA
Slip on wet / dusty road 3x1=3 1x1=1
Crane Parking area shall be barricaded and no

one allowed to work under heavy load. Crane
Material Fall X 5x2=10 shall be not overloaded. Sling belts shall be used 2x1=2 NA NA
4. Lifting for painted materials to avoid slip. Shackles
5. Installation shall be inspected before lifting.
Safety Harness shall be used and clamped on
Fall permanent structure. Scaffolding shall be inspected
X
Tools Fall 5x2=10 every week. Chin strap shall be used strictly. Tools 2x1=2 NA NA
X shall be hand tied. Net shall be used.
Fire Blankets shall be used below the cutting area.

Fire Fire Extinguisher shall keep near working area.
X X 5x2=10 2x3=6 NA NA
Wooden materials like easily fired material shall be
kept away from cutting area.
32
Work Plan Procedure For Emergency Diesel Generator Installation
REV : C
Grinding machines, cables, electric panels

6.Cutting /Grinding shall be inspected before use. Plug points
Electric shock X shall be checked for damages and cable NA NA
Eye Irritation handling shall be out of hazards.
X Proper goggles shall be used. Face shield
shall be used.
Fire Blankets shall be used below the cutting area.

Fire Fire Extinguisher shall keep near working area.
X X 5x2=10 2x3=6 NA NA
Wooden materials like easily fired material shall
be kept away from cutting area.
Grinding machines, cables, electric panels shall
Electric shock be inspected before use. Plug points shall be
X checked for damages and cable handling shall be NA NA
7. Welding out of hazards.
Eye Irritation Proper goggles shall be used. Face shield shall be
used.
X NA NA
Heat Welder shall be use long sleeve leather jacket,
Leather hand gloves. Advice the welders to drink
X NA NA
more water to avoid dehydration.
Respiratory illness X Face shield, respiratory mask shall be used. NA
NA
Slip, Trip, Fall Remove potential tripping hazards. Clear the
8 House keeping area with unnecessary materials. Reorganize
X barricading, remove unwanted materials. NA NA
(JEL) (JEL) (JEL) (JEL)

EMERGENCY SAFETY SITE CHIEF ENGINEER EHSS
NUMBERS SUPERVISOR MANAGER MANAGER
33
REV : C
RISK RATING MATRIX
Scor 1 2 3 4 5
e
Probability Most Unlikely Unlikel Likel Most Inevitab
y y Likely le
Consequence First Aid treatment Medical treatment Lost Time Injury Serious Injury / Hospital Fatalit
Treatment y
1–5= 6 – 14 = 15 – 25 –
LOW MEDIUM HIGH
Awareness education is required by Further control measures will be Full mitigation required to
Risk Rating means of required reduce residual risk to
(RR) Prob x TBT Impacts on: Localized low.
Cons = RR . Country Impacts on:
Impacts on: International
Worksite
Aspect Code: Impact Codes:
1. Waste Generation A. Impacts on flora
2. Waste water Discharge B. Impacts on fauna
3. Storm water Discharge C. Impacts on biological
diversity
4. Point Source Air Emission D. Impacts on habitat
5. Fugitive Air Emission E. Impacts on landscape and
natural beauty
6. Automobile Exhaust Emission F. Impacts on agricultural lands
7. Chemical Use Operations G. Impacts on water supplies
8. Water Use Operations H. Impacts on minerals
9. Energy Use Operations I. Impacts on marine resources
10. Use of Natural Resources J. Impacts on Air
11. Product disposal K. Impacts on water
33
REV : C
JEL RISK ASSESSMENT MATRIX

SEVERITY CRITERIA PROBABILITY FOR POTENTIAL INCIDENT SEVERITY
ASSET (1) (2) (3) (4) (5)
(amount base VERY
PERSONNEL on cash and ENVIRONMENTAL REPUTATION UNLIKELY POSSIBLE but LIKELY not VERY
UNLIKELY
type of though unusual surprising LIKELY
but possible conceivable no doubt
equipment or under
(1) (1) vehicle) (1) (1)Local extreme
exposure circumstanc
Slight<SD1000 Slight<4Liters 1 2 3 4 5
First Aid es
(worksite)
(2) (2) (2) (2)
Medical Minor Minor State Exposure 2 4 6 8 10
Treatment <SD2500 <8Liters (district)
(3) (3) (3) (3)
National
LTI Medium Medium Exposure 3 6 9 12 15
RWC <SD5000 <150Liters (countrywide)
(4)
Injury (4) (4) (4)
Regional
Single Fatality Major Major 4 8 12 16 20
Exposure
<SD10,000 <1500Liters (Asia)
(5) (5) (5) (5)
International
Multiple Extensive Massive Exposure 5 10 15 20 25
Fatality >SD10,000 >1500Liters (worldwide)
Explanation:
SERVERITY PROBABILITY = RISK RATING
X
2 x 3 = 6 (the product falls in the category of MEDIUM RISK which is tabulated from 6 to 14)
NOTE 1:
This Risk Assessment Matrix is proposed in replacement of the previous submittal to which this JSA/RA form fairly explained the categories in SEVERITY
with criteria on Personnel, Asset, Environmental, and Reputation.
The PROBABILITY same as on the previously submitted were the same and only differs on definition. The exp lanation of Probability, Consequence, and
calculations of Risk Rating can be found described after the Emergency Numbers Rows above.
In soft copy, the Risk Rating was colour coded. LOW RISK (Green), MEDIUM RISK (Yellow), and HIGH RISK (Red)
34
REV : C
This JSA / RA (Job Safety Analysis / Risk Assessment) is a formal written safety assessment for every job method statement or worki ng plan.
It contains the Job Steps, Hazards and Risk Assessed, identifies impact to Personnel, Asset, Environment and Reputation, t he Initial Risk, the
Mitigating controls with assessment of Residual controls, and Impact assessment to Environment. Training will be introduced t o all personnel
managing this safety document.
NOTE 2:
Explanation of low risk, medium risk, and high risk.
1-5 LOW RISK Acceptable. Job may proceed assuming that competent personnel are performing it.
However, review to see if the risk can be reduced further.
6 - 14 MEDIUM RISK Job should only proceed with appropriate supervisory authorization. Check to see if the job
could be modified or if more controls can be added to reduce the risk.
15 - 25 HIGH RISK Job must not proceed. It should be redefined or further control measures put in place to reduce
risk. The controls should be re-assessed for adequacy prior to restarting the job. The job may
not proceed until proper managerial approval is given.
NOTE 3:
Explanation of investigation and reporting level:
1-5 INVESTIGATE INCIDENT at the site manager level, incident notification report
6 – 14 sufficient. INVESTIGATE INCIDENT at site manager level with concurrence of
15 - 25 SMC/EVN Representative
INVESTIGATE INCIDENT with local authorities, TPMB3 Representatives and SMC Management.
Risk – The probability for a hazard to cause an accident and has a measure of the potential severity. Severity x Probability = Risk
Risk Assessment – is a careful examination of what, in your work, could cause harm to people, property or th e environment.
It allows appropriate measures to be developed.
35
Work Plan Procedure for GCB and Generator Accessories
NOTE 4:
Table 1 – Definitions of Likelihood (for environmental)
1 = Remote Unlikely, although potential exists
2 = Possible Definite potential exists – could occur
3 = Probable Foreseeable – has happened before on occasions
4 = Likely Strong possibility of occurrence has happened before
5 = Frequent Almost certain to happen or a continuous operational condition
Table 2 – Description of the Severity or Consequence of an Event occurring (for

environmental)
Minor or Negligible Environmental Harm – No Regulatory Exposure, Minimal Cost

1
Exposure. Easily controlled at local level. Involves use of a renewable resource.
Low Level Environmental Harm - No regulatory exposure, Minimal to Intermediate

Cost
2 Exposure. No go beyond of environmental quality criteria. No assistance required with
remediation; minor contribution to regional effects. No reputation issues likely. Minor
effect on neighbours’.
Moderate Environmental Harm – Regulatory exposure but
controllable within Regulatory limits. Breach of Company or Client Policy &
3 Procedures. Moderate Cost Exposure. Possible financial costs. Localized go beyond of
environmental quality criteria. Environment will recover quickly. Involves continuous
use of a non-renewable resource with an on-going contribution to regional effects. May
effect reputation locally.
Serious Environmental Harm – Breach of Legislation. Significant Criminal & Civil
4 Penalties with high cost exposure.
Environment will recover with remediation. May jeopardize future contracts.
Major & Difficult to Rectify Environmental Damage, effect lasting for many years –
5 Certain & Substantial Criminal & Civil penalties.
36

Working Plan Procedure For GCB and Generator Accessory Installation

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Working Plan Procedure For GCB and Generator Accessory Installation

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Revised as

A 06-Apr-16 A.Benoni SSA.Suresh R.Prakash R Subramaniam First issue

REV. DATE PREPARED BY CHECKED BY REVIEWED BY APPROVED BY DESCRIPTION

DOCUMENT STATUS: FOR APPROVAL

WORK PLAN PROCEDURE FOR GCB AND GENERATOR

Contractor Document No.:

This document does not contain pre-commissioning and commissioning procedures

1.3 Man Power List

JEL (M&E Erection Works) Organization

Ngai Sek Kee E Loo Hock Chye E Gurusamy Jeyamohan E

Tran Thao Uyen L Vo Thi Ngoc Hien L

LILAMA - 18 LILAMA - 69.1

Nguyen Trong Tuan Tran Manh Hung Ngo Quang Hung

Pham Truong Giang

Nguyen Van Chien Do truong Gang

Pham Hong Trong Ngo Văn Minh

ORGANIZATION CHART: DUYEN HAI 3 EXTENTION PROJECT

2. ERECTION SEQUENCE – FLOW

2. ERECTION SEQUENCE – FLOW CHART

Support, Structure Assembly and

Connect NGR to IPB Connect GCB to IPB Connect VT cubicle, Excitation

Finishing Work (Touch up paint,

2. Chain block, crane

3. Lifting beam, shackle bow, wire sling

3.3. Transportation, loading/unloading, preservation

keep the vehicle turning safely.

3.4. Installation details.

 Installation of Generator Circuit Breaker starts after all foundations and

GCB connection with IPB

 Consult approved layout and outline drawing.

 Fix NGR to supporting structures

3.4.3 VT cubicle installation to the concrete foundation.

 Installation of VT cubicle starts after all foundations IPB installation.

5. SAFETY PLAN AND EMERGENCY

5. Safety plan and Emergency procedure.

5.3. Crane and Rigging

ground level must be performed a properly constructed & maintain working

5.4. Personal Safety

+ The pitch or frequency of the noise

5.5. House Keeping

improve efficiency and reduce cost.

5.6. Waste Industrial Material

5.8. Confined space work

by a railing, temporary cover, or other temporary barrier.

5.9. Emergency Procedure and Emergency Flow Chart

5.10 Template Permit to Work

6. JOB SAFETY ANALYSIS AND RISK

JOB SAFETY ANALYSIS / RISK ASSESSMENT

Project Reference: JOB SAFETY ANALYSIS / RISK ASSESSMENT Contract No.:

Use the same language or dialect of the

1. Conduct safety tool box talk Miscommunication x

Incorrect tools for the

Fork lift Operators and Job Supervisor shall

Severe/Adverse weather 3x2=6 Pre-planning weather tracking. Maintain 1x1=1 NA

Crane Parking area shall be barricaded and no

Fire Blankets shall be used below the cutting area.

Grinding machines, cables, electric panels

Fire Blankets shall be used below the cutting area.

(JEL) (JEL) (JEL) (JEL)

RISK RATING MATRIX

JEL RISK ASSESSMENT MATRIX

6 – 14 sufficient. INVESTIGATE INCIDENT at site manager level with concurrence of