METHOD STATEMENT for

GSUT INSTALLATION
Doc. No:

PP13-00-BAT-ENL-GAM-001

Date:

28.03.2016

CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.

9.
10.
11.
12.
13.
14.

PURPOSE ---------------------------------------------------------------------------------------SCOPE OF WORK ----------------------------------------------------------------------------RESPONSIBILITIES --------------------------------------------------------------------------DEFINITIONS / ABBREVIATIONS---------------------------------------------------------PERSONNEL -----------------------------------------------------------------------------------MATERIALS ------------------------------------------------------------------------------------EQUIPMENT ------------------------------------------------------------------------------------EXECUTION ------------------------------------------------------------------------------------8.1.
MATERIAL ARRIVAL ---------------------------------------------------8.2.
GENERAL REQUIREMENTS AND RECOMMENDATIONS--8.3.
INSTALLATION OF MAIN TANK ------------------------------------8.4.
RADIATORS ASSEMBLY & COOLING FANS -------------------8.5.
WIRING AND CABLE CONNECTION ------------------------------8.6.
HIGH VOLTAGE BUSHING INSTALLATION ---------------------8.7.
LOW VOLTAGE BUSHING INSTALLATION --------------------8.8.
OIL CONSERVATOR ---------------------------------------------------8.9.
PIPEWORK FOR THE OIL SYSTEM. COOLER ASSEMBLY8.10. TREATMENT OF OILL BEFORE FILLING IN THE TRANSFORMER8.11. OIL FILLING FOR THE MAIN TANK --------------------------------8.12. CIRCULATION OF THE OIL IN THE MAIN TANK --------------8.13. FILLING OF SEPARATE RADIATOR ------------------------------8.14. CONSREVATOR OIL FILLING ----------------------------------------

03
03
03
03
04
04
04
04
04
05
05
06
06
06
06
08
09
11
12
12
12

PROGRESS MEASUREMENT -------------------------------------------------------------QUALITY REQUIREMENTS ----------------------------------------------------------------HEALTH, SAFETY AND ENVIRONMENT REQUIREMENTS ----------------------RISK ASSESSMENTS -----------------------------------------------------------------------REFERENCES ----------------------------------------------------------------------------------ATTACHMENTS --------------------------------------------------------------------------------

13
14
14
14
14
14

10

METHOD STATEMENT for

GSUT INSTALLATION
Doc. No:

PP13-00-BAT-ENL-GAM-001

Date:

28.03.2016

1. PURPOSE.
This document is to clarify the general overview of the execution plan and method for the
Generator Step-Up Transformer (GSUT) installation works for the SEC POWER PLANT PP-13
Project, Riyadh.
The purpose of this Method Statement is to state the minimum key activities which shall be
carried out properly to execute the project objectives and requirements during contract period
up to the issuance of Final Acceptance Certificate (FAC) by Employer for the project.

2. SCOPE OF WORK.
This method statement describes how to create a complete secure GSUT installation work and
ensure the system sustainability during the power plant operation in light of the project related
drawings and standards.
Respectively, works will be in accordance to the related Specification, Codes and Standards,
HSE Procedures and Approved Drawings.

3. RESPONSIBILITIES.
GAMA is responsible to ensure the healthiness of GSUT and their related other materials
during construction and guarantee to keep the installed GSUT in good condition as per the
project technical specification and general implementation rules and ensure the Quality
Assurance.
In order to provide performance of every sort of activities and operations (affecting the quality
of the product) pursuant to the defined documents, all deviations, errors or negative issues
shall be reported.

4. DEFINITIONS / ABBREVIATIONS.
PPE:
QCP:
QA/QC:
MV:
LV:
GAMA:
FAC:
QMS:
ITP:
HSE:
GSUT:

Personal Protective Equipments.

Quality Control Procedure.
Quality Assurance / Quality Control.
Medium Voltage
Low Voltage.
GAMA G Sistemleri Mhendislik ve Taahht A..and GAMA Ltd.
Final Acceptance Certificate.
Quality Management Systems.
Inspection and Test Plan.
Health, Safety and Environment.
Generator Step-Up Transformer

METHOD STATEMENT for

GSUT INSTALLATION
Doc. No:

PP13-00-BAT-ENL-GAM-001

Date:

28.03.2016

5. PERSONNEL.
Following personnel have been assigned for the performing of the field work by GAMA.

Site Electrical Engineer

Electrical Supervisor
QA/QC Responsible
HSE Responsible.
Foreman
Electrician

6. MATERIALS.
All the Tools, Transformers, Lifting Equipments, Transport vehicles (Trailer, truck etc.) shall be
supplied by GAMA during the construction.

7. EQUIPMENT.

Hi-up (Supplied by GAMA)

Crane (Supplied by GAMA)
Scaffolding (Supplied by GAMA)
Flood light set.(Supplied by GAMA)
Vacuum Pump.(Supplied by GAMA)
Oil Filtering M/C.(Supplied by GAMA)
Storage Tank.(Supplied by GAMA)

8. EXECUTION.
The transformer, along with all its accessories and fittings should be installed, commissioned,
operated and maintained under the supervision of a competent electrical engineer from the
manufacturer (ABB), in accordance with relevant statutory requirements and good engineering
practice, including Code of Practice, where applicable and properly used within the terms of
specification.
8.1 MATERIAL ARRIVAL.

On arrival of the transformer at site the impact check will be done.

Impact record shall be checked with manufacture.
The transformer shall be checked immediately for damages.
Inspect if the transformer is tight.
Check the packing parcels for completeness and damages.
High voltage and low voltage bushings should be checked for cracks.
All external accessories should be checked for breakage, loss, and leaks.
Tank and radiators should be inspected for dents, scratches, and other signs of rough
handling
4

METHOD STATEMENT for

GSUT INSTALLATION
Doc. No:

PP13-00-BAT-ENL-GAM-001

Date:

28.03.2016

If the transformer was damaged during transport, complete the respective form
and inform the forwarding agents liable for such defects. In such case the Transformer mustnt be unloaded from the truck before reporting or taking photograph.
8.2 GENERAL REQUIREMENTS AND RECOMMENDATIONS
During mounting works on the transformer, care has to be taken that the active part does
not contact with the air: The insulation material in a transformer has been dried to very
low moisture content in the factory. It is extremely important to preserve this dryness as
far as possible during the field assembly. The insulation eagerly picks up moisture from
the natural air, and therefore exposure to the external atmosphere must be restricted.
This is of absolutely vital importance - particularly for units of very high system voltage.
It is a good rule, for instance, not to leave more than one opening to the tank
uncovered at any time, and to put the cover back provisionally or to use e.g. plastic foil
as provisional cover whenever the work through an opening is interrupted.
When the weather is variable it should be avoided to start work through openings on
days with rain. A tarpaulin weather-shed may be necessary as protection against high
wind and foul weather. The earlier habit to enter the tank, for inside visual inspection
only, is not encouraged. The transformer designs are not arranged to permit easy
access inside. The breathing and skin evaporation from a human individual is a source
of considerable moisture development. Inspection of the interior may be performed,
through openings, with optical aids mirrors or fibre-optics, if necessary. A usual method
to prevent or at least reduce the ingress of ambient air through an opening is to inject
dry air from an air-dryer set or from a pressure bottle through a suitable valve on the
tank. Another method which provides large quantities of dry ventilation air is to use airdryer apparatus, connected to a second opening on the tank. This method is
recommendable in cases when people have to stay inside the tank for a long time,
performing assembly work.
Work With Gasket Seals: Flange and cover seals against oil are made with rubber 0rings in grooves. These 0-rings have an oversize cross-section, and are mounted
under considerable tightening pressure. The rubber material is squeezed plastically,
fills the groove completely, and forms a lip or burr beside. Such gaskets have taken an
imprint of the groove surface. If they are taken out of the groove they cannot be reused. A fresh gasket has to be used for the reassembly. Sets of fresh gaskets for the
assembly on site are packed in a separate, marked case.
8.3 INSTALLATION OF MAIN TANK
The transformer should be unloaded by suitable lifting device of sufficient capacity on the
foundation.
Erection place shall be according to survey final position of transformers.
Land survey to be done.
Detailed installation plan will be submitted for this part as per the site condition.

METHOD STATEMENT for

GSUT INSTALLATION
Doc. No:

PP13-00-BAT-ENL-GAM-001

Date:

28.03.2016

8.4 RADIATORS ASSEMBLY & COOLING FANS

Inspect all radiator panels and flange mating surfaces for shipping damage
Confirm the number, size and locations of anchor bolts are matching radiator plate.
Lift the radiator with lifting facilities as per the permitted lifting methods by vendor.
Install radiators on the final position.
Fix the radiator on the anchor bolt and then tight all nuts and washers.
Mount the cooling fan on the radiators.

8.5 WIRING AND CABLE CONNECTION.

Lead the cables on the air blower according to the wiring scheme for cooling plant
Lead the cables on the protective devices according to the wiring scheme for cooling
plant
8.6 HIGH VOLTAGE BUSHING INSTALLATION
Bushings should be absolutely clean and dry when installed
The bushing has a central tube, which carries the current.
The transformer winding terminal inside the tank is a round contact stud, carrying a
central steel rod pointing upwards with a threaded end, and a cone of plastic to guide
the stud centrally in line with the tube.
The rod ends below the cover of the bushing hole in the tank cover or turret. When the
bushings are to be fitted, one more, by packed section of the draw rod is used.
A special bracket is used to guide a rope holding the rod in position when the bushing is
raised. With the bushing above its final position the rod is lowered and joined with the
piece of rod remaining in the tank.
The bushing is then lowered down into position, the rod with its cone helping to steer the
bottom end into the static shield correctly.
The rod must not be pulled upwards, until the bushing has been lowered down into
position.
The rod is finally tightened up to prescribed tension at the top of the bushing. The
terminal stud at the bottom end then makes contact with the end face of the central
tube. (The steel rod is not supposed to carry any appreciable current).

8.7 LOW VOLTAGE BUSHING INSTALLATION :

The winding ends with an Iitz cable, which is coiled under the bushing hole cover during
shipment.
When the bushing is to be fitted, the litz cable is fished up and straightened by means of
a rope through the central hole of the bushing, while lowering the bushing down into
position.
The Iitz cable has been cut to length in the factory, and provided with a brazed-on, solid
stud. This stud is fastened in the top terminal of the bushing.

METHOD STATEMENT for

GSUT INSTALLATION
Doc. No:

PP13-00-BAT-ENL-GAM-001

Date:

28.03.2016

METHOD STATEMENT for

GSUT INSTALLATION
Doc. No:

PP13-00-BAT-ENL-GAM-001

Date:

28.03.2016

8.8 OIL CONSERVATOR

The system consists of an oil conservator with a built-in NBR air cell separating the
transformer oil from the surrounding air. As the oil is in contact with only the outer
surface of the air cell, and the air with only the inner surface, there is no direct contact
between the oil and the surrounding air.
The air cell is made of oil-resistant rubber on the oil side and of ozone resistant rubber on the
airside. Between these layers there is a reinforcement of nylon fabric.

1. Oil conservator
2. Rubber air cell
3. Float-arm
5. Transmission for oil level indicator
6. Connection
7. Air-venting valve
8. Shut-off valve
9. Drain valve.
13. Sealed entry (plug).
The bottom of the conservator forms a sump and has a shut-off valve (8) in the pipe between
conservator and transformer and a drain valve (9). In the bottom of the conservator there is
also a junction flange with a float-arm (3) for the oil-level indicator. The float rides on the oil
surface underneath the air cell thus indicating the oil level via the transmission (5) or in some
cases displayed directly by an oil level gauge mounted in the same position as the
transmission.

METHOD STATEMENT for

GSUT INSTALLATION
Doc. No:

PP13-00-BAT-ENL-GAM-001

Date:

28.03.2016

The air cell (2) is attached to the manhole flange on top of the conservator by a bolted flange.
The manhole cover is provided with a threaded tap (6) for connection to the dehydrating
breather of the transformer and a sealed entry (13) into the air cell to permit calibration of the
oil level gauge.
The conservator is normally not built vacuum-proof but can on customer request so bee. If the
conservator is vacuum-proof or not can be read on the rating plate.

During the transport to site, the air cell of the conservator is filled with dry air to an overpressure of 0.01
MPa (0.1 bar). A filling device with valve (10) and a pressure gauge (11) is connected to the tap of the
manhole cover (6) - see the figure below.
To install the conservator, support plate shall install first on the embedded anchor bolts,
after confirming the number and size and location of the bolts.
Lift the conservator as per the permitted lifting methods by vendor, and place it in the final
position.
8.9 PIPEWORK FOR THE OIL SYSTEM. COOLER ASSEMBLY.
The components or sub-assemblies are sealed with blanking plates for shipment.
These should be removed as late as possible during the assembly to minimize the risk
of contamination. Directions for final oil filling and oil handling in general are given in
Assembly instructions 1ZSE 937006 (about oil filling, alternative methods) and 937005
(about receiving and processing of oil on site).

METHOD STATEMENT for

GSUT INSTALLATION
Doc. No:
8.10

PP13-00-BAT-ENL-GAM-001

Date:

28.03.2016

TREATMENT OF OIL BEFORE FILLING IN THE TRANSFORMER

Transformers shall be vacuum-filled on site as soon as possible during the process of
assembly, so that the windings will be covered and protected from moisture pickup.
The necessary quantity of oil shall be collected and prepared in one or more clean
storage tanks, before being used, the tanks are visually inspected inside for cleanness.
The oil, received in bulk or in drums, is pumped through the vacuum filter plant into the
storage tank.
The drums or trailer tanks shall not be emptied to the last drop - a sump of an inch or so
is left, to avoid possible solid dirt or water on the bottom.
The vacuum filter is then reconnected for circulation of the oil in the tank under continued
heating and degassing, until samples taken from the storage tank shows that the
breakdown strength in the IEC gap has reached at least 60 kV (or 35 kV in ASTM
cylindrical gap).
When the transformer has been checked for tightness under vacuum (cf. Instruction
1ZSE937006-2), and the oil in the storage tank has been prepared as above, the
vacuum filling into the transformer may be started.
The figure below shows the oil in the storage tanks is further heated and degassed
before filling into the transformer by circulation through the vacuum filter.

10

METHOD STATEMENT for

GSUT INSTALLATION
Doc. No:
8.11

PP13-00-BAT-ENL-GAM-001

Date:

28.03.2016

OIL FILLING FOR THE MAIN TANK

During the assembly on site, the transformer will be sealed off after working hours. It is
practical to apply a slight overpressure overnight with dry air inside, - less than 20 kPa
(0.2 atmospheres).
Next morning it is checked that the pressure still remains. Suspected leaks may be
located with leak detection instruments, with soap water, or with plastic bags tightened
around valve (being inflated by leaking air), etc. in this way the assembled seals may
be checked successively as the work goes on.
Before the oil filling is started, a final check will be made of the tightness of the complete
transformer with its cooling equipment, this is done with vacuum.
The preferred method of filling is to feed oil from the storage tank through the filter for
heating and degassing and from there into the tank by the lower filter valve.
Vacuum is pulled on the transformer tank all the time (0.15 kPa - 1 mm Mercury or less),
until the oil covers the core and coils and has reached a level about 50 - 100 mm from
the cover.
A vacuum-proof plastic tube may be connected to valves at the top and bottom for use
as an oil level indicator. Further, a vacuum-meter is connected with a plastic tube to the
bleeding cock of the Buchholtz relay. The valve between the Buchholtz and the
conservator is closed.
When the oil has reached the level indicated above, the valve in the vacuum line is
closed. Filling of oil from the bottom continues. The vacuum in the closed volume
above the oil in the tank rises, as the volume shrinks. This is monitored with the
vacuum-meter on the Buchholtz. At last the tank is completely filled, and the meter
shows atmospheric pressure.
The filling is continued for a short time, so that a slight overpressure builds up in the tank.
Then the valve between the Buchholtz and the conservator is gently opened. Filling is
continued until the conservator has correct oil level. In the meantime, bleed all air
cocks on turrets and bushings that have communication to the tank.

11

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GSUT INSTALLATION
Doc. No:
8.12

PP13-00-BAT-ENL-GAM-001

Date:

28.03.2016

CIRCULATION OF THE OIL IN THE MAIN TANK

When the main tank with core and coils has been filled at a controlled speed under vacuum,
the insulation system should be virtually free from trapped gas bubbles, which might be
dangerous for the voltage withstand strength. As additional precautions towards perfect
impregnation, the oil in the tank shall further be circulated through the filter, and then the unit
shall be left to soak for a specified time before energizing is permitted. The circulation
procedure for the main tank is as follows:
The transformer is connected to the filter in a loop through the upper and lower filter
valves the direction of circulation shall be from the transformer to the filter at the
bottom, and from the filter to the transformer at the top.
The rate of circulation shall be 2 - 5 m3/hour and the temperature of the oil from the filter
to the transformer shall be approximately 70C.
The circulation shall proceed until a volume of oil has passed through the loop
corresponding to 2 times the total oil volume in the tank. In cold weather it is
recommended to arrange a tarpaulin tent with aerotempers. Otherwise the circulation
time has to be increased. If the temperature around the tank is below the freezing
point, the circulation time shall correspond to 3 times the volume of the tank. If below 20C, increase to 4 times.
After completed filling procedure an oil sample is taken from the tank and tested for
breakdown strength. This is part of the commissioning checks to be made on the
transformer, and the result shall be entered in the Report.

8.13

FILLING OF SEPARATE RADIATOR

Separate, vacuum-proof cooler plant suspended on the tank or pedestal-mounted - may
be left alone and shut off from the tank during the main filling procedure. They are tested for
tightness with vacuum in the same way as the main tank, filled separately, and then
connected to the tank by the following procedure:
They will be filled with dean, degassed oil through the vacuum filter.
When they are full, the hoses are reconnected so that the oil may be circulated through
the filter. The lower header connection between the cooling plant and the transformer
tank is opened to equalize the static head of the two systems. The oil in the cooler is
then circulated through the filter until a volume corresponding to two times the cooler
volume it has passed around.
Only then, the shut-off valves in the upper level headers between tank and cooler will be
opened. The filter plant is disconnected.

8.14

CONSREVATOR OIL FILLING

The oil conservator is fitted on site with filling device in place on the transformer, and is
supplemented with the components, which had been removed for transport.
The system consisting of oil conservator with NBR air cell does not normally require any
other maintenance than inspection of the breather silica gel.

12

METHOD STATEMENT for

GSUT INSTALLATION
Doc. No:

PP13-00-BAT-ENL-GAM-001

Date:

28.03.2016

If the air cell should break and the air cell is filled with oil, the conservator will function as a
normal conservator. The sinking air cell will affect the float-arm and indicate an oil level,
which is too low.
Normally the conservator is filled with oil according to the following:
1- Check that the air cell is still filled to an overpressure of 0.01 MPa (0.1 bar). If not,
top up with dry air through the filling device and close the valve (10) when the
correct pressure has been reached.
2- Open the air-venting valves (7) on the ends of the conservator.
3- Open the shut-off valve (8) between conservator and transformer and press up oil
with a speed not greater than that the air pressure in the air cell does not exceed
0.013 MPa (0.13 bar).
4- Continue the oil flow until oil flows from the air-venting valves.
5- Close the shut-off valve (8) and the air-venting valves (7), open the valve (10) in
the filling device and release the surplus air in the air cell.
6- When the pressure in the air cell has decreased to atmospheric pressure - the
pressure gauge (11) in the filling device will then show no deflection - screw out the
plug (12) in the filling device. Open the shut-off valve (8) again, and continue the oil
filling until the oil level specified on a separate rating plate has been reached.
7- Remove the filling device from the tapping (6) of the manhole cover, and connect
the breather to the tapping.

10. Valve
11. Pressure gauge
12. Plug.

PROGRESS MEASUREMENT.
Progress will be followed by GAMA Site Representatives by daily.

13

METHOD STATEMENT for

GSUT INSTALLATION
Doc. No:

PP13-00-BAT-ENL-GAM-001

Date:

28.03.2016

10 QUALITY REQUIREMENTS.
GAMA shall strictly comply with the SEC Project QA/QC Plan. GAMA is committed to establish,
document, implement, and maintain the project quality management system (QMS) and
continually improve its effectiveness in accordance with international standards.
Inspection and Test Plan (ITP) for GSUT Installation (PP13-00-Y-QPT-GAM-505). Shall be
followed during the execution of works. Works and reporting shall be carried out by the
Subcontractor in accordance to the ITP and required documents mentioned on the ITP shall be
submitted to SEC for his review.

11. HEALTH, SAFETY AND ENVIRONMENT REQUIREMENTS.

All works shall be in compliance with the local laws and regulations, SEC HSE Plan, HSE
Procedures, requirements and instructions.
In addition all employees on site will have through GAMA and WORLEY PARSON Project
Safety Induction for site safety, health and environmental prior to work activities. Other training
courses will be attended as required by WORLEY PARSON or GAMA.
Each work scope or task will have a completed and approved Job Safety Analysis and Risk
Assessment identifying the potential hazards and control measures that will be implemented to
protect people and environment.

In addition to the above, all employees conducting the works defined in this
Method
Statement will wear basic PPE which is highly visible vest, hardhat, safety
shoe, safety googles.
12. RISK ASSESSMENTS.

Risk Assessment can be found in Attachment 1.

13. REFERENCES.

ProjectQualityplane(PP1314-00-Y-UP-WP003).
ProjectSafetyPlan(PP1314-00-Y-UP-WP-029).
Applicableconstructiondrawings(civilandelectrical).
ProjectQA/QCinspectionlist(PP1300YQPTGAM505).
Installationmanual(PP131400BATOIMABB004)
14. ATTACHMENTS.

Riskassessment,attachment1.

14

Back to Index

PP-13

SEC-PP13 COMBINED CYCLE PLANT PROJECT

Date of this Revision:

28Feb,2016

MECHANICAL | I&C | ELECTRICAL WORKS

Date of last Revision:

26Feb,2016

RISK ASSESSMENT

Location Work Area:

Revision No. 17

Percent Complete
5%

21

21

Completion
Date

Rank(3)

23

Lo

D-Un

Low

D-Unlikely

24

Low

D-Unlikely

Target Date

Low

D-Unlikely

17

By Whom
Person To Action

Level(3)

Likelihood(3)

Jacking/Sliding
Operator &
Supervisor

2-M

Moderate

Site Engineer /
supervisor

2-Minor

Moderate

D-Unlikely

Site Engineer /
supervisor

1-Insignificant

Rank(2)

Moderate

D-Unlikely

TBTmustbeconductedandrisk
17 assessmentwillcommunicattothe
relatedworkers

3-Moderate

ToolBoxtalk
Communication,Coordination,
Consultationshouldbemaintained

1-Insignificant

Level(2)

D-Unlikely

3-Moderate

Consequence(3)

Likelihood(2)

3-Moderate

17

Recommended Action
(Improve existing controls
/ implement new controls)

Comments

Transformer installation
Site induction for the new personnel will provide, Risk Assessment,Work
Method Statement shall available and implemented
Respect (local) traffic rules
Risk assessment should be implemented
PTW must be obtained for Transformer installation work

Unfamiliar with local

conditions, client
health and safety
regulations

Lack of sight,
bumping / falling of
load, hit objects,
damage
jacking/sliding / load /
objects

Extreme

Slips, trips and falls

Fatalities,
Injuries
Damages

4-Major

General Activities

C-Possible

Traffic accidents

Item1

Existing Controls

Final Risk

Consequence(2)

Rank(1)

Level(1)

Likelihood(1)

Consequence(1)

Rank on Current
Sort(2)

21.0

Un-wanted Event

STATUS

Residual Risk

Inherent Risk

Hazard

Contract Number : SC-03 4400006162

RISK REDUCTION PLAN

RISK ASSESSMENT RECORD

Task

Company : Saudi Electricity Company

Joint inspection must be conducted for the area by HSE personnel and
construction department
The area should be barricaded
Warning sign must be posted
Only authorized personnel can entered the barricaded area
Need closed supervision
Consultation between the key personnel regarding the task
Instruction in manual handling techniques, use of mechanical handling
equipment where possible, provision of PPE
The tools and equipments must be job suitable and inspected
Use lights, place additional flood lights, use of reflecting material / clothing,
proper communication between Operator(s), Supervisor & Riggers
Wear of PPE + additional protection like dust masks & ear protection, cease
operations in case of severe obstruction of safety

Poor visibility,
slipping, irritated eyes
& skin, induced
deafness,
communication errors

Home made tools are not allowed to use on site

Damaged tools must be removed from site
Good housekeeping
Assessment will conduct for the access and identify all the possible
obstructions and controll measures will apply.
Transportation Layout must be provided prior to start transporatation on site.
Trained flagmans will assigned with wistles.
Traffic will contorl in the area.
Only certified operator will operate the SPMT
Signal man will assign in front and back
Operators and Job Supervisor shall ensure that the vehicle is not overloaded
High

C-Possible

Transporation of
Transformer on site.

Serious personnel
injury, Property
damaged

3-Moderate

Item2

Vehicle incidents,
Long trailer hiting
structure, Over turning
of trailer

Ensure that all materials are properly secured by means of correct sling belt

13 to prevent materials from falling during delivery.

No overloading of materials on the trailers.

All drivers shall have valid SAG driving licenses.

Enforcement of traffic regulations.
Strictly follow speed limit.
Approved transportation route map for vehicle traffic in accordance with SECPP-13 Project rules.
Safe access shall be maintained at site for vehicles and equipment
Flags and Flash ligh will use during transportaion.
Ensure that crane operator is certified by Third party, and has valid
certificates and driver's licenses.
Ensure that all lifting gear/lifting tackle is properly inspected and color coded.

High

Serious personnel
injury, Property
damaged

C-Possible

Lack of Lifting Plan,

Lack of Competency,
Poor lifting gears,
Droping of load

3-Moderate

Item3

Lifting and Rigging

13

Daily crane inspections.

Ensure automatic safe load indicator is avaible in the crane.
Proper set up of crane ; i.e. out riggers fully extended.
Barricade the working area with sign boards indicating crane lifting is in
progress to prevent unauthorized entry.
Rigger shall be 100% visible to the crane operator & clearly relay the
information to the crane operator.
Ensure all lifts will be controlled and supervised by a supervisor.
Ensure firm footing ground condition. Check wind velocity.

Toolboxmustbeconductedandrisk
assessmentwillcommunicated

Provision of banksman at the lifting area to keep personnel away from the
lifting operation.
Tag lines are to be used to control loads.
The ground must be compacted and use proper out rigger pads
All lifting gears must be free from defects.
Newer exeed the SWL.
Need closed supervision
Tool Box talk must conducted before commencing activities.

Mod

D-Un

13

Site Supervisor

3-Mo

C-Po

Installation of
Personnel injury and
T
f
b
C:\Users\Resty Aguinaldo\Desktop\method\RISK ASSESSMENT GENERAL_REV 17

3-Mo

Failure of hydraulic
system, Ruptures of
air and compressed
hoses High wind

Regular checks and testing on all electrical circuits, appliance testing, safety
awareness in the use of electricity and portable electrical appliances
All trailers and vehicles are equipped with fire extinguisher. Engines have shut
off switches in the event of fire.
All the pressurized hoses must have whep check
The Hydraulic jacks must have SWL capacity to lift the load

17

TBT

Jacking/sliding
Operator &
Supervisor

Page 1

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PP-13

SEC-PP13 COMBINED CYCLE PLANT PROJECT

Date of this Revision:

28Feb,2016

MECHANICAL | I&C | ELECTRICAL WORKS

Date of last Revision:

26Feb,2016

RISK ASSESSMENT

Location Work Area:

Revision No. 17

Percent Complete
%

22

24

Completion
Date

Rank(3)

D-Unlikely

21

Low

Site Engineer /
supervisor

Low

C-Possible

TheMedicalemergencyContact
numberandflowcartmustbe
communicatedwithworkers

21

Low

Site Engineer /
supervisor

ow

Theprecautionmustbeexpalinein
thestartcard

Level(3)

D-Unlikely

Moderate

nlikely

E-Rare

Likelihood(3)

Moderate

3-Moderate

20

Site Engineer /
supervisor

1-Insignificant

Moderate

D-Unlikely

17

Needclosedsupervision

1-Insignifican

Rank(2)

derate

D-Unlikely

17

Target Date

2-Minor

Level(2)

nlikely

TBTmustbeconducted

By Whom
Person To Action

Consequence(3) Minor

Likelihood(2)

17

3-Moderate

High

13

Proper communication
Consult manufacturers specification in Jacking/sliding
Manual, lower boom, suspend Jacking/Sliding
activities, consult meteo services forecasts, monitor
wind speed with jacking/sliding equipped anemometer
All the hydraulic system will inspect by competent person before to use.
Only authorized personnel can work with the transformer installation crew
Regular checks and testing on all electrical circuits,
appliance testing, safety awareness in the use of
electricity and portable electrical appliances.
The electrical tools must be double insulated
GFCI will provide to the elctrical generators
Cable will mange 2 meters high with non conductor support
The power tools should have dead man switch

Recommended Action
(Improve existing controls
/ implement new controls)

3-Moderate

Rank(1)

High

13 The SPMT will park at level and stable surface.

Existing Controls

Final Risk

Consequence(2) oderate

Level(1)

Injuries,
possible
electrocution
Damage

C-Possible

Defective
equipment/tools
damage in cables

ossible

Personnel injury and

property damage

Likelihood(1)

hoses High wind

speed, tipping of
jacking/sliding,
tumbling of load,
falling of load

3-Moderate

Working with electric

equipment/tool

Un-wanted Event

Consequence(1) oderate

Rank on Current
Sort(2)

Item5

Transformer by
sliding/jacking

Hazard

STATUS

Residual Risk

Inherent Risk

Item4

Contract Number : SC-03 4400006162

RISK REDUCTION PLAN

RISK ASSESSMENT RECORD

Task

Company : Saudi Electricity Company

Comments

Inspect all the power tools before using

High

Emergency

Lack of emergency
procedure, Lack of
Emergency
Awarness, Lack of
Emergency contact
number and flow chart

Personnel injuries,
Fatalities

C-Possible

Extreme

Item9

C-Possible

Item8

13

4-Major

Item7

Working with
engines/tools

Possible
deafness
Possible
damages

3-Moderate

Item6

Excessive noise,
breakdown in verbal
communication

Failure of Oil hose

resulting in spillage and
resulting in spillage
environmental
and environmental
contamination or
contamination or
contact with personnel
contact with personnel
Damage to
transformer/reactor
tank or vacuum
hoses, or inadvertent
opening of valves

C:\Users\Resty Aguinaldo\Desktop\method\RISK ASSESSMENT GENERAL_REV 17

Noise assessments will be carried out on equipment and warning sign will
provid.
determine noise levels, where possible equipment will be
silenced, and if not personnel will be provided with
appropriate personal protective equipment. Health
surveillance of operatives will reveal any defects to hearing
GAMA emergency respons plan must be implemented
GAMA medical emergency contact numbers and flow chart must be posted
on site
GAMA site doctor or nurse should be available on site full working shift
Ambulance must be available at the site clinic
The Ambulance driver must be trained by doctor and nurse for first Aid.
The access for the ambulance must identified
The security manager number should be addedd to emergency contact
numbers
The ambulance driver should be familiar with the working site
The ambulance driver should also be know the primary and secondary
evacuation procedure
HSE officer should go on ambulance point during emergency to guide the
Ambulance driver towards emergency location.
All hoses will be inspected prior to use and at regular intervals during
pumping. Buckets will be placed
under hoses joints when making disconnections.
All non-essential staff will be excluded from the immediate area around the
transformer/reactor during
the vacuum proces.
The cover
of the transformer should only be attended if necessary during the vacuum
process, the ABB Supervisor decides when it is necessary.

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