METHOD STATEMENT FOR INSTALLATION OF
ROTATING EQUIPMENT
● PROJECT CODE
: B70170EA
● PROJECT NAME
: PULAU INDAH COMBINED CYCLE POWER
PLANT
● OWNER
: PULAU INDAH POWER PLANT SDN BHD
● EQUIPMENT NAME
: GENERAL
Purpose
C
03/03/2022
B
03/03/2022
A
08/02/2022
Rev.
No.
□ For
Information
□ For
Approval
■ For
Construction
● DOCUMENT NUMBER : 0-WD000-CM620-10002
● TITLE
Page 1 of 31
: METHOD STATEMENT FOR INSTALLATION OF
ROTATING EQUIPMENT
Zafran Zaharol
H.W Park
J.H Lim
Y.H Ku
Zafran Zaharol
H.W Park
J.H Lim
Y.H Ku
Zafran Zaharol
WS Low
Almudin
H.W Park
PREPARED
REVIEWED
CHECKED
APPROVED
□ For (
)
APPROVED
DATE
CONTRACTOR
OWNER
OWNER / OE
OWNER’S ENGINEER
PULAU INDAH POWER
PLANT SDN. BHD.
JACOBS ENGINEERING
MALAYSIA SDN. BHD.
OFFSHORE CONTRACTOR
POSCO ENGINEERING
AND CONSTRUCTION
ONSHORE CONTRACTOR
PEC POWERCON SDN.
BHD.
MITSUBISHI
CORPORATION
SUBCONTRACTOR
EQUATOR
ENGINEERING SDN BHD
PULAU INDAH COMBINED CYCLE POWER PLANT
METHOD STATEMENT FOR INSTALLATION
OF ROTATING EQUIPMENT
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REVISION HISTORY
REV.
DESCRIPTIONS AND/OR REVISED SHEETS
REFERENCE
REV. DATE
A
First issue.
08/02/2022
B
Second issue (Amended as per DRS-0-WD000-CM620-10002)
03/03/2022
C
Issue for construction
01/04/2022
PULAU INDAH COMBINED CYCLE POWER PLANT
METHOD STATEMENT FOR INSTALLATION
OF ROTATING EQUIPMENT
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Table of Contents
NO
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
DESCRIPTION
INTRODUCTION
DEFINITION & ABBREVIATION
REFERENCE CODES AND STANDARDS
SCOPE OF WORKS
RESPONSIBILITY
EQUIPMENT AND TOOLS
ERECTION PROCEDURE
PAGE
NO
4
4
4
5
7
10
11
7.1 TRANSPORTATION, HANDLING AND RECEIVING INSPECTION
7.2 PREPARATION WORKS
7.3 INSTALLATION WORKS OF HORIZONTAL PUMP
7.4 INSTALLATION WORKS OF VERTICAL PUMP
7.5 FINAL ALIGNMENT INSPECTION
7.6 WORKING ON EXTENDED HOURS
7.7 WORKING IN CONFINED SPACE
12
12
13
14
14
15
15
QUALITY ASSURANCE AND CONTROL
SAFETY, HEALTH & ENVIRONMENTAL REQUIREMENTS
15
15
9.1 SITE SAFETY AND HEALTH REQUIREMENTS
9.2 ENVIRONMENTAL REQUIREMENTS
9.3 ASSEMBLY POINT
9.4 EMERGENCY CONTACT
9.5 WELFARE AND FIRST AID
9.6 COVID-19 SAFETY MEASURE
15
16
18
18
19
19
HAZARD IDENTIFICATION, RISK ASSESSMENT & CONTROL
20
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1.0 INTRODUCTION
The purpose of this method statement is to guide on the proper and safety erection work of Rotating
Equipment for Pulau Indah Combined Cycle Power Plant; as such it will be executed through
disciplined approach by Contractor. This method statement attempts to include, describe and outline the
methods and procedures to be adopted, and to provide specific instructions in safety and environment
controls associated with the works.
2.0 DEFINITION AND ABBREVIATION
AFC
Approved for Construction
PIPP
Pulau Indah Power Plant (Owner)
HSE
Health, Safety & Environment
POSCO
Offshore Contractor
FITP
Field Inspection Test Plan
QC
Quality Control
OEM
Original Equipment Manufacturer
3.0 REFERENCE DOCUMENTS AND DRAWINGS
 0-WD010-MZ711-10015 Lifting Safety Procedure
 0-WD010-MZ711-10024 Rigging and Slinging Procedure
 0-WD000-CZ250-10001 Field Inspection Test Plan for Rotating Equipment
 0-WD010-MZ711-10001 HSE Management Plan
 0-WD010-MZ711-10018 & 10019 Environment Protection Procedure
& Waste Management Procedure
 PIPP-HIRARC-EESB-05 REV A
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4.0 SCOPE OF WORKS
This method statement identifies the general steps, arrangements & precautions which shall be followed
for the erection of Rotating Equipment. The supplier’s erection procedure precedes the method
statement. If any discrepancy is found, the subcontractor shall comply with the supplier’s instruction
unless the supplier give the confirmation by any correspondence.
NO
EQUIPMENT
SYSTEM
1
Air Compressor
Compressed Air system
2
Air Dryer
Compressed Air system
3
Demin Water Supply Pump
General Service Pump
4
Desalination & Service Water
General Service Pump
Supply Pump
5
Potable Water Booster Pump
General Service Pump
6
Oil Unloading Pump
General Service Pump
7
Oil Drain Pump
General Service Pump
8
SWRO make up Pump
General Service Pump
9
Condensate Drain Pump
General Service Pump
10
HRSG Blowdown Transfer Pump
General Service Pump
11
CWP Area Sump Pump
Sump Pump
12
BSDG Trench Sump Pump
Sump Pump
13
Main Cable Route Trench Sump
Sump Pump
Pump(#1~#13)
14
#1 HRSG Blowdown PIT Chemical Sump
Sump Pump
Pump
15
#2 HRSG Blowdown PIT Chemical Sump
Sump Pump
Pump
16
#1 CEP Area Chemical Sump Pump
Sump Pump
17
#2 CEP Area Chemical Sump Pump
Sump Pump
18
#1 TR Area Oily Sump Pump
Sump Pump
19
#2 TR Area Oily Sump Pump
Sump Pump
20
FGC Area Oily Sump Pump
Sump Pump
21
Oil / Water Separator Sump Pump
Sump Pump
22
CWP_Pump
Circulating Water Pump
23
CWP_Motor
Circulating Water Pump
24
ACWP_Pump
Circulating Water Pump
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OF ROTATING EQUIPMENT
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25
ACWP_Motor
Circulating Water Pump
26
Hypochlorite Generator
Chlorination System
27
Seawater Supply Pump for ECP
Chlorination System
28
Hypochlorite Continuous Dosing Pumps
Chlorination System
29
Hypochlorite Shock Dosing Pumps
Chlorination System
30
Air Blowers for H2 Removal
Chlorination System
31
Sump Pump for ECP
Chlorination System
32
Ultrafiltration(UF) B/W pump A/B
Pretreatment System
33
Filter Backwash Pump for MMF A/B
Pretreatment System
34
Filter B/W blower for MMF A/B
Pretreatment System
35
Filtered Water Feed pump A/B
Desalination System
36
BWRO High Pressure Pump A/B
Desalination System
37
CIP Pump A/B
Desalination System
38
RO Flushing Pump (Motor drive)
Desalination System
39
HCl Unloading Pump A/B
Demineralization System
40
NaOH Unloading Pump A/B
Demineralization System
41
MBP feed pump A/B
Demineralization System
42
MBP Regeneration Pump A/B
Demineralization System
43
Air Blower for MBP A/B
Demineralization System
44
Sump Pump A/B,
Demineralization System
45
Sanitary Water Transfer Pump A/B
Demineralization System
46
Agitator With Motor
Demineralization System
47
Potable water Feed Pump A/B
Potable Water System
48
Clarifier
Waste Water Treatment
49
Thickener
Waste Water Treatment
50
Normal Waste Water Pump A/B
Waste Water Treatment
51
Abnormal Waste Water Pump A/B
Waste Water Treatment
52
Sludge Transfer Pump A/B
Waste Water Treatment
53
Clarified Water Pump A/B
Waste Water Treatment
54
Backwash Pump for Filter A/B
Waste Water Treatment
55
Sump Pump for Pump Room A/B
Waste Water Treatment
56
Oily Waste Water Feed Pump A/B
Waste Water Treatment
57
Progressive Cavity Pump A/B
Waste Water Treatment
58
Root blower for WWT A/B/C
Waste Water Treatment
59
Air blower for sanitary A/B
Waste Water Treatment
60
Chemical Pump
Waste Water Treatment
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5.0 RESPONSIBILITY
Site Manager
Site Manager has the responsibilities for Civil, Mechanical, Electrical, Architecture, Material,
Commissioning, QA/QC and safety works.
Safety and Health Officer/Supervisor
Safety officer and safety supervisors are responsible in ensuring that all HSE requirements are strictly
adhered to at all times.
Construction Manager
Construction manager is responsible for this Method of Statement, he is supporting and ensuring that all
entitles at the worksite actively participate.
Chief Engineer
Ensure the full implementation of this Method of Statement and identifies the requirements and add on
resources for the effective accomplishment of the equipment installation.
QA/QC Manager
Responsible for the implementation of all required controlled activities. Maintain the required
documentation as per approved Field Inspection Test Plan (FITP) for the final acceptance and hand over
of the system. Monitor the QC personnel in their daily functions and conducts reviews of documentation
and inspection / verification activities. Ensures adequately qualified and experienced QC Personnel are
assigned to inspection duties.
QA/QC Engineer
QC Engineer shall be responsible for the QC activities, material control and traceability, nonconformance management and compilation of inspection and test.
Superintendent / Supervisor
Secure all necessary work permits. Confirm the availability of all materials, tools, equipment and
required personnel to accomplish the work.
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Lifting Supervisor
 Co-ordinate all lifting activities and ensure that the ground conditions are safe for any
lifting operation to be performed.
 Be present at the workplace and supervise the lifting operation work.
 Brief crane operator, rigger and signalman on the safe lifting procedures prior lifting
operation.
 To stop lifting operation if there is unsafe condition or equipment faulty and resume
the operation after full rectification of the unsafe condition or repair/replace of
faulty/damage equipment by competent person.
 Ensure all lifting equipment such as lifting gears (LG), lifting machines (LM) and
lifting appliances (LA) used at the workplace have valid inspection/test certificates by
an Authorized Examiner (AE).
 Conduct regular inspection of the LG, LM and LA for its integrity.
 Participate in conducting job risk assessment.
 Participate in conducting lifting plan for each task. Obtain approved lifting plan and
ensure lifting gears are selected in accordance with those included in the lifting plan.
Rigger

Conduct checking of slings to be used for slinging the loads to ensure that the slings
are of good construction and material and free of defects.

Ensure that an adequate number of legs of the sling are used and that the slinging
angle is correct so as to prevent the sling from being overloaded during the hoisting.

Ascertain the weight of the load which is to be lifted and inform the crane operator of
the weight of the load.

Ensure that only suitable lifting gears are used in conjunction with the sling.

Ensure that the load to be lifted is secure, stable and balance with center of gravity.

Ensure that any loose load e.g. stones and timber etc., is placed in a receptacle to
prevent it from falling during the lifting operation.

To place adequate padding at the edges of the load which come in contact with the
sling so as to prevent the sling from being damaged. And to conduct regular checking
of all LG used and report any defect on the LG to Lifting Supervisor.
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Signalman

Ensure that the verification with the Rigger had been given to proceed with the lifting
work.

Clearance continue with the signaling to Crane Operator for hoisting the load.

To give correct and clear signals in guiding the Crane Operator in the maneuver of
the load safely to its destination by means of clear radio communication.

To ensure that no person under suspended load.

To ensure no person standing or working under the suspended load, within the

Route of lifting from point to the other.

Maintain clear vision of distance with the Crane Operator so that all hand signals can
be clearly seen by the Crane Operator.
Scaffolding Supervisor
•
Ensure that all its employees adhere to the standard or code of practice with respect to
the selection of scaffolds, erection and possible modification.
•
Scaffolding Foreman, Scaffolding Supervisor who are competent must supervise the
scaffolding installation or dismantling activities onsite.
•
Ensure all scaffolder wear required safety clothing and equipment such as gloves,
overalls, helmets, safety shoes and harness, lifelines, and ensure the proper use of the
safety equipment.
•
Carry out regular quality control checks on scaffolding materials and on erected
scaffolds.
•
Comply with the written hand-over procedure and maintain good communication with
the Scaffolding Supervisor at all times.
•
Ensure safe dismantling of scaffolding and site clearance upon completion of the job.
Material Controller
Will handle the material requisitioning, physical receipt of goods, inspection, storage and delivery of
materials.
PULAU INDAH COMBINED CYCLE POWER PLANT
METHOD STATEMENT FOR INSTALLATION
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6.0 EQUIPMENT AND TOOLS
No.
1
Equipment & Tools
Name
Theodolite / Auto Level
Unit
Qty
Nos
1
Function
Remark
To survey & check
foundation
Chipping
2
Power Tools
Nos
1
3
Mobile Crane
Nos
1
4
Cement Mixer
Nos
1
Foundation
machine, drilling
preparation,
machine, grinder,
modification works
etc.
Lifting activity
Mixing of cement
grout
Bolt tightening,
5
Hand tools
Nos
1
equipment
installation
PULAU INDAH COMBINED CYCLE POWER PLANT
METHOD STATEMENT FOR INSTALLATION
OF ROTATING EQUIPMENT
7.0 ERECTION PROCEDURE
Figure 1: General Work Sequence
of equipment installation
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PULAU INDAH COMBINED CYCLE POWER PLANT
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7.1 Transportation, Handling and Receiving Inspection
a)
Join inspection of the pump package with the QC Team, this will be done to check if the
package received is as per packing list.
b)
Upon opening of the package the item will be checked for any damage during
transportation and hauling, if any damage these will be reported immediately and to be
documented properly.
7.2 Preparation Works
a.
Obtain the necessary work permit(s) from contractor to start any installation or extended
works.
b.
Proceed with dimensional acceptance inspection of anchor bolt during foundation handover.
c.
Marking of centerlines on every pump foundation the x and y axis according to drawing and
the bench marks.
d.
Locate elevation bench marks and transfer it to the nearest convenient place. This is very
important for the leveling plate inspection and pump elevation check.
Figure 2: Elevation inspection of packer plate
e.
Chip the pump foundation in accordance with the manufacturer’s recommendation.
f.
Install the foundation packer plate or leveling plate as per approved for construction drawing.
g.
Proceed with elevation/levelling inspection of packer plate as per approved for construction
drawing. Levelling plate inspection shall be done and to be witnessed by the QC Engineer.
Note:
 Pad Elevation Inspection tolerance ± 3mm
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Figure 3: Surface chipping and levelling
plate installation plate
7.3
Installation Works of Horizontal Pump
a. After the curing of the grouted leveling plates, by crane lift the pump/motor skid
properly and carefully set it on the leveling plate.
Note:
 All lifting activity shall comply to Lifting Safety Procedure
0-WD010-MZ711-10015 and Rigging and Slinging Procedure
0-WD010-MZ711-10024
b. Conduct elevation check and centerline alignment of the pump skid based on the
markings and the bench marks.
Note:
 Skid Centering ± 3mm
c. Once the skid is centered, the anchor boxes are then grouted.
d. After curing of the anchor bolt grout, conduct the final anchor bolt tightening.
e. After the anchor bolt tightening, preliminary coupling alignment shall be done.
Note:
 Radial: ± 0.05mm at 90° and 270° ± 0.10mm at 180°
 Face: ± 0.05mm at 90° and 270° ± 0.05mm at 180°
 Bolt tightening should be following the supplier recommendation
Note: Coupling alignment work is not applicable to closed coupling type (Single Shaft Connection)
PULAU INDAH COMBINED CYCLE POWER PLANT
METHOD STATEMENT FOR INSTALLATION
OF ROTATING EQUIPMENT
7.4
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Installation Works of Vertical Pump
a) For installation of horizontal pump, tailing lift method is necessary. Using two
cranes, one for main lift and the other for tailing, lift the vertical pump and install it
to the pump barrel. Check again elevation and alignment of the pump.
Note:
 All lifting activity shall comply to Lifting Safety Procedure 0WD010-MZ711-10015 and Rigging and Slinging Procedure 0WD010-MZ711-10024
b) Once confirm the reading is acceptable. Tighten the pump to barrel bolts properly and
prepare for full grouting.
c) By crane lift the motor and install on the vertical pump head.
d) Preliminary coupling alignment to be done prior to start the installation of
suction and discharge piping.
Note:
 Radial: ± 0.05mm at 90° and 270° ± 0.10mm at 180°
 Face: ± 0.05mm at 90° and 270° ± 0.05mm at 180°
 Bolt tightening should be following the supplier recommendation
7.5
Final Alignment Inspection
a) After the piping connection is completed, final coupling alignment shall be
done and witnessed by the QC Engineer and should be properly documented.
Note:
 Radial: ± 0.05mm at 90° and 270° ± 0.10mm at 180°
 Face: ± 0.05mm at 90° and 270° ± 0.05mm at 180°
 Supplier’s recommended tolerance shall be prioritized if vary.
PULAU INDAH COMBINED CYCLE POWER PLANT
METHOD STATEMENT FOR INSTALLATION
OF ROTATING EQUIPMENT
7.6
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Working on Extended Hours
In case of required to work on extended hours (Night Work), the work area lighting shall comply to
the HSE Management Plan, Section B-24-4-3 Work Area Illumination (0-WD010-MZ71110001)
7.7
Working in Confined Space
In case of required to work inside confined space area, the work shall comply to the HSE
Management Plan, Section B-4 Confined Space (0-WD010-MZ711-10001)
8.0
QUALITY ASSURANCE & QUALITY CONTROL (QAQC).
The activities shall be conducted in accordance to the Project Specification, requirement and Code
of Standard. All testing and inspection requirement shall be referred to the Field Inspection Test
Plan (FITP) 0-WDxxx-xxxxx-xxxxx Field Inspection Test Plan for Rotating Equipment.
9.0
SAFETY, HEALTH & ENVIRONMENTAL REQUIREMENTS
9.1
Site Safety and Health Requirements
Construction team shall be responsible to ensure that all the safety controls are in place as per work activity’s
HIRARC and MSRA; and should empowered to stop work to rectify any unsafe condition or act. The HSE
team is responsible to enforcement of this expectation and the construction team to be responsible for the
implementation thereof. Safety procedures will be applied and controlled full time by experienced site
supervisor and site safety supervisor.
 All equipment shall be inspected and tested on a regular schedule by qualified/competent personnel.
Maintenance supervisor shall check and record all relevant documents for reference.
 All safety activities and result of inspection will be reported to Project Manager.
 Prior to start work, daily Tool Box Meeting shall be held & Risk Assessment of daily work to be briefed.
 HSE Team will regularly inspect all areas and take all required action to ensure the works do not cause
risk to the health, safety of personnel and environmental matter.
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 All equipment shall be jointly examined by company prior to admission to site and if suitable for use on
site a sticker will be applied to the item of equipment.
 To prevent any vehicle accidents caused by entry and exit at the main access road gate, warning sign
board will be erected on both side of road. Signal man will be arranged when anticipated vehicle passage
increase.
 Detail plan and procedure for safety assurance will be implemented according to the Site Safety and
Health Plan and Emergency Response Plan.
When required, the barricades are established for limited access/ The type of barricades is the warning
tape and poles to increase the awareness of surrounding parties.
As per the HSE Management Plan (0-WD010-MZ711-10001), where PPE is required, personnel must
wear as minimum:
 Safety-toed footgear in compliance with the CE standard/ DOSH-SIRIM MS Standard
 Hard hats in compliance with the CE standard/ DOSH-SIRIM MS Standard
 Safety glasses with side shields in compliance with the CE standard/ DOSH- SIRIM MS
Standard
 Adequate coveralls. Where there is a fire hazard, coveralls will be worn and be fire retardant.
 Luminescent work vests.
9.2
Environmental Requirements
The HSE Manager Shall be responsible for monitoring of the implementation of the
Environmental and Waste Management Protection Procedure (0-WD010-MZ711-10018 & 10019)
On the project. Review and update the procedure if necessary. Shall appoint a competent
Environmental Officer that appropriately certified by DOE.
The environmental officer will be responsible for the implementation and monitoring of the
environmental impact according to the environmental protection procedure and conditions by DOE.
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The construction activity shall comply with relevant construction requirements and local
environmental legislation. All construction works are to be carried out in such a way so as to
minimize disturbance to the environment. Construction work shall be carried out in such a manner
that there is no damage to or interference with the following (other than to the extent that is
necessary for them to be removed or diverted to permit the execution of the works within the
defined operational perimeter):
•
Natural and man-made drainage systems;
•
Public utilities;
•
Structures, roads, or other property; and
•
Public and private vehicular and pedestrian access.
The construction activities will be carried out / staged in a way as to minimize exposure / interruptions
(e.g. noise, air emissions to surrounding communities and reduce the potential for environmental
impacts. The construction team will maintain and clean all working areas and temporary buildings on
a regular basis and shall at all times keep access to work sites free of all debris, waste and excavated
material and other obstructions.
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9.3 ASSEMBLY POINT
In case of emergency, evacuate and move towards to the nearest assembly point for head count section and wait
for further instruction.
9.4 EMERGENCY CONTACT
Contact Person
MALAYSIA EMERGENCY RESPONSE
Phone No
999
SERVICE
PEC POWERCON HSE MANAGER
PEC POWERCON SAFETY & HEALTH
019-3962947
016-2042205
OFFICER
PEC POWERCON ENVIRONMENTAL
ENGINEER
019-3708226
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9.5 WELFARE AND FIRST AID
 Rest room
 First aid box
 Drinking Water
 Sanitary facilities
Note: Sanitary facilities to be cleaned and sanitized at least twice a day
9.6 COVID-19 SAEFTY MEASURE
9.6.1 MANDATORY SAFETY MEASURE
 Mandatory wearing of masks in public places and workplaces.
 Availability of hand washing/sanitizing stations in frequented places and high-touch areas.
 Mandatory physical and social distancing at 1 to 2 meters between individuals.
 Procurement of Covid-19 testing kits, PPEs, etc.
 Contact-tracing systems in place.
 Placement of relevant signage and on-line information materials.
 Implementation, monitoring and maintenance of planned schedule for workers
traveling to and from respective workplaces, including chartering of transport
services.
 Implementation of measures dealing with workers confirmed positive for Covid-19
by authorized testing/medical facilities.
 Establishment of “Workforce and Workplace Management Plan”, showing also
information on number of employees, working hours, workplace condition/office
floor areas, etc.
 Provision for Isolation Room for big identified establishments separated from the
company clinic and separate bin for infectious materials.
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9.6.2 INSIDE WORK PLACE SAFETY MEASURE
 Use face masks at all times.
 Use of gloves, face shield encouraged.
 Putting plastic or Plexiglas shields for front line service desks and between desks that face each other.
 Physical distancing at all times.
 Taping off areas not to be used to allow social distancing.
 Patrol of project site for the Day to ensure compliance.
 Doors kept partly open to prevent need to handle door knobs.
 Disinfection of frequently handled objects (door knobs, phones) and common areas (kitchen,
conference rooms) every 2 hours or after every use, when applicable.
 Limit number of people who use elevators or man-lifting facilities.
 Providing sanitizers in corridors, conference areas and other common areas.
 Providing clean water, no-touch soap dispensers, sanitizers, and hand dryer in washrooms and toilets.
No rolled tissues.
 No eating in communal areas. Workers to eat in their individual work areas.
 No gathering of more than 6 (six) people in one room.
 No lending of office/ personal items and tools. If needed, disinfect items before and after transfer.
 Display of COVID prevention infographics.
 Providing separate bin for hazardous waste like masks, gloves, etc.
10.0 HAZARD IDENTIFICATION, RISK ASSESSMENT & CONTROL
HIRARC (Hazard Identification, Risk Assessment and Risk Control) will be implemented prior to any
activity. HIRARC is detailed in appropriate safe work instructions or job specific, job safety &
environmental analysis. Hazards will vary as the location and all personnel undertaking the works
shall be made aware of particular location hazards. Daily Equipment Inspection will be conducted and
recorded after morning Tool box meting (TBM). Daily start up meetings will be conducted and
documented by supervisors to ensure all safety measures are in place for the day’s activities. Refer
PIPP-HIRARC-EESB- 05 Rev. 0 for Risk Assessment details.
APPENDIX 1
HIRARC FORM
Severity (S)
Catastrophic
Fatal
TABLE 1- Consequence (Severity) Rating Guidance
Risk
Description
Action
Example
15 - 25
High (H)
5 - 12
Medium (M)
1–4
Low (L)
A HIGH risk requires immediate action to
control the
hazard as detailed in the hierarchy of
control. Actions
taken must be documented on the risk
assessment form
including the date for completion.
A MEDIUM risk requires a planned
approach to
controlling the hazard and applying
temporary measures if
required. Actions taken must be
documented on the risk
assessment form including the date for
completion
A risk identified as LOW may be
considered as
acceptable and further reduction may
not be necessary.
Numerous fatalities, irrecoverable property damage and
productivity
Rating
5
Approximately one single fatality major property damage if
hazard is realized
4
Serious
Non-fatal injury, permanent disability
3
Minor
Disabling but not permanent injury
2
Minor abrasions, bruises, cuts, first-aid type injury 1
1
Negligible
TABLE 2- Likelihood Rating Guidance Description
Likelihood
(L)
Most likely
Possible
Conceivable
Remote
Inconceivable
Example
Rating
The most likely result of the hazard/event being realized
5
Has a good chance of occurring and is not unusual
4
It might be occurring at some time in future
3
Has not been known to occur after many years
2
Is practically impossible and has never occurred
1
TABLE 3- Risk Matrix
Severity
Likelihood
1
2
3
4
5
5
5
10
15
20
25
4
4
8
12
16
20
3
3
6
9
12
15
2
2
4
6
8
10
1
1
2
3
4
5
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PULAU INDAH COMBINED CYCLE POWER PLANT
HAZARD IDENTIFICATION RISK ASSESSMEN RISK CONTROL
PULAU INDAH COMBINED CYCLE POWER PLANT
HIRARC FORM
HIRARC Title:
ROTATING EQUIPMENT INSTALLATION
HIRARC Ref. No.
Date
PIPP-HIRARC-EESB-05 Rev. A
26-01-2022
(Psychosocial)
- Poor
Communication
• Stop Work
• Delay of PTW
approval from
POSCO
• NO VALID PTW, NO WORK
• Read and understand PTW content
before commencing any work
2
• Conduct pre-task toolbox and brief
work scope, communicate the hazards
and control measure
(Psychosocial)
- Untrained
workers,
• Personal Injury
• Damaged to
equipment
• Loss
of
property
• Deployment of competent and
skilled workers as per statutory and
project requirement.
• All workers must possess a valid
3
CIDB card and attend POSCO site
safety induction training.
• Mandatory PPE must always be
worn i.e., safety helmet, vest, safety
glass, and safety shoes.
• Conduct pre-task toolbox and brief
work scope, communicate the hazard
and control measure.
• To performed covid-19 RTK-Ag/RTPCR before entering to site
• Compliance of SOP e.g. use of 3ply
face mask, use of hand sanitizer and
sanitizing work, social distancing, to
avoid crowded and gathering.
PEC HOD
RISK CONTROL
Severity (S)
Preparation:
Mobilization of
workforce
EFFECT
EXISTING CONTROL
MEASURE
(If any)
Approved by:
PEC HSE
RISK ANALYSIS
Probability
(p)
Permit to Work
Application
HAZARDS
Reviewed by:
ENGINEER
HAZARD IDENTIFICATION
JOB SEQUENCE
Prepared by:
Zafran Zaharol
2
2
Risk Rating
(P*S)
Score
4
6
Level
(L)
(M)
RECOMMENDED CONTROL
MEASURE
RESPONSIBLE
PERSON (PIC)
• Closed monitoring from the
engineer supervisor ensuring
the permit applied for each
activity
• Site inspection on PTW from
the safety department
• Engineer/
Supervisor/
Safety
• Every worker should be
checking accordingly their
competency and designation
by safety and HR department
prior to hiring.
• Continues training should be
given to the workers to
• To ensure training of COVID19 management given to the
staff and workers.
• Human Resource/
Safety/
Engineer/
Supervisor
PULAU INDAH COMBINED CYCLE POWER PLANT
HAZARD IDENTIFICATION RISK ASSESSMEN RISK CONTROL
HAZARD IDENTIFICATION
EFFECT
• Physical Injury
Mobilization of (Mechanical)
- Collision with moving • Property
equipment &
damage
objects
materials
Traffic
movements
(deliveries
etc.)
(Physical)
- Uncontrolled or
unexpected
movement of
machinery,
components, work
pieces, vehicles, or
loads
-Pinch Point
(Ergonomic)
• Overexertion due
to manual handling
• PTW shall be applied as required
• POSCO must inspect all types of
machinery/equipment
3
• The operator must have full
attention and not be allowed to
use a cell phone or walkie-talkie
• Banksman shall be present at the
site to
direct the traffic.
• Keep all other works clear of
operating machinery / Vehicle
• Driver / Operator is not allowed to
use an earphone.
• Verify the soil condition (access)
before entering the vehicle to the
site
• Place vehicle at a designated
location
• Use Wheel stopper
• Adhere to laydown area speed limit
25km/h
• Securing of tools/materials during
transportation
• Vehicle routes kept free of
obstructions (with spillages being
cleaned up promptly
• Parking of cars and vans is only
allowed in marked spaces, well
away from external
• Any reversing that is necessary
should be overseen by a trained
reversing (banksman).
RISK CONTROL
Severity (S)
HAZARDS
EXISTING CONTROL
MEASURE
(If any)
Probability
(p)
JOB SEQUENCE
RISK ANALYSIS
DOC. No. : PIPP-HIRARC-EESB-05
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2
Risk Rating
(P*S)
Score
6
Level
(M)
RECOMMENDED CONTROL
MEASURE
RESPONSIBLE
PERSON (PIC)
• Barricade of loading/unloading
activity area to prevent any
unauthorized entrance
• Person in charge supervision
should be on the working place
• Drivers to follow directions of the
signalman.
Driver or operator must be inducted
before entering the worksite
• Material and
transportation
supervisor
PULAU INDAH COMBINED CYCLE POWER PLANT
HAZARD IDENTIFICATION RISK ASSESSMEN RISK CONTROL
HAZARD IDENTIFICATION
Risk Rating
Severity (S)
Loading and
unloading
materials
(Crane /
Forklift /
Manual
Handling)
EXISTING CONTROL
MEASURE
(If any)
RISK CONTROL
Probability
(p)
JOB SEQUENCE
RISK ANALYSIS
Score
(Ergonomic)
• Utilize mechanical lifting aids or
equipment
• Providing personal protective
equipment, e.g., non-slip gloves
and footwear
3
2
6
(Physical)
• Physical
Injury
• Twisting, turning,
•
Property
grabbing, picking,
damage
or wringing actions
with fingers, hands,
or arms
(Physical)
Failure or collapse
or overturning of
crane, winch, hoist,
excavator, or other
appliance used in
raising or lowering
persons or goods,
or parts thereof
(Physical)
• Trips/falls due to
uneven/ slippery
surfaces
• Appropriate PPE mainly and gloves
must be provided to the workers.
• Use mechanical equipment such as
wheelbarrow/trolley or other similar
equipment.
• Workers handling sharp edges
require to use cut resistance hand
gloves to prevent hand injury.
• Ascertain work area and ensure that
ground surface is free from tripping
hazards. All materials are to be kept
tidy.
• Suspend lifting work during strong
wind, heavy rain, or lightning.
2
3
6
HAZARDS
EFFECT
• Back
Injuries
• Overexertion due
• Muscular
to manual handling
injury
(Physical)
Working in
exposed lightning,
bad weather, and
vital wind area
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(P*S)
Level
(M)
(M)
RECOMMENDED CONTROL
MEASURE
RESPONSIBLE
PERSON (PIC)
• Reduce the load risk by using lighter
weights or more stable containers
• Ensure appropriate rest break, job
rotation, and training is involved
• Material and
transportation
supervisor
• . Ensure workers are in fit health
• Material/
condition to perform the task.
transportation/
• Barricade the working Area and displa
Crane
warning signs
Operator and
• Standby personnel must be on standb
lifting
to control and prevent unauthorized
supervisor
entry to the working area.
• Visible inspection of the ladder before
use.
• Close supervision by work supervisor
• Plan the unloading area
• To protect or remove the sharp edges
before working
• Proper housekeeping is to be done all
the times
• Operator crane to check the wind
speed at crane anemometer before
lifting activity during the windy time.
• Provide lightning detector
PULAU INDAH COMBINED CYCLE POWER PLANT
HAZARD IDENTIFICATION RISK ASSESSMEN RISK CONTROL
HAZARD IDENTIFICATION
Foundation
survey,
centerline,
marking,
chipping
(Physical)
• Trips/falls due to
uneven/ slippery
surfaces
(Physical)
• Contact with rough
concrete surface
Erection of
vertical and
horizontal
type pump
(Physical)
•
•
•
•
•
Working at height
Falling objects
Overloading
Tripping
Pinch Point
EFFECT
• Back Injuries
• Muscular
injury
• Physical
Injuries
• Physical
Injury
• Muscular
Injury
Risk Rating
Severity (S)
HAZARDS
EXISTING CONTROL
MEASURE
(If any)
RISK CONTROL
Probability
(p)
JOB SEQUENCE
RISK ANALYSIS
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Score
3
2
6
(M)
• Pre-start talk must before be starting • , Site
of the activity
Engineer
• Only trained workers to execute the
• Supervisor
task
• Supervisor to have close monitor while
the task being performed
To ensure work area being barricade
and signage display to notify others
3
2
6
(M)
• Pre-start talk must before be starting • Supervisor,
of the activity
Foreman, Site
• Only trained workers to execute the
Engineer
task
• Supervisor to have close monitor while
the task being performed
• To ensure work area being barricade
and signage display to notify others
• Cable stand to be used and must be
higher from head to avoid cable from
laying on the ground.
• Blocking materials at access way to be
keep/arrange properly.
• Opening at platform to be hard
barricade or cover temporary using
metal deck.
• Uneven floor/grating to be put signage
and marking using adhesive floor tape
• Ensure the workers are brief
regarding pinch point hazard and
effect of the hazard during toolbox
meeting.
• For working at height to install
lifeline/railing using scaffolding pipe
as anchorage for the harness lanyard
• Wear proper hand gloves while
marking on the foundation
• Wear proper safety glass
• Ensure use of proper hand gloves
• Ensure use of PPE
• Cover opening with plate/ barricade
the opening with scaffolding.
• Provision of signage at the location
of the holes.
• Highlight hazard during toolbox
meeting
• opening area to hard barricade
• Ensure PTW is in place
• Ensure proper working platform with
complete fall protection
• Ensure full-body harness and 100%
Tie-off
• Ensure the scaffold platform is
erected correctly with the "Safe to
use "tag.
• Hand tools and the loose item must
be secured with wire, rope as
lanyard to the anchorage to prevent
fall from height
• Works materials strictly not allowed
to be stored on the platform except
for working tools
• Ensure avoid overreaching and
climbing on the handrail.
• Ensure the unauthorized person is
not allowed to modify the
scaffolding, and if needed, changes
must be modified by a trained and
certified scaffolder.
• Ensure safe access to the working
platform
• Scaffold access must be free from
(P*S)
Level
RECOMMENDED CONTROL
MEASURE
RESPONSIBLE
PERSON (PIC)
PULAU INDAH COMBINED CYCLE POWER PLANT
HAZARD IDENTIFICATION RISK ASSESSMEN RISK CONTROL
obstruction
• Ensure sufficient illumination in the
work area machine to avoid finger
injury.
• special care of body and eye
protection with
• Must clean the debris after
completing the job and maintain
good housekeeping.
• Proper PPE to be used to protect
the hand from getting direct hit by
tools (such as a hammer)
• ensure hands are away from pinch
point
• Lifting work to be performed by
competent rigger and crane
operator
• Crane obtain safe to use sticker
verify by POSCO
Use of power
tools such as
Grinder 4’/ 9’/
Cutter & Drill
machine
(Electrical)
• Damaged socket &
Cable insulation.
(Physical)
• Slip/Trip
• Noise
• Vibration
(Environmental)
• Dust
• Electrocution
• Physical
Injury
• Loss Hearing
Ill Health
• All portable electrical must be
Inspected, color-coded, and
verified by POSCO safe to use.
Makes sure the test dates are
visible on equipment.
• Ensure all grinding/cutting wheels
shall be appropriate
• Ensure all power tools are in good
condition and appropriately
maintained
• PTW to be obtained before
commencing the task.
• To ensure no use of damaged
industrial sockets and power
cables.
• Ensure cables from power tools
shall be organized as not to
present a tripping hazard
• Only trained competent person
operatives to operate the power
tools.
• Ensure proper and regular
maintenance of equipment that
takes account of noise.
• Ensure proper hearing protection
always
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• All workers required to attend and
complete the WAH training by
POSCO prior working at height at
site
• For working at height more than 1.8
meter required to use full body
harness with double lanyard and
100% tied off
• To ensure all working platform
inspected and safe to use by
scaffolding inspector
• To install working platform complete
with guardrail, toe board and lifeline
for fall protection.
.
1
4
4
(L)
• Supervisor,
Foreman, Site
Engineer
PULAU INDAH COMBINED CYCLE POWER PLANT
HAZARD IDENTIFICATION RISK ASSESSMEN RISK CONTROL
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• Ensure the workers use the right
tools and are trained to use them
correctly.
Ensure defective tools that require
maintenance is reported for repair
or replacement
HAZARD IDENTIFICATION
(Physical)
• Falling from height
• Trips/falls due to
uneven/ slippery
surfaces
• Hit by falling
objects from height
• Pinch Point
Working under
suspended load
(platform
installation)
EFFECT
• Physical
injury
•
•
•
•
•
•
•
•
Severity (S)
Bolt tightening
HAZARDS
EXISTING CONTROL
MEASURE
(If any)
RISK CONTROL
Risk Rating
Probability
(p)
JOB SEQUENCE
RISK ANALYSIS
Score
1
4
4
Provide safe working platform
Training for worker / staff WAH,
lifeline approved,
All tools must be secured
Work zone to be barricaded with
warning sign
Wear full body harness with double
lanyard and shall 100% tied-off
Install hard barricade at the edge
of the floor opening
Proper PPE to be use to protect
hand from get direct hit by tools
(such as hammer)
ensure hands are away from pinch
point
Ensure the area are barricaded at
ground level.
(P*S)
Level
(L)
RECOMMENDED CONTROL
MEASURE
RESPONSIBLE
PERSON (PIC)
• Pre-start talk must be done before
• Supervisor,
start of the activity
Foreman,
• Only trained workers to execute the
Site
task
Engineer
• Supervisor to have close monitor while
the task being performed
To ensure work area being barricade
and signage display to notify others
PULAU INDAH COMBINED CYCLE POWER PLANT
HAZARD IDENTIFICATION RISK ASSESSMEN RISK CONTROL
HAZARD IDENTIFICATION
(Electrical)
• Damaged socket &
Cable insulation.
(Physical)
• Slip/Trip
• Noise
• Vibration
• Contact with hot
surface
(Environmental)
• Dust
EFFECT
• Electrocution
• Physical
Injury
• Loss Hearing
• Ill Health
• All portable electrical must be
Inspected, color-coded, and
verified by POSCO safe to use.
Makes sure the test dates are
visible on equipment.
• Ensure all grinding/cutting wheels
shall be appropriate
• Ensure all power tools are in good
condition and appropriately
maintained
• PTW to be obtained before
commencing the task.
• To ensure no use of damaged
industrial sockets and power
cables.
• Ensure cables from power tools
shall be organized as not to
present a tripping hazard
• Only trained competent person
operatives to operate the power
tools.
• Ensure proper and regular
maintenance of equipment that
takes account of noise.
• Ensure proper hearing protection
always
• Ensure the workers use the right
tools and are trained to use them
correctly.
• Ensure defective tools that require
maintenance is reported for repair
or replacement
Risk Rating
Severity (S)
Hot Work
Welding,
Grinding &
Cutting
Drilling
HAZARDS
EXISTING CONTROL
MEASURE
(If any)
RISK CONTROL
Probability
(p)
JOB SEQUENCE
RISK ANALYSIS
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Score
3
2
6
(P*S)
Level
(M)
RECOMMENDED CONTROL
MEASURE
RESPONSIBLE
PERSON (PIC)
• Pre-start talk must be done before
• Supervisor,
start of the activity
Foreman, Site
• Only trained workers to execute the
Engineer
task
• Supervisor to have close monitor while
the task being performed
To ensure work area being barricade
and signage display to notify others
• Fire extinguisher to be place standby
near to the hot works area.
Trained fire watcher to be place to
monitor the hot work activity.
PULAU INDAH COMBINED CYCLE POWER PLANT
HAZARD IDENTIFICATION RISK ASSESSMEN RISK CONTROL
HAZARD IDENTIFICATION
EFFECT
(Physical)
• strain
which can
• Lack of
lead
to
illumination or poor
fatigue,
illumination
headaches,
• Falling from height
burnout and
anxiety
• Physical
(Psychosocial)
injury
• Lack of
psychological
support
• Apply PTW for the extended night
works before work starts.
• Shall sufficient lighting have provided
for work area
• Reflective clothing must be worn
while working at night
• provide proper access/egress
• apply buddy system for working at
night
• All the spotlight shall function before
starting the night works
• Apply PTW for the extended night
works before work starts.
• Shall sufficient lighting have provided
for work area
• Reflective clothing must be worn
while working at night
• provide proper access/egress
• apply buddy system for working at
night
• All the spotlight shall function before
starting the night works
• Sufficient illumination.
• To assign buddies system for
observing the group
• Opening area to be hard barricaded.
• To monitored the fatigue
management to avoid over working
hours and shift.
RISK CONTROL
Severity (S)
Extended
working
hours or
Night work
HAZARDS
EXISTING CONTROL
MEASURE
(If any)
Probability
(p)
JOB SEQUENCE
RISK ANALYSIS
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Risk Rating
(P*S)
Score
Level
RECOMMENDED CONTROL
MEASURE
RESPONSIBLE
PERSON (PIC)
• Ensure the workers must fit
• Supervisor,
doing the work
Foreman, and
• Closed supervision from the person in
Engineer
charge person for working at night
•
2
2
4
(L)
PULAU INDAH COMBINED CYCLE POWER PLANT
HAZARD IDENTIFICATION RISK ASSESSMEN RISK CONTROL
HAZARD IDENTIFICATION
EFFECT
(Mechanical)
• Physical
Injury
• Twisting, turning,
•
Muscular
grabbing, picking,
Injury
or wringing actions
with fingers,
hands, or arms.
(Ergonomic)
• Overexertion due
to manual handling
• Utilize mechanical lifting aids or
equipment
• Providing personal protective equipmen
e.g., non-slip gloves and footwear
• Wear suitable work gloves appropriate
to the task.
• Keep hand clear of load before lifting
2
• Pinch point topic to be highlighted in
toolbox talk
• Use the buddy system with the help of
friends
• Proper body posture for lifting manual
handling
• Proper waste disposal method
RISK CONTROL
Severity (S)
Housekeeping
& Waste
Disposal
HAZARDS
EXISTING CONTROL
MEASURE
(If any)
Probability
(p)
JOB SEQUENCE
RISK ANALYSIS
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Risk Rating
(P*S)
Score
Level
RECOMMENDED CONTROL
MEASURE
• Ensure the workers must fit doing the
work
• Proper segregation of food waste,
plastic, metal, construction, and
scheduled waste.
2
4
(L)
RESPONSIBLE
PERSON (PIC)
• Supervisor,
Foreman, and
Engineer