METHOD STATEMENT

FOR DCS,PLC/CONTROL PANEL INSTALLATION

DP16003-DD09-P0ZEN-750015

Revision History

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 METHOD STATEMENT
FOR DCS,PLC/CONTROL PANEL INSTALLATION
DP16003-DD09-P0ZEN-750015

Rev Date Prepared Checked Approved Details of Revision

CONTENTS

1. PURPOSE

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 METHOD STATEMENT
FOR DCS,PLC/CONTROL PANEL INSTALLATION
DP16003-DD09-P0ZEN-750015

2. SCOPE
3. PRINCIPLE
4. RESPONSIBILITY
5. WORK PROCEDURE
6. INSTALLATION
7. INSPECTION AND TEST
8. ENVIRONMENT, HEALTH AND SAFETY (EHS)
9. JOB SAFETY ANALYSIS (J.S.A.)
10. RISK ASSESSMENT

1. PURPOSE
The purpose of this method Statement is to explain the procedure of the DCS, PLC, CONTROL PANEL
installation work for JAWAHARPUR SUPER THERMAL POWER STATION. With this, we can perform
construction safely and consistently.

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 METHOD STATEMENT
FOR DCS,PLC/CONTROL PANEL INSTALLATION
DP16003-DD09-P0ZEN-750015

2. SCOPE
This method statement covers the general requirements of installation for DCS,PLC/CONTROL PANEL
installation of JAWAHARPUR SUPER THERMAL POWER STATION.

3. PRINCIPLE

All the concerning works’ procedure should follow this method statement.

4.RESPONSIBILITY

Resident Construction Manager - Shall report to Project Manger

Shall be overall responsible for Project
Management.

Site QA/QC In-charge - Shall report to the Resident

Construction Manager.

Electrical Engineer - Shall report to the Resident

Construction Manager

Shall be responsible for compliance of

this procedure

Store Incharge - Shall report to Resident Construction

Manger
Shall be responsible for handling,
storage & issuance of material as per
procedures.
Document Controller -- Shall be reporting to Planning
Engineer.

Shall be responsible for overall control

& management of project documents.

5.WORK PROCEDURE
5.1Required tools & equipment:

5.1.1 Electrician tool kit

5.1.2 Drill machine Tools and spanner sets

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 METHOD STATEMENT
FOR DCS,PLC/CONTROL PANEL INSTALLATION
DP16003-DD09-P0ZEN-750015

5.1.3 Crimping tools.

5.1.4 Measuring tape
5.1.5 Flat file
5.1.6 Screw drivers
5.1.7 Spirit-level

5.2Prior to installation work:

1. Installation works shall be carried out only with respect to approved shop drawings of latest
revision
2. Site Engineer (Electrical) has to ensure that all the materials are received at site as per BOM
3. Ensure all civil works are completed for the area of installation and released / cleared by civil section to
proceed on with the installation of DCS, PLC/CONTROL PANE.L
4. Ensure that the necessary tools and tackles are made available for installation purpose.

5.3Work Procedure / Description:

5.3.1 Examine the drawing of DCS, PLC/ CONTROL PANEL erection layout with respect To the general layout.
5.3.2 Shift the Panel from stores to location by means of suitable Truck/lifting arrangement.
5.3.3 Carryout physical verification or any possible damage.
5.3.4 Check for necessary lifting tools &tackles in relation with load to be lifted and ensure safe lifting.
5.3.5 Check for the level alignment of the foundation before starting the erection.

6.Inspection and Test:

6.1.1 Testing and commissioning shall be done as per approved drawings and manual.
6.2.1 Tightness of connection of all sections including terminating.
6.3.1 Continuity of all the sections.
6.4.1 Insulation resistance test as per standard
6.5.1 As per manufacturers test report.

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 METHOD STATEMENT
FOR DCS,PLC/CONTROL PANEL INSTALLATION
DP16003-DD09-P0ZEN-750015

7.Environment, Health Safety (EHS)

7.1 Responsibilities and Instructions

7.1.1 Safety training should be conducted to all personnel assigned at site prior to commence
any work.
7.1.2 Personal Protective Equipment (PPE) shall be worn at all times.
7.1.3 Good housekeeping shall be observed in work areas.
7.1.4 Construction wastes shall be segregated and disposed to an approved dump yard area.
7.1.5 Proper inspection of all equipment prior to use to avoid leakage and equipment failure.
7.1.6 Permit to work shall be obtained appropriately for the type of work and location.
7.1.7 All vehicles must comply proper speed on site.
7.1.8 Adequate lighting equipment.
7.1.9 Periodic refresher trainings, tool box talk and audit shall be conducted.
7.1.10 Ensure that the processing of work is carried out according to the plant construction
program and as per contract agreement.
7.1.11 Ensure that all tools/equipment and required material for execution of work are available
at site/store according to the planned construction program.
7.1.12 Shall provide all necessary information and distribute responsibilities to the construction
team, monitor the progress of work in relation with the plant program and coordinate
with the safety officer for ensuring that the work is carried out in safe practicing methods.

7.2 Safety ( PPE )

7.2.1 Wearing of the basic PPE will be enforced fully.
7.2.2 All new recruits will undergo proper orientation and safety induction before they could
deployed at site for work.

7.3 First Aid Facilities

7.3.1 Ambulance car with driver, helper and stand by nurse are available at site or First Aid
Station at all times.

8.JOB SAFETY ANALYSIT (JSA)

List of All Job
List of All Known Hazards How to Eliminate Hazards
Steps

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 METHOD STATEMENT
FOR DCS,PLC/CONTROL PANEL INSTALLATION
DP16003-DD09-P0ZEN-750015

A. Workers A.1 Not properly equipped with PPE A.1 Instructing to wear proper PPE
A.2 Worker abnormal physical condition A.2 Make the worker to take enough rest
(drunken &fatigue)
B. Transportation of B. Crash/ traffic accident B.1 Check the access road before passing the area
equipment & delivery of B.2 Designate a signalman who wear the red suit and safety helmet and
materials control the work
C.Heavy Lifting Works C. Crushing may cause fatal injury or permanent C.1 Preparation of a rigging lift list and plans for lifts of ten (10) tons
disability or greater.
C.2 Only a qualified and Certified operators. Signalman should be
n-place
C.3 Do not stand beneath the lifting areas
C.4 Ensure loads are fixed with sling belt correctly
C.5 All lifting equipment must be in good conditions
C.6 Experienced lifting supervisor at all times
C.7 Only monthly checking color attached lifting tools allowed to use
C.8 All lifting tools must have identification tag (including serial number,
certification number, SWL inspection date and due date)
C.9 Provide safe entrance and exit access road for the labors passing

D. Unloading Equipment D.1 Struck down by things and materials D.1.a Make sure the sling is tied / bound / tightened correctly
and Materials D.1.b Check the lifting devices(slings, shackles, etc…) for proper and
safe use
D.1.c Analyzing the load (weight, shape, lifting points, etc…) and the
lifting device
D.1.d Only monthly checking color attached lifting tools allowed to use
D.1.e All lifting tools must have identification tag (including serial
number, certification number, SWL inspection date and due date)
D.1.f Provide safe entrance and exit access road for the labors
passing
D.2 Squeezed by the sling D.2.a Use hand gloves when tighten the slings
D.2.b Tighten the slings before carrying-out lifting

D.3 Squeezed by the materials D.3.a Use wooden bar or support of the materials on the ground

D.4 Crane fall accidentally D.4.a Analyzing the loads (weight, shape, lifting points, etc…) and lifting
E. Working Operation device to suit the crane capacity
During Night Time. E.1 Working operation of the equipment may cause E.1.a Must provide sufficient lightening on the entire working area
injury to personnel due to E.1.b All equipment must ensure all lights are operational and not
poor visibility of the area. obscured by dirt or mud
E.1.c Supervisor must always be present for the entire working
operation
E.1.d All workers must be wearing proper PPE
E.1.e Ambulance and nurse must be available in first aid station

E.1.f Must use and connect 3 core codes electric wire and separate
distribution panel (must pass arrangement of ELCB) and avoid any water affect
E.1.g Provide safe entrance and exit access road for the labors passing
E.1.h All kinds of electric cable must be hanged over ground
E.1.i Must use industrial socket and plug
E.1.j Electric cabinet should not affect any water
E.2.a Daily check of the equipment prior to start of work
E.2.b Regular check & monitoring of the equipment prior to use
E.2 Generator (Diesel) equipment oil leakage E.2.c Provide secondary containment protection under the equipment top prevent
contamination of soil by oil spillage

List of All Job

List of All Known Hazards How to Eliminate Hazards
Steps

G. Welding G.1 Electric shock, fire, burn to body and injury to G.1.a Proper earthing and connection of welding machines and

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 METHOD STATEMENT
FOR DCS,PLC/CONTROL PANEL INSTALLATION
DP16003-DD09-P0ZEN-750015

Cutting, grinding eye may cause death or permanent disability generators

works G.1.b Flashback arrestor and gauge should be installed prior to use
cutting cylinders
G.1.c Proper PPE to be worn at all times
G.1.d Must use and connect 3 core codes electric wire and separate
distribution panel (must pass arrangement of ELCB) and avoid
any water affect
G.1.e All kinds of electric cable must be hanged over ground
G.1.f Must use industrial socket and plug
G.1.g Electric cabinet should not affect any water
G.2 Generator(diesel) equipment oil leakage during
operation G.2.a Daily check of the equipment prior to start of work
G.2.b Regular monitoring of the equipment in order to control and
prevent oil leakage and other engine trouble
G.2.c Provide secondary containment protection under the equipment
to prevent contamination of the soil by oil spillage
G.2.d If oil leakage, must remove the oil and contaminated soil
immediately

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 METHOD STATEMENT
FOR DCS,PLC/CONTROL PANEL INSTALLATION
DP16003-DD09-P0ZEN-750015

RISK ASSESSMENT REPORT

Main Process : CC TV & PASYSTEM Installation Risk CONTRACTTOR :DPSI
grade
Job / Task Risk Factor Accident L1 S1 controls Remarks
TYPE
When receiving materials worker must wear
Workers are not wearing safety helmet safety safety shoes .
Earthing & shoes then conflict with furnace wall panel Injury 3 3 M(3)
lighting work header , other pressure part material is during
the work
Worker abnormal physical condition(DURNKEN Injury Drunken worker could not be allow and make
& FATIGUE) 2 3 T(4) the worker to take enough rest.
Transportation Crash /traffic accident i. Check the access road before passing the area.
of equipment ii. Designate a signal main when moving the
Injury 2 3 T(4)
& delivery of equipment.
material
I)Only a qualified and certified operators.
Signalman should be in place.
Ii) DO not stand beneath lifting areas.
Iii) Ensure bads are fixed with sling belt correctly.
Iv) Experience lifting supervisor at all times.
Heavy lifting Crushing may cause fatal injury or permanent V)Only monthly checking color attach lifting tools
work disability Injury 2 3 T(4) allowed to use.
Vi) All lifting tools must have identification
tag(include serial number, certification number
,swl inspection date and due date).
Vii) Provide safe entrance and exit access road
for the labor passing.

Checked by: Signature: Approved by: Signature: Approved by: Signature:

Position : Date: Position: Date: Position: Date:

Likely hood(L1) Severity(s1) RISK LEVEL RANGE RISK GRADE

1.Unlikely/ improbable 1.Negligible U(1)Grade:10-15 U(1)Grade :Unacceptable /intolerable(very high risk)
2. Remote 2. Slight S(2) Grade:10-15 S(2)Grade: Substantial(high risk)
3.Quite Possible/Occasional 3.Modrate M(3)Grade: 6-9 M(3)Grade: Moderate to acceptable with review (middle risk)
4.Likely probable 4.Critical/High T(4)Grade:3-5 T(4)Grade: Tolerable (low risk)
5.Very likely 5.Catasrophic/very high A(5)Grade:1-2 A(5)GRADE: Acceptable to trivial (Very low risk)

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 METHOD STATEMENT
FOR DCS,PLC/CONTROL PANEL INSTALLATION
DP16003-DD09-P0ZEN-750015

RISK ASSESSMENT REPORT

Main Process : CC TV & PASYSTEM Installation Risk CONTRACTTOR :DPSI
grade
Job / Task Risk Factor Accident type L1 S1 controls Remarks
i) Make sure the sling is tied / binded /
tightened correctly.
Ii)Check the lifting devices (sling,
shackles, etc..) for proper and safe use
iii) Analyzing the load (Wight shape,
lifting point etc..)And the lifting device.
Iv )only monthly checking color attach
2 3 T(4)
Struck down by things and Injury lifting tools allowed to use .
materials v)All lifting tools must have identification
Unloading tag(include serial number, certification
equipment number, swl inspection date and due
and materials date).
Vi) Provide safe entrance and exit
access road for the labor passing
i).Use hand gloves when tightening the
Squeezed by the sling slings
Injury 3 6 M(3)
ii) Tightening the slings before carrying
out lifting .
Analyzing the loads (weight shape, lifting
Crane fall accidentally points ,etc..)And lifting device to suit the
Injury 3 3 M(3) crane capacity.

Checked by: Signature: Approved by: Signature: Approved by: Signature:

Position : Date: Position: Date: Position: Date:

Likely hood(L1) Severity(s1) RISK LEVEL RANGE RISK GRADE

1.Unlikely/ improbable 1.Negligible U(1)Grade:10-15 U(1)Grade :Unacceptable /intolerable(very high risk)
2. Remote 2. Slight S(2) Grade:10-15 S(2)Grade: Substantial(high risk)
3.Quite Possible/Occasional 3.Modrate M(3)Grade: 6-9 M(3)Grade: Moderate to acceptable with review (middle risk)
4.Likely probable 4.Critical/High T(4)Grade:3-5 T(4)Grade: Tolerable (low risk)
5.Very likely 5.Catasrophic/very high A(5)Grade:1-2 A(5)GRADE: Acceptable to trivial (Very low risk)

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 METHOD STATEMENT
FOR DCS,PLC/CONTROL PANEL INSTALLATION
DP16003-DD09-P0ZEN-750015

RISK ASSESSMENT REPORT

Main Process : CCTV Installation Risk CONTRACTTOR :DPSI
grade
Job / Task Risk Factor Accident L1 S1 controls Remarks
type
Eye damaged by foreign sparkle due to When use the grinder worker must be
Worker not wearing safety glasses AND Injury 3 3 M(3) wear safety glass & PPE
PPE
Finger cutting when change grinder When changes the grinder wheel to
wheel. Due to improper handling. Injury 2 4 M(3) ensure grinder plug out

Grinder wheel damaged and that Setting cover to grinder and grinder
fragment hit worker may cause of injury. Injury 3 3 M(3) wheel can use only authorized and
Dangerous
approve by test.
tool(GRINDER)
Grounder and ungrounded plug mismatch Electric Only grounded plug must be use into
may cause of electric shock. shock 3 3 M(3) grounded in let

When using the side wheel of grinder. If wheel not allow to use side of wheel
Fragment impact to worker. Injury 2 2 T(4) which prohibit use side of wheel

Worker use grinder at unsafe a tune safe Injury 3 4 S(2) When use the grinder must be safety
cause injury. cover
Worker use unconnected circuit breaker Electric Grinder used to connect the circuit
& grinder use may cause of electric shock. shock 2 3 M(3) breaker and ground conducted main
panel IELB ATTACHED

Checked by: Signature: Approved by: Signature: Approved by: Signature:

Position : Date: Position: Date: Position: Date:

Likely hood(L1) Severity(s1) RISK LEVEL RANGE RISK GRADE

1.Unlikely/ improbable 1.Negligible U(1)Grade:10-15 U(1)Grade :Unacceptable /intolerable(very high risk)
2. Remote 2. Slight S(2) Grade:10-15 S(2)Grade: Substantial(high risk)
3.Quite Possible/Occasional 3.Modrate M(3)Grade: 6-9 M(3)Grade: Moderate to acceptable with review (middle risk)
4.Likely probable 4.Critical/High T(4)Grade:3-5 T(4)Grade: Tolerable (low risk)
5.Very likely 5.Catasrophic/very high A(5)Grade:1-2 A(5)GRADE: Acceptable to trivial (Very low risk)

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 METHOD STATEMENT
FOR DCS,PLC/CONTROL PANEL INSTALLATION
DP16003-DD09-P0ZEN-750015

RISK ASSESSMENT REPORT

Main Process : CCTV Installation Risk CONTRACTTOR :DPSI
grade
Job / Task Risk Factor Accident L1 S1 controls Remarks
TYPE
Eye damaged by foreign sparkle due to Injury 3 3 M(3) When use the grinder worker must be
Worker not wearing safety glasses AND wear safety glass & PPE
PPE
Finger cutting when change grinder Injury 2 4 M(3) When changes the grinder wheel to
wheel. Due to improper handling. ensure grinder plug out

Grinder wheel damaged and that Injury 3 3 M(3) Setting cover to grinder and grinder
fragment hit worker may cause of injury. wheel can use only authorized and
Dangerous approve by test.
tool(GRINDER) Grounder and ungrounded plug mismatch Electric 3 3 M(3) Only grounded plug must be use into
may cause of electric shock. shock grounded in let

When using the side wheel of grinder. Injury 2 2 T(4) If wheel not allow to use side of wheel
Fragment impact to worker. which prohibit use side of wheel

Worker use grinder at unsafe a tune safe Injury 3 4 S(2) When use the grinder must be safety
cause injury . cover
Worker use unconnected circuit breaker Electric 2 3 M(3) Grinder used to connect the circuit
& grinder use may cause of electric shock. shock breaker and ground conducted main
panel IELB attached.

Checked by: Signature: Approved by: Signature: Approved by: Signature:

Position : Date: Position: Date: Position: Date:

Likely hood(L1) Severity(s1) RISK LEVEL RANGE RISK GRADE

1.Unlikely/ improbable 1.Negligible U(1)Grade:10-15 U(1)Grade :Unacceptable /intolerable(very high risk)
2. Remote 2. Slight S(2) Grade:10-15 S(2)Grade: Substantial(high risk)
3.Quite Possible/Occasional 3.Modrate M(3)Grade: 6-9 M(3)Grade: Moderate to acceptable with review (middle risk)
4.Likely probable 4.Critical/High T(4)Grade:3-5 T(4)Grade: Tolerable (low risk)
5.Very likely 5.Catasrophic/very high A(5)Grade:1-2 A(5)GRADE: Acceptable to trivial (Very low risk)

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 METHOD STATEMENT
FOR DCS,PLC/CONTROL PANEL INSTALLATION
DP16003-DD09-P0ZEN-750015

RISK ASSESSMENT REPORT

Main Process : CCTV & PA SYSTEM Installation Risk CONTRACTTOR :DPSI
grade
Job / Task Risk Factor Accident L1 S1 controls Remarks
TYPE
Burn due to worker not wearing welding
Welder must be wear Welding face shield
face shield welding gloves during welding Injury 2 3 M(3)
welding gloves Welding Apron etc
works
Not perform special safety instruction may Electric To perform training for prevent for electric
2 2 T(4)
cause OF electric shock shock shock before start welding work.
During welding work base metal or
During welding electric shock damage of Electric grounded area do not contact with
3 3 M(3)
eyes and burn of skin. shock welding rod holder. Install ELEB and
worker must wear PPE
If welding are wetted that cause electric Electric Welding machine must grounded and not
3 3 M(3)
shock shock welding in wetted area
Welding machine recharge parts are not Electric Welding machine recharge part must be
Electric facility 3 3 M(3)
insulated that may cause of electric shock shock insulated by insulation tap.
(Welding Welding machine is not in the use not When welding machine is not use welding
machine)s power of the welding machine may cause Electric machine shall e power off when install
3 3 M(3)
of electric shock.(grounded area contact shock panel board consider about easy to power
with welding machine holder) off.
ELCB must be grounded and welding
If ELCB is not install with ground & the
Electric machine must be grounded by holder. If
welding machine with ground by holder 3 3 M(3)
shock there are no electric load maintain less
may cause of electric shock
then 25v.
Welding holder damaged part is not Damage welding holder change
Electric
insulated may cause of electric shock by 3 3 M(3) immediately and maintain insulated
shock
contact with the worker. condition.
Work area in 5m set extinguisher and anti
Fire due to splash welding sparkle . Fire 3 3 M(3) sparkle rag . Assign person for watch
sparkle.
Make vertical oxygen and acetylene by use
of Trolley. Using the Flash Back Arrester.
Explosion when cutting work Explosion 2 4 M3
Worker must be wear b e wear burn
prevention gloves when cutting work.

Checked by : Signature: Approved by: Signature: Approved by: Signature:

Position : Date: Position: Date: Position: Date:

Likely hood(L1) Severity(s1) RISK LEVEL RANGE RISK GRADE

1.Unlikely/ improbable 1.Negligible U(1)Grade:10-15 U(1)Grade :Unacceptable /intolerable(very high risk)
2. Remote 2. Slight S(2) Grade:10-15 S(2)Grade: Substantial(high risk)
3.Quite Possible/Occasional 3.Modrate M(3)Grade: 6-9 M(3)Grade: Moderate to acceptable with review (middle risk)
4.Likely probable 4.critical/High T(4)Grade:3-5 T(4)Grade: Tolerable (low risk)
5.Very likely 5.Catasrophic/very high A(5)Grade:1-2 A(5)GRADE: Acceptable to trivial (Very low risk)

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