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SEC POWER PLANT PP-13 PROJECT
METHOD STATEMENT FOR ERECTION OF HSRG WORK DOCUMENT NO:NIS/626/MS/001_REV 00 SUBCONTRACTOR:NASS INDUSTRIAL SERVICES
GAMA REVIEW Discipline Superintendent
HSE Manager
QA/QC Manager
Site Manager
Name Date Sign Remarks: Any such review or consent by GAMA, shall not relieve the Subcontractor, in any case or for any reason whatsoever, from any obligation, liability or responsibility arising out of or in connection with the Contract, including without being limited thereto, to the responsibility for errors, omissions, discrepancies and non-compliances. Within this context, this document shall not prevail over or amend the Contract, or relieve the Subcontractor from any of its duties, obligations, responsibilities or liabilities under the Contract. Anything presented herein by the Subcontractor shall in no event i) excuse the Subcontractor’s non-performance under the Contract, or
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ii) entitle him to a variation under the Contract or an adjustment to the Contract Price.
SUBCONTRACTOR Rev. No.
Date
Description*
Prepared by
HSE Manager
QA/QC Manager
Site Manager
Project Manager
0
DOCUMENT HISTORY: Remarks
Rev. No.
Date (Reason for Revision)
* Description: Document issue purpose -
First Issue
-
For Information
-
For Review
-
For Approval (or Issued for Construction)
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CONTENT
1.0
PURPOSE ..................................................................................................................................... 4
2.0
SCOPE OF WORK ........................................................................................................................ 4
3.0
RESPONSIBILITIES ...................................................................................................................... 4
4.0
DEFINITIONS / ABBREVIATIONS ................................................................................................ 4
5.0
PERSONNEL................................................................................................................................. 5
6.0
MATERIALS .................................................................................................................................. 5
7.0
EQUIPMENT.................................................................................................................................. 5
8.0
SUBCONTRACTORS’ SUB-TIER CONTRACTORS .................................................................... 5
9.0
EXECUTION .................................................................................................................................. 5
10.0
TIME LINE OF ACTIVITIES ......................................................................................................... 29
11.0
PROGRESS MEASUREMENT .................................................................................................... 29
12.0
QUALITY REQUIREMENTS........................................................................................................ 29
13.0
HEALTH, SAFETY and ENVIRONMENTAL REQUIREMENTS.................................................. 30
14.0
RISK ASSESSMENTS ................................................................................................................ 32
15.0
REFERENCES ............................................................................................................................ 32
16.0
TECHNICAL APPENDICES ........................................................................................................ 32
17.0
ATTACHMENTS .......................................................................................................................... 32
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PURPOSE This Method statement describes in detail of 3 Nos.Heat Recovery Steam Generator Erection works for SEC Power Plant Project PP-13 being carried at KSA by M/s NIS , Bahrain. This includes addressing programs for implementing commitments regarding the quality and Safety of works.
2.0
SCOPE OF WORK This document outlines the method for Receiving & Shifting of OWNER’S materials from Warehouse to Site/Laydown Yard, Unloading and Storage of Equipments/Materials, Checking the Quality & Quantity of Incoming Materials, Erection & Installation of All Equipments relevant to the Plant,Assembly of the parts that make up the bearing Structures,relevant stairs and walkways,Main & Intermediate connection pipelines,drains & Vents,Valves,İnlet & Outlet ducts,Main Stacks etc.,Non destructive testing including PWHT,testing,Insulation & Touch-up painting wherever applicable.
3.0
RESPONSIBILITIES Operation Manager/Project Manager shall be responsible for overall coordination of the activities and allocation of resources such that it meets the requirements of this MS.
4.0
DEFINITIONS / ABBREVIATIONS OWNER:
SEC (Saudi Electricity Company)
CONSULTANT:
Worley Parson
SUPPLIER:
S.T.F.S.p.A
MAIN CONTRACTOR:
GAMA
ERECTION CONTRACTOR: Nass Industrial Service ,Bahrain (NIS) ITP:
Inspection Test Plan
QAP:
Quality Assuranse Plan
WPS:
Welding Procedure Specification
PQR:
Procedure Qualification record
WQT:
Welder Qualification Test
HSE:
Health Safety Environment
TBN:
To be nominated
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PERSONNEL Planned Manpower Distribution Histogram attached.
6.0
MATERIALS NASS shall mobilise required materials ,tools & consumables as per the Scope and project schedule.
7.0
EQUIPMENT Equipment Histogram Attached.
8.0
SUBCONTRACTORS’ SUB-TIER CONTRACTORS Details of Sub-Contractor along with responsibilities shall be provided as a when freezed or mobilised.
9.0
EXECUTION 9.1 Shifting,Storage & Handling of FIM: a)Transportation of Materials All relevant project materials shall be transported from Warehouse to NIS Laydown Area /Erection Site on a Trailor after completion of required Formalities. b) Unloading & Storage Materials shall be unloaded with a help of Forklift/Crane and store with Utmost care either in covered or Open area depending upon the requirement. Materials in the open area shall be stored above ground (200mm) on a wood, on platforms or pallets in a manner that will prevent any deterioration from debris, grease, paint spray or any other foreign matter. c) Inspection/Verification: Incoming materials shall be offered for Inspection/Verification to ensure that the correct grade, quality, condition, painting, identification and dimension have been supplied and are in accordance with the Packing lists. Owner shall be informed immediately incase on any defects in Incoming materials with reports & photograph. Materials that cannot be identified by identification markings, new identification label have to be provided on that particular item. Damaged materials and Spare Materials shall be placed in a separate storage area from other usable materials, with sufficient safeguard to prevent its use. Daily Material Receipt (DMR) Accepted FIM Materials shall be documented in the form of MRIR report for easy tracking.
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9.2 Planning & Construction A detailed Construcion Schedule shall be prepared using Primavera Project Planner/ Microsoft Project/Spread Sheet highlighting: a) Sequence of Erection of HRSG Components. b) Critical Path c) Manpower Histogram The construction schedule shall be regularly updated every week in accordance to Contractor and Consultant requirements in terms of progress of works and forecast to finish. The sequence of activities indicated in the construction schedule may be modified or updated at later stage of execution due to non availability of Erection Front,Owner’s requirement,Climatic and Environmental Condition,Routes Operability etc. Materials receipt status, Work front status along with quarantine list if any shall be published weekly in excel format. 9.2 Erection of By-Pass Stack a) By-Pass stack erection sequence shall be as follows: 1) Stack foundation preparation. 2) Erection of Steel Structure shall be done by the use of suitable crane. 3) Installation of Diverter box. 4) Installation of Upper steel structure. 5) Pre-Assembly of Stack Section-1 along with platform,ladder,gratings and other accessories if applicable. 6) Installation of Stack Section-1. 7) Pre-Assembly of Stack Section-2 along with platform,ladder,gratings and other accessories if applicable. 8) Installation of Stack Section-2. 9) Pre-Assembly of Stack Section-3 along with platform,ladder,gratings and other accessories if applicable. 10) Installation of Stack Section-3. 11) Installation of CEMS Unit.
9.3 Erection of HRSG. a) HRSG Casing erection Sequence:
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HRSG Casing Module shall be erected from Grid G to Grid N as follows: 1) Suitable Shimming shall be provided and Installed as required. 2) Suitable Main and Trail Crane located for lifting of Casing Modules 1,primary-self standing type,casing (left or right) side panel. 3) Main crane Lifts Module 1 (Left or Right) side panel until become upright position. 4) Module 1 (Left or Right) side shall be place on foundation and bolts will be tightens. 5) Counterweight block Shall be placed on both side for fastening Module 1; 6) Modules 1 (Left or Right) side will be fatened to counterweight by steel ropes; 7) Crane is located for lifting of Module1,primary self standing type,horizontal bottom beams of casing floor panel; 8) Crane lifts Module 1,primary-self standing type,horizontal bottom beams of casing floor panel; 9) Temporary supports are prepared to keep horizontal bottom beams of casing floor panel; 10) Main and Trailing crane shall be marched to other position for lifting the opposite casing side panel of Mdule 1 to the one already put in position. Above sequence is repeated for next self standing type Module but when erecting this module the casing floor shall be lifted as a complete panel,since there is no matter of interference with the susequent internal piping installation. After completion of Casing for primary Module,the erection proceed with the installation of not self standing modules. Casing Erection shall proceed by the Installation of casing enclosures panels as follow: 1) Installation of bottom panels to be levelled,aligned to the HRSG main longitudinal and tranversal axles,tack welded on the internal flanges of bottom beams. (Note: Bottom panels of Module 1 shall be installed at a later stage when pressure part modules are set to the installation of boiler internal piping header.) 2) Installation Vertical side panels of bolier alignment using fit-up bolts,verifying that the panels are correctly oriented towards the flue gas path in accordance to the drawings.The installtion of same panels on both side alternatively shall be done It is recommended to complete the installtion of the same.Alighnment,Squaring,verticality of whole casing structure has to be maintained within tolerance especially the value at the top level.Transversal beams shall be progressively removed when vertical panels are fitted up and when squaring tolerance are well within limit. 3) Installation of front and rear panel. 4) Execution of final alignment, levelling and verticality of the whole casing structure, relevant control and control certification, to be carried out when all casing structures are erected, bolted and tack welded. Final checks have to be completed and certified in accordance to SUPPLIER design tolerances and Site Quality Control Plan before any final welding of the casing structures is allowed to commence.Measured values of alignment, levelling and
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verticality of casing structures have to be recorded in a dedicated form to be arranged at site by CONTRACTOR and delivered to SUPPLIER.Upon completion of casing alignment, and before commencing final welding, it is important to verify the dimensions of casing opening where pressure part modules shall be placed into theHRSG.The inside top flange - to- top flange internal dimensions between the adjacent roof beams should be checked and documented against the corresponding dimensions of the modules, to ensure that each module can be set properly into casing structure. 5) Execution of final welding of all casing panels, in accordance to here above listed drawings of the Project. All external welding have to be carried out in a continuous way, stitch welding inside, in accordance to the details shown on the here above listed erection drawings of the casing. 6) Installation of the field casing plates for sealing of the gap between the vertical panels and the bottom panels, as per details shown on the here above listed erection drawings of the casing. 7) Execution of final connections and welding of the truss guide beams. 8) Execution of paint touch up on all casing welds carried out at site, especially in the areas where insulation mattresses have to be installed, in accordance to the painting cycle applicable for the external casing sheets. It is compulsory that said activity is executed before starting with the restoration of insulation and setting of liner plates. 9) Execution of the insulation in the naked strips left void between adjacent vertical side panels, between vertical side panels and horizontal bottom panels, between adjacent horizontal panels,laying and pinning suitable mattresses of ceramic fibre between the panels (double layer,staggered when required) to be packed and covered by the loose lining filler plates. Fixing pins have to be installed and welded at site, retaining studs are installed on the casing sheets of the panels during prefabrication. 10) Installation of the loose lining enclosures plates, sent on site already pre fabricated, each of them identified by marking, with holes drilled, cut at suitable dimensions such as to mach shape and width/length of the specific area to be restored/coated. Loose lining filler plates are kept in position by round washers to be fixed to the lining threaded studs using nuts. Nuts have to be tack welded to the studs, no welding has to be carried out between adjacent loose lining filler plates. The liner assembly of casing/inlet duct sections is designed to allow the protective internal liner system to expand freely due to the temperature expansion of the components. The liner system is composed of a series of overlapping plates, pinned to the outside casing. It is important that the installation of the field seams be understood prior to beginning work. Failure to install field seams correctly can lead to casing hot spots, loss of insulation and general failure to the integrity of the liner system. 11. Restoration of insulation and lining at the junction area of panels of HRSG casing and inlet ducthas to be carried out with the up most care and precision, to avoid any possible gas leakage throughout lining plates and insulation. Said hot gas paths, that are not easily detected and eliminated during boiler operation, will cause burning and damage of the external casing and duct structures of the HRSG. 12. Installation of bumper pipes . Suitable scaffoldings have to be erected at each side of boilercasing to allow positioning and welding of the guiding boxes. Said scaffolding shall remain in place to allow the installation and shimming of the setting plates to be fixed to the tube bundles of the pressure part modules. 13. Installation and bolting of buckstays to the main columns.
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14. Installation of Header Spacers, provided to counter the thrust of the headers towards the casing panels in case of the occurrence of a disrupting earthquake. Backstays are shop welded to the casing panels. 15. Installation and welding of the plates connecting the external stiffeners of the casing panels to the HRSG main structures (columns, beams), in accordance to the applicable drawings of the Project. 16. When casing panels are fully welded and all non destructive tests and controls foreseen by the applicable site Quality Control Plan (QCP) are executed, witnessed and certified by the OWNER it is requested that base plates of columns are grouted by the Civil Contractor, using a suitable non shrinkable-self levelling mortar, leaving the shim packing in position. 17. Final tightening of the nuts of embedded anchor bolt to the base plates of the casing columns shall be executed when grouting has sufficiently set. 18. Beginning of the erection of pressure part modules is bound to completion of the erection and welding of all casing structures, execution and certification of required NDT and the inspections listed in the Site Quality Control Plan.
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9.4 Inlet Duct The inlet duct, possibly supplied in form of panels similar to casing panels,either insulated or to be insulated at site condition. Prefabrication and inner insulation before erection shall be evaluated keeping into account availability of area, accessibility to the erection areas and availability of crane and truck. The erection sequence is as follows: 1. Positioning and welding of floor panels; 2. Positioning of supporting lateral panels; 3. Positioning and welding of lateral panels; 4. Positioning and welding of roof panels; 5. Preparation of internal scaffolding for internal welding and insulation and external welding. 6. Positioning, welding and insulation of the connection pieces between exhauster (round) and duct (rectangular section).
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9.5 Outlet Duct HRSG Outlet Duct connects the boiler casing to the stack breeching using a fabric expansion joint. The type and degree of prefabrication, sequence and methods of erection of the boiler outlet duct main components are similar to the ones of the boiler inlet duct.
9.6 HRSG Casing & Ducts Access Doors. Casing and inlet duct access doors shall be installed on the panels and sealed with a designated bolting type gasket. Care shall be taken to insure that the gasket is not damaged when doors are opened and/or closed in the site. Casing access door gaskets should be replaced at the first sign of becoming brittle. The bolting tape shall lay flat against the surface with no laps or gathering on the material. 9.7 HRSG Stack Each stack (5.5m of diameter, 60m high) shall be site pre-assembled in several segments of variable length complete of all accessories and auxiliary components (access doors, ladders, platforms, rain damper, silencer, personnel protection, mass damper and nozzles). Each segment shall then be erected in sequential order by means of heavy lifting equipment and jointed together by circumferential field welding. The stack preassembly operations consist of prefabricating, at ground level in dedicated area according to the general plant layout, the stack segments in which the whole stack is divided into. Stack segments are made of several shell courses. Maximum height and weight of segments shall depend on the lifting equipment availability at site. The erection sequence is as follows STACK SECTION 1: SHELL + BASE PLATE STACK SECTION 2: SHELL + REINFORCEMENTS + HOOD STACK SECTION 3: SHELL + REINFORCEMENTS + PLATFORMS STACK SECTION 4: SHELL + REINFORCEMENTS + SILENCERS + PLATFORMS Or there maybe 5th Section also, depending upon available materials, Weight, Available Equipment etc. Each shell course (OD=5520mm) is made of 3 curved and beveled shell plates welded with internal angle of 120° (at the time of welding there is to be no paint within 50mm of the weld). Alignment of vertical joints is obtained by strong packs tack welded across the seams (50mm clear from weld as a minimum) and by means of shim plates and wedges. All seam welds are to be in accordance with the applicable WPS. The strong packs will be removed by cutting after the completion of the vertical seams. The surface where they were attached will be ground smooth and inspected for cracks by DPT.
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Shell courses are to be completed with welding attachments according to the drawings. Once the prefabrication operation of the segments are completed, all their surfaces shall be spray / brush coated according to the corrosion protection specification prior to erection and assembly of appurtenances with the only exception of the ends to be coupled. Before starting with the erection of the segments making the stack, the installation of the following stack components shall be completed: - The silencer will be fixed on segment on which it is coming - The rain damper on segment on which it is coming - Platforms, ladders, landings, inspection doors, personnel protection on segments as per drawings. - The ladders across the joints will be fixed after the completion of the erection Once the above mentioned stack accessories have been assembled, stack section no. 2 shall be assembled directly on the main stack section no. 1. The base plate will sit on steel packs and wedges to ensure the level and the planarity of the underside of the base plate not to deviate from the specified values. After segments 1 and 2 have passed the verticality check, manual torque will be applied to the nuts of holding down bolts. Stack erection will proceed in accordance with the following phases: - Remove lifting lugs from stack section no. 2; - Lift stack section no. 3, fitted with appurtenances and temporary platforms near the top end, if required; - Align stack section no. 3 with strong packs tack welded across the seams (50mm clear from weld as a minimum) and by means of shim plates and wedges; - Release slings from temporary platforms fitted near the top of stack section no. 3 when provisional connection to stack section no. 2 allows a safe release; - Complete weld of circumferential butt joint, inclusive of back gauge, if foreseen - Internal scaffolding is required to execute the back gauge weld of the two stack segments joint. The access to the scaffold will be through a manhole 600x600 mm located some 800 mm lower than the joint. The scaffold shall be removed after weld acceptance GAMA/Owner. - Remove lifting lugs from stack section no. 3: - All temporary attachment shall be removed without damaging the base material. Any portion of the weld on the internal surface of the stack subjected to flue gas shall be made flush and ground smooth - Coating shall be applied to circumferential joint, touch up and remove temporary platforms from stack section no. 2 to be re-used for next stack section coupling operation; - Lift stack sections no. 4 according to the same sequence and procedure;
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- Remove any temporary work and temporary aviation warnings; - Install ladders across the joints. Vertically check will be performed at completion of each stack section assembly. Stack base plate will be grouted after the positioning of the last highest stack section and in any case after stack verticality check acceptance. The grout shall be non-shrink type. Immediately before grouting, the space under the base plate will be cleaned. Steel packs will be left in place and totally enclosed by the grout. After curing time, when grout has developed its nominal strength, holding down bolts will be snug tight. Anchor bolts shall be re-tightened 30 days after grouting application.
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Note: The erection of the HRSG main stack has to be limited to the top height of the boiler casing at elevation ~ 30.00 to 35.00 meter, for safety reasons, due to the rotation of the main crane loaded with pressure part modules.
9.8 HRSG Pressure Part Modules: Pressure Parts Modules for 1 HRSG consist of 8 (eight) modules probably shipped at site completed with roof casing plate, hangers and interconnecting pipes between. Unloading, Storage & Lifting of Modules shall be done with the help of 600 MT main crane and 300 MT trailing crane and as per the special instruction of Supplier if any.
Pressure part modules shall be arranged inside the casing in 2 Nos./Row and from casing module 1 to 4 or vice versa. Preconditions for pressure modules installation shall be as follows: The boiler casing structure is fully installed, tightened, welded and NDEs tested. Restoration of insulation and liner between adjacent modules shall be completed. Bumpers have been installed. All NDT activities has been performed and certified as quality plan. Grouting and mortar has sufficiently matured as per specification
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While settling the modules into casing structure the nozzle connections shall be checked against SUPPLIER specific erection drawings of the Project for correct displacement in location and elevation. Nozzle location shall be checked with an inspection. No other crane shall work in areas adjacent to the lifting area, including Civil Contractor tower cranes if any, while pressure part modules lifting operation are in progress. Tube skin thermocouple shall be welded on pressure part module on site wherever applicable. Lifting of pressure part modules shall be carried out in full accordance to specific drawings and instructions issued by SUPPLIER to avoid any damaging of the modules. All lifting equipment’s and devices at completion of each lift shall be checked to assure that no damage has occurred during lifting. Any bent, worn or damaged component shall be replaced.
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9.9 Internal Piping & Structure When all pressure parts modules are installed into the boiler casing, it is possible to commence the erection of boiler internal piping, headers and auxiliary structures, like: 1 Trusses for stiffening the tube bundles, guiding the down-comers, horizontal gas baffle plates to confine the gas flow to the tube bundles of the pressure part modules. 2 Vertical Gas Baffle Plates for sealing the hot gas passes through the adjacent modules and through casing structures (floor, walls, roof) and modules. 3 Connection Piping and Internal Headers. Internal details and piping shall be introduced into the boiler casing through the access doors and the opening left by the bottom panels not installed during casing erection. When all risers have been welded to steam drums, temporary boiler internal supporting plates of evaporator pressure modules shall be removed.
9.10 Trusses, Horizontal & Vertical Gas Baffles Plates Trusses can be classified as follows: a. Upper trusses, the ones installed between adjacent rows of modules, and between the first/last row of modules and the casing front/rear panels, at the elevation of the upper headers b. Intermediate trusses (only for Module 1) c. Lower trusses, the ones installed between adjacent rows of modules, at the elevation of the lower headers
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Suitable scaffoldings have to be erected in the row between two adjacent modules, starting from casing floor up to the top of the tube bundles of the modules, to allow the installation of aforesaid components. The horizontal gas baffles, fixed to the upper and lower trusses by bolting because trusses act as supporting frames for the gas baffles, are installed as a barrier to the hot gas flue creating a dead chamber at the boiler floor (lower dead chamber) and the boiler roof (upper dead chamber). Upper and lower trusses and the horizontal gas baffles are delivered at site prefabricated, singularly marked for an easy identification and installation. Intermediate trusses at two different elevations (+10195 e +19995) for reinforcement porpoises have to be installed only on MODULE 1. Access doors to pressure part module connecting piping and tube bundles are provided at suitable positions on the lower baffle plates. Prefabricated Vertical Baffle plates duly marked for easy identification shall be installed at both gas inlet and outlet side of each module.
9.11 Connection piping & Internal headers: During the installation of internal headers and fitting of piping it’s recommended that the liner of floor panels is suitably protected with wooden boards and fire proof blankets, to avoid contamination and scratching of liner sheets with grinding slag and welding spatters. Extra lengths are left on header nozzles and piping spool, to be trimmed at site, to facilitate the erection and fitting up of the lines. Piping bevels shall be carried out in accordance to SUPPLIER design and applicable WPS. It is of paramount importance that the execution of welding, Post Weld Heat Treatment (PWHTs), Nondestructive Tests (NDTs) are strictly executed and monitored in accordance to the approved WPSs/WPQRs, PWHTs and NDTs specifications, prepared by the Erection Contractor(s) and approved by NoBo. Internal scaffolding previously installed before the installation of the pressure part modules shall be modified accordingly. 9.12 Piping through Boiler Casing. Suitable metallic and textile expansion bellows shall be provided to allow the expansion of piping linked to the pressure part modules throughout the casing lateral walls, roof and floor. Some of the roof expansion joints which are not shop installed on pressure part modules shall be installed at site, as per the applicable drawings and supplier Instruction. Expansion bellows shall be protected from weld spatters and puncture during the erection phase. Internal insulation if any shall be properly installed and secured. 9.13 Steel Structure While mounting main and auxiliary frameworks, including ladders, gangways, service platforms and gratings, it cannot be completely sequenced. It all depends on the availability
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of material, lifting equipment, personnel, drawings and access availability and accordingly Erection sequence shall be scheduled. However, sequencing shall be done in such a way in order to avoid clashes with other equipment or installation of our own or those already erected and/or installed by other sub-contractors on site. Auxiliary structures, to allow accessibility to all components of the boilers include: - Prefabricated columns, beams and bracers - Bolts - Handrails - Ladders - Gratings - Stair-steps Secondary structures assembly shall consist of following activities: Assembly and installation of the main boiler stairway, complete with gratings, handrails and foot guards including the final tightening of the bolts after checking the verticality and dimensions of the structure; On-site assembly of all the secondary structures, beams, stairs, walkways, handrails, foot guards, gratings etc., with arrangement and welding of cantilever attachments / connection brackets with reinforcement to the bearing structures; On-site assembly of the frame for the top support structures of the silencers; Assembly of hoist tower structures. A general sequence for steel structures erection shall be as follows: 1. Transportation of prefabricated sections to the erection area; 2. Installation of stairs-towers sections; Note: After each section of Installation, it shall be checked for verticality and tightening of bolts. 2. Final check for verticality and, after shimming, if necessary, pouring of concrete; 3. Installation of steam drums supporting structures; 4. Installation of auxiliary structures, including gratings handrails and details at elevation above steam drums 6. Completion of auxiliary structures at all elevations The structural erection shall be sequenced in such a way that they do not interfere with major installation and as per reference documents. Consequently, stairs and gangways shall be erected as the progress of the main activities allows it, for easier accessibility to the working areas. Main stairs shall be erected first provided that they do not interfere with major plant erection. During the assembly, following operation order shall be taken care:
Perpendicular check and transversal survey;
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Bolts tightening;
The grouting of the base plates of columns;
The coupling bolts of the secondary structures shall be protected, right after their tightening, with a coat of organic or inorganic zinc plating;
The assembly of stairs and gratings will start right after the execution of the final perpendicular check of the single structure and shall be completed swiftly. Regulation railings shall be immediately installed on the boiler floors and also in spots which may be temporarily exposed (for example in correspondence of the boiler itself); those not compatible with access needs will be dismantled at the end of the assembly;
Column-column couplings: Couplings between column sections, the surfaces of the tips in contact are worked. The coupling covers shall be mounted with the relative fillings and the complete contact between surfaces to be tightened as well as coaxially of the holes shall be obtained.
Varnishing and coupling protection;
Final verifications of perpendicularity, squaring and frame and/or case leveling after the execution of the entire assembly;
Touch up painting on the welded surfaces;
9.14 Grating Assembly: Gratings supplied in shaped-on-design panels with toe-guard already welded shall be directly installed on the structure as per the drawings with the help of crane. Loose toe-guard shall be welded after erection of gratings panel wherever applicable. For the small bore piping and/or process pipes the passing hole shall be provided if applicable or existing cut-out shall be adjusted. The assembly of stairs and handrails, including gratings, shall be performed parallel to allow the immediate access to erected components or to the ones still to be erected 9.15 Bolts Tightening The tightening of bolts shall be carried out by using a suitable mean to achieve desired result. The contact surfaces between washer, nut and thread shall be greased. The riveted part surfaces in contact with the head of the bolt and with the nuts shall be parallel. As an exception, the surfaces can present inclinations as long as they are not compared to a surface perpendicular to the bolt axis. For inclinations, inclined washers shall be used in order to guarantee a correct asset of the nut head. Coupling tightening shall be performed tightening first the central bolts and then alternating those adjacent to them.
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As soon as the bolts have been tightened it shall be clearly marked. Before beginning the assembly of the parts under pressure, high resistance bolt tightening shall be completed. Exceptions to this rule may be allowed only in special cases.
9.16 HP, IP & LP Drum Steam drums shall be positioned on supporting structures, previously installed and welded to the main roof beams of HRSG casing, just after completion of the erection of pressure part modules. Lifting of HP drum shall be carried out using the 600 MT crane used for lifting the pressure part modules, provided with cable slings of correct length and diameter, to be rigged not breaking against any nozzle or nozzle reinforcement pad of the drum. Proper Packing shall be used with cable slings to prevent scratching and/or damage to the material.
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Dedicated lifting plan shall be prepared for handling and lifting of the drum well in advance before erection.
Drums shall be positioned in accordance to specific project erection drawings, taking into consideration that the support saddles of drum shall be provided with Teflon pads, sliding on steel plates lined with Teflon too. Check shall be done to make sure to attach the Teflon sliding packs to both the drum base plates and support steel prior to setting the drum on the support structure. Guides shall be installed around each saddle after the drum is set in its final position Anchor bolts for saddles should be warm tight. All anchor bolts shall be equipped with double nuts. It is important in having drums correctly installed and leveled with a difference in elevation of the drum center line from one end to the other not greater than 10 mm. The elevation and the location of drum nozzles shall be within the following tolerances: Elevation: +/- 10 mm. Location: +/- 6 mm. After that final positioning of the HP drum has been completed, following activities shall be carried out: a) Erection and welding of all lines connected to the nozzles of the drum, including vents and drains.
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b) Erection of drum safety valves, silencers of safety valves and supporting structures (to be carried out after completion of the hydraulic tests), valves, vents and drains. c) Execution of pressure tests of the drum in accordance with contractual standards and codes and SUPPLIER DESIGN. d) Installation of internal filter pads (to be carried out after completion of HRSG chemical cleaning). e) Execution of final inspection, and general cleaning of the drum after completion of chemical cleaning. f) Replacement of manhole gaskets at completion of HRSG chemical cleanings. The filters shall be removed before carrying out drum pressure test for being reinstalled inside the drum after completion of the boiler chemical cleaning. The installation of all internals parts like cyclones and demisters commences after the completion of all Mechanical Activities and when the Boiler has completed its chemical cleaning and/or blowing. 9.17 Blow Down tank: The atmospheric blow down tank shall be installed on ground designed and specified within the erection drawings. Placement and assembly will follow the site requirements after a proper check of the foundation provided. Installation shall be as per relevant approved drawings issued for such a purpose. Hereby listed activities shall be carried out at site: 1. Control of elevation and dimension of civil foundations and tank embedment; 2. Cleaning and brushing of tank embedment; 3. Positioning of tank on foundations, leveling the tank with suitable shim packing; 4. Installation of piping, vents, silencer, valves, drains, supports; 5. Connection of piping, vents, drains, details and accessories to the tanks; 6. Execution of hydraulic pressure tests, including preparatory operations for the execution of pressure tests, supplying of base materials for laying of temporary lines, blinding and/or capping of flanges and nozzles, eventual removal of instrumentation, execution of pressure tests, final restoring of lines and instrumentation after completion of the tests; 7. Replacement of manhole gaskets and closing of manholes; 9.18 Pressure Part Piping: Piping shall be installed to meet the requirements of drawings, Codes & Standards as they pertain to welding, procedure, qualification, post weld heat treatment, nondestructive examination.
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Piping erection being major and the most critical activity of the whole construction schedule of the HRSG, therefore best resource shall be deployed for erecting the piping in accordance to contractual schedule. Prior to any operations, a check shall be made to ensure that the supplied spools and components are in accordance with the relevant documents (specifications, drawings, certifications). If anything found deviating from (specification, drawings, certification), same shall be reported to Owner. A correct marking is the necessary prerequisite for proper checking operations: - Identification of materials shall remain possible, either by retaining or by transferring the mark stipulated by the product standard or by a unique code (Stamping by round edges is recommended). - Piping ≤ 2” spools, further cutting and adjustments on site, shall report on each part spared from the identification number a new marking (equal from the original mark) to ensure material traceability. - Appropriate measures shall be taken to avoid corrosion-inducing contamination of stainless steel and non-ferrous materials. If contamination occurs, it shall be removed as soon as practicable. -Drain line, which are likely to cause condensation shall be installed with adequate slopes and traps. - Internal and external surfaces to be welded shall be clean and free from paint, oil, rust, scale and other material that would be detrimental to either the weld or the base metal when heat is applied. - Coated parts shall be free of coating products for a sufficient length of both sides of the weld. - To protect the ends of piping (e.g. bevels, screwed ends, flange faces) suitable measures shall be taken e.g. covering, coating, etc. The applied protection shall be removed only before the parts are joined. - Prefabrication of Spools (Cutting, Beveling, Welding) shall be done as per WPS, Drawings, Codes & Standards. - Pre-assembly of spools at ground shall be done as much as permitted for handling and accessibility for erection. - Before starting pipelines erection, pipe routing and accessibility of spools shall be checked, to anticipate and correct any interference with structures or parts already installed. Particularly, pipes connecting harp lower headers to headers external to the HRSG, shall be positioned, if available, before installation of the overhanging harps, to avoid possible interference during erection. -
While Installation proper dummies shall be installed in place of Non available valves. Large Bore Piping & Supports.
-
All lines > 2” shall be considered to be supplied as prefabricated, with primer coating applied.
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-
All modification works shall be indicated on Erection drawings that have been carried out because of route changes of lines (mark-up drawings at site), to allow the easiest execution of the “as built” drawings,
-
Excess length available in pipe spools shall be trimmed to fit site condition.
-
Pipes supports shall be trial fit, trim to fit and shall be finally installed.
-
All piping spools shall be air blown using Compressor before erection in order to remove any foreign materials trapped inside spools. Small bore Piping & Support
-
All piping equal or lower than 2” shall be fabricated and erected in suit to site condition.
-
All modification works shall be indicated on Erection drawings that have been carried out because of route changes of lines (mark-up drawings at site), to allow the easiest execution of the “as built” drawings,
-
Vents and drains of all HRSG equipment, piping, valves and safety valves, primary tubing, tanks, pumps and any other boiler components, shall be routed to the nearer collecting /discharging pit or equipment, even if the location of the discharging point and detailed routing of lines is not precisely shown on drawings and isometric drawings. General Checking of spools, fittings, valves, supports, any component of the line, before commencing the erection of each specific pipe line. In case that any piping spool, support, valve and/or accessory has no identification tag shall be immediately notified to SUPPLIER. a) All site welding and associated Non Destructive Tests and controls shall be carried out in accordance to specifications, Code & ITP. b) Basic coated electrodes must be exclusively used for site welding. c) It is compulsory that welding on pressure parts commences only when the execution of associated Non Destructive Tests is assured. d) Welded joints have to be carried out by electric arc welding. Electric arc manual welding process shall be in accordance with Standards and Codes e) All site welders shall be qualified according to all Standards and Codes. f) Before starting any site welding, updated list of all welders shall be submitted for an approval , showing for each welder his welding qualification for different welding categories, positions and materials. Said list shall be kept updated during execution of work and shall be handed over to concern person if required. g) Each site welding shall be stamped with the number and/or initials of the qualified welder who carried out the welding. h) Welding record master book shall be maintained, indicating the names and punch numbers of all welders, the list of performed welding with date of execution, reference of any repairs that has been carried out. Such register shall be made available to concern person upon request.
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i) Preparation of the pipe edges to be welded (beveling) shall be in accordance to applicable WPS, Standards and Codes. The edges themselves shall be finished by means of tools and/or grinding. Surfaces cut with oxyacetylene torch shall be ground to remove the de-carbureted base material. Surfaces shall be cleaned with accuracy so as to appear perfectly free from oxides, greases, paints, scales, etc. j) Spools to be welded, especially for high alloy steel, shall be linked and aligned to each other by means of suitable coupling devices before the execution of the first welding layer foreseen by WPS. Temporary tack-welding has to be carried out by qualified welders and shall be eliminated by grinding. Temporary tack welding is forbidden for materials to be heat treated. k) Welding rods to be used shall ensure a deposit having the same chemical and physical characteristics of the base material to be welded. l) Packages of welding rods shall be preserved in a suitable oven in the store. Each welder shall be equipped on site with a portable oven for the preservation/protection of the welding rods during working hours. All welding rods shall be preserved in the oven in the store during the whole night, suitably labelled to allow an easy identification, for being redistributed the next morning. m) All welding defects shall be attended as per applicable procedure and standard. n) Butt weld joints of carbon steel piping and low alloy steel piping shall be carried out with a root pass made by TIG process (in Argon atmosphere). o) In case that the thickness of spools and/or valves to be welded is different, the spool with bigger thickness has to be internally/externally beveled and ground to get same diameters in correspondence of the welding. p) All primary lines starting from piping and/or equipment shall be completed up to the second root valve (included). q) All threaded junctions shall be in accordance with all applicable Standards and Codes. r) Tack welding between flanges and bolts shall not be done. s) Vertical runs of piping shall be supported by suitable blocks which shall be welded to piping using approved welding procedures and welding rods t) During the execution of works, care shall be taken to avoid any possible corrosion, damage or presence of any foreign matter into piping, tanks or any other components of the HRSG, by means of sealing caps installed at the piping and/or nozzle ends. Caps shall be removed only just before lifting the pipe spool and, when possible, just before carrying out the welding. It is compulsory that all piping spool have to be carefully blown before being fitted up. u) All valves, particularly the motorized ones, have to be welded keeping the actuator in closed (valve flap or plug in contact with relevant seat but not in a forced position) or open in accordance to the instruction of the Valve Manufacturer and up to the completion of pressure test of the line. v) Fixing pins of spring supports shall be removed after completion of pressure tests and final setting of the supports.
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w) Primer coating shall be immediately applied to each welded joint for protection after completion of welding, heat treatment and NDT, in accordance to contractual painting specification. x) Calibrated diaphragms of flanged flow meters shall be immediately removed after the erection and installed only after completion of boiler steam blowing. Welded flow meters have to be installed after completion of steam blowing at least for the main steam ad hot reheated steam lines, using a temporary spool during HRSG steam blowing, to be erected, welded, removed. y) Temporary spools shall be welded for welded flow meters before carrying out boiler pressure tests, including the execution of required NDT and PWHT Piping Supports & Hangers Supports and hangers shall be erected according to erection drawing. Prior to erection, hangers shall be inspected for damage, proper assembly and greasing. - Structural attachment shall be accurately located with relation to columns and frame center line, equipment location and required offset. Attachments for sliding supports, anchor bases and floor stands shall be accurately leveled. Sliding supports and guide bearings shall be arranged in the cold position such that the sliding pad is located on its supporting parts for all movements predicted by the design. - Variable spring hangers and constant hangers delivered by manufacturers as locked, shall be kept locked during the installation and assembly of the piping, unless otherwise specified by SUPPLIER. - Supports shall be installed to ensure that the identification, load and travel scales are readily visible. All threaded parts shall be fully engaged and locking nuts tightened. - The fixing of the support to the structure shall be adjusted to ensure that the angles of support rods are in accordance with the specified limits. LP Economizer Recirculating Pumps: Pump assembly with all auxiliaries and accessories shall be stored indoor strictly in accordance with Manufacturer’s instruction and on the basis of what indicated in the paragraph dedicated to preservation of aforesaid machinery. During storing into warehouses, installation, alignment and pre commissioning operations preceding the first start up, the pumps shall be adequately protected with temporary sheds and/or polythene sheets. Pump rotors shall be weekly rotated to avoid damaging of the pump seals. Pumps are supplied on skids, therefore following assembly activities shall be carried out: a) Control of foundations and relevant embedment, cleaning included, before positioning the pump skid. b) Control and execution, by means of suitable plates and/or shims, of pump elevation and preliminary alignment. Shims shall be made of rustproof material, possibly of unitary thickness and any packing of shims shall anyway not include more than three shims.
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c) Execution of the final alignment before and after connecting suction and discharge piping, in accordance with tolerances required by the Supplier of machinery, inclusive of the coupling/uncoupling operations of the pump/motor union joint. 9.19 Touch Up Painting All equipment and accessories will be supplied with surface preparation and at least with primer coating. Where necessary, touch up painting shall be done after erection in full compliance with the applicable paint specification. All burrs and edges shall be removed before touch up painting. Inspections and, if required, touch up of the painted surfaces of the equipment will be carried out prior to the final erection and completion. At touch up painting completion, an inspection will be undertaken of all activities and witnessed by parties as per ITP. The acceptance of work and comments if any, shall be recorded on a general approved format Note: Any damages of painting during Transportation shall be reported to Owner in the MRIR and supported by photo records. 10.0
TIME LINE OF ACTIVITIES Detailed Schedule attached.
11.0
PROGRESS MEASUREMENT Detailed progress measurement Sheet shall be submitted after taking off complete BOQ for GAMA approval.
12.0
QUALITY REQUIREMENTS Inspection and Recording Requirements The engineer shall verify that the Engineer/Supervisor/Foreman with construction responsibilities for the execution of works is familiar with this method statement and is issued with copies of the inspection checklists and test plans. The engineer should satisfy procedures provided by QA/QC inspections to ensure the pipe welding works meet specified engineering requirements and drawings. As part of the assessment, the QC Inspection Procedures must ensure a quantitative or qualitative acceptance criteria for determining the prescribed activities have been accomplished satisfactorily. The QC inspection personnel, in coordination with Site Engineer/Supervisor, shall verify that the quality of the works and related testing activities are within the project specifications requirements. The Engineer/Supervisor shall verify that the works is accomplished in accordance with the specifications and the Supplier’s procedures. The Supervisor should verify any as-built record of works and testing, and confirm that the information meets the project requirements. All inspection shall be done as per approved QAP & ITP. Dok. No: PR-004-T05, Rev. No: 1
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Training and Qualification of Personnel The Supervisor shall verify that the personnel have sufficient knowledge of the procedure requirements. The Supervisor shall review any training and qualification records for those individuals who shall do the task to determine whether they are skilled enough to follow the procedure before the actual work is carried out. Non Destructive Testing (NDT) All NDE shall be performed in accordance with applicable Codes /Project Specification. Minimum NDE percentage shall be done as per applicable Project Specification. A separate written relevant NDE procedure shall be submitted to GAMA for approval. NDE shall be performed and interpreted by qualified personnel only. Quality Assurance plan & Inspection Test Plan attached. Details & Responsibilities of the Sub-Contractor for NDT work shall be submitted at a later stage. CV of the QA/QC manager attached. Non-Conformities procedure attached. List of the Control and Test Equipment & Tools attached. Calibration certificate shall be submitted progressively after mobilizing to site. QA/QC Team: 1) QA/QC Manager Mr. Yahiya Mahdi Hilal Abdualla Madan Diploma in Mechanical & Plant Engineering with 20 years of Experience. Additional Certifcation: NDT-ASNT LEVEL II in RT, UT, PT,MT& VT CSWIP 3.1 - Certified Welding Inspector, TWI 2008 CSWIP BGAS 3.2– Certified Painting Inspector, TWI 2010 IOSH Safety Management Electrical wire man license 2) QA/QC Supervisor 3) Mr. A. Shajahan Higher Secondary school Certificate with 17+ years of Experience.
Additional Certifcation: Certified Associated welding Inspector (CAWI –AWS). Certified ASNT Level II in RT, UT, MT ,PT &VBT
13.0
HEALTH, SAFETY and ENVIRONMENTAL REQUIREMENTS Contact Details of HSE Site Team: Dok. No: PR-004-T05, Rev. No: 1
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1) HSE Manager Mr.Edwin Suganob Qualification: Diploma in Safety Engineering with 14+ years of Experience Additional Certifcation: Certificate of Attendance for incident/injury free Certificate of Attendance for chemical spill control Certificate of participation for Oxy-Acetylene training Certificate of completion for Fire safety training Certificate of Training for Excavation and training safety Certificate of attendance for Site incident prevention program Certificate of Training for Scaffolds and ladder safety Certificate of attendance for tools and equipment maintenance Certificate of completion for Control of hazardous energies (COHE/LOTO) Certificate of Training for fall protection and Ladder safety Certificate of completion for Basic and advance electrical safety Certificate of training for Safe Rigging and Slinging Certificate of Training for Tower crane Rescue (High Angle training Centre) Certificate for Instructional Training course for Assisted Rescue Kit (ARK) Certificate of completion for First Aid and Adult CPR/AED Certificate of completion for Basic Occupational Safety and Health Certificate of completion in supervisor skills workshop 2) HSE Supervisor TBN General PPE’S like Helmet, Safety Shoes, safety Glass, coverall, Safety Harness etc. shall be provided to all workforce. Special PPE’S like Breathing Devices shall be arranged if required. HSE PLAN ATTACHED.
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RISK ASSESSMENTS Hazard Identification & Risk Assessment Procedure attached.
15.0
16.0
17.0
REFERENCES PP1314-00-Y-UP-WP-003
Project Quality Plan
GEMSS-G-05
Quality Control & Quality Assurance Plan.
TECHNICAL APPENDICES NIS/GAMA/ITP/626-01
Quality Plan & Inspection & Test Program.
QCP-34
Non Conformance Procedure.
ATTACHMENTS Attachment-1 Attachment-2 Attachment-3 Attachment-4 Attachment-5 Attachment-6 Attachment-7 Attachment-8 Attachment-9
Planned Manpower Distribution Histogram. Equipment Histogram (Subcontractor & GAMA) Detailed Schedule Quality Assurance Plan & Inspection Test Plan CV of the QA/QC Manager Non-Conformities Procedure List of the Control and Test Equipment & Tools attached. Calibration Certificate shall be submitted progressively after mobilizing to site. HSE Plan Hazard Identification & Risk Assessment Procedure.
Dok. No: PR-004-T05, Rev. No: 1
Attachment No.: 01 Planned Manpower Distribution Histogram
ANNEXURE‐I
NASS INDUSTRIAL SERVICES SEC POWER PLANT PP‐13 PROJECT MANPOWER HISTOGRAM SL.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
SL.NO 1 2 3 5 6 7 8 11 12 13 14 15
DURMA PROJECT
CATEGORY (INDIRECT)
Month
Resident Project Manager Unit Incharge QA/QC Manager HSE Manager Planning Dept Administative Officer Accountant Stores Incharge QA/QC Engineer/Supervisor QC Inspector & NDT Technician Execution Engineer Execution Supervisor Safety Officer/Supervisor Survey Team Lifting Supervisor/Rigger-1 Foremen Store Keeper Time Keeper Data Operator TOTAL CATEGORY (DIRECT)
STRUCTURE FITTER PRESSURE PARTS / PIPING FITTER MILL WT FITTER TIG WELDER STUCTURE & OTHER WELDER GRINDER/GAS CUTTER ERECTOR/RIGGER PAINTER HIAB/TRAILOR/FORLIFT OPERATOR ELECTRICIANS/MAINTENANCE WATCHMAN/OFFICE BOY HELPERS/OTHERS TOTAL
Nov'15
Dec'15
Jan'16
Feb'16
Mar'16
Apr'16
May'16
Jun'16
Jul'16
Aug'16
Sept'16
Oct'16
Nov'16
Dec'16
Jan'17
1
1
1
1
1
1
2
2
2
2
2
1
COMMON FOR HRSG & GTG 1
1
1
1
1
1
1
2
2
2
2
2
1 1 COMMON FOR HRSG & GTG COMMON FOR HRSG & GTG 2 2 COMMON FOR HRSG & GTG COMMON FOR HRSG & GTG COMMON FOR HRSG & GTG
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
1
1 1 1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
3
3
3
3
3
3
3
2
1
3 3 COMMON FOR HRSG & GTG COMMON FOR HRSG & GTG COMMON FOR HRSG & GTG
Month
0
6
11
12
13
13
13
13
13
13
13
13
13
12
9
Nov'15
Dec'15
Jan'16
Feb'16
Mar'16
Apr'16
May'16
Jun'16
Jul'16
Aug'16
Sept'16
Oct'16
Nov'16
Dec'16
Jan'17
2
6
10
14
14
14
14
14
14
14
14
14
10
5
1
2
3
5
5
5
5
5
5
4
3
2
1
2
3
3
3
3
3
3
3
3
3
3
2
1
4
4
5
5
5
5
5
4
4
2 10
2
5
12
15
15
15
15
15
15
15
15
15
15
1
5
10
15
15
15
15
15
15
15
15
15
15
8
2
10
15
20
25
25
25
25
25
25
25
25
20
12
1
2
2
2
4
4
4
4
4
4
2
4 4 COMMON FOR BOTH HRSG & GTG COMMON FOR BOTH HRSG & GTG COMMON FOR BOTH HRSG & GTG
0
10
40
50
95
125
125
125
125
125
125
125
125
80
60
17
68
102
167
206
210
211
211
211
211
211
209
154
103
CLIENT:GAMA
Attachment No.: 02 Equipment Histogram (Subcontractor & GAMA)
NASS INDUSTRIAL SERVICES EQUIPMENT MOBILISATION PLAN FOR HRSG & GTG SEC POWER PLANT PP‐13 PROJECT <<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<< MONTH >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>> Sr.No
EQUIPMENT
NOS.
1
600 MT. CRANE
1
2
300 MT. CRANE
1
3
150MT. CRANE
2
4
90 MT. CRANE
2
1
4
50MT. CRANE
2
1
5
30 MT. CRANE
6
Apr'16
May'16
Jun'16
Jul'16
Aug'16
Sept'16
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
1
1
1
1
1
2
2
2
2
2
2
2
2
1
1
1
2
2
2
2
2
2
2
2
2
2
1
1
1
3
2
2
3
3
3
3
3
3
3
2
1
1
1
AIR COMPRESSOR
2
1
2
2
2
2
2
2
2
2
2
1
1
7
20 MT. TRAILOR
2
2
2
2
2
2
2
2
2
2
2
1
1
8
40 MT. TRAILOR
2
1
2
2
2
2
2
2
2
2
2
1
1
9
FORKLIFT (5/7/10)
3
2
3
3
3
3
3
3
3
3
3
2
2
1
10
5/7‐ HIAB
2
1
2
2
2
2
2
2
2
2
2
2
2
1
1
11
DIESEL GENERATOR MOUNTING LIGHT
8
2
6
8
8
8
8
8
8
8
8
8
5
5
5
12
SPREADER BEAM
3
1
2
3
3
3
3
3
3
3
3
3
2
2
1
13
WELDING MACHINE
37
6
15
21
34
37
37
37
37
37
37
37
37
26
16
14
HEAT INDUCTION MACHINE
1
<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<< AS PER REQUIREMENT >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
15
PIPE BENDING MACHINE
1
<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<< AS PER REQUIREMENT >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
16
SCAFFOLDING MATERIALS
LOT
<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<< AS PER REQUIREMENT >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
17
OTHER LIFTING TOOLS
APR
<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<< AS PER REQUIREMENT >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
18
Insulation & Painting Equipment
Nov'15
Dec'15
1
Jan'16
Feb'16
Mar'16
<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<< AS PER REQUIREMENT >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>> ** NOTE: CLIENT HAS TO PROVIDE DETIALS REGARDING AVAILABILITY OF MATERIALS/EQUIPMENT AT SITE.
Oct'16
Nov'16
Dec'16
Jan'17
TOTAL
6 8 15 21 24 30 21 1
24 21 34 25 95 35 414
Attachment No.: 03 Detailed Schedule
GAMA-GTG HRSG # 1 2 3
Activities/Activity Usage Spreadsheet
Activity ID
Activity Name
GAMA GAMA-GTG & HRSG HRS GAMA.2 HRSG INSTALLATION INSTALLA SCHEDULE
Start
Finish
Original Duration
19-Dec-15 14:56 2016
Nov
Dec
Apr
May
0d
5
const9560
Issuance & Signing of LOI
11-Nov-15*
18-Nov-15
7d
18-Nov-15,
6
const9890
Kick off meeting
19-Nov-15
19-Nov-15
0d 5
19-Nov-15,
7
const9891
Signing of Sub-Contract Agreement
19-Nov-15*
26-Nov-15
7d *
01-Dec-15
18-Jan-17
GAMA.2.1.1 NMC MOBILIZATION MOBILIZATIO GAMA.2.1.1.1 Mechanical W Works const6530 HRSG Mobilzation
01-Dec-15 01-Dec-15 01-Dec-15*
29-Dec-15 29-Dec-15 29-Dec-15
12 13 14 15 16 17
GAMA.2.1.2 Block 20 GAMA.2.1.2.1 Unit 23 GAMA.2.1.2.1.1 HRSG-23 GAMA.2.1.2.1.1.1 By Pass P Stack const6540 by pass stack foundation preparation const6550 erection of bypass stack steel structure
04-Jan-16 04-Jan-16 04-Jan-16 04-Jan-16 04-Jan-16 19-Jan-16
18-Jan-17 13-Nov-16 13-Nov-16 09-Jul-16 18-Jan-16 17-Feb-16
326d 269d 269d 160d 12d 25d
25d 25d 25dc-15*
18-Jan-17, GA 29-Dec-15, GAMA.2.1.1 NMC MOBILIZATION 29-Dec-15, GAMA.2.1.1.1 Mechanical Works 29-Dec-15, 18-Jan-17, GA 13-Nov-16, GAMA.2.1.2.1 Unit 23 13-Nov-16, GAMA.2.1.2.1.1 HRSG 09-Jul-16, GAMA.2.1.2.1.1.1 By Pass Stack 04-Jan-16 19-Jan-16
18-Jan-16, 17-Feb-16,
installation of diverter box
18-Feb-16*
13-Mar-16
20d
const6570
installation of upper steel structure
14-Mar-16*
31-Mar-16
15d
20
const6580
pre-assembly of stack section1 (round reducer ,silencer ,square to round transition
02-Apr-16*
10-Apr-16
7d
21
const6590
installation of stack section 1
11-Apr-16*
12-Apr-16
1d
11-Apr-16*
22
const6600
pre-assembly of slack section 2 (round reducer,silencer,square to round transition e
11-Apr-16*
19-Apr-16
7d
11-Apr-16*
23
const6610
installation of stack section 2
20-Apr-16*
21-Apr-16
1d
20-Apr-16*
24
const6620
pre-assembly of slack section 3(round reducer,silencer,square to round transition e
20-Apr-16*
28-Apr-16
7d
20-Apr-16*
25
const6630
installation of stack section 3
30-Apr-16*
01-May-16
1d
30-Apr-16*
26
const6640
installation of CEMS Unit
01-May-16*
15-May-16
12d
01-May-16*
27
const6641
installation of OUT LET duct
15-May-16
21-May-16
5d
28
const6642
installation of bellow
21-May-16
23-May-16
2d
21-May-16
29
const6650
By Pass Stack Precommissioning
23-May-16*
09-Jul-16
40d
23-May-16*
16-Jan-16 16-Jan-16
30-Apr-16 24-Jan-16
90d 7d
18-Feb-16*
13-Mar-16,
14-Mar-16*
16-Jan-16
0d
33
const6680
Main stair tower &platform pre-assembly
25-Jan-16
10-Feb-16
14d
25-Jan-16
34
const6690
Casing Panel Installation
26-Jan-16
13-Feb-16
15d
26-Jan-16
35
const6700
bottom plate installation
13-Feb-16
18-Feb-16
5d
36
const6710
vertical side panels
20-Feb-16
24-Feb-16
4d
37
const6720
Main stair tower and platform erection
01-Feb-16*
16-Feb-16
14d
38
const6730
Lower front panel casing
17-Feb-16*
20-Feb-16
3d
39
const6740
Installation of field casing plates
21-Feb-16*
23-Feb-16
3d
40
const6750
Erection of side platform
13-Feb-16
07-Mar-16
20d
41
const6751
installation of liner system
24-Feb-16
27-Feb-16
3d
42
const6752
installation of insulation & lining at junction of casing & duct
28-Feb-16
29-Feb-16
2d
28-Feb-16
43
const6753
installation of Backstays and header spacers
01-Mar-16
02-Mar-16
2d
01-Mar-16
44
const6754
installation of connecting plates (external stiffners to casing panels )
03-Mar-16
07-Mar-16
4d
03-Mar-16
45
const6762
execution of final allignment ,levelling & verticality of casing structure
08-Mar-16
12-Mar-16
4d
46
const6771
Bumper Installation
22-Feb-16*
15-Mar-16
20d
47
const6772
final bolt tightening of main columns
17-Mar-16*
19-Mar-16
2d
48
const6790
Installation of CEMS skid
22-Mar-16*
02-Apr-16
10d
49
const6800
HRSG block 20 Elevator structure installation
14-Feb-16*
30-Apr-16
65d
20-Mar-16 04-May-16*
25-Jun-16 09-May-16
84d 5d
20-Mar-16 20-Mar-16
10-May-16 23-Mar-16
45d 4d
installation of module 2A &2 B
24-Mar-16
29-Mar-16
5d
const10020
installation of module of 3A & 3B
30-Mar-16
05-Apr-16
6d
56
const10030
installation of module 4A & 4B
06-Apr-16
11-Apr-16
5d
57
const10040
restoration of insulation and liner between modules
26-Apr-16
28-Apr-16
3d
Page 1 of 8
19-Apr-16, 21-Apr-16, 28-Apr-16, 01-May-16, 15-May-16, 21-May-16, 23-May-16, 09-Jul-16,
24-Jan-16,
24-Jan-16
const10010
12-Apr-16,
30-Apr-16, GAMA.2.1.2.1.1.2 HRSG Steel Structure & Casing Erection
Crane available at site
55
10-Apr-16,
15-May-16
const6670
54
31-Mar-16,
02-Apr-16*
32
summary
ar
26-Nov-15,
const6560
Critical Remaining Work
Feb
26-Nov-15, GAMA.2.3 Milestone
19
Milestone
Jan
10-Nov-15,
18
Remaining Work
Dec
356d
9 10 11
GAMA.2.1.2.1.1.3.4 Module Erection const10000 installation of module 1A&1B
Nov
18-Jan-17, GA
15d
52 53
Oct
374d
10-Nov-15
GAMA.2.1.2.1.1.3 Module Mod & Drum const6820 Drum supporting Structure preparation / Installation
Sep
18-Jan-17 26-Nov-15
50 51
Aug
10-Nov-15
10-Nov-15
GAMA.2.1.2.1.1.2 HRS HRSG Steel Structure & Casing Erection const6660 foundation preparation
2017 Jul
18-Jan-17, GA
10-Nov-15
30 31
Jun
374d
Award of Contract
GAMA.2.1 CONSTRUCTION
Mar
18-Jan-17
const9550
8
Feb
10-Nov-15
4
GAMA.2.3 Milestone
Jan
Crane available at site 10-Feb-16, 13-Feb-16,
13-Feb-16
18-Feb-16,
20-Feb-16
24-Feb-16,
01-Feb-16*
16-Feb-16,
17-Feb-16*
20-Feb-16,
21-Feb-16*
23-Feb-16,
13-Feb-16
07-Mar-16,
24-Feb-16
27-Feb-16, 29-Feb-16, 02-Mar-16, 07-Mar-16,
08-Mar-16 22-Feb-16*
12-Mar-16, 15-Mar-16,
17-Mar-16*
19-Mar-16,
22-Mar-16*
02-Apr-16,
14-Feb-16*
30-Apr-16, 25-Jun-16, GAMA.2.1.2.1.1.3 Module & Drum 04-May-16*
09-May-16, 10-May-16, GAMA.2.1.2.1.1.3.4 Module Erection
20-Mar-16
23-Mar-16,
24-Mar-16
29-Mar-16,
30-Mar-16
05-Apr-16,
06-Apr-16
11-Apr-16,
26-Apr-16
28-Apr-16,
TASK filter: All Activities © Oracle Corporation
GAMA-GTG HRSG #
Activities/Activity Usage Spreadsheet
Activity ID
Activity Name
58
const10050
installation of nozzle connection & piping
59 60
GAMA.2.1.2.1.1.3. GAMA.2.1.2.1.1.3.4.1 Installation of trusses const10060 installation of upper trusses
Start
Finish
Original Duration
30-Apr-16
10-May-16
10d
12-Apr-16 12-Apr-16
25-Apr-16 16-Apr-16
12d 4d
61
const10070
installation of intermediate trusses
17-Apr-16
20-Apr-16
4d
62
const10080
installation of lower trusses
21-Apr-16
25-Apr-16
4d
10-May-16 10-May-16
21-Jun-16 10-May-16
37d 1d
18-May-16
21-Jun-16
30d
11-May-16 11-May-16
15-Jun-16 11-May-16
31d 1d
24-May-16
15-Jun-16
20d
14-May-16 14-May-16
25-Jun-16 15-May-16
37d 2d
28-May-16
25-Jun-16
25d
16-May-16 18-May-16*
06-Sep-16 23-May-16
98d 5d
63 64
GAMA.2.1.2.1.1.3.1 HP drum const9280 HP drum erection
65
const9290
66 67
HP down comer piping
GAMA.2.1.2.1.1.3.2 IP drum const9300 IP drum erection
68
const9310
69 70
IP down comer piping
GAMA.2.1.2.1.1.3.3 LP drum const9320 LP drum erection
71
const9330
72 73
LP down comer piping
GAMA.2.1.2.1.1.4 Pipin Piping & Instruments const6850 install blow down tank
74
const6860
Valves & Instruments Installation
25-May-16*
31-Aug-16
85d
75
const6870
Piping test preparation
21-Aug-16*
06-Sep-16
15d
76 77
GAMA.2.1.2.1.1.4.1 Large Bore Piping const6880 LP Feedwater
16-May-16 16-May-16*
29-Aug-16 30-Jun-16
91d 40d
19-Dec-15 14:56 2016
Nov
Dec
Jan
Feb
Mar
Apr
May
30-Apr-16
Jun
2017 Jul
Aug
17-Apr-16
18-May-16
21-Jun-16, 15-Jun-16, GAMA.2.1.2.1.1.3.2 IP drum
11-May-16
11-May-16,
24-May-16
15-Jun-16, 25-Jun-16, GAMA.2.1.2.1.1.3.3 LP drum
14-May-16
15-May-16,
28-May-16
25-Jun-16, 06-Sep-16, GAMA.2.1.2.1.1.4 Piping & Instruments
18-May-16*
23-May-16,
25-May-16*
31-Aug-16, 21-Aug-16*
06-Sep-16, 29-Aug-16, GAMA.2.1.2.1.1.4.1 Large Bore Piping
16-May-16*
30-Jun-16,
30-May-16*
14-Jul-16,
79
const6900
IP Feedwater
29-May-16*
13-Jul-16
40d
29-May-16*
13-Jul-16,
80
const6910
RH
30-May-16*
01-Aug-16
55d
30-May-16*
81
const6920
LP Eva- Sh-Eco
28-May-16*
16-Aug-16
70d
28-May-16*
82
const6930
IP-Eva-Sh-Eco
09-Jun-16*
29-Aug-16
70d
83
const6940
HP-Eva-Sh-Eco
31-May-16*
20-Aug-16
70d
14-Jun-16 14-Jun-16*
01-Sep-16 04-Aug-16
69d 45d
01-Aug-16, 16-Aug-16,
09-Jun-16*
29-Aug-16,
31-May-16*
20-Aug-16, 01-Sep-16, GAMA.2.1.2.1.1.4.2 Small Bore Piping 04-Aug-16,
14-Jun-16*
86
const6960
HP Feedwater
28-Jun-16*
07-Aug-16
35d
28-Jun-16*
87
const6970
IP Feedwater
28-Jun-16*
30-Aug-16
55d
28-Jun-16*
88
const6980
RH
28-Jun-16*
23-Aug-16
49d
28-Jun-16*
89
const6990
LP Eva- Sh-Eco
26-Jun-16*
16-Aug-16
45d
26-Jun-16*
90
const7000
IP-Eva-Sh-Eco
12-Jul-16*
01-Sep-16
45d
91
const7010
HP-Eva-Sh-Eco
03-Jul-16*
23-Aug-16
45d
16-May-16 16-May-16*
30-Jun-16 07-Jun-16
40d 20d
const7030
Silencer Installation
09-Jun-16*
15-Jun-16
6d
const7040
Spring Hangers
20-Jun-16*
30-Jun-16
10d
08-Mar-16 08-Mar-16*
04-May-16 09-Mar-16
50d 2d
96 97
GAMA.2.1.2.1.1.6 Inlet Duct Steel Structure const7050 Inlet duct foundation preparation
98
const7060
inlet duct support structure erection
12-Mar-16*
22-Mar-16
10d
99
const7070
inlet duct floor casing alignment & welding
26-Mar-16*
05-Apr-16
10d
100
const7080
inlet duct left side casing alignment & welding
31-Mar-16
11-Apr-16
10d
101
const7090
inlet duct right side casing alignment & welding
07-Apr-16
18-Apr-16
10d
102
const7100
inlet duct roof side casing alignment & welding
13-Apr-16
24-Apr-16
10d
103
const7110
Inlet duct front casing & expansion joint alignment & welding
20-Apr-16
01-May-16
10d
104
const7170
installation & insulation of connecting pieces b/n exhaust & duct
02-May-16
04-May-16
3d
14-Feb-16 14-Feb-16 14-Feb-16*
16-Aug-16 22-Mar-16 17-Feb-16
159d 33d 4d
105 106 107
GAMA.2.1.2.1.1.7 Stack GAMA.2.1.2.1.1.7.1 STACK section 1 const9020 pre assembly shell no1
09-Jun-16* 20-Jun-16* 08-Mar-16*
05-Apr-16,
31-Mar-16
11-Apr-16,
07-Apr-16
18-Apr-16,
13-Apr-16
24-Apr-16,
20-Apr-16 02-May-16
01-May-16, 04-May-16,
16-Aug-16, GAMA.2.1.2.1.1.7 Stack 22-Mar-16, GAMA.2.1.2.1.1.7.1 STACK section 1 17-Feb-16,
14-Feb-16* 18-Feb-16
109
const9030
inspection and welding vertical joint
22-Feb-16*
27-Feb-16
5d
22-Feb-16*
110
const9040
erection and allingment no 1
28-Feb-16*
02-Mar-16
4d
111
const9050
shell no 1 joint welding (circum)
03-Mar-16*
08-Mar-16
5d
112
const9060
Stack section 1 installation
09-Mar-16*
20-Mar-16
10d
113
const9120
anchor bolt tightening
21-Mar-16
22-Mar-16
2d
09-Mar-16 09-Mar-16*
13-Apr-16 13-Mar-16
31d 4d
summary
30-Jun-16,
22-Mar-16,
26-Mar-16*
3d
Critical Remaining Work
15-Jun-16,
09-Mar-16,
12-Mar-16*
21-Feb-16
Page 2 of 8
01-Sep-16, 23-Aug-16,
04-May-16, GAMA.2.1.2.1.1.6 Inlet Duct Steel Structure
18-Feb-16
Milestone
16-Aug-16,
30-Jun-16, GAMA.2.1.2.1.1.5 Auxillary Steel Structure 07-Jun-16,
16-May-16*
installation of ladders ,platforms and inspection doors
Remaining Work
30-Aug-16, 23-Aug-16,
03-Jul-16*
const9021
GAMA.2.1.2.1.1.7.2 STACK section 2 const9070 pre assembly shell no2
07-Aug-16,
12-Jul-16*
108
114 115
ar
10-May-16,
40d
95
Feb
21-Jun-16, GAMA.2.1.2.1.1.3.1 HP drum 10-May-16
14-Jul-16
94
Jan
25-Apr-16,
30-May-16*
GAMA.2.1.2.1.1.5 Auxillary Auxi Steel Structure const7020 silencer support structure installation
Dec
20-Apr-16,
21-Apr-16
HP Feedwater
92 93
Nov
25-Apr-16, GAMA.2.1.2.1.1.3.4.1 Installation of trusses 16-Apr-16,
12-Apr-16
const6890
GAMA.2.1.2.1.1.4.2 Small Bore Piping const6950 LP Feedwater
Oct
10-May-16,
78
84 85
Sep
21-Feb-16,
28-Feb-16*
27-Feb-16, 02-Mar-16,
03-Mar-16* 09-Mar-16* 21-Mar-16 09-Mar-16*
08-Mar-16, 20-Mar-16, 22-Mar-16, 13-Apr-16, GAMA.2.1.2.1.1.7.2 STACK section 2 13-Mar-16,
TASK filter: All Activities © Oracle Corporation
GAMA-GTG HRSG #
Activities/Activity Usage Spreadsheet
Activity ID
Activity Name
Start
Finish
Original Duration
19-Dec-15 14:56 2016
Nov
Dec
Jan
Feb
Mar
Apr
116
const9072
installation of ladders ,platforms and inspection doors
14-Mar-16
16-Mar-16
3d
14-Mar-16
117
const9080
inspection and welding vertical joint
17-Mar-16*
22-Mar-16
5d
17-Mar-16*
118
const9090
erection and allingment no 2
23-Mar-16*
27-Mar-16
4d
119
const9100
shell no 2 joint welding (circum)
28-Mar-16*
02-Apr-16
5d
120
const9110
Stack section 2 Installation
03-Apr-16*
13-Apr-16
10d
03-Apr-16*
03-Apr-16 03-Apr-16*
15-May-16 06-Apr-16
37d 4d
03-Apr-16*
121 122
GAMA.2.1.2.1.1.7.3 STACK section 3 AND DAMPER const9130 pre assembly shell no3
May
10-Apr-16
3d
07-Apr-16
11-Apr-16*
16-Apr-16
5d
11-Apr-16*
125
const9145
pre assembly of damper
17-Apr-16*
20-Apr-16
4d
126
const9147
inspection and welding joint circum
20-Apr-16*
24-Apr-16
4d
127
const9150
erection and allingment no 3 with damper
24-Apr-16*
27-Apr-16
4d
128
const9160
shell no2 to 3 joint welding (circum)
28-Apr-16*
03-May-16
5d
129
const9170
Stack section 3 Installation
04-May-16*
15-May-16
10d
04-May-16*
04-May-16 04-May-16*
23-Jul-16 08-May-16
69d 4d
04-May-16*
20-Apr-16,
20-Apr-16*
24-Apr-16,
24-Apr-16*
27-Apr-16,
28-Apr-16*
03-May-16, 15-May-16, 23-Jul-16, GAMA.2.1.2.1.1.7.4 STACK section 4 08-May-16,
const9181
installation of ladders ,platforms and inspection doors
09-May-16
11-May-16
3d
09-May-16
const9190
inspection and welding vertical joint
12-May-16*
17-May-16
5d
12-May-16*
134
const9200
erection and allingment no 4
02-Jul-16*
05-Jul-16
4d
135
const9210
shell no 4 joint welding (circum)
06-Jul-16*
11-Jul-16
5d
136
const9220
Stack section 4 installation
12-Jul-16*
23-Jul-16
10d
11-May-16 11-May-16*
16-Aug-16 15-May-16
84d 4d
11-May-16, 17-May-16, 02-Jul-16*
05-Jul-16,
06-Jul-16*
11-Jul-16,
12-Jul-16*
23-Jul-16, 16-Aug-16, GAMA.2.1.2.1.1.7.5 STACK section 5
11-May-16*
15-May-16,
139
const9231
installation of ladders ,platforms and inspection doors
16-May-16
18-May-16
3d
16-May-16
140
const9240
inspection and welding vertical joint
16-May-16*
21-May-16
5d
16-May-16*
141
const9250
erection and allingment no 5
24-Jul-16*
27-Jul-16
4d
142
const9260
shell no 5 joint welding (circum)
28-Jul-16*
02-Aug-16
5d
143
const9261
installation of silencer
03-Aug-16
04-Aug-16
2d
03-Aug-16
144
const9270
Stack section 5 installation
06-Aug-16*
16-Aug-16
10d
06-Aug-16*
25-Feb-16 11-Sep-16*
13-Nov-16 03-Oct-16
225d 20d
18-May-16, 21-May-16, 24-Jul-16*
27-Jul-16,
28-Jul-16*
02-Aug-16, 04-Aug-16, 16-Aug-16, 13-Nov-16, GAMA.2.1.2.1.1.8 Prec 11-Sep-16*
147
const7220
ReInstatement
04-Oct-16*
20-Oct-16
15d
04-Oct-16*
148
const7230
Chemical cleaning & Restore (by others )
05-Oct-16*
02-Nov-16
25d
05-Oct-16*
149
const7240
Insulation
06-Oct-16*
12-Nov-16
32d
06-Oct-16*
150
const7510
final touch up painting
25-Feb-16
13-Nov-16
225d
21-Jan-16 21-Jan-16 21-Jan-16 21-Jan-16*
14-Dec-16 14-Dec-16 16-Jul-16 04-Feb-16
281d 281d 151d 12d
25-Feb-16
erection of bypass stack steel structure
06-Feb-16*
06-Mar-16
25d
installation of diverter box
06-Mar-16*
29-Mar-16
20d
157
const7280
installation of upper steel structure
29-Mar-16*
16-Apr-16
15d
158
const7290
pre-assembly of stack section1 (round reducer ,silencer ,square to round transition
16-Apr-16*
24-Apr-16
7d
159
const7300
installation of stack section 1
24-Apr-16*
25-Apr-16
1d
24-Apr-16*
160
const7310
pre-assembly of slack section 2 (round reducer,silencer,square to round transition e
26-Apr-16*
04-May-16
7d
26-Apr-16*
161
const7320
installation of stack section 2
05-May-16*
07-May-16
1d
162
const7330
pre-assembly of slack section 3(round reducer,silencer,square to round transition e
07-May-16*
15-May-16
7d
163
const7340
installation of stack section 3
15-May-16*
16-May-16
1d
15-May-16*
164
const7350
installation of CEMS Unit
16-May-16*
30-May-16
12d
16-May-16*
165
const7351
installation of out let duct
30-May-16
05-Jun-16
5d
166
const7352
installation of bellow
05-Jun-16
07-Jun-16
2d
167
const7360
By Pass Stack Precommissioning
30-May-16*
16-Jul-16
40d
14-Feb-16 14-Feb-16*
16-Jun-16 22-Feb-16
106d 7d
23-Feb-16*
171
const7390
Main stair tower &platform pre-assembly
24-Feb-16*
10-Mar-16
14d
172
const7400
Casing Panel Installation
27-Feb-16*
14-Mar-16
15d
Remaining Work
Milestone
Critical Remaining Work
summary
06-Feb-16*
06-Mar-16,
06-Mar-16*
29-Mar-16,
29-Mar-16*
16-Apr-16,
16-Apr-16*
24-Apr-16, 25-Apr-16, 04-May-16,
05-May-16* 07-May-16*
07-May-16, 15-May-16, 16-May-16,
30-May-16 05-Jun-16
30-May-16, 05-Jun-16, 07-Jun-16,
30-May-16*
16-Jul-16, 16-Jun-16, GAMA.2.1.2.9.1.2 HRSG Steel Structure & Casing Erection
14-Feb-16*
0d
Page 3 of 8
12-Nov-16,
04-Feb-16,
const7270
Crane available at site
02-Nov-16,
16-Jul-16, GAMA.2.1.2.9.1.1 By Pass Stack 21-Jan-16*
const7260
const7380
20-Oct-16,
14-Dec-16, GAMA.2.1.2.9 14-Dec-16, GAMA.2.1.2.9
156
170
03-Oct-16,
13-Nov-16,
155
GAMA.2.1.2.9.1.2 HRS HRSG Steel Structure & Casing Erection const7370 foundation preparation
ar
16-Apr-16,
17-Apr-16*
133
168 169
Feb
10-Apr-16,
132
GAMA.2.1.2.9 Unit 22 GAMA.2.1.2.9.1 HRSG 22 GAMA.2.1.2.9.1.1 By Pass P Stack const7250 by pass stack foundation preparation
Jan
15-May-16, GAMA.2.1.2.1.1.7.3 STACK section 3 AND DAMPER
07-Apr-16
151 152 153 154
Dec
06-Apr-16,
inspection and welding vertical joint
GAMA.2.1.2.1.1.8 Precomissioning Prec & Tests const7210 Hydrotest
Nov
13-Apr-16,
installation of ladders ,platforms and inspection doors
145 146
Oct
02-Apr-16,
const9140
GAMA.2.1.2.1.1.7.5 STACK section 5 const9230 pre assembly shell no5
Sep
27-Mar-16,
28-Mar-16*
const9131
137 138
Aug
22-Mar-16,
23-Mar-16*
124
GAMA.2.1.2.1.1.7.4 STACK section 4 const9180 pre assembly shell no4
2017 Jul
16-Mar-16,
123
130 131
Jun
22-Feb-16, Crane available at site
24-Feb-16* 27-Feb-16*
10-Mar-16, 14-Mar-16,
TASK filter: All Activities © Oracle Corporation
GAMA-GTG HRSG #
Activities/Activity Usage Spreadsheet
Activity ID
Activity Name
Start
Finish
Original Duration
2016 Nov
Dec
Jan
Feb
Mar
const7410
bottom plate installation
15-Mar-16*
20-Mar-16
174
const7420
vertical side panels
22-Mar-16*
26-Mar-16
4d
175
const7430
Main stair tower and platform erection
07-Mar-16*
22-Mar-16
14d
176
const7440
Lower front panel casing
23-Mar-16*
26-Mar-16
3d
177
const7450
Installation of field casing plates
27-Mar-16*
29-Mar-16
3d
178
const7460
Erection of side platform
14-Mar-16*
05-Apr-16
20d
179
const7461
installation of liner system
06-Apr-16
09-Apr-16
3d
180
const7462
installation of insulation & lining at junction of casing & duct
10-Apr-16
11-Apr-16
2d
181
const7463
installation of Backstays and header spacers
12-Apr-16
13-Apr-16
2d
12-Apr-16
182
const7464
installation of connecting plates (external stiffners to casing panels )
14-Apr-16
18-Apr-16
4d
14-Apr-16
183
const7465
execution of final allignment ,levelling & verticality of casing structure
19-Apr-16
23-Apr-16
4d
19-Apr-16
184
const7480
final bolt tightening of main columns
24-Apr-16*
28-Apr-16
5d
24-Apr-16*
185
const7490
Bumper Installation
29-Mar-16*
20-Apr-16
20d
const7500
Installation of CEMS skid
06-Jun-16*
16-Jun-16
10d
GAMA.2.1.2.9.1.3 Module Mod & DRum const7530 Drum supporting Structure preparation / Installation
30-Apr-16 09-Jun-16*
31-Jul-16 14-Jun-16
80d 5d
30-Apr-16 30-Apr-16
20-Jun-16 03-May-16
45d 4d
187 188 189 190
GAMA.2.1.2.9.1.3.4 module erection const10090 installation of module 1A&1B
191
const10100
installation of module 2A &2 B
04-May-16
09-May-16
5d
192
const10110
installation of module of 3A & 3B
10-May-16
16-May-16
6d
193
const10120
installation of module 4A & 4B
17-May-16
22-May-16
5d
194
const10130
restoration of insulation and liner between modules
06-Jun-16
08-Jun-16
3d
195
const10140
installation of nozzle connection & piping
09-Jun-16
20-Jun-16
10d
196 197
GAMA.2.1.2.9.1.3. GAMA.2.1.2.9.1.3.4.1 installation of trusses const10150 installation of upper trusses
23-May-16 23-May-16
05-Jun-16 26-May-16
12d 4d
198
const10160
installation of intermediate trusses
28-May-16
31-May-16
4d
199
const10170
installation of lower trusses
01-Jun-16
05-Jun-16
4d
15-Jun-16 15-Jun-16
27-Jul-16 15-Jun-16
37d 1d
23-Jun-16
27-Jul-16
30d
16-Jun-16 16-Jun-16
21-Jul-16 16-Jun-16
31d 1d
29-Jun-16
21-Jul-16
20d
19-Jun-16 19-Jun-16
31-Jul-16 20-Jun-16
37d 2d
03-Jul-16
31-Jul-16
25d
21-Jun-16 22-Jun-16*
04-Oct-16 27-Jun-16
91d 5d
200 201
GAMA.2.1.2.9.1.3.1 HP drum const9340 HP drum erection
202
const9350
203 204
HP down comer piping
GAMA.2.1.2.9.1.3.2 IP drum const9360 IP drum erection
205
const9370
206 207
IP down comer piping
GAMA.2.1.2.9.1.3.3 LP drum const9380 LP drum erection
208
const9390
209 210
LP down comer piping
GAMA.2.1.2.9.1.4 Pipin Piping & Instruments const7560 install blow down tank
211
const7570
Valves & Instruments Installation
28-Jun-16*
28-Sep-16
80d
212
const7580
Piping test preparation
18-Sep-16*
04-Oct-16
15d
213 214
GAMA.2.1.2.9.1.4.1 Large Bore Piping const7590 LP Feedwater
21-Jun-16 21-Jun-16*
21-Sep-16 06-Aug-16
80d 40d
15-Mar-16*
Apr
173
186
5d
19-Dec-15 14:56
May
Jun
22-Mar-16* 07-Mar-16*
Sep
Oct
23-Mar-16*
09-Apr-16,
10-Apr-16
11-Apr-16, 13-Apr-16, 18-Apr-16, 23-Apr-16, 28-Apr-16,
29-Mar-16*
20-Apr-16, 06-Jun-16*
16-Jun-16, 31-Jul-16, GAMA.2.1.2.9.1.3 Module & DRum
09-Jun-16*
14-Jun-16, 20-Jun-16, GAMA.2.1.2.9.1.3.4 module erection
30-Apr-16
03-May-16,
04-May-16
09-May-16,
10-May-16
16-May-16,
17-May-16
22-May-16,
06-Jun-16
08-Jun-16,
09-Jun-16
20-Jun-16, 05-Jun-16, GAMA.2.1.2.9.1.3.4.1 installation of trusses 26-May-16,
23-May-16 28-May-16
31-May-16,
01-Jun-16
05-Jun-16, 27-Jul-16, GAMA.2.1.2.9.1.3.1 HP drum
15-Jun-16
15-Jun-16,
23-Jun-16
27-Jul-16, 21-Jul-16, GAMA.2.1.2.9.1.3.2 IP drum
16-Jun-16
16-Jun-16,
29-Jun-16
21-Jul-16, 31-Jul-16, GAMA.2.1.2.9.1.3.3 LP drum
19-Jun-16
20-Jun-16,
03-Jul-16
31-Jul-16, 04-Oct-16, GAMA.2.1.2.9.1.4 Piping & Instrume
22-Jun-16*
27-Jun-16,
28-Jun-16*
28-Sep-16, 18-Sep-16*
04-Oct-16, 21-Sep-16, GAMA.2.1.2.9.1.4.1 Large Bore Piping
21-Jun-16*
06-Aug-16,
216
const7610
IP Feedwater
28-Jun-16*
13-Aug-16
40d
217
const7620
RH
05-Jul-16*
06-Sep-16
55d
218
const7630
LP Eva- Sh-Eco
30-Jun-16*
13-Sep-16
65d
219
const7640
IP-Eva-Sh-Eco
04-Jul-16*
17-Sep-16
65d
04-Jul-16*
220
const7650
HP-Eva-Sh-Eco
05-Jul-16*
21-Sep-16
68d
05-Jul-16*
20-Jul-16 20-Jul-16*
25-Sep-16 10-Sep-16
58d 45d
03-Jul-16*
17-Aug-16,
28-Jun-16*
13-Aug-16,
05-Jul-16*
06-Sep-16,
30-Jun-16*
13-Sep-16, 17-Sep-16, 21-Sep-16, 25-Sep-16, GAMA.2.1.2.9.1.4.2 Small Bore Piping 10-Sep-16,
20-Jul-16*
223
const7670
HP Feedwater
26-Jul-16*
04-Sep-16
35d
26-Jul-16*
224
const7680
IP Feedwater
27-Jul-16*
25-Sep-16
52d
27-Jul-16*
25-Sep-16,
225
const7690
RH
28-Jul-16*
24-Sep-16
50d
28-Jul-16*
24-Sep-16,
226
const7700
LP Eva- Sh-Eco
27-Jul-16*
22-Sep-16
50d
27-Jul-16*
22-Sep-16,
227
const7710
IP-Eva-Sh-Eco
02-Aug-16*
22-Sep-16
45d
02-Aug-16*
22-Sep-16,
228
const7720
HP-Eva-Sh-Eco
31-Jul-16*
21-Sep-16
46d
31-Jul-16*
21-Sep-16,
21-Jun-16 21-Jun-16*
08-Aug-16 13-Jul-16
42d 20d
Critical Remaining Work
summary
Page 4 of 8
ar
05-Apr-16,
06-Apr-16
40d
Milestone
Feb
29-Mar-16,
14-Mar-16*
17-Aug-16
Remaining Work
Jan
26-Mar-16,
27-Mar-16*
03-Jul-16*
GAMA.2.1.2.9.1.5 Auxillary Auxi Steel Structure const7730 silencer support structure installation
Dec
26-Mar-16,
HP Feedwater
229 230
Nov
22-Mar-16,
const7600
GAMA.2.1.2.9.1.4.2 Small Bore Piping const7660 LP Feedwater
Aug
20-Mar-16,
215
221 222
2017 Jul
21-Jun-16*
04-Sep-16,
08-Aug-16, GAMA.2.1.2.9.1.5 Auxillary Steel Structure 13-Jul-16,
TASK filter: All Activities © Oracle Corporation
GAMA-GTG HRSG #
Activities/Activity Usage Spreadsheet
Activity ID
Activity Name
231 232 233 234
Start
Finish
Original Duration
const7740
Silencer Installation
17-Jul-16*
23-Jul-16
6d
const7750
Spring Hangers
28-Jul-16*
08-Aug-16
10d
22-Mar-16 22-Mar-16*
23-May-16 23-Mar-16
54d 2d
GAMA.2.1.2.9.1.6 Inlet Duct Steel Structure const7760 Inlet duct foundation preparation
235
const7770
inlet duct support structure erection
26-Mar-16*
30-Mar-16
5d
236
const7780
inlet duct floor casing alignment & welding
31-Mar-16
11-Apr-16
10d
237
const7790
inlet duct left side casing alignment & welding
18-Apr-16
28-Apr-16
10d
238
const7800
inlet duct right side casing alignment & welding
24-Apr-16
04-May-16
10d
239
const7810
inlet duct roof side casing alignment & welding
30-Apr-16
10-May-16
10d
240
const7820
Inlet duct front casing & expansion joint alignment & welding
09-May-16
19-May-16
10d
241
const7821
installation & insulation of connecting pieces b/n exhaust & duct
21-May-16
23-May-16
3d
10-Mar-16 10-Mar-16 10-Mar-16*
26-Sep-16 11-Apr-16 14-Mar-16
172d 28d 4d
242 243 244
GAMA.2.1.2.9.1.7 Stack GAMA.2.1.2.9.1.7.1 STACK section 1 const9400 pre assembly shell no1
19-Dec-15 14:56 2016
Nov
Dec
Jan
Feb
Mar
Apr
22-Mar-16*
08-Aug-16,
23-May-16, 26-Sep-16, GAMA.2.1.2.9.1.7 Stack
11-Apr-16, GAMA.2.1.2.9.1.7.1 STACK section 1 14-Mar-16,
10-Mar-16* 15-Mar-16
20-Mar-16
5d
15-Mar-16*
247
const9420
erection and allingment no 1
21-Mar-16*
24-Mar-16
4d
248
const9430
shell no 1 joint welding (circum)
26-Mar-16*
30-Mar-16
5d
249
const9480
Stack section 1 installation
31-Mar-16*
11-Apr-16
10d
31-Mar-16*
31-Mar-16 31-Mar-16*
02-May-16 04-Apr-16
28d 4d
31-Mar-16*
17-Mar-16, 20-Mar-16,
21-Mar-16*
24-Mar-16,
26-Mar-16*
30-Mar-16, 11-Apr-16, 02-May-16, GAMA.2.1.2.9.1.7.2 STACK section 2 04-Apr-16,
252
const9441
installation of ladders ,platforms and inspection doors
05-Apr-16
07-Apr-16
3d
05-Apr-16
253
const9450
inspection and welding vertical joint
05-Apr-16*
10-Apr-16
5d
05-Apr-16*
254
const9460
erection and allingment no 2
11-Apr-16*
14-Apr-16
4d
255
const9470
shell no 2 joint welding (circum)
16-Apr-16*
20-Apr-16
5d
256
const9490
Stack section 2 Installation
21-Apr-16*
02-May-16
10d
05-Apr-16 05-Apr-16*
16-May-16 09-Apr-16
36d 4d
07-Apr-16, 10-Apr-16,
11-Apr-16*
14-Apr-16,
16-Apr-16*
20-Apr-16,
21-Apr-16*
02-May-16, 16-May-16, GAMA.2.1.2.9.1.7.3 STACK section 3 AND DAMPER
05-Apr-16*
09-Apr-16,
259
const9501
installation of ladders ,platforms and inspection doors
10-Apr-16
12-Apr-16
3d
10-Apr-16
12-Apr-16,
260
const9510
inspection and welding vertical joint
10-Apr-16*
14-Apr-16
5d
10-Apr-16*
14-Apr-16,
261
const9511
pre assembly of damper
16-Apr-16*
19-Apr-16
4d
262
const9512
inspection and welding joint circum
20-Apr-16*
24-Apr-16
4d
263
const9520
erection and allingment no 3 with damper
25-Apr-16*
28-Apr-16
4d
264
const9530
shell no2 to 3 joint welding (circum)
30-Apr-16*
04-May-16
5d
265
const9540
Stack section 3 Installation
05-May-16*
16-May-16
10d
05-May-16*
05-May-16 05-May-16*
30-Aug-16 09-May-16
101d 4d
05-May-16*
16-Apr-16*
19-Apr-16,
20-Apr-16*
24-Apr-16,
25-Apr-16*
28-Apr-16,
30-Apr-16*
04-May-16, 16-May-16, 30-Aug-16, GAMA.2.1.2.9.1.7.4 STACK section 4
268
const9571
installation of ladders ,platforms and inspection doors
10-May-16
12-May-16
3d
10-May-16
269
const9580
inspection and welding vertical joint
14-May-16*
18-May-16
5d
14-May-16*
270
const9590
erection and allingment no 4
09-Aug-16*
13-Aug-16
4d
271
const9600
shell no 4 joint welding (circum)
14-Aug-16*
18-Aug-16
5d
272
const9610
Stack section 4 installation
20-Aug-16*
30-Aug-16
10d
10-May-16 10-May-16*
26-Sep-16 14-May-16
120d 4d
09-May-16, 12-May-16, 18-May-16, 09-Aug-16*
13-Aug-16,
14-Aug-16*
18-Aug-16,
20-Aug-16*
30-Aug-16, 26-Sep-16, GAMA.2.1.2.9.1.7.5 STACK section 5
10-May-16*
275
const9621
installation of ladders ,platforms and inspection doors
15-May-16
17-May-16
3d
15-May-16
276
const9630
inspection and welding vertical joint
18-May-16*
23-May-16
5d
18-May-16*
277
const9640
erection and allingment no 5
31-Aug-16*
04-Sep-16
4d
278
const9650
shell no 5 joint welding (circum)
05-Sep-16*
10-Sep-16
5d
279
const9651
installation of silencer
11-Sep-16
14-Sep-16
4d
280
const9660
Stack section 5 installation
15-Sep-16*
26-Sep-16
10d
07-Apr-16 09-Oct-16*
14-Dec-16 01-Nov-16
216d 21d
14-May-16, 17-May-16, 23-May-16, 31-Aug-16*
04-Sep-16,
05-Sep-16*
10-Sep-16,
11-Sep-16
14-Sep-16,
15-Sep-16*
26-Sep-16, 14-Dec-16, GAMA.2.1.2.9
09-Oct-16*
283
const7930
ReInstatement
02-Nov-16*
19-Nov-16
15d
02-Nov-16*
284
const7940
Chemical cleaning & Restore (by others )
02-Nov-16*
06-Dec-16
30d
02-Nov-16*
285
const7950
Insulation
02-Nov-16*
12-Dec-16
35d
02-Nov-16*
286
const8220
final touch up painting
07-Apr-16
14-Dec-16
216d
02-Feb-16
18-Jan-17
301d
287
GAMA.2.1.2.2 Unit 21
Remaining Work
Milestone
Critical Remaining Work
summary
Page 5 of 8
ar
19-May-16,
21-May-16
15-Mar-16*
GAMA.2.1.2.9.1.8 Precommissiong Prec & Test const7920 Hydrotest
Feb
23-Jul-16,
10-May-16,
09-May-16
inspection and welding vertical joint
281 282
Jan
04-May-16,
30-Apr-16
const9410
GAMA.2.1.2.9.1.7.5 STACK section 5 const9620 pre assembly shell no5
Dec
28-Apr-16,
24-Apr-16
246
273 274
Nov
11-Apr-16,
18-Apr-16
3d
GAMA.2.1.2.9.1.7.4 STACK section 4 const9570 pre assembly shell no4
Oct
30-Mar-16,
31-Mar-16
17-Mar-16
266 267
Sep
23-Mar-16,
26-Mar-16*
15-Mar-16
GAMA.2.1.2.9.1.7.3 STACK section 3 AND DAMPER const9500 pre assembly shell no3
Aug
28-Jul-16*
installation of ladders ,platforms and inspection doors
257 258
2017 Jul
23-May-16, GAMA.2.1.2.9.1.6 Inlet Duct Steel Structure
const9401
GAMA.2.1.2.9.1.7.2 STACK section 2 const9440 pre assembly shell no2
Jun 17-Jul-16*
245
250 251
May
07-Apr-16
01-Nov-16, 19-Nov-16, 06-Dec-16, 12-Dec-16, 14-Dec-16, 18-Jan-17, GA
TASK filter: All Activities © Oracle Corporation
GAMA-GTG HRSG # 288
Activities/Activity Usage Spreadsheet
Activity ID
Activity Name GAMA.2.1.2.2.1 HRSG 21
289 290
GAMA.2.1.2.2.1.1 By Pass P Stack const7960 by pass stack foundation preparation
Start
Finish
Original Duration
02-Feb-16
18-Jan-17
301d
02-Feb-16 02-Feb-16*
21-Jul-16 16-Feb-16
146d 12d
19-Dec-15 14:56 2016
Nov
Dec
Jan
Feb
Mar
Apr
May
erection of bypass stack steel structure
16-Feb-16*
16-Mar-16
25d
const7980
installation of diverter box
16-Mar-16*
09-Apr-16
20d
293
const7990
installation of upper steel structure
09-Apr-16*
26-Apr-16
15d
294
const8000
pre-assembly of stack section1 (round reducer ,silencer ,square to round transition
26-Apr-16*
04-May-16
7d
295
const8010
installation of stack section 1
04-May-16*
05-May-16
1d
04-May-16*
296
const8020
pre-assembly of slack section 2 (round reducer,silencer,square to round transition e
04-May-16*
12-May-16
7d
04-May-16*
297
const8030
installation of stack section 2
14-May-16*
15-May-16
1d
298
const8040
pre-assembly of slack section 3(round reducer,silencer,square to round transition e
12-May-16*
19-May-16
6d
299
const8050
installation of stack section 3
19-May-16*
21-May-16
1d
300
const8060
installation of CEMS Unit
21-May-16*
04-Jun-16
12d
301
const8061
installation of outlet duct
04-Jun-16
09-Jun-16
5d
302
const8062
installation of bellow
09-Jun-16
12-Jun-16
2d
303
const8070
By Pass Stack Precommissioning
05-Jun-16*
21-Jul-16
40d
16-Mar-16 16-Mar-16*
16-Jun-16 24-Mar-16
79d 7d
16-Feb-16*
15-May-16,
12-May-16*
19-May-16,
19-May-16*
21-May-16,
21-May-16*
04-Jun-16,
04-Jun-16
16-Mar-16*
24-Mar-16,
12-Apr-16
14d
28-Mar-16*
12-Apr-16,
308
const8110
Casing Panel Installation
29-Mar-16*
14-Apr-16
15d
29-Mar-16*
14-Apr-16,
309
const8120
bottom plate installation
16-Apr-16*
20-Apr-16
5d
310
const8130
vertical side panels
21-Apr-16*
25-Apr-16
4d
311
const8140
Main stair tower and platform erection
06-Apr-16*
21-Apr-16
14d
312
const8150
Lower front panel casing
23-Apr-16*
25-Apr-16
3d
313
const8160
Installation of field casing plates
26-Apr-16*
28-Apr-16
3d
314
const8170
Erection of side platform
13-Apr-16*
05-May-16
20d
315
const8171
installation of liner system
07-May-16
09-May-16
3d
316
const8172
installation of insulation & lining at junction of casing & duct
10-May-16
11-May-16
2d
10-May-16
317
const8173
installation of Backstays and header spacers
12-May-16
14-May-16
2d
12-May-16
318
const8174
installation of connecting plates (external stiffners to casing panels )
15-May-16
18-May-16
4d
319
const8175
execution of final allignment ,levelling & verticality of casing structure
19-May-16
23-May-16
4d
19-May-16
320
const8190
final bolt tightening of main columns
24-May-16*
25-May-16
2d
24-May-16*
321
const8200
Bumper Installation
26-Apr-16*
16-May-16
18d
const8210
Installation of CEMS skid
04-Jun-16*
16-Jun-16
12d
GAMA.2.1.2.2.1.3 Mdu Mdule & Drum const8240 Drum supporting Structure preparation/ Installation
26-May-16 03-Jul-16*
23-Aug-16 07-Jul-16
77d 5d
26-May-16
17-Jul-16
45d
26-May-16
30-May-16
4d
31-May-16
05-Jun-16
5d
328
const10220
installation of module of 3A & 3B
06-Jun-16
12-Jun-16
6d
329
const10230
installation of module 4A & 4B
13-Jun-16
18-Jun-16
5d
330
const10240
restoration of insulation and liner between modules
03-Jul-16
05-Jul-16
3d
331
const10250
installation of nozzle connection & piping
06-Jul-16
17-Jul-16
10d
332 333
GAMA.2.1.2.2.1.3. GAMA.2.1.2.2.1.3.4.1 installation of trusses const10260 installation of upper trusses
19-Jun-16 19-Jun-16
02-Jul-16 22-Jun-16
12d 4d
334
const10270
installation of intermediate trusses
23-Jun-16
27-Jun-16
4d
335
const10280
installation of lower trusses
28-Jun-16
02-Jul-16
4d
09-Jul-16 09-Jul-16
20-Aug-16 09-Jul-16
37d 1d
17-Jul-16
20-Aug-16
30d
10-Jul-16 10-Jul-16
14-Aug-16 10-Jul-16
31d 1d
23-Jul-16
14-Aug-16
20d
12-Jul-16 12-Jul-16
23-Aug-16 13-Jul-16
37d 2d
26-Jul-16
23-Aug-16
25d
336 337
GAMA.2.1.2.2.1.3.1 HP drum const9670 HP drum erection
338
const9680
339 340
HP down comer piping
GAMA.2.1.2.2.1.3.2 IP drum const9690 IP drum erection
341
const9700
342 343
IP down comer piping
GAMA.2.1.2.2.1.3.3 LP drum const9710 LP drum erection
344
const9720
LP down comer piping
Remaining Work
Milestone
Critical Remaining Work
summary
Page 6 of 8
21-Jul-16, 16-Jun-16, GAMA.2.1.2.2.1.2 HRSG Steel Structure & Casing Erection
28-Mar-16*
installation of module 2A &2 B
12-Jun-16,
05-Jun-16*
Main stair tower &platform pre-assembly
installation of module 1A&1B
09-Jun-16,
09-Jun-16
const8100
const10210
ar
12-May-16,
307
const10200
Feb
05-May-16,
14-May-16*
0d
327
Jan
04-May-16,
26-Mar-16*
326
Dec
26-Apr-16,
26-Apr-16*
Crane available at site
GAMA.2.1.2.2.1.3.4 module erection
Nov
09-Apr-16,
09-Apr-16*
const8090
325
Oct
16-Mar-16,
16-Mar-16*
306
323 324
Sep
16-Feb-16,
const7970
322
Aug
21-Jul-16, GAMA.2.1.2.2.1.1 By Pass Stack 02-Feb-16*
292
GAMA.2.1.2.2.1.2 HRS HRSG Steel Structure & Casing Erection const8080 foundation preparation
2017 Jul
18-Jan-17, GA
291
304 305
Jun
Crane available at site
16-Apr-16*
20-Apr-16,
21-Apr-16*
25-Apr-16,
06-Apr-16*
21-Apr-16,
23-Apr-16*
25-Apr-16,
26-Apr-16*
28-Apr-16,
13-Apr-16*
05-May-16,
07-May-16
09-May-16, 11-May-16, 14-May-16,
15-May-16
18-May-16, 23-May-16,
26-Apr-16*
25-May-16, 16-May-16,
04-Jun-16*
16-Jun-16, 23-Aug-16, GAMA.2.1.2.2.1.3 Mdule & Drum
03-Jul-16*
07-Jul-16, 17-Jul-16, GAMA.2.1.2.2.1.3.4 module erection
26-May-16
30-May-16,
31-May-16
05-Jun-16,
06-Jun-16
12-Jun-16,
13-Jun-16
18-Jun-16,
03-Jul-16
05-Jul-16,
06-Jul-16
17-Jul-16, 02-Jul-16, GAMA.2.1.2.2.1.3.4.1 installation of trusses 22-Jun-16,
19-Jun-16 23-Jun-16
27-Jun-16,
28-Jun-16
02-Jul-16, 20-Aug-16, GAMA.2.1.2.2.1.3.1 HP drum
09-Jul-16
09-Jul-16,
17-Jul-16
20-Aug-16, 14-Aug-16, GAMA.2.1.2.2.1.3.2 IP drum
10-Jul-16
10-Jul-16,
23-Jul-16
14-Aug-16, 23-Aug-16, GAMA.2.1.2.2.1.3.3 LP drum
12-Jul-16 26-Jul-16
13-Jul-16, 23-Aug-16,
TASK filter: All Activities © Oracle Corporation
GAMA-GTG HRSG #
Activities/Activity Usage Spreadsheet
Activity ID
345 346
Activity Name GAMA.2.1.2.2.1.4 Pipin Piping & Instruments) const8270 install blow down tank
Start
Finish
Original Duration
14-Jul-16 14-Jul-16*
07-Nov-16 19-Jul-16
100d 5d
347
const8280
Valves & Instruments Installation
20-Jul-16*
01-Nov-16
90d
348
const8290
Piping test preparation
22-Oct-16*
07-Nov-16
15d
349 350
GAMA.2.1.2.2.1.4.1 Large Bore Piping const8300 LP Feedwater
16-Jul-16 16-Jul-16*
18-Oct-16 30-Aug-16
82d 40d
19-Dec-15 14:56 2016
Nov
Dec
Jan
Feb
Mar
Apr
May
Jun
2017 Jul
14-Jul-16*
16-Jul-16*
352
const8320
IP Feedwater
23-Jul-16*
06-Sep-16
40d
353
const8330
RH
02-Aug-16*
04-Oct-16
55d
02-Aug-16*
354
const8340
LP Eva- Sh-Eco
27-Jul-16*
10-Oct-16
65d
27-Jul-16*
355
const8350
IP-Eva-Sh-Eco
01-Aug-16*
15-Oct-16
65d
01-Aug-16*
356
const8360
HP-Eva-Sh-Eco
04-Aug-16*
18-Oct-16
65d
08-Aug-16 08-Aug-16*
18-Oct-16 28-Sep-16
62d 45d
HP Feedwater
18-Aug-16*
27-Sep-16
35d
IP Feedwater
15-Aug-16*
17-Oct-16
55d
361
const8400
RH
25-Aug-16*
06-Oct-16
37d
362
const8410
LP Eva- Sh-Eco
14-Aug-16*
10-Oct-16
50d
363
const8420
IP-Eva-Sh-Eco
22-Aug-16*
12-Oct-16
45d
364
const8430
HP-Eva-Sh-Eco
28-Aug-16*
18-Oct-16
45d
07-Jul-16 07-Jul-16*
17-Aug-16 30-Jul-16
36d 20d
365 366
GAMA.2.1.2.2.1.5 Auxillary Auxi Steel Structure const8440 silencer support structure installation
367
const8450
Silencer Installation
31-Jul-16*
06-Aug-16
6d
368
const8460
Spring Hangers
07-Aug-16*
17-Aug-16
10d
04-Apr-16 04-Apr-16*
23-Jun-16 05-Apr-16
70d 2d
369 370
GAMA.2.1.2.2.1.6 Inlet Duct Steel Structure const8470 Inlet duct foundation preparation
371
const8480
inlet duct support structure erection
07-Apr-16*
12-Apr-16
5d
372
const8490
inlet duct floor casing alignment & welding
01-May-16*
11-May-16
10d
373
const8500
inlet duct left side casing alignment & welding
12-May-16
23-May-16
10d
374
const8510
inlet duct right side casing alignment & welding
18-May-16
29-May-16
10d
375
const8520
inlet duct roof side casing alignment & welding
28-May-16
07-Jun-16
10d
376
const8530
Inlet duct front casing & expansion joint alignment & welding
08-Jun-16
19-Jun-16
10d
377
const8540
installation & insulation of connecting pieces b/n exhaust & duct
20-Jun-16
23-Jun-16
4d
04-Apr-16 04-Apr-16 04-Apr-16*
05-Oct-16 12-May-16 07-Apr-16
159d 34d 4d
378 379 380
GAMA.2.1.2.2.1.7 Stack GAMA.2.1.2.2.1.7.1 STACK section 1 const9730 pre assembly shell no1
26-Jul-16*
27-Sep-16, 17-Oct-16, 06-Oct-16, 10-Oct-16,
22-Aug-16*
12-Oct-16,
28-Aug-16*
18-Oct-16,
17-Aug-16, GAMA.2.1.2.2.1.5 Auxillary Steel Structure 30-Jul-16,
07-Jul-16* 31-Jul-16* 07-Aug-16*
06-Aug-16, 17-Aug-16,
23-Jun-16, GAMA.2.1.2.2.1.6 Inlet Duct Steel Structure 04-Apr-16*
05-Apr-16,
07-Apr-16*
12-Apr-16,
01-May-16*
11-May-16,
12-May-16
23-May-16,
18-May-16
29-May-16,
28-May-16
07-Jun-16,
08-Jun-16
19-Jun-16,
20-Jun-16
23-Jun-16,
05-Oct-16, GAMA.2.1.2.2.1.7 Stack 12-May-16, GAMA.2.1.2.2.1.7.1 STACK section 1 04-Apr-16*
07-Apr-16,
382
const9740
inspection and welding vertical joint
13-Apr-16*
18-Apr-16
5d
13-Apr-16*
383
const9750
erection and allingment no 1
19-Apr-16*
23-Apr-16
4d
384
const9760
shell no 1 joint welding (circum)
24-Apr-16*
28-Apr-16
5d
385
const9810
Stack section 1 installation
30-Apr-16*
10-May-16
10d
386
const9880
anchor bolt tightnening
11-May-16
12-May-16
2d
GAMA.2.1.2.2.1.7.2 STACK section 2 const9770 pre assembly shell no2
30-Apr-16 30-Apr-16*
31-May-16 03-May-16
28d 4d
12-Apr-16, 18-Apr-16,
19-Apr-16*
23-Apr-16,
24-Apr-16*
28-Apr-16,
30-Apr-16*
10-May-16,
11-May-16 30-Apr-16*
12-May-16, 31-May-16, GAMA.2.1.2.2.1.7.2 STACK section 2 03-May-16,
389
const9771
installation of ladders,platforms&inspection doors.
04-May-16
08-May-16
4d
04-May-16
08-May-16,
390
const9780
inspection and welding vertical joint
04-May-16*
09-May-16
5d
04-May-16*
09-May-16,
391
const9790
erection and allingment no 2
10-May-16*
14-May-16
4d
392
const9800
shell no 2 joint welding (circum)
15-May-16*
19-May-16
5d
393
const9820
Stack section 2 Installation
21-May-16*
31-May-16
10d
04-May-16 04-May-16*
19-Jun-16 08-May-16
40d 4d
10-May-16*
14-May-16,
15-May-16*
19-May-16,
21-May-16*
31-May-16, 19-Jun-16, GAMA.2.1.2.2.1.7.3 STACK section 3 AND DAMPER
04-May-16*
396
const9831
installation of ladders,platforms&inspection doors.
09-May-16
12-May-16
4d
09-May-16
397
const9840
inspection and welding vertical joint
14-May-16*
18-May-16
5d
14-May-16*
398
const9841
pre assembly of damper
19-May-16*
23-May-16
4d
399
const9842
inspection and welding joint circum
24-May-16*
28-May-16
4d
400
const9850
erection and allingment no 3 with damper
29-May-16*
01-Jun-16
4d
401
const9860
shell no2 to 3 joint welding (circum)
02-Jun-16*
07-Jun-16
5d
summary
18-Oct-16, GAMA.2.1.2.2.1.4.2 Small Bore 28-Sep-16,
14-Aug-16*
09-Apr-16
Critical Remaining Work
18-Oct-16,
25-Aug-16*
4d
Page 7 of 8
15-Oct-16,
18-Aug-16*
12-Apr-16
Milestone
10-Oct-16,
15-Aug-16*
09-Apr-16
Remaining Work
04-Oct-16,
08-Aug-16*
installation of ladders,platforms and inspection doors.
GAMA.2.1.2.2.1.7.3 STACK section 3 AND DAMPER const9830 pre assembly shell no3
07-Nov-16,
06-Sep-16,
04-Aug-16*
const9731
394 395
ar
10-Sep-16,
23-Jul-16*
381
387 388
Feb
30-Aug-16,
40d
const8390
Jan
18-Oct-16, GAMA.2.1.2.2.1.4.1 Large Bore
10-Sep-16
const8380
Dec
01-Nov-16, 22-Oct-16*
26-Jul-16*
360
Nov
19-Jul-16,
HP Feedwater
359
Oct
20-Jul-16*
const8310
GAMA.2.1.2.2.1.4.2 Small Bore Piping const8370 LP Feedwater
Sep
07-Nov-16, GAMA.2.1.2.2.1.4 Piping
351
357 358
Aug
08-May-16, 12-May-16, 18-May-16,
19-May-16* 24-May-16* 29-May-16*
23-May-16, 28-May-16, 01-Jun-16,
02-Jun-16*
07-Jun-16,
TASK filter: All Activities © Oracle Corporation
GAMA-GTG HRSG #
Activities/Activity Usage Spreadsheet
Activity ID
402
Activity Name const9870
403 404
Stack section 3 Installation
GAMA.2.1.2.2.1.7.4 STACK section 4 const9900 pre assembly shell no4
Start
Finish
Original Duration
08-Jun-16*
19-Jun-16
10d
09-May-16 09-May-16*
08-Sep-16 12-May-16
106d 4d
19-Dec-15 14:56 2016
Nov
Dec
Jan
Feb
Mar
Apr
May
Jun
08-Jun-16*
installation of ladders,platforms&inspection doors.
14-May-16
17-May-16
4d
14-May-16
17-May-16,
const9910
inspection and welding vertical joint
14-May-16*
18-May-16
5d
14-May-16*
18-May-16,
407
const9920
erection and allingment no 4
18-Aug-16*
22-Aug-16
4d
408
const9930
shell no 4 joint welding (circum)
23-Aug-16*
28-Aug-16
5d
409
const9940
Stack section 4 installation
29-Aug-16*
08-Sep-16
10d
14-May-16 14-May-16*
05-Oct-16 17-May-16
125d 4d
18-Aug-16*
Nov
installation of ladders,platforms&inspection doors.
18-May-16
22-May-16
4d
18-May-16
22-May-16,
inspection and welding vertical joint
18-May-16*
23-May-16
5d
18-May-16*
23-May-16,
414
const9970
erection and allingment no 5
10-Sep-16*
13-Sep-16
4d
415
const9980
shell no 5 joint welding (circum)
14-Sep-16*
19-Sep-16
5d
416
const9981
installation of silencer
20-Sep-16
24-Sep-16
4d
417
const9990
Stack section 5 installation
25-Sep-16*
05-Oct-16
10d
14-May-16 13-Nov-16*
18-Jan-17 06-Dec-16
215d 21d
08-Sep-16,
10-Sep-16* 14-Sep-16* 20-Sep-16 25-Sep-16*
13-Sep-16, 19-Sep-16, 24-Sep-16, 05-Oct-16, 18-Jan-17, GA 13-Nov-16*
420
const8640
ReInstatement
07-Dec-16*
22-Dec-16
14d
07-Dec-16*
421
const8650
Chemical cleaning & Restore (by others )
07-Dec-16*
10-Jan-17
30d
07-Dec-16*
422
const8660
Insulation
07-Dec-16*
16-Jan-17
35d
07-Dec-16*
423
const8670
final touch up painting
14-May-16
18-Jan-17
215d
Critical Remaining Work
summary
ar
17-May-16,
const9960
Page 8 of 8
Feb
05-Oct-16, GAMA.2.1.2.2.1.7.5 STACK section 14-May-16*
const9951
Milestone
Jan
28-Aug-16,
29-Aug-16*
413
Remaining Work
Dec
22-Aug-16,
23-Aug-16*
412
GAMA.2.1.2.2.1.8 Precommissioning Prec & Tests const8630 Hydrotest
Oct
12-May-16,
const9901
418 419
Sep
08-Sep-16, GAMA.2.1.2.2.1.7.4 STACK section 4 09-May-16*
406
GAMA.2.1.2.2.1.7.5 STACK section 5 const9950 pre assembly shell no5
Aug
19-Jun-16,
405
410 411
2017 Jul
14-May-16
06-Dec-16, 22-Dec-16, 10-Jan-17, 16-Jan-17, 18-Jan-17,
TASK filter: All Activities © Oracle Corporation
Detailed Schedule
ID
Name
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
HRSG INSTALLATION SCHEDULE Milestone Signing of Sub‐Contract Agreement Award of Contract Issuance & Signing of LOI Kick off meeting CONSTRUCTION NMC MOBILIZATION Mechanical Works HRSG Mobilzation Block 20 Unit 23 HRSG‐23 By Pass Stack by pass stack foundation preparation erection of bypass stack steel structure installation of diverter box installation of upper steel structure pre‐assembly of stack section1 (round reducer ,silencer ,square to round transition element installation of stack section 1 pre‐assembly of slack section 2 (round reducer,silencer,square to round transition element ) installation of stack section 2 pre‐assembly of slack section 3(round reducer,silencer,square to round transition element ) installation of stack section 3 installation of CEMS Unit By Pass Stack Precommissioning installation of OUT LET duct installation of bellow HRSG Steel Structure & Casing Erection foundation preparation Crane available at site Main stair tower &platform pre‐assembly Casing Panel Installation bottom plate installation vertical side panels Main stair tower and platform erection Lower front panel casing Installation of field casing plates Erection of side platform final bolt tightening of main columns Bumper Installation Installation of CEMS skid HRSG block 20 Elevator structure installation execution of final allignment ,levelling & verticality of casing structure installation of liner system installation of insulation & lining at junction of casing & duct installation of Backstays and header spacers installation of connecting plates (external stiffners to casing panels )
Duration
Start
Finish
374 days 15 days 7 days 0 days 7 days 0 days 356 days 25 days 25 days 25 days 326 days 269 days 269 days 160 days 12 days 25 days 20 days 15 days 7 days 1 day 7 days 1 day 7 days 1 day 12 days 40 days 5 days 2 days 90 days 7 days 0 days 14 days 15 days 5 days 4 days 14 days 3 days 3 days 20 days 2 days 20 days 10 days 65 days 4 days 3 days 2 days 2 days 4 days
11/10/2015 0:00 11/10/2015 11/19/2015 11/10/2015 11/11/2015 11/18/2015 12/1/2015 12/1/2015 12/1/2015 12/1/2015 1/5/2016 1/5/2016 1/5/2016 1/5/2016 1/5/2016 1/20/2016 2/20/2016 3/15/2016 4/3/2016 4/12/2016 4/12/2016 4/21/2016 4/21/2016 5/1/2016 5/2/2016 5/24/2016 5/16/2016 5/22/2016 1/17/2016 1/17/2016 1/24/2016 1/26/2016 1/27/2016 2/14/2016 2/21/2016 2/1/2016 2/17/2016 2/21/2016 2/14/2016 3/17/2016 2/22/2016 3/22/2016 2/15/2016 3/8/2016 2/24/2016 2/28/2016 3/1/2016 3/3/2016
1/18/2017 11/26/2015 11/26/2015 11/10/2015 11/18/2015 11/18/2015 1/18/2017 12/29/2015 12/29/2015 12/29/2015 1/18/2017 11/13/2016 11/13/2016 7/9/2016 1/18/2016 2/17/2016 3/13/2016 3/31/2016 4/10/2016 4/12/2016 4/19/2016 4/21/2016 4/28/2016 5/1/2016 5/15/2016 7/9/2016 5/21/2016 5/23/2016 4/30/2016 1/24/2016 1/24/2016 2/10/2016 2/13/2016 2/18/2016 2/24/2016 2/16/2016 2/20/2016 2/23/2016 3/7/2016 3/19/2016 3/15/2016 4/2/2016 4/30/2016 3/12/2016 2/27/2016 2/29/2016 3/2/2016 3/7/2016
Detailed Schedule 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98
Module & Drum Drum supporting Structure preparation / Installation Module Erection installation of module 1A&1B installation of module 2A &2 B installation of module of 3A & 3B installation of module 4A & 4B restoration of insulation and liner between modules installation of nozzle connection & piping Installation of trusses installation of upper trusses installation of intermediate trusses installation of lower trusses HP drum HP drum erection HP down comer piping IP drum IP drum erection IP down comer piping LP drum LP drum erection LP down comer piping Piping & Instruments install blow down tank Valves & Instruments Installation Piping test preparation Large Bore Piping LP Feedwater HP Feedwater IP Feedwater RH LP Eva‐ Sh‐Eco IP‐Eva‐Sh‐Eco HP‐Eva‐Sh‐Eco Small Bore Piping LP Feedwater HP Feedwater IP Feedwater RH LP Eva‐ Sh‐Eco IP‐Eva‐Sh‐Eco HP‐Eva‐Sh‐Eco Auxillary Steel Structure silencer support structure installation Silencer Installation Spring Hangers Inlet Duct Steel Structure Inlet duct foundation preparation inlet duct support structure erection inlet duct floor casing alignment & welding
84 days 5 days 45 days 4 days 5 days 6 days 5 days 3 days 10 days 12 days 4 days 4 days 4 days 37 days 1 day 30 days 31 days 1 day 20 days 37 days 2 days 25 days 98 days 5 days 85 days 15 days 91 days 40 days 40 days 40 days 55 days 70 days 70 days 70 days 69 days 45 days 35 days 55 days 49 days 45 days 45 days 45 days 40 days 20 days 6 days 10 days 50 days 2 days 10 days 10 days
3/20/2016 5/4/2016 3/20/2016 3/20/2016 3/24/2016 3/30/2016 4/6/2016 4/26/2016 4/30/2016 4/12/2016 4/12/2016 4/17/2016 4/21/2016 5/10/2016 5/10/2016 5/18/2016 5/11/2016 5/11/2016 5/24/2016 5/14/2016 5/14/2016 5/28/2016 5/16/2016 5/18/2016 5/25/2016 8/21/2016 5/16/2016 5/16/2016 5/30/2016 5/29/2016 5/30/2016 5/28/2016 6/9/2016 5/31/2016 6/14/2016 6/14/2016 6/28/2016 6/28/2016 6/28/2016 6/26/2016 7/12/2016 7/3/2016 5/16/2016 5/16/2016 6/9/2016 6/20/2016 3/8/2016 3/8/2016 3/12/2016 3/26/2016
6/25/2016 5/9/2016 5/10/2016 3/23/2016 3/29/2016 4/5/2016 4/11/2016 4/28/2016 5/10/2016 4/25/2016 4/16/2016 4/20/2016 4/25/2016 6/21/2016 5/10/2016 6/21/2016 6/15/2016 5/11/2016 6/15/2016 6/25/2016 5/15/2016 6/25/2016 9/6/2016 5/23/2016 8/31/2016 9/6/2016 8/29/2016 6/30/2016 7/14/2016 7/13/2016 8/1/2016 8/16/2016 8/29/2016 8/20/2016 9/1/2016 8/4/2016 8/7/2016 8/30/2016 8/23/2016 8/16/2016 9/1/2016 8/23/2016 6/30/2016 6/7/2016 6/15/2016 6/30/2016 5/4/2016 3/9/2016 3/22/2016 4/5/2016
Detailed Schedule 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148
inlet duct left side casing alignment & welding inlet duct right side casing alignment & welding inlet duct roof side casing alignment & welding Inlet duct front casing & expansion joint alignment & welding installation & insulation of connecting pieces b/n exhaust & duct Stack STACK section 1 pre assembly shell no1 Inspection and welding vertical joint erection and allingment no 1 shell no 1 joint welding (circum) Stack section 1 installation anchor bolt tightening installation of ladders ,platforms and inspection doors STACK section 2 pre assembly shell no2 Inspection and welding vertical joint erection and allingment no 2 shell no 2 joint welding (circum) Stack section 2 Installation installation of ladders ,platforms and inspection doors STACK section 3 AND DAMPER pre assembly shell no3 Inspection and welding vertical joint erection and allingment no 3 with damper shell no2 to 3 joint welding (circum) Stack section 3 Installation pre assembly of damper inspection and welding joint circum installation of ladders ,platforms and inspection doors STACK section 4 pre assembly shell no4 inspection and welding vertical joint erection and allingment no 4 shell no 4 joint welding (circum) Stack section 4 installation installation of ladders ,platforms and inspection doors STACK section 5 pre assembly shell no5 inspection and welding vertical joint erection and allingment no 5 shell no 5 joint welding (circum) Stack section 5 installation installation of ladders ,platforms and inspection doors installation of silencer Precomissioning & Tests Hydrotest ReInstatement Chemical cleaning & Restore (by others ) Insulation
10 days 10 days 10 days 10 days 3 days 159 days 33 days 4 days 5 days 4 days 5 days 10 days 2 days 3 days 31 days 4 days 5 days 4 days 5 days 10 days 3 days 37 days 4 days 5 days 4 days 5 days 10 days 4 days 4 days 3 days 69 days 4 days 5 days 4 days 5 days 10 days 3 days 84 days 4 days 5 days 4 days 5 days 10 days 3 days 2 days 225 days 20 days 15 days 25 days 32 days
3/31/2016 4/7/2016 4/13/2016 4/20/2016 5/2/2016 2/14/2016 2/14/2016 2/14/2016 2/22/2016 2/28/2016 3/3/2016 3/9/2016 3/21/2016 2/18/2016 3/9/2016 3/9/2016 3/17/2016 3/23/2016 3/28/2016 4/3/2016 3/14/2016 4/3/2016 4/3/2016 4/11/2016 4/24/2016 4/28/2016 5/4/2016 4/17/2016 4/20/2016 4/7/2016 5/4/2016 5/4/2016 5/12/2016 7/2/2016 7/6/2016 7/12/2016 5/9/2016 5/11/2016 5/11/2016 5/16/2016 7/24/2016 7/28/2016 8/6/2016 5/16/2016 8/3/2016 2/25/2016 9/11/2016 10/4/2016 10/5/2016 10/6/2016
4/11/2016 4/18/2016 4/24/2016 5/1/2016 5/4/2016 8/16/2016 3/22/2016 2/17/2016 2/27/2016 3/2/2016 3/8/2016 3/20/2016 3/22/2016 2/21/2016 4/13/2016 3/13/2016 3/22/2016 3/27/2016 4/2/2016 4/13/2016 3/16/2016 5/15/2016 4/6/2016 4/16/2016 4/27/2016 5/3/2016 5/15/2016 4/20/2016 4/24/2016 4/10/2016 7/23/2016 5/8/2016 5/17/2016 7/5/2016 7/11/2016 7/23/2016 5/11/2016 8/16/2016 5/15/2016 5/21/2016 7/27/2016 8/2/2016 8/16/2016 5/18/2016 8/4/2016 11/13/2016 10/3/2016 10/20/2016 11/2/2016 11/12/2016
Detailed Schedule 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198
final touch up painting Unit 22 HRSG 22 By Pass Stack by pass stack foundation preparation erection of bypass stack steel structure installation of diverter box installation of upper steel structure pre‐assembly of stack section1 (round reducer ,silencer ,square to round transition element installation of stack section 1 pre‐assembly of slack section 2 (round reducer,silencer,square to round transition element ) installation of stack section 2 pre‐assembly of slack section 3(round reducer,silencer,square to round transition element ) installation of stack section 3 installation of CEMS Unit By Pass Stack Precommissioning installation of out let duct installation of bellow HRSG Steel Structure & Casing Erection foundation preparation Crane available at site Main stair tower &platform pre‐assembly Casing Panel Installation bottom plate installation vertical side panels Main stair tower and platform erection Lower front panel casing Installation of field casing plates Erection of side platform final bolt tightening of main columns Bumper Installation Installation of CEMS skid execution of final allignment ,levelling & verticality of casing structure installation of liner system installation of insulation & lining at junction of casing & duct installation of Backstays and header spacers installation of connecting plates (external stiffners to casing panels ) Module & DRum Drum supporting Structure preparation / Installation module erection installation of module 1A&1B installation of module 2A &2 B installation of module of 3A & 3B installation of module 4A & 4B restoration of insulation and liner between modules installation of nozzle connection & piping installation of trusses installation of upper trusses installation of intermediate trusses installation of lower trusses
225 days 281 days 281 days 151 days 12 days 25 days 20 days 15 days 7 days 1 day 7 days 1 day 7 days 1 day 12 days 40 days 5 days 2 days 106 days 7 days 0 days 14 days 15 days 5 days 4 days 14 days 3 days 3 days 20 days 5 days 20 days 10 days 4 days 3 days 2 days 2 days 4 days 80 days 5 days 45 days 4 days 5 days 6 days 5 days 3 days 10 days 12 days 4 days 4 days 4 days
2/25/2016 1/23/2016 1/23/2016 1/23/2016 1/23/2016 2/7/2016 3/7/2016 3/30/2016 4/17/2016 4/25/2016 4/27/2016 5/7/2016 5/8/2016 5/16/2016 5/17/2016 5/31/2016 5/31/2016 6/6/2016 2/15/2016 2/15/2016 2/23/2016 2/24/2016 2/27/2016 3/15/2016 3/22/2016 3/7/2016 3/23/2016 3/27/2016 3/14/2016 4/24/2016 3/29/2016 6/6/2016 4/19/2016 4/6/2016 4/10/2016 4/12/2016 4/14/2016 4/30/2016 6/9/2016 4/30/2016 4/30/2016 5/4/2016 5/10/2016 5/17/2016 6/6/2016 6/9/2016 5/23/2016 5/23/2016 5/28/2016 6/1/2016
11/13/2016 12/14/2016 12/14/2016 7/16/2016 2/4/2016 3/6/2016 3/29/2016 4/16/2016 4/24/2016 4/25/2016 5/4/2016 5/7/2016 5/15/2016 5/16/2016 5/30/2016 7/16/2016 6/5/2016 6/7/2016 6/16/2016 2/22/2016 2/23/2016 3/10/2016 3/14/2016 3/20/2016 3/26/2016 3/22/2016 3/26/2016 3/29/2016 4/5/2016 4/28/2016 4/20/2016 6/16/2016 4/23/2016 4/9/2016 4/11/2016 4/13/2016 4/18/2016 7/31/2016 6/14/2016 6/20/2016 5/3/2016 5/9/2016 5/16/2016 5/22/2016 6/8/2016 6/20/2016 6/5/2016 5/26/2016 5/31/2016 6/5/2016
Detailed Schedule 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248
HP drum HP drum erection HP down comer piping IP drum IP drum erection IP down comer piping LP drum LP drum erection LP down comer piping Piping & Instruments install blow down tank Valves & Instruments Installation Piping test preparation Large Bore Piping LP Feedwater HP Feedwater IP Feedwater RH LP Eva‐ Sh‐Eco IP‐Eva‐Sh‐Eco HP‐Eva‐Sh‐Eco Small Bore Piping LP Feedwater HP Feedwater IP Feedwater RH LP Eva‐ Sh‐Eco IP‐Eva‐Sh‐Eco HP‐Eva‐Sh‐Eco Auxillary Steel Structure silencer support structure installation Silencer Installation Spring Hangers Inlet Duct Steel Structure Inlet duct foundation preparation inlet duct support structure erection inlet duct floor casing alignment & welding inlet duct left side casing alignment & welding inlet duct right side casing alignment & welding inlet duct roof side casing alignment & welding Inlet duct front casing & expansion joint alignment & welding installation & insulation of connecting pieces b/n exhaust & duct Stack STACK section 1 pre assembly shell no1 Inspection and welding vertical joint erection and allingment no 1 shell no 1 joint welding (circum) Stack section 1 installation installation of ladders ,platforms and inspection doors
37 days 1 day 30 days 31 days 1 day 20 days 37 days 2 days 25 days 91 days 5 days 80 days 15 days 80 days 40 days 40 days 40 days 55 days 65 days 65 days 68 days 58 days 45 days 35 days 52 days 50 days 50 days 45 days 46 days 42 days 20 days 6 days 10 days 54 days 2 days 5 days 10 days 10 days 10 days 10 days 10 days 3 days 172 days 28 days 4 days 5 days 4 days 5 days 10 days 3 days
6/15/2016 6/15/2016 6/23/2016 6/16/2016 6/16/2016 6/29/2016 6/19/2016 6/19/2016 7/3/2016 6/21/2016 6/22/2016 6/28/2016 9/18/2016 6/21/2016 6/21/2016 7/3/2016 6/28/2016 7/5/2016 6/30/2016 7/4/2016 7/5/2016 7/20/2016 7/20/2016 7/26/2016 7/27/2016 7/28/2016 7/27/2016 8/2/2016 7/31/2016 6/21/2016 6/21/2016 7/17/2016 7/28/2016 3/22/2016 3/22/2016 3/26/2016 3/31/2016 4/18/2016 4/24/2016 4/30/2016 5/9/2016 5/21/2016 3/10/2016 3/10/2016 3/10/2016 3/15/2016 3/21/2016 3/26/2016 3/31/2016 3/15/2016
7/27/2016 6/15/2016 7/27/2016 7/21/2016 6/16/2016 7/21/2016 7/31/2016 6/20/2016 7/31/2016 10/4/2016 6/27/2016 9/28/2016 10/4/2016 9/21/2016 8/6/2016 8/17/2016 8/13/2016 9/6/2016 9/13/2016 9/17/2016 9/21/2016 9/25/2016 9/10/2016 9/4/2016 9/25/2016 9/24/2016 9/22/2016 9/22/2016 9/21/2016 8/8/2016 7/13/2016 7/23/2016 8/8/2016 5/23/2016 3/23/2016 3/30/2016 4/11/2016 4/28/2016 5/4/2016 5/10/2016 5/19/2016 5/23/2016 9/26/2016 4/11/2016 3/14/2016 3/20/2016 3/24/2016 3/30/2016 4/11/2016 3/17/2016
Detailed Schedule 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298
STACK section 2 pre assembly shell no2 Inspection and welding vertical joint erection and allingment no 2 shell no 2 joint welding (circum) Stack section 2 Installation installation of ladders ,platforms and inspection doors STACK section 3 AND DAMPER pre assembly shell no3 Inspection and welding vertical joint erection and allingment no 3 with damper shell no2 to 3 joint welding (circum) Stack section 3 Installation pre assembly of damper inspection and welding joint circum installation of ladders ,platforms and inspection doors STACK section 4 pre assembly shell no4 inspection and welding vertical joint erection and allingment no 4 shell no 4 joint welding (circum) Stack section 4 installation installation of ladders ,platforms and inspection doors STACK section 5 pre assembly shell no5 inspection and welding vertical joint erection and allingment no 5 shell no 5 joint welding (circum) Stack section 5 installation installation of ladders ,platforms and inspection doors installation of silencer Precommissiong & Test Hydrotest ReInstatement Chemical cleaning & Restore (by others ) Insulation final touch up painting Unit 21 HRSG 21 By Pass Stack by pass stack foundation preparation erection of bypass stack steel structure installation of diverter box installation of upper steel structure pre‐assembly of stack section1 (round reducer ,silencer ,square to round transition element installation of stack section 1 pre‐assembly of slack section 2 (round reducer,silencer,square to round transition element ) installation of stack section 2 pre‐assembly of slack section 3(round reducer,silencer,square to round transition element ) installation of stack section 3
28 days 4 days 5 days 4 days 5 days 10 days 3 days 36 days 4 days 5 days 4 days 5 days 10 days 4 days 4 days 3 days 101 days 4 days 5 days 4 days 5 days 10 days 3 days 120 days 4 days 5 days 4 days 5 days 10 days 3 days 4 days 216 days 21 days 15 days 30 days 35 days 216 days 301 days 301 days 146 days 12 days 25 days 20 days 15 days 7 days 1 day 7 days 1 day 6 days 1 day
3/31/2016 3/31/2016 4/5/2016 4/11/2016 4/16/2016 4/21/2016 4/5/2016 4/5/2016 4/5/2016 4/10/2016 4/25/2016 4/30/2016 5/5/2016 4/16/2016 4/20/2016 4/10/2016 5/5/2016 5/5/2016 5/14/2016 8/9/2016 8/14/2016 8/20/2016 5/10/2016 5/10/2016 5/10/2016 5/18/2016 8/31/2016 9/5/2016 9/15/2016 5/15/2016 9/11/2016 4/7/2016 10/9/2016 11/2/2016 11/2/2016 11/2/2016 4/7/2016 2/3/2016 2/3/2016 2/3/2016 2/3/2016 2/17/2016 3/17/2016 4/10/2016 4/27/2016 5/5/2016 5/5/2016 5/15/2016 5/14/2016 5/21/2016
5/2/2016 4/4/2016 4/10/2016 4/14/2016 4/20/2016 5/2/2016 4/7/2016 5/16/2016 4/9/2016 4/14/2016 4/28/2016 5/4/2016 5/16/2016 4/19/2016 4/24/2016 4/12/2016 8/30/2016 5/9/2016 5/18/2016 8/13/2016 8/18/2016 8/30/2016 5/12/2016 9/26/2016 5/14/2016 5/23/2016 9/4/2016 9/10/2016 9/26/2016 5/17/2016 9/14/2016 12/14/2016 11/1/2016 11/19/2016 12/6/2016 12/12/2016 12/14/2016 1/18/2017 1/18/2017 7/21/2016 2/16/2016 3/16/2016 4/9/2016 4/26/2016 5/4/2016 5/5/2016 5/12/2016 5/15/2016 5/19/2016 5/21/2016
Detailed Schedule 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348
installation of CEMS Unit By Pass Stack Precommissioning installation of outlet duct installation of bellow HRSG Steel Structure & Casing Erection foundation preparation Crane available at site Main stair tower &platform pre‐assembly Casing Panel Installation bottom plate installation vertical side panels Main stair tower and platform erection Lower front panel casing Installation of field casing plates Erection of side platform final bolt tightening of main columns Bumper Installation Installation of CEMS skid execution of final allignment ,levelling & verticality of casing structure installation of liner system installation of insulation & lining at junction of casing & duct installation of Backstays and header spacers installation of connecting plates (external stiffners to casing panels ) Mdule & Drum Drum supporting Structure preparation/ Installation module erection installation of module 1A&1B installation of module 2A &2 B installation of module of 3A & 3B installation of module 4A & 4B restoration of insulation and liner between modules installation of nozzle connection & piping installation of trusses installation of upper trusses installation of intermediate trusses installation of lower trusses HP drum HP drum erection HP down comer piping IP drum IP drum erection IP down comer piping LP drum LP drum erection LP down comer piping Piping & Instruments) install blow down tank Valves & Instruments Installation Piping test preparation Large Bore Piping
12 days 40 days 5 days 2 days 79 days 7 days 0 days 14 days 15 days 5 days 4 days 14 days 3 days 3 days 20 days 2 days 18 days 12 days 4 days 3 days 2 days 2 days 4 days 77 days 5 days 45 days 4 days 5 days 6 days 5 days 3 days 10 days 12 days 4 days 4 days 4 days 37 days 1 day 30 days 31 days 1 day 20 days 37 days 2 days 25 days 100 days 5 days 90 days 15 days 82 days
5/22/2016 6/6/2016 6/5/2016 6/11/2016 3/17/2016 3/17/2016 3/26/2016 3/28/2016 3/29/2016 4/16/2016 4/21/2016 4/6/2016 4/23/2016 4/26/2016 4/13/2016 5/24/2016 4/26/2016 6/4/2016 5/19/2016 5/7/2016 5/10/2016 5/12/2016 5/15/2016 5/26/2016 7/3/2016 5/26/2016 5/26/2016 5/31/2016 6/6/2016 6/13/2016 7/3/2016 7/6/2016 6/19/2016 6/19/2016 6/23/2016 6/28/2016 7/9/2016 7/9/2016 7/17/2016 7/10/2016 7/10/2016 7/23/2016 7/12/2016 7/12/2016 7/26/2016 7/14/2016 7/14/2016 7/20/2016 10/22/2016 7/16/2016
6/4/2016 7/21/2016 6/9/2016 6/12/2016 6/16/2016 3/24/2016 3/26/2016 4/12/2016 4/14/2016 4/20/2016 4/25/2016 4/21/2016 4/25/2016 4/28/2016 5/5/2016 5/25/2016 5/16/2016 6/16/2016 5/23/2016 5/9/2016 5/11/2016 5/14/2016 5/18/2016 8/23/2016 7/7/2016 7/17/2016 5/30/2016 6/5/2016 6/12/2016 6/18/2016 7/5/2016 7/17/2016 7/2/2016 6/22/2016 6/27/2016 7/2/2016 8/20/2016 7/9/2016 8/20/2016 8/14/2016 7/10/2016 8/14/2016 8/23/2016 7/13/2016 8/23/2016 11/7/2016 7/19/2016 11/1/2016 11/7/2016 10/18/2016
Detailed Schedule 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398
LP Feedwater HP Feedwater IP Feedwater RH LP Eva‐ Sh‐Eco IP‐Eva‐Sh‐Eco HP‐Eva‐Sh‐Eco Small Bore Piping LP Feedwater HP Feedwater IP Feedwater RH LP Eva‐ Sh‐Eco IP‐Eva‐Sh‐Eco HP‐Eva‐Sh‐Eco Auxillary Steel Structure silencer support structure installation Silencer Installation Spring Hangers Inlet Duct Steel Structure Inlet duct foundation preparation inlet duct support structure erection inlet duct floor casing alignment & welding inlet duct left side casing alignment & welding inlet duct right side casing alignment & welding inlet duct roof side casing alignment & welding Inlet duct front casing & expansion joint alignment & welding installation & insulation of connecting pieces b/n exhaust & duct Stack STACK section 1 pre assembly shell no1 Inspection and welding vertical joint erection and allingment no 1 shell no 1 joint welding (circum) Stack section 1 installation installation of ladders,platforms and inspection doors. anchor bolt tightnening STACK section 2 pre assembly shell no2 Inspection and welding vertical joint erection and allingment no 2 shell no 2 joint welding (circum) Stack section 2 Installation installation of ladders,platforms&inspection doors. STACK section 3 AND DAMPER pre assembly shell no3 Inspection and welding vertical joint erection and allingment no 3 with damper shell no2 to 3 joint welding (circum) Stack section 3 Installation
40 days 40 days 40 days 55 days 65 days 65 days 65 days 62 days 45 days 35 days 55 days 37 days 50 days 45 days 45 days 36 days 20 days 6 days 10 days 70 days 2 days 5 days 10 days 10 days 10 days 10 days 10 days 4 days 159 days 34 days 4 days 5 days 4 days 5 days 10 days 4 days 2 days 28 days 4 days 5 days 4 days 5 days 10 days 4 days 40 days 4 days 5 days 4 days 5 days 10 days
7/16/2016 7/26/2016 7/23/2016 8/2/2016 7/27/2016 8/1/2016 8/4/2016 8/8/2016 8/8/2016 8/18/2016 8/15/2016 8/25/2016 8/14/2016 8/22/2016 8/28/2016 7/7/2016 7/7/2016 7/31/2016 8/7/2016 4/4/2016 4/4/2016 4/7/2016 5/1/2016 5/12/2016 5/18/2016 5/28/2016 6/8/2016 6/20/2016 4/4/2016 4/4/2016 4/4/2016 4/13/2016 4/19/2016 4/24/2016 4/30/2016 4/9/2016 5/11/2016 4/30/2016 4/30/2016 5/4/2016 5/10/2016 5/15/2016 5/21/2016 5/4/2016 5/4/2016 5/4/2016 5/14/2016 5/29/2016 6/2/2016 6/8/2016
8/30/2016 9/10/2016 9/6/2016 10/4/2016 10/10/2016 10/15/2016 10/18/2016 10/18/2016 9/28/2016 9/27/2016 10/17/2016 10/6/2016 10/10/2016 10/12/2016 10/18/2016 8/17/2016 7/30/2016 8/6/2016 8/17/2016 6/23/2016 4/5/2016 4/12/2016 5/11/2016 5/23/2016 5/29/2016 6/7/2016 6/19/2016 6/23/2016 10/5/2016 5/12/2016 4/7/2016 4/18/2016 4/23/2016 4/28/2016 5/10/2016 4/12/2016 5/12/2016 5/31/2016 5/3/2016 5/9/2016 5/14/2016 5/19/2016 5/31/2016 5/8/2016 6/19/2016 5/8/2016 5/18/2016 6/1/2016 6/7/2016 6/19/2016
Detailed Schedule 399 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422
pre assembly of damper inspection and welding joint circum installation of ladders,platforms&inspection doors. STACK section 4 pre assembly shell no4 inspection and welding vertical joint erection and allingment no 4 shell no 4 joint welding (circum) Stack section 4 installation installation of ladders,platforms&inspection doors. STACK section 5 pre assembly shell no5 inspection and welding vertical joint erection and allingment no 5 shell no 5 joint welding (circum) Stack section 5 installation installation of ladders,platforms&inspection doors. installation of silencer Precommissioning & Tests Hydrotest ReInstatement Chemical cleaning & Restore (by others ) Insulation final touch up painting
4 days 4 days 4 days 106 days 4 days 5 days 4 days 5 days 10 days 4 days 125 days 4 days 5 days 4 days 5 days 10 days 4 days 4 days 215 days 21 days 14 days 30 days 35 days 215 days
5/19/2016 5/24/2016 5/9/2016 5/9/2016 5/9/2016 5/14/2016 8/18/2016 8/23/2016 8/29/2016 5/14/2016 5/14/2016 5/14/2016 5/18/2016 9/10/2016 9/14/2016 9/25/2016 5/18/2016 9/20/2016 5/14/2016 11/13/2016 12/7/2016 12/7/2016 12/7/2016 5/14/2016
5/23/2016 5/28/2016 5/12/2016 9/8/2016 5/12/2016 5/18/2016 8/22/2016 8/28/2016 9/8/2016 5/17/2016 10/5/2016 5/17/2016 5/23/2016 9/13/2016 9/19/2016 10/5/2016 5/22/2016 9/24/2016 1/18/2017 12/6/2016 12/22/2016 1/10/2017 1/16/2017 1/18/2017
Attachment No.: 04 Quality Assurance Plan & Inspection Test Plan
Attachment No.: 05 CV of the QA/QC Manager
Curriculum Vitae QA/QC Manager House 990, Road 1415, Manama 314. Email:
[email protected] Yahiya Mahdi Hilal Abdualla Madan PERSONAL INFORAMTION
Date of Birth: 11th April, 1974 Place of Birth: AL-Hajar Village Nationality: Bahraini CPR No.: 740404687 Marital Status: Married Phone No.: 39862355, 17-591087 &39153955
SUMMARY OF QUALIFICATIONS Bahrain Training Institute in partnership with Wigan and Leigh College P.O. Box: 33090, kingdom of Bahrain
1999 -1999: Trainee Mechanical Technician (BAPCO) 1996 -1999: BTEC National Diploma in Mechanical and Plant Engineering. 1993 -1994: BTEC First Diploma in Engineering. 1989 -1992: Secondary Technical Certificate (Elect.). 1986 -1989: Intermediate School Certificate. 1980 -1986: Primary School Certificate.
ADDITIONAL QUALIFICATION
NDT-ASNT LEVEL II in RT, UT, PT,MT& VT CSWIP 3.1 - Certified Welding Inspector, TWI 2008 CSWIP BGAS 3.2– Certified Painting Inspector, TWI 2010 IOSH Safety Management Electrical wire man license
COMPUTOR SKILLS Windows 7 Microsoft Office 2010 AutoCad 2010
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CAREER SUMMARY Over 14 years work experience in Gas Power Plant, Water Desalination plant, Gas Power Plant & Construction Storage Tanks, gas Pipelines, Diffuser, Cement silo, Diverter, Damper, Exhaust system, Superstructure, Ship loader, Ejector compressor, Wind Turbine Bridge, Dredge, pressure vessels , air receiver, Heat exchangers, Columns, Drums, & Structural Steels. EXPERIENCE SUMMARY A. From 2001 to till Date NASS Mechanical Contracting Co. W.L.L Kingdom of Bahrain
Project Handled (Starting from 2001 to till date) Reliance Industries Ltd. – High Purity ISO-Butylene (H.P.I.B) Project Jamnagar 3 Expansion Program, India, CS Pressure Vessels (Qty.09 No’s). Code - ASME VIII Div-1 2. Reliance Industries Ltd. – Supply and Fabrication of CS Pipe Spools (38000 Inch Diameters) for J3 Project, India. Code - Process Piping ASME B31.3, Power Piping ASME B31.1 1.
3. TEKFEN /SADARA – Propylene Oxide Plant Project Unit 360, Saudi Arabia, Fabrication of piping spools ( 27500 Inch Diameters) and Tanks 9 Nos. Code - Process Piping ASME B31.3, API-650 & API-620. 4. HHI- Tihama Cogeneration Expansion Project stage II (540 MW), Fabrication, construction of Inlet Duct, HRSG 3 Units, Saudi Arabia. 5. SAUDI TECHNOLOGY BASE LUBE OIL PLANT (STBE) – Fabrication, construction of 44 Nos of storage tanks, Vessels & Colum’s- Saudi Arabia. Code - ASME VIII Div-1 6. TATWEER PERTOLEUM- Bahrain, New Tank Batteries & Well Manifolds – Treated Produced Water, Tank, Surge tanks, Slope Tanks, Skimmer tanks (Train 1 & 2) 7. BRADAN, Riyadh PP-11 1750 MW power plant Project– Fabrication , construction of Inlet Duct, Outlet Duct, Stack, Diverter, Damper, HRSG 6 Units. 8. BRADAN- Sabiya Power Plant 2000 MW Project, Fabrication, construction of Inlet Duct, Outlet Duct & Diverter, HRSG & GTG 6 Units, Kuwait. 9. SIEMENS AG Power Generation, Al Ezzel Power Project, Bahrain –Combine Cycle Power Plant 950 MW (Boiler, Feed Water line, economizer, super heater deaerator storage tank). 10. BECHTEL, Alba (Aluminum Bahrain Smelting Plant), Line-5 Expansion Project –POT Superstructures 337 Nos. 11. BAPCO, Bahrain - New Khuff Gas Development Program Project- New Gas pipe line & condensate pipe Line K34, K32, K29 & K8.
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Other Duties & Responsibilities Materials Inspections: Identification/verification of MTC according to the Standards / Applicable codes. Dimensional Inspections: Dimensional inspection of Fabrication Products for conformity by the approved Drawings, with respect to applicable Codes & Standards. Visual Welding Inspections: Visual welding Examination of the completed welds, including in process activities like verification of actual Welding parameters, Process, consumables handling etc. NDT Inspection: Carry out the Non-Destructive Testing Such as MT, PT, UT weldment and Thickness Measurement, according to the requirements of the Quality and Test Plan. Air Leak Test / Hydrotest Inspection: witness air Leak Test / Hydrotest Inspection according to the requirements of the Quality and Test Plan. Preassembly/ Trial Assembly Inspection: witness Preassembly/ Trial Assembly Inspection according to the requirements of the Quality and Test Plan. Surface Preparation Inspection: Carryout the inspection for surface preparation for the coating, according o the standards/Specification. Coating Inspections: Carry out the in process inspection of coating and finished coat inspection (WFT & DFT). Final Inspections: Verification of the Packing List, Loading of the finished products, coordination with 3rdparty inspectors / Client inspectors. Process Piping ASME B31.3, Power Piping ASME B31.1 & ASME VIII Div-1 & Div-2 (Vessels) Inspection of new dry gas and condensate line, new wellhead surface facilities-pipe line from wellhead to GDU, well flare line, Inspection of GDU package-erection of Gas/Glycol Exchanger/air-cooling tower, interconnecting piping work as per contract specification, drawings, codes, and ITP Inspection of pipeline routing layout, fit-up, visual welding as per WPS, tie-in, jump-over, hydro-testing, pigging, purging. Different stages of inspection reports preparing including dossier. Co-ordination with client project Engineer
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B. From July, 1997 to March 2000: AI-Koohji Construction Company Kingdom of Bahrain Position: Electrical Technician C. From 1st October, 1999 to 31st December 1999: Bahrain Petroleum Company (BAPCO) Kingdom of Bahrain Position: Trainee Mechanical Technician D. From October, 1996 to March, 1997 Ministry of Electricity and Water Personnel and Training Directorate Kingdom of Bahrain Position: Trainee Electrical Technician E. From November, 1995 to October, 1996 AI-Daleem construction Kingdom of Bahrain Position: Electrical Technician Languages Known Arabic, English (speak and write) Hindi (speak as beginner’s) Hobbies & Interests 1. Reading and music 2. Sports Declaration The above furnished information is true and correct to the best of my knowledge.
Yahiya Mahdi Hilal Abdualla Madan
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Attachment No.: 06 Non-Conformities Procedure
Attachment No.: 07 List of the Control and Test Equipment & Tools attached. Calibration Certificate shall be submitted progressively after Mobilizing to Site.
Attachment No.: 08 HSE Plan
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NIS SITE HSE PLAN FOR POWER ISLAND ME&I AND EQUIPMENT INSTALLTION WORKS FOR SEC POWER PLANT PP-13, KSA.
VALIDATION
DEPT
SIGNATURE
Prepared by NIS
Reviewed by NIS
HSE DEPT
PROJECT MANAGER
Approved by GAMA
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HSE Plan
TABLE OF CONTENTS SECTION 1) a) b) c) d)
Project Policy Statement HSE Policy Environmental Policy Alcohol and Drug Policy Smoking Policy
a) b) c) d) e) f) g)
Duty and responsibilities of the Project`s Officer(s) Project Manager Site / Construction Manager HSE Manager Safety Supervisor Field Superintendent/Supervisor Security Officer Employee(Worker)
a) b) c) d)
Formal Inspection of Construction site The Purpose of HSE Inspections Scope of Inspection and Audit HSE Audit Items HSE Inspection Items
a) b)
HSE Meeting(s) Weekly HSE Coordination Meeting Monthly HSE Committee Meeting
a) b) c)
Accident & Investigation Investigation Accident Reporting Monthly Safety Health and Fire Report
a)
EQUIPMENT SAFETY Housekeeping
2)
3)
4)
5)
6)
7)
DESCRIPTION
Job Safety Analysis & Risk Assessment(s)
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Medical Facilities and Procedure
9)
Safety Training
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9.1 Types and Requirements of HSE Training 9.1.2 HSE Induction Training for New Personnel 9.1.3 Tool Box talks 10) PURPOSE
11) Emergency Response Plan 11.1 General 11.2 Members of Emergency Response Team 11.3 Communication System 11.4 Emergency telephone Numbers 11.5 Assembly point Location 12) Rules & Regulations 12.1 Discipline 12.2 Admittance, Traffic and Parking 12.3 Personal Attire 12.4 Hole Protection 12.5 Compressed Gases 12.6 Material Handling 12.7 Electrical Work 12.8 Working at Heights 12.9 Refueling of Vehicles/Mobile Equipment 12.10 Smoking 12.11 Prevention of Heat Stress 12.12 Environment Requirements of Construction 13) Cranes & Lifting Equipment 13.1 Certification, colour coding, Register of Inspections. 13.2 Responsibility 13.3 Fire/Explosion Prevention 13.4 Weather Conditions 13.5 Load Control 13.6 Slings and Cables 13.7 End of Day work. 14) Site HSE Procedure and Formats available as per company standard
.
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15) Incentive /Disciplinary Action as per company Standard.
1. PROJECT POLICY STATEMENT 1.1 HSE POLICY The final goal of NIS HSE philosophy is, to ensure the health and safety of all personnel, to eliminate property damage and to provide a safe and comfortable working and living environment, during the entire construction period.
NIS will maintain its own safety philosophy as described below. HSE is a value and the top project priority of NIS. All incidents and accidents are preventable. All tasks shall be planned and performed with concern for HSE. Emphasize design as the best preventative measure to reduce risk and adverse HSE effects. HSE is a line management responsibility. Identify and eliminate or minimize inherent hazard in the work. Closely monitor each steps of the work to detect and promptly eliminate hazards and unsafe pra ctices. Provide clear and concise written instruction, rules and plans for the work to be performed. Use trained and qualified workers and supervisors. Recognize and reward outstanding performance. Provide adequate personnel protective equipment (PPE) Monitor the correct use of PPE. Provide mechanically correct tools and equipment. Maintain a fire prevention and protection program. Provide suitable first aid and medical facilities. Equip all persons on site with information, instruction, training and supervision needed for safe working. Maintain a safe off site transport system to convey all persons to and from the camp facilities in the safest manner possible.
1.2 Environmental Policy Statement The Environmental Protection Act and various directives issued by the European Community have placed strict controls on the Pollution of our Environment. The Company recognizes its duties and responsibilities towards protecting our environment and has formulated the following statement of policy: We will so far as is reasonably practicable, ensure that: a) This policy is drawn to the attention of all employees and will be made available to interested parties on request.
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b)
c) d) e) f)
g) h)
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All activities undertaken by the Company will be conducted in such a way to cause the minimum impact upon environment and as far as is reasonably practicable we will follow the principle of sustainable development. Any possible impact which activities have on the environment will be identified and suitable precautions taken to reduce the impact. Procedures are developed and implemented to ensure that risk of spillages or discharges of chemicals, paint or other environmentally hazardous materials are minimized. Where spillages or discharges occur, procedures exist for dealing with them quickly and Effectively. Where the company has choice, and the product is not specified by the client or subject to any warranties and guarantees, products with the lowest impact upon the environment will be used in preference to others, all other factors being equal. Disposal of waste products is in a controlled and proper manner using registered carriers. The company shall strive to continually improve its environmental performance and systems through setting targets and objectives monitoring these and conducting audit and review.
It shall be the duty of every employee of the Company: a) To be aware of the Company Environmental Policy and to take all reasonable steps to Implement it personally. b) To co-operate with management so far as is necessary to enable the policy and duties to be fulfilled. c) To inform management or supervision of any work situation or defect, of which they are Aware, that may endanger the environment. 1.3 ALCOHOL AND DRUG POLICY
It is a termination offence for any EMPLOYEE(s) / SUBCONTRACTOR(s) of NIS to be under the influence of alcohol, or in possession of or under the influence of any non- prescribed drug, Such as cocaine, Marijuana, Heroin, hashish or other illegal substance, while working or residing on any job site including all operations, or property under the control of NIS. This rule applies to all operations and all locations.
OWNER reserve the right to carry out random testing of any person on site. Those found to be in an intoxicated will be removed from the site and forbidden to work further on the Project.
All persons involved in accidents, however minor, shall be subjected to testing by OWNER.
In addition, all persons who are found to be not in compliance with safety procedures during periodic safety inspection shall also be tested for intoxicants.
An intoxicated state shall mean under the influence of alcohol, chemicals, or drugs
1.4 SMOKING POLICY
Smoking is harmful to health and a potential safety hazard as well. Smoking in public places exposes non-smokers to health related hazards and it is the duty of
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NIS to protect employees from unnecessary exposure to hazards. Smoking is prohibited in working areas except designated areas approved by OWNER /NIS’s representative.
2. DUTY AND RESPONSIBILITIES OF THE PROJECT’S OFFICER(S)
HSE and security in the work place is everybody's responsibility. However, certain individuals shall be required to accept additional responsibilities based on job assignment.
2.1 PROJECT MANAGER
Coordinate with OWNER’s Project Manager and HSE Representative. Relay OWNER’s requirement of HSE to Site Manager. Make clear that HSE is line organizations responsibility. Set up policies and procedures ensuring that all equipment provided and used on site shall be maintained in good condition and shall meet all applicable requirements. Verify that all relevant site information (hazard, site specific procedure, etc) used in the job planning stages is available and applicable.
2.2 SITE/CONSTRUCTION MANAGER
Has the overall accountability for HSE at the construction Site. Be accountable for achieving HSE targets. Be responsible for ensuring that Subcontractor’s implement, administer, plan, train, and enforce the HSE plan. Set up Site HSE plan/manual and be responsible for their implementation. Use only competent and trained personnel to work on Site. Issue, where necessary, in accordance with the policy on high-risk activities written instructions setting out the method of healthy and safe work. Plan and maintain housekeeping to high standards. Inform OWNER Representative immediately of any accidents, incidents, and mishaps with the potential of injury and illness consequences. Encourage the reporting by all persons of ‘near miss incidents’ and ‘unsafe acts’. Arrange for thorough investigations to be made of all ‘near miss incidents’ and ‘unsafe acts’ with lessons learned openly publicized to all persons concerned. Cease all activities in the area of an identified HSE problem until it is resolved. Immediately remove from the Site any people (staff, Subcontractors, or third parties) who are not willing to comply with the HSE requirements. Provide equal HSE training opportunity to all employees. Perform corrective actions for any identified unsafe acts and conditions.
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2.3 HSE MANAGER
Assist the Site Manager in the management and execution of the HSE plan. Conduct regular SITE inspections and prepare reports for Site Manager for corrective actions. Check and advice on each work plan or procedures for HSE prior to commencement of work. Coordinate with OWNER’s Representatives on matters regarding HSE. Provide advice, guidance such as may be needed in accident prevention. Coordinate with Government Authorities, especially Ministry of Labor on matters pertaining to legal HSE requirements. Establish and maintain a professional HSE administrative system. Investigate all incidents and accidents and submit reports complete with remedial actions to NIS HSE Dept. through Site Manager for corrective action and report to OWNER. Ensure that Safety Supervisor conducts their safety activities If safety violations are determined high risk then stop the work as necessary.
2.4 SAFETY SUPERVISOR
Assist HSE Manager and perform the safety activities under his direction. Check each work plan or work procedures from the view of safety point and report to HSE Manager Advise the supervisory personnel of each function for safety activities Patrol the construction site daily to check that work force are execute in accordance with the HSE Construction Procedures. Report immediately to the HSE manager any violations that may require work to be stopped.
2.5 FIELD SUPERINTEDENT /SUPERVISOR
Monitor daily Tool Box Meeting for their work crews. Execute and convert the HSE Plan into safe work activities and ensure success. Enforce safety discipline in accordance to NIS HSE rules, regulations, and Bahrain national statutory requirements. Supervise the health and safety of daily work. Ensure all to understand the job requirements and HSE Procedures before starting work. Report, advise and/or take corrective actions if safety violations or unsafe work conditions are detected. Stop the work if necessary and resume when corrective actions have been taken. Provide the written instructions to establish proper work methods in proper sequence including precautionary measures to be adopted. Set good health and safety example.
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2.6 SECURITY SUPERVISOR
Assist the Site Manager/HSE Manager in the management and execution of the HSE plan. Conduct regular Site inspections and prepare reports for security prior to Work commencement. Check and advice on each work plan or procedures for security prior to Work commencement. Coordinate with OWNER security section on matters regarding security. Provide advice, guidance, and such as may be needed in security prevention. Establish and maintain an effective NIS security system.
2.7 EMPLOYEE (Worker)
Comply with HSE rules and regulations.
Work safely and shall not do anything that can cause injury to him (her) or others.
Ensure work tools, apparatus, appliances, materials, and/or equipment including Personal Protective Equipment (PPE) are used correctly and maintained in good serviceable conditions.
Report any unusual occurrences and all defects of plant and equipment to your immediate supervisor.
Report all near misses, incidents and accidents to immediate supervisor.
Attend all Tool Box Meetings, other meetings and/or training relating to HSE.
Observe all written and verbal HSE instructions issued from time to time by HSE Manager and/or HSE Supervisor.
Observe and obey all HSE signs/notices.
Develop a personal concern.
Keep work place clean and tidy.
Seek medical assistance for all injuries
Report to the medical Centre if feeling unwell.
Do not participate in horseplay, running or fighting.
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3. FORMAL INSPECTION OF CONSTRUCTION SITE 3.1 THE PURPOSE OF HSE INSPECTIONS. Scheduled HSE inspections are essential for hazard identification and accident prevention programs. The purpose of the inspection is to identify and correct unsafe equipment, situations, conditions, and practices to prevent accidents. 3.2 SCOPE OF INSPECTION AND AUDIT The HSE inspection and audit activity is to conduct organized Site inspections so as to keep under control and correct all circumstances, which affect the HSE of all persons working/visiting the Project. Inspectors and auditors shall check for general housekeeping, safety violations committed by workers, any discrepancies that violate legal regulations or requirements.
3.3 HSE AUDIT ITEMS: HSE Management HSE consciousness HSE facilities Fire prevention Health and hygiene Environmental control
3.4 HSE INSPECTIONS ITEMS: Unsafe action (safety violation) Tools and electrical equipment (e.g. welding machine, grinding machine etc) Physical condition - House keeping - Protection from falling hazard - Personal Protection Equipment - Electrical hazard - Guarding of machinery - Site security - Cranes and lifting operations - Fire & Explosion hazard - Bulletin and Signboards - Scaffold - Protection of excavations. - Others
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4. HSE MEETING(s)
CONTRACTOR HSE Manager shall establish a weekly HSE coordination meeting and maintain records of personnel attendance to manage and communicate HSE matters effectively. The Site Manager shall manage and monitor HSE activities by taking action and provide resources to support their objectives and work activities. All meetings on whatever subject shall ‘kick off’ with HSE as the first item on the agenda (brief HSE discussion between meeting members)
4.1 WEEKLY HSE COORDINATION MEETING
All responsible HSE personnel shall attend this meeting. They shall discuss the weekly inspection reports and shall plan and coordinate all HSE activities including inspection and audits. This meeting shall support the monthly HSE Committee meeting.
4.2 MONTHLY HSE COMMITTEE MEETING
SITE superintendent and SUBCONTRACTOR(s)’ manager shall attend at this monthly HSE Committee meeting. OWNER Representatives are invited to the HSE Committee Meeting to communicate their opinions and/or direction to all members when needed. The HSE Committee shall plan, coordinate, implement and maintain the overall HSE activities control during construction including pre-commissioning/commissioning.
5. ACCIDENT & INVESTIGATION 5.1 INVESTIGATION All accidents / incidents and near misses, no matter how small they may be, shall be investigated and reported as the agreed procedure between OWNER and CONTRACTOR. The objective is to prevent recurrence of events of a similar nature. The consequences requiring an in depth investigations are
Recordable injury (OSHA Definition) Fatal injury Lost time injury / illness Property damage exceeding.
The supervisor shall attend all investigation of accident that occurs at Site under his charge.
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The HSE Manager, HSE Officer and line supervisor, after being notified of the accident, shall immediately carry out on investigation, but not before the circumstances leading to the accident are under control and the victim has already received medical attention. Base on the actual consequence of the accident or potential risk as assessed, a further investigation by a special investigation team may be required. OWNER representative(s) will form part of this investigation team. The team's analysis of the cause and recommended corrective actions shall form part of the detailed accident report. 5.2 ACCIDENT REPORTING For serious injury, avoid removing the injured person. Unless the immediate area is potentially dangerous, call for help immediately. Meantime, the supervisory personnel or his designee shall verbally notify Site Manager and/or HSE Manager, Safety Officer by fastest means possible (Radio) especially which involves the following. All accident resulting in a fatality or hospitalization or possible lost time shall report to OWNER immediately. Other injuries or damage to property shall be reported within one working day. All “near miss” or potential hazards to health shall be reported within two working days. After first aid, the supervisory personnel shall complete the Preliminary Accident Report. For serious injury, a verbal or written mid-report shall be submitted to Site Manager. After the accident investigation, a detailed written report shall be prepared by HSE Manager, HSE Officer and be submitted to Site Manager. Investigation shall be completed with a report with recommendations for preventive measures within 2 working days
5.3 MONTHLY SAFETY AND HEALTH REPORT. A weekly log of all injuries, including first aid cases, shall be submitted to OWNER. CONTRACTOR will submit OWNER a Safety Health and fire Report that cover below items as minimum by 8th day of each month. List of accidents with causes. List of lost time injuries with causes.
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List of first aid treatments. List of fires. List of Health hazards identified and corrective actions taken. Number of man-hours worked. Lost time injuries and reportable frequency records. List of “near misses”.
6. EQUIPMENT SAFETY All of tools and equipment e.g. hand and power tools, slings etc require special attention and protection for their use and guidelines for storage. All tools and equipment shall be inspected in accordance with CONTRACTOR and OWNER’s procedures.
(Plant & Equipment Inspection). (Machine and Hand Tool Tagging.) (Color Coding System –Slings, Shackles and Electrical Tools).
6.1 HOUSEKEEPING Scrap, trash and other wastes shall be placed in designated containers. Work areas shall be kept clean and orderly. A safety access way to all work areas shall be maintained. 7. JOB SAFETY ANALYSIS & RISK ASSESSMENT(s) NIS will prepare work method statements and risk assessments by identifying hazards and reduce risks as low as possible. The main aim throughout will be to follow the principles of Prevention-Protection-Informationmonitoring-review. If possible, avoid the risk completely, by using alternative methods or materials. Combat risks at source, rather than by measures which leave the risk in place but attempt to prevent contact with the risk. Wherever possible, adapt work to the individual particularly in the choice of work equipment and methods of work. This will make work less monotonous and improve concentration, and reduce the temptation to improvise equipment and methods. Take advantage of technological progress, which often offers opportunities for safer and more efficient working methods.
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Incorporate the preventive measures into a coherent plan to reduce progressively those risks which cannot be avoided and which take into account working conditions, organizational factors, the working environment and social factors. Give priority to those measures which protect the whole workforce or activity and yield the greatest benefit, e.g. give collective protective measures, such as suitable working platforms with edge protection, priority over individual measures such as safety harnesses. Supervision and the workforce need to understand what they need to do, e.g. by training, instruction and communication of plans and risk assessments. Monitor the control measures on a regular basis to determine the effectiveness of the Risk Assessment. Review and Revision of the risk assessment to be carried out if there are developments that suggest it may no longer be valid (or that it can be improved). In most cases, it is prudent to plan to review risk assessments at regular intervals - the time between reviews being dependent on the nature of the risks and the degree of change likely in the work activity. Such reviews should form part of the standard HSE Management Practice.
8. MEDICAL FACILITIES and PROCEDURE(s) 8.1 GENERAL Prior to start of Work, NIS will maintain and hygienically clean the first-aid facilities at the respective locations where first aid treatment is provided. These fully equipped medical facilities shall cover each WORK. Assessment of the employee’s fitness for work, note any pre-existing conditions and screening for intoxicants.
Special medical screening will take place on persons whose duties include: Operating cranes (especially eye sight testing). Working at height (especially blood pressure) Working in confined spaces (especially respiratory system) due to the requirement to wear sel f-contained breathing apparatus. Working in hot/humid conditions (exposure to heat stress) In addition to the above medical screening, persons working on site will be subject to random alcohol tests by the use of a detector.
9. SAFETY TRAINING HSE training is essential for executing work safely during the entire construction, pre commissioning and commissioning of the project.
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The Site Manager and the HSE Manager shall establish an On-site HSE Training Program before commencing the work. The training program shall be approved by NIS prior to mobilization to site. This guidance provides essentials of establishing an On-site HSE Training Program featuring the following six categories:
HSE Induction Training for New Personnel HSE Training for Manager and Supervisor HSE Training for Specific Hazardous Job Emergency and Evacuation Training HSE Training for Refresher course HSE Tool box talks
All training will be carried out in a specifically designed and suitably equipped training room provided by the NIS NIS will conduct HSE training for its staff. The HSE Manager shall prepare training materials in order to effectively conduct safety training such as handouts or PROJECT specific HSE book let. HSE training shall be conducted by the HSE Manager and/or by competent persons designated by the HSE Manager. All courses will be conducted in English Language. Following completion of each HSE Induction/Training Course, participants shall be provided with a Training Assessment Form and requested to complete the form to assess the quality of information provided to them. A discussion of environmental control equipment and environmental procedures will also be included in the training and indoctrination, test will be arranged to measure employees’ understanding. They will be informed the consequences of failure to follow environmentally responsible practices (possible dismissal.) All personnel working inside the limits of the operating refinery must undergo OWNER’s Training program on Work Permits and general refinery safety. The record of HSE training shall be documented and maintained. 9.1 9.1.1
TYPES AND REQUIREMENTS OF HSE TRAINING HSE INDUCTION TRAINING FOR NEW PERSONNEL
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1) Coverage: All new employees including CONTRACTORS, and management staff, Workforce, delivery personnel, lorry and bus drivers. 2) When: Upon arrival at the construction site and in advance of assignment to site. 3) Also refresher training as deemed necessary by NIS e.g. Major changes in project Work, Pre commissioning / commissioning etc.
Other languages will be added as necessary. A supervisor’s safety Manual will be prepared by NIS and issue to all supervisors. To be recorded on register.
4)
Instructors: NISHSE Manager or the designated persons for NIS employees and the CONTRACT OR(s) Construction Manager, HSE Manager and Supervisory personnel. A demonstration of the instructor ability to relay HSE information in the chosen langu age will be required to be given to all prior to the instructor gaining approval. The use of translators to participate in the training course shall not be allowed.
5)
Contents of Training HSE Induction Training include but not limited to: Emphasize the importance of HSE HSE Policy and Philosophy Orientation of the site layout and the work place, using maps/drawings, etc., especiall y for the restricted areas to entry, such as the OWNER property, etc. Outline of the work scope HSE Organization and the individual's duties and responsibilities for HSE. Working rules (duty hours, over-time work, holidays, transportation, housekeeping, et c.) HSE, Security rules and regulations (gate control, possession of ID card, smoking rule s, substance abuse rules, traffic rule, etc.) Enforce use of proper personal protective equipment (safety harness, helmets, goggles, gloves, dust/gas masks, respirators, etc.) Proper working garment and footwear Outline of HSE Contraction Procedures Working at height. Work Permit procedures (Work items or locations to be subjected, obtaining procedur e, if required etc.) Confined space entry Excavation. Overhead/underground utilities. Safe driving. Emergency and evacuation procedure (emergency alarm system, emergency communi cation system, evacuation route and assembly area, etc.) How to use firefighting equipment.
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Participation in Tool Box Meeting (when, where, how) Keep clean (after day’s work, weekly site cleaning, etc.) Encourage reporting accidents and near-misses. Encourage reporting unsafe acts and unsafe working conditions. First-Aid Facilities (location, how to use, etc.) HSE incentive scheme to create interest and enthusiasm in HSE. Confirmation of Personal Information submitted prior to the HSE induction training (i ndividual’s work experience, license/permits, physical condition, etc.)
Attendance list: Attendance register for HSE training should be kept and updated.
7)
Exemption
A worker who has a license or permit issued by a third party or who is acknowledged by HSE Manager to be experienced with the job may be exempt from the above training course
9.1.2 TOOL BOX TALKS
‘Tool box talks’ will be held on a daily basis for all members of the work force ensuring that each person receives at least one talks each week. The constantly changing work patterns and areas of working can be discussed and reviewed at these sessions. It is envisaged that the duration of the talks would be approximately 10 minutes. The meeting should take place as close to the work place as possible so that any examples of HSE practices or proposed changes are more easily viewed at the time. ‘Tool box talks’ will normally be given by Site Supervision; however, members of the Site HSE Department will also provide assistance as required.
10. PURPOSE
This is to set out clear procedures and HSE requirements for the many diverse categories of work to be performed at the Site in order to ensure that such works are carefully planned and safety executed to prevent property damages, injurious accidents and any detrimental consequences.
Permits to work procedures are necessary for performing work safely in high hazard areas (close to existing Roads and on water).
11. EMERGENCY RESPONSE COMMUNICATION PLAN 11.1 GENERAL
NIS INDUSTRIAL SERVICES (NIS)
HEALTH, SAFETY & ENVIRONMENTAL PLAN FOR GAMA PROJECT IN KSA Doc. #
HSE-P-01
Rev. #
01
Rev. Date:
12.11.2015
Page 17 of 23
The Emergency Response Chief (NIS HSE Manager) shall have prime responsibility for the development of an Emergency Response Plan, auditing of the effectiveness of the plan and the preparedness of members of the Emergency Response Team.
He shall have the responsibility for the declaration and execution of an emergency response.
Weekly safety tool box talks to discuss safety with all workers. Refresh induction items minutes of meeting/talks. All site workers attendance register to be signed.
11.2 MEMEBERS OF THE EMERGENCY RESPONSE TEAM Shall consist of the assigned HSE and Security Officers, Safety Wardens and Fire Watchmen who are working in an area at any given time. 11.3 COMMUNICATION SYSTEM A communication system shall be established between each ERT Leader, the Emergency Response Chief (NIS HSE Manager), and the First Aid Room so that a contact can be made at any time.
11.4 EMERGENCY TELEPHONE NUMBERS Emergency Telephone Numbers shall be posted at all Assembly Points, in phone location points available to ERT at all times and other persons who may need to telephone for emergency services. 11.5 ASSEMBLY POINT LOCATIONS At least one designated “Assembly Point” shall be established in a safe location for each of the Emergency Response areas. Assembly points will be clearly sign posted and all persons instructed as to the locations to all. 12.
RULES & REGULATIONS 12.1 DISCIPLINE The following violations are of a serious nature and are subject to immediate dismissal from the Site. Firearms, bladed weapons, fire crackers, explosives. Entering work area in possession of or under the influence of liquor, prohibited drugs and othe r intoxicating substances. Violation of any provision in any work permit that is considered of serious nature. Driving a vehicle in excess of the site speed limit. Non-compliance with the 100% fall protection and 100% tie-off policy. Putting the lives of themselves or other person(s) at risk (imminent danger).
NIS INDUSTRIAL SERVICES (NIS)
HEALTH, SAFETY & ENVIRONMENTAL PLAN FOR GAMA PROJECT IN KSA Doc. #
HSE-P-01
Rev. #
01
Rev. Date:
12.11.2015
Page 18 of 23
Violent actions e.g. fighting (both parties will be dismissed). Ignoring barriers, warning signs displaying unauthorized access, restricted areas etc. Energizing or de energizing a power supply without authorization. Smoking in areas other than approved, defined locations. Operating equipment without a valid operator’s license. Using equipment that is not color-coded in accordance with the current color- coding schedule. Carrying out activities and operations when not trained in accordance with the OWNER traini ng requirement. Other Safety violations including ‘horseplay’. Using Motorcycles, scooters, and other similar powered vehicles. Persons found guilty of less serious safety violations will have their ID badge punched with a hole for each violation if they have demonstrated a blatant disregard for safety rules. 12.2 ADMITTANCE, TRAFFIC AND PARKING Security Officer shall authorize admittance of personnel and equipment. Normal working hours shall be observed as per owner’s request. Schedule heavy equipment materials to enter /leave the site at other than peak traffic period. Park all vehicles in their authorized spaces only. All site vehicles shall be fitted with audible reversing alarms and flashing warning lights. This includes buses and construction equipment. Pedestrian traffic shall enter and exit through designated routes controlled by Security. Special arrangements to use other points of entry/exit shall be subject to OWNER approval. Employees are not permitted to ride in the back of any vehicle that is not designed as being fit for purpose. Ensure that the operators of all vehicles strictly follow traffic signs and regulations. Post speed limit signs at appropriate locations. Record all transportation accidents with history and causes. 12.3 PERSONAL ATTIRE The standard attire at all times for Personal Protective Equipment for persons working at Site is:
Safety helmet and eye protection glasses. Steel toe-cap work shoes Fireproof overalls (when needed) Hand Protection Wet and / or cold weather clothing as required
Depending on the risk analysis more specific PPE must be supplied and used. (e.g. Goggles face shield, chemical gloves, rubber boots for concreting, hearing protection, fall protection, chemical suits, specialist respiratory protection, etc.) 12.4 Hole Protection
NIS INDUSTRIAL SERVICES (NIS)
HEALTH, SAFETY & ENVIRONMENTAL PLAN FOR GAMA PROJECT IN KSA Doc. #
HSE-P-01
Rev. #
01
Rev. Date:
12.11.2015
Page 19 of 23
Personal whose job classification is such that they are required to wear respiratory protection must not have facial hair that could interfere with the seal of the respiratory protection against the face.
12.5 COMPRESSED GASES Compressed gas cylinder valves shall be closed whenever: 1. Work is finished 2. The cylinders are empty, or 3. The cylinders are moved.
Gauges shall be removed and valve protection caps in place before moving cylinders, except when cylinders are secured in a carrier designed for such use. Gas bottles shall be fitted with flame arrestors. Compressed gas cylinders shall not be hoisted by the valve cap or by means of magnets or slings. Compressed gas cylinders shall be secured in an upright position at all times, except for short periods when being carried or hoisted. Cylinders shall be transported in an upright position and shall not be hauled in equipment beds or truck beds on their side. Cylinders lifted from one elevation to another shall be lifted only in racks or containers designed for that purpose. Compressed gas cylinders shall be stored / located to avoid exposure to sparks, hot slag, or flames. If these cannot be avoided, fire-resistant shields shall be provided. Compressed gas cylinders shall not be used as, or placed where they may become part of, an electrical circuit. Compressed gas cylinders shall not be taken into a confined space. Compressed gas cylinders shall not be used as rollers. Cylinders in storage shall be separated (oxygen from fuel gas) by a 5-foot-high (1.5 meters) barrier with a 1-hour fire rating or by a distance of 20 feet (6.1 meters). Welding gases shall be stored in isolated areas and segregated by type of gas. Cylinders shall be stored in well-protected, ventilated, dry locations, at least 20 feet (6.1 meters) from highly combustible materials, and away from egress routes such as stairways and elevators. Bars shall not be used to pry or loosen protective caps. Damaged or defective cylinders shall not be used, but shall be tagged, stored in a safe quarantine and returned to the vendor as soon as possible, Oxygen cylinders shall be kept free of oil and grease. Compressed gas cylinders shall be used and stored in an upright position. Compressed gas cylinders must not be exposed for long periods to direct sunlight. All compressed gas cylinders shall be secured in place during use and storage. Securing shall be around the body of the cylinder, midway between top and bottom. Securing around the cylinder neck or by its cap shall be prohibited. Cylinders shall be secured with rope or strong plastic band strips. Cylinders shall not be tied to any part of any scaffold structure. Cylinders whether in use or not should not be exposed to strong sunlight for long periods of time. They must be moved to a shaded area and or covered with wet ‘burlap’ sacking material to prevent overheating of the contents.
NIS INDUSTRIAL SERVICES (NIS)
HEALTH, SAFETY & ENVIRONMENTAL PLAN FOR GAMA PROJECT IN KSA Doc. #
HSE-P-01
Rev. #
01
Rev. Date:
12.11.2015
Page 20 of 23
Cylinders shall be returned to the main storage area when empty. Empty cylinders must be removed immediately from the work area and returned to the main storage area. If a key wrench is required, it shall be in place on the valve of acetylene bottles at all times during use. The valves of compressed gas cylinders shall be completely closed when not in use. Compressed gas cylinders shall not be transported with gauges attached. The gauges shall be removed from cylinders and protective caps installed during transportation.
12.6 MATERIAL HANDLING Based on material delivery and condition with the schedule, all material requires special attention and protection for their usage and guidelines for storage.
12.7 ELECTRICAL WORK
All electrical work shall be done under the supervision of certified electrical personnel in accordance with the National Electrical Code. All electrical tools and like equipment used for construction and commissioning shall be 230 volts. A site investigation to be made to exactly establish the voltages available on site. Equipment casing will be intact with no loose fittings or exposed cables. Plug fitting will be of an approved industrial type. Condition will be good and the tool will be subject to preventative maintenance schedules. For confined space work 24 volt supply with protection shall be provided. All temporary lighting (intrinsically safe) and powered equipment shall be protected by the use of a ground fault circuit interrupter (GFCI) and portable electrical equipment should:Be connected, individually or collectively, to an earth-free, extra-low voltage (24V) supply from an isolating transformer(s), with the transformer(s) being located outside the confined space; andBe protected through a residual current device, with the device being located outside the confined space. Additionally, the equipment should be fitted with a flexible supply cable not inferior to a heavy-duty type. The cables should be located, suspended or guarded to minimize accidental damage. It is recommended that double-insulated electrical tools be used.
12.8 WORKING ON HEIGHTS
Special precautions shall be planned and implemented for all elevated work to protect persons working above and below height. To comply with a 100% fall protection program, NIS will provide safe working platforms e.g. scaffolds, man lifts etc.when working above 1.8 meters. A SCAFFTAG system for control scaffolding use shall be implemented by NIS. In addition, protection shall be installed to prevent persons working below from being struck by falling tools or materials including, barricading off areas of overhead work to prevent persons from ‘straying’ into an area where overhead work is ongoing.
NIS INDUSTRIAL SERVICES (NIS)
HEALTH, SAFETY & ENVIRONMENTAL PLAN FOR GAMA PROJECT IN KSA Doc. #
HSE-P-01
Rev. #
01
Rev. Date:
12.11.2015
Page 21 of 23
To further the reduce the risks associated with working at height, NIS will wherever possible practice ‘dressing up’ of equipment during work at ground level prior to the equipment being ‘lifted’ into its final position. If it is not possible to comply with the 100% fall protection program e.g. persons erecting scaffolds, life lines etc. then NIS will enforce the use of full body safety harnesses with double shock absorbing lanyards to allow for 100% tie-off at all times.
12.9 REFUELLING OF VEHICLES/MOBILE EQUIPMENT SUBCONTRACTOR(s) shall set up a procedure for refueling of mobile equipment which shall include; Refueling of equipment in area isolated from the general work area and from any source of ignition. The area shall be curbed to contain possible oil/fuel spillage Provision of "No Smoking" and "Turn off Ignition" signs Grounding of refueling vehicles/containers shall be carried out. The majority of equipment will be re fuelled ‘off site’ at the designated fuelling station(s). Due to the impractical logistics of moving heavy equipment off site for refueling, this can take place on site provided the following minimum requirements are implemented:1. 2. 3. 4. 5. 6.
No fuelling to take place within 30 meters of any hot work including grinding, welding etc. No equipment will be refueled while the engine is running. No smoking. Discharge nozzles on fuel bowsers shall be fitted with an automatic shut off valve. Dip trays shall be placed under all portable equipment to contain any leaks. Fuel bowsers to be provided with adequate amounts of absorbent material which must be applied immediately to any fuel spillage. 7. Any spillage shall be immediately dealt with and the contaminated absorbent material and contaminated soil must be disposed of immediately in accordance with the control and disposal of hazardous substances. 12.10 SMOKING
Smoking is strictly prohibited at the Site except at suitably signed designated smoking areas. When hydrocarbons are introduced, smoking is not permitted in the plant.
12.11 PREVENTION OF HEAT STRESS.
Persons working outside can be exposed to extreme weather conditions that, not only affects their production output but also can also seriously affect their health. Heat stress is one of the most common and potentially serious illnesses that construction workers confront where high temperatures are normally encountered. Its results can be mild resulting in fatigue, irritability, anxiety, decreased concentrations and movement however, these conditions can and do lead to death. Preventative measures and immediate first aid treatment are essential to protect all persons on the project.
NIS INDUSTRIAL SERVICES (NIS)
HEALTH, SAFETY & ENVIRONMENTAL PLAN FOR GAMA PROJECT IN KSA Doc. #
HSE-P-01
Rev. #
01
Rev. Date:
12.11.2015
Page 22 of 23
NIS will train all persons via HSE induction and toolbox talks in how to avoid heat stress and recognizing the symptoms of heat stress. Add to the water re hydration minerals (electrolyte powder) or make it available for individuals use. Salt tablets will NOT be issued unless strictly controlled by medically qualified personnel after they have checked the person’s blood pressure and medical history. Provision of shaded areas for persons to take rest. Rotation of workers duties to avoid continual working in extremely hazardous areas e.g. confined spaces, working at height, welding etc. Re scheduling of hot/hazardous jobs to be done at cooler times of the day. Clinic to be equipped with medical supplies to be able to deal with heat stress emergencies.
12.12 ENVIRONMENT SAFETY & HOUSEKEEPING 1. 2. 3. 4. 5.
Run off and aquifer protection for Non-Potable water used for construction purposes and the groundwater during excavation e.g. betonies shall be properly drained to designated dewatering channels. All sanitary water produced shall be stored in tanks and transported to the sanitary wastewater treatment plant by approved sanitary transportation companies. Urinals and Toilets shall be provided at various points at work site for people working at site. Dust Conditions shall be kept at a minimum level by traffic control and periodic watering. Hazardous substances required for the plant construction, pre-commissioning and commissioning shall be in compliance with Hazardous Material Storage and Handling regulations from concerned authorities. It is not allowed to eat food on site, except in an approved purpose built eating area. Minimize fugitive dust emissions from construction and transportation activities by: Periodic water spraying of bare surfaces Proper maintenance of road surfaces. Regular maintenance of equipment and vehicles to reduce exhaust emissions. Use of tarpaulins over transported earth/sand loads. During catalyst loading operations, minimize release of catalyst dust to the environment by use of suppression devices.
13. CRANES & LIFTING EQUIPMENT 13.1 CERTIFICATION
All cranes and lifting equipment shall have a valid “Crane Certificate” and be in accordance with the LOCAL statutory requirements before entering the Construction Project work-site. This lifting equipment shall be visually inspected by Rigging Supervisor on a daily basis before start of Job .A Valid Crane Certificate shall be in the driver’s possession at all times as long as the equipment is on site. Inspection / Checklist must be carried out by Crane Operator on Daily basis before start of Lifting activities, Checklist must be produced to Safety during Audit/Inspection.
NIS INDUSTRIAL SERVICES (NIS)
HEALTH, SAFETY & ENVIRONMENTAL PLAN FOR GAMA PROJECT IN KSA Doc. #
HSE-P-01
Rev. #
01
Rev. Date:
12.11.2015
Page 23 of 23
13.2 RESPONSIBILITY
If executing lifting activities NIS has full responsibility for safe operations when using hoisting equipment to make lifts. NIS will verify the weight of all loads prior to them being lifted. No load shall be lifted which exceeds the manufacturer’s rated capacity of the crane.
13.3 FIRE/EXPLOSION PREVENTION
All cranes and hoisting equipment shall be provided with a suitable fire extinguisher. An exhaust sparks arrestor to be fitted when working in ‘live plant’ locations.
13.4 WEATHER CONDITIONS
Regular weather forecasts shall be obtained before hoisting work commences. lifting supervisor shall inform NIS HSE Manager prior to commencing lifting work whenever wind speeds are higher than 20 Km/hr; work is stopped and lifting man basket should operate if the wind speed is more than 15KM/HR.
13.5 LOAD CONTROL
During hoisting operations, the load shall be controlled from the ground by means of one or more ropes, "tag lines", to prevent the load from turning and swinging. Lifting operations can only be carried out with assistance of a competently trained signalman who shall be clearly identified. The operator shall be able to observe the load continually during lifting. Mirrors shall be provided whenever necessary to give full observation. Cranes with outriggers shall set outriggers to full extent prior to use. Crane mats or steel plates shall be placed under the outriggers if ground conditions necessitate this. Crane wheels shall be slightly elevated.
13.6 SLINGS AND CABLES
All slings and lifting cables must be certified in accordance with the law and inspected on a scheduled basis with faulty slings and cables being destroyed. All rigging material shall be color-coded, according to the Construction Project guidelines. A material and inspection log register and/or logbook shall be maintained at the store office.
13.7 END OF WORKDAY Operators of lifting equipment shall do the following at the end of the workday:
Put down the load Lift down the hook Switch off motors, disconnect tension Close cabins and make operation equipment inaccessible for unauthorized people
Attachment No.: 09 Hazard Identification & Risk Assessment Procedure.
Link to Worksheet
Worksheet Contents:
!!!!!!!!!READ ME FIRST!!!!!!
Useful hints and guide Risk Assessment Record and Risk Reduction Plan Measures of Consequence and Likelihood for OH&S Risks
Risk Assessment Generator OH&S Risk Matrix
1. Enter each Risk Assessment under the last to allow the filter format to work. 2. Because this document is a template, it must be saved as a normal excel spreadsheet. This will prevent any modifications to the formatting. 3. To preserve the preformatted risk numbering and drop down menus in cells, insert new risks rows between existing rows and NOT at the bottom. 4. You can use multiple filters to generate a list, ie "Area" "Final Level" "Percentage Complete" 5. To show the entire database, all filters must be selected as "All" in the drop down menus. 6. When printing, make sure you select how many pages are to be printed or otherwise you will print the entire database.
Back to Index
Location Work Area:
PP-13
SEC-PP13 COMBINED CYCLE PLANT PROJECT
Date of this Revision:
11-Nov-2015
MECHANICAL | I&C | ELECTRICAL WORKS
Date of last Revision:
New
RISK ASSESSMENT RISK REDUCTION PLAN
RISK ASSESSMENT RECORD
STATUS
Rank(3)
Percent Complete
Low Low Low Low Low Low Low Low
E‐
L
INSTALLATION AND ERECTION HRSG AND GTG
Fatal, serious injuries
High
Electrical Shock
B‐Likely
Hand Injury , cut
3‐Moderate
Sharp edges
13 Use Leather Hand gloves.
Site Engineer / supervisor
8
All employees
Use double insulated or properly grounded equipment.
Extreme
4‐Major
C‐Possible
5
Use only inspected and Tagged tools and cables.
Carry out visual inspection of equipment prior to use .
0%
0%
0%
0%
0%
0%
0%
Use Rubber Hand gloves with adequate PPE’S.
1
Mechanical Cutting of Steel Materials.
Moving parts
Ensure all safety guards are present before start of any operation.
Major Injuries
Use a push stick while using a cutting machine.
High
C‐Possible
3‐Moderate
15 All electrical equipment, appliances, cables shall be maintained (inspected, repaired and tested) to eliminate any unsafe conditions.
Preventive maintenance should be carried out periodically.
Technician
Site Engineer / supervisor
Only a competent person shall carryout maintenance.
Use safety Glasses.
High
D‐Unlikely
Injuries to the Eye
3‐Moderate
Flying metals particles
8
Face shield must be used while using portable cutting tools. Use flash back arresters, regulator and ensure it is regularly maintained. Fabricator should check the cutting set before each use.
High
4‐Major
Major fire, explosion
D‐Unlikely
Gas cylinder / cutting set
8 Use only flint sparking device to start flame. Regular checks on condition of hoses.
Necessary work permit should be valid obtained before start work
Site Engineer / supervisor
Monitoring should be done by competent person
Site Engineer / supervisor
Site Engineer / supervisor
All employees
Proper PPE precaution during torch heating of component.
High Medium
D‐Unlikely
Medium
Fire, burns
18
3‐Moderate
Hot molten metals
2‐Minor
Burn
10
C‐Possible
High temperature
4‐Major
Gas cutting operation
Fire, explosion & injury
D‐Unlikely
2
Unsecured / unprotected gas cylinders
17
Maintain good hose management Transport gas cylinders in trolley. Inspect the trolley before in use. Gas cylinders must be kept in vertical position and secured to avoid falling. It must have protective cap.
Use adequate hand gloves and personnel protective clothing Area must be clean of flammable materials. Use PPE appropriately so that the molten metals do not enter inside coveralls, boots etc Make sure to cover the sewer manhole without fail.
Area to be barricated while work , use fire blanket if required .
Ensure drains are flushed and have a water seal
H
C‐Po
3‐Mo
Use safety glasses.
Inspect equipment before using ensure
Completion Date
Level(3)
25
2‐M
Me
E‐Rare
D‐U
26
2‐Minor
Medium
3‐Mo
E‐Rare
D‐Unlikely
22
2‐Minor
Medium
3‐Moderate
E‐Rare
Medium
D‐Unlikely
20
2‐Minor
D‐Unlikely
E‐Rare
Medium
3‐Moderate 3‐Moderate
20
2‐Minor
D‐Unlikely
E‐Rare
Medium
3‐Moderate
22
2‐Minor
D‐Unlikely
E‐Rare
Medium
3‐Moderate
20
20
2‐Minor
D‐Unlikely
20 Conduct toolbox talk prior to start job
0%
E‐Rare
Medium
3‐Moderate
15
23
2‐Minor
D‐Unlikely
13
E‐Rare
Medium
3‐Moderate
12 Conduct toolbox talk prior to start job
Target Date
2‐Minor
Rank(2)
D‐Unlikely
18
By Whom Person To Action
Likelihood(3)
Level(2)
3‐Moderate
15 Conduct toolbox talk prior to start job
Recommended Action (Improve existing controls / implement new controls) Including reference to procedures Blue highlight denotes Contractor procedures
Consequence(3)
Likelihood(2)
Existing Controls
Final Risk
Consequence(2)
Rank(1)
Level(1)
Un-wanted Event
Likelihood(1)
Hazard
Consequence(1)
Task
Revision No. 0
Residual Risk
Inherent Risk
Item
Company : Saudi Electrical Company Contract Number :
Comments
Location Work Area:
PP-13
SEC-PP13 COMBINED CYCLE PLANT PROJECT
Date of this Revision:
11-Nov-2015
MECHANICAL | I&C | ELECTRICAL WORKS
Date of last Revision:
New
RISK ASSESSMENT RISK REDUCTION PLAN
RISK ASSESSMENT RECORD
Percent Complete
0%
21
0%
20
0%
20
0%
25
Check that disk guard is secured and validity of grinder disk Follow manufacturer instructions.
High
D‐Unlikely
Injury to person
4‐Major
Grinding disk (if broken)
Trial run machine before use.
13 Use appropriate PPE. Do not throw or keep weight on disks, to avoid developing hair line cracks. Face shield to be used. Grinder must have handle with care Distribution boards to be fitted with ELCB and checked on a daily a basis.
High
E‐Rare
Fatality
5‐Catasrophic
Electric shock
Check that equipment is in good condition and tagged.
5
Check extension cables check for damage, replace if necessary.
Carry out visual inspection equipment prior to use equipment
Use inspected grinding machine Maintain good cable management
3
Grinding operation Ensure all safety guards are present before operation. Use a push stick while using a cutting machine. Hand gloves must be fitting to the hand / fingers.
High
C‐Possible
Major Injuries
3‐Moderate
Moving parts
18 Loose gloves may come in contact with the rotating disc and cause major cut injuries. All Grinders shall have handles when in use except at odd situations where using Grinders with handles are not possible.
0%
Grinders having Dead Man Switch shall be used so that it automatically stops when left.
Low
Site Engineer / supervisor
E‐Rare
25 Conduct toolbox talk prior to start job
2‐Minor
Medium
D‐Unlikely
20 Use Hearing protection.
3‐Moderate
Medium
D‐Unlikely
Temporary deafness, stress
3-Moderate
Noise
28
Completion Date
Rank(3)
E‐Rare
22
Low
2‐Minor
0%
Low
E‐Rare
20
Low
2‐Minor
0%
Low
E‐Rare
22
Low
2‐Minor
Target Date
Low
E‐Rare
Machine guard to be checked and ensure it is in its place
By Whom Person To Action
Low
2‐Minor
20 Ensure employee competency
Recommended Action (Improve existing controls / implement new controls) Including reference to procedures Blue highlight denotes Contractor procedures
Level(3)
E‐Rare
Medium
2‐Minor
Medium
E‐Rare
Medium
2‐Minor
Medium
D‐Unlikely
‐Rare
Medium
12
3‐Moderate
Minor
Medium
D‐Unlikely
Likelihood(3)
Rank(2)
edium
16 Ensure employee competency
3‐Moderate
Consequence(3)
Level(2)
D‐Unlikely
Site Engineer / supervisor
16
3‐Moderate
All employees
D‐Unlikely
Site Engineer / supervisor
16 Assign job watcher
3‐Moderate
Remove all combustible material from the area.
All employees
D‐Unlikely
Grinding carried out such that spark travel away from
10 personnel.
Site Engineer / supervisor
19
3‐Moderate
High
Fire extinguisher available and hoses connected to the hydrants Face shield and safety glasses to be used.
Site Engineer / supervisor
D‐Unlikely
High
7
Check regulator, hose, hose connection, and joints Stored cylinders shall be secured and should be in a well ‐ventilated place and in an upright position, and shielded from direct sunlight or other heat source. Temporary overlay plates installed.
Continual monitoring required , if found any damage of equipment immediately replace
oderate 3‐Moderate
16
All employees
Unlikely
Medium
C‐Possible
Injuries to eye / fire / combustion of materials
3‐Moderate
Flying metals, spark
D‐Unlikely
Explosion / combustion of flammable material
D‐Unlikely
Outbreak of fire
ossible
Suffocation
4‐Major
Gas leakage
oderate 3‐Moderate
Injuries to eyes
Inspect equipment before using , ensure safety guard in place
18
INSTALLATION AND ERECTION HRSG AND GTG Flying metals, sparks
STATUS Final Risk
Likelihood(2)
Rank(1)
High
15 Face shield must be worn while using portable tools.
Existing Controls
Consequence(2)
Level(1)
Un-wanted Event
Likelihood(1)
Hazard
Consequence(1)
Task
Revision No. 0
Residual Risk
Inherent Risk
Item
Company : Saudi Electrical Company Contract Number :
Comments
Location Work Area:
PP-13
SEC-PP13 COMBINED CYCLE PLANT PROJECT
Date of this Revision:
11-Nov-2015
MECHANICAL | I&C | ELECTRICAL WORKS
Date of last Revision:
New
RISK ASSESSMENT RISK REDUCTION PLAN
RISK ASSESSMENT RECORD
STATUS Percent Complete
20
0%
20
0%
24
0%
23
0%
Low
24
0%
Low
20
0%
Low
22
0%
Low
20
0%
INSTALLATION AND ERECTION HRSG AND GTG
Sharp edges
Injury
Use appropriate PPE.
Medium
D‐Unlikely
“Arc eye” skin burn
3‐Moderate
“Arc flash” and hot metal
6
Restrict personnel in vicinity of welding operations. Use “anti flash” safety glasses. Welding helmets fitted with correct UV lenses.
Medium
10
Use respiratory mask 3M‐8214 if required. Use forced ventilation when required.
High
B‐Likely
3‐Moderate
Personnel tripping, fall and injury
C‐Possible
Loose welding rods / stubs
Metal fume fever, dizziness, nausea
3‐Moderate
Generation of toxic gases and fumes
While working, crew must place themselves up wind, if possible, so that fumes and gases are blown away from them.
Local exhaust ventilation to be used. Used electrode pieces must be collected / kept in bucket or bin containers.
13
Keep the area clean.
Use inspected cables
Extreme
C‐Possible
4
Fire / electric shock /Fatality
5‐Catasrophic
Electric, welding cables and Earthing /Grounding
Welding earth shall be connected at work piece only
5
Maintain good cable management
Continual monitoring required , if found any damage of equipment immediately replace
Welding operations Use fire extinguisher , fire blanket and fire watcher Use ventilation or exhaust to keep area as air‐ breathing zone clear and comfortable.
Metal fume
High High
after completion of the job.
6
Hig
5
Used Electrode pieces must be collected / kept in bucket or a tin container. The area must be cleaned after the work is over. All radiography shall be preplanned and all to be informed to minimize the exposure of other persons to radiation hazards. Note: Whenever possible, radiographic inspection work will be performed during the night time or other than normal working hours.
D‐Unl
High
4‐Ma
All cables, hoses and other portable equipment should be placed in a safe area and cables; hose lines
3‐Mod
High
10 must be laid in one side of the pathway and recoiled
post sign boards.
3‐Moderate 3‐Moderate 3‐Moderate 3‐Moderate
High
12 Warn others from getting in contact with hot metal or
D‐Unl
Use hand gloves and avoid getting in contact with hot metal.
B‐Likely
Radiations burns and sickness
Wear cotton coverall and provide non‐flammable shielding to protect others.
C‐Possible
Radiation
20
Use 3M 8524 while welding on aluminum, galvanized and Stainless steel. Use correct filter lens and always use welding hood / helmet.
C‐Possible
Radiography
Injury, Trip
18
Crew, while working must place them self in the up wind direction, so that the fumes and gases are blown away from them. Use suitable Respirators especially when working in confine space
3‐Moderate 3‐Moderate 3‐Moderate
Bad House ‐keeping
Injuries
E‐Rare
Tripping Hazards
Burns
4‐Major
Hot Metal
Damage to eyes and skin.
D‐Unlikely
Ultra violet radiation.
3‐Moderate
fever, dizziness, nausea Toxic Fumes
5
Grounding shall be connected at plant permanent earth connector only
Completion Date
Rank(3)
0%
Low
E‐Ra
21
Low
2‐Mi
0%
Low
E‐Rare
20
Low
2‐Minor
0%
Low
E‐Rare
Site Engineer /
23
Low
2‐Minor
All employees
Target Date
Low
All employees
By Whom Person To Action
Level(3)
E‐Rare
Med
All employees
2‐Minor
Medium
E‐Rare
Medium
Site Engineer / supervisor
2‐Minor
Medium
D‐Unlikely D‐Unlikely
E‐Rare
Medium
D‐Unlikely
Site Engineer / supervisor
2‐Minor
Medium
E‐Rare
E‐Rare
D‐Unlikely
Obtain necessary valid safe work permit if 12 required ,Area to be barricated while working ,
Site Engineer / supervisor
2‐Minor
Medium
3‐Moderate
16 Continual Housekeeping
E‐Rare
D‐Unlikely
15 Toolbox talk , Routine inspection
Site Engineer / supervisor
2‐Minor
Medium
3‐Moderate
18 Area to be barricated while working
E‐Rare
D‐Unlikely
22 Ensure employee competency
Site Engineer / supervisor
2‐Minor
Medium
3‐Moderate
20 Continual monitoring required
E‐Rare
D‐Unlikely
16
Site Engineer / supervisor
2‐Minor
Medium
3‐Moderate
16 Conduct toolbox talk prior to start job
E‐Rare
D‐Unlikely
15 Continual monitoring required
Site Engineer / supervisor
2‐Minor
Medium
3‐Moderate
16 Conduct toolbox talk prior to start job
Likelihood(3)
Rank(2)
D‐Unlikely
20 Conduct toolbox talk prior to start job
Recommended Action (Improve existing controls / implement new controls) Including reference to procedures Blue highlight denotes Contractor procedures
Consequence(3)
Level(2)
3‐Moderate
High
Likelihood(2)
Rank(1)
C‐Possible
15 Use hand gloves.
Existing Controls
Final Risk
Consequence(2)
Level(1)
3‐Moderate
Un-wanted Event
Likelihood(1)
Hazard
Consequence(1)
Task
Revision No. 0
Residual Risk
Inherent Risk
Item
Company : Saudi Electrical Company Contract Number :
Comments
Location Work Area:
PP-13
SEC-PP13 COMBINED CYCLE PLANT PROJECT
Date of this Revision:
11-Nov-2015
MECHANICAL | I&C | ELECTRICAL WORKS
Date of last Revision:
New
RISK ASSESSMENT RISK REDUCTION PLAN
RISK ASSESSMENT RECORD
STATUS
Rank(3)
Percent Complete
w
0%
E‐Rare
Low
21
2‐Minor
E‐Rare
Low
22
Proper working platforms are to be provided for working at height. Scaffoldings are to be erected / modified / dismantled by qualified persons. Do not overload scaffolding. Check the scaffolding before use for proper condition and tagging is valid for purpose. Always use buckets to store tools, consumables and scrap materials.
Extreme
B‐Likely
Working at height
Collapse of platform, major injuries, and damage to crew and equipment.
5‐Catasrophic
6
Substandard platforms, unsecured platform, fall objects, unauthorized alterations.
4
Never carry any materials by hand while ascending or descending ladders. Maintain proper good housekeeping at work location.
Continual monitoring required , Conduct tool box talk prior to starts job at height
Site Engineer / supervisor
Continual monitoring required , Conduct tool box talk prior to starts job.
Site Engineer / supervisor
0%
0%
Ensure all platform gaps must be closed to reduce falling materials Maintain three point contacts while ascending or descending ladders. anchor it at all times during working hours while working at height. Provide barrication and sign board at ground level when people working at height. Do not enter restricted testing areas. Check all equipment and joints for any leaks and defects. Do not try to tighten any leaking joints when the line is pressurized. Gaskets of proper material & grade shall be used during hydro testing. The test area shall be properly supervised and barricaded with red and white tape. Only essential personnel performing the testing operation shall be permitted in the area. Warning signs shall be posted to keep unauthorized persons away. A written procedure shall be in hand while performing hydro tests where required (water type , temperature ,MPT, maximum dp .etc) The equipment being tested must be able to withstand the extra weight of the test liquid. Trapped air shall be vented off at the height point of the equipment being tested before raising the test pressure. A shop set , safety pressure relief valve shall be fitted on the hydro test pump.
High
Personnel and property damage
4‐Major
Leakage, sudden release of pressure
D‐Unlikely
7
Hydro testing and pressure testing
5
The pressure source supply hose shall be disconnected or isolated after test pressure is achieved. Note: A relief valve must be used to protect the system from over pressurizing caused due to temperature fluctuation during the day (Hot weather). Depressurizing of systems shall be performed in a safe manner. System shall not be left unattended while being pressurized or at hydro test pressure. Never open joints or flanges to release pressure, use a pressure release valve. Only a calibrated pressure gauge to be used for hydro testing.
Completion Date
Level(3)
20
2‐Minor
Medium
nor
D‐Unlikely
are
Medium
3‐Moderate
16
supervisor
Target Date
Likelihood(3)
Rank(2)
ium
D‐Unlikely
15
By Whom Person To Action
Consequence(3)
Level(2)
12 required ,Area to be barricated while working , Sign board required , Job watcher assigned ,
3‐Moderate
Recommended Action (Improve existing controls / implement new controls) Including reference to procedures Blue highlight denotes Contractor procedures
ikely
Any area where radiography work is to be performed, must be barricaded with yellow and black stripe rope or tape. Ensure all non‐classified personnel are away from any test area.
Final Risk
derate
gh
ikely
caused due to exposure
ajor
Radiation
Likelihood(2)
Rank(1)
5
INSTALLATION AND ERECTION HRSG AND GTG
Radiography
Existing Controls
Consequence(2)
Level(1)
Un-wanted Event
Likelihood(1)
Hazard
Consequence(1)
5
Task
Revision No. 0
Residual Risk
Inherent Risk
Item
Company : Saudi Electrical Company Contract Number :
Comments
Location Work Area:
PP-13
SEC-PP13 COMBINED CYCLE PLANT PROJECT
Date of this Revision:
11-Nov-2015
MECHANICAL | I&C | ELECTRICAL WORKS
Date of last Revision:
New
RISK ASSESSMENT RISK REDUCTION PLAN
RISK ASSESSMENT RECORD
STATUS Final Risk Percent Complete
21
0%
Low
22
0%
INSTALLATION AND ERECTION HRSG AND GTG Note: Crew must fully depressurize the system before removing any warning signs and then disconnect the supply hoses. Recycle / dispose the water in an environment friendly manner by avoiding spillage. Use two pressure gauges one at top and other at bottom Use standard HT fittings as per pressure rating Use only certified, competent and qualified personnel like Grade 1 riggers for Signalling . Use inspected and tagged slings and shackles (lifting gears) colour coding to be done as per company requirements.
Place warning signs and barricade area off limits. Check working load and type of slings required, preventive inspection of lifting equipment.
Extreme
B‐Likely
Lifting / Rigging
Injury to crew and other operatives in and around the job site damage to plant and equipment.
4‐Major
8
Failure of slings, lifting gear, hoisting and unstable crane, failure of rope and hydraulic system
3
Ensure out riggers are fully extended, ground is compacted and level. Always use blocks under outrigger floats. Specify equipment to rigging supervisor to ensure that the crane is suitable. Load test certificate (certificate must be kept in operator cabin). Conduct visual inspection before and after operations. Carry out periodic maintenance. Do not lift during heavy windy condition ( as per Rigging standard 15knts is a limit). Lift / lower load slowly without any sudden acceleration or stopping. Only grade 1 rigger can provide a signals to the crane operator. Use certified lifting equipment and tackles only. Riggers shall carry out inspection of all lifting equipment and tackles and provide inspection stickers / colour coding before mobilizing equipments for use working areas. All equipment involved in loading, unloading and transporting work must have valid inspection certificates. The equipment operator must have a valid operating license and the approved rigger shall control loading and unloading operations.
Road plates shall be placed below the out‐rigger mats of crane / hiab where required in view of the soil condition at site. Injury to personnel, damage to equipment and materials.
Extreme
Dropping of load
4‐Major
Loading , unloading , transporting& storage of materials
C‐Possible
9
4
The lifting / loading / unloading area shall be cordoned off to ensure that no person is under or near the load during loading, unloading, and/or shifting operation. The equipment / lifting gears shall be checked daily by operator / rigger to ensure its suitability. Load shall be moved very slowly while rigging and transporting near existing company facilities.
Completion Date
Rank(3)
E‐Rare
Target Date
Low
By Whom Person To Action
Level(3)
Site Engineer / supervisor
2‐Minor
Medium
E‐Rare
D‐Unlikely
project Manager /Site Engineer / supervisor
2‐Minor
3‐Moderate
15 Ensure employee competency .
Likelihood(3)
Rank(2)
Medium
Obtain necessary valid safe work permit if required ,Area to be barricated while working , 15 Display Lifting Sign board in lifting area .Lifting shall be carried out only as per Approved Rigging plan .
Consequence(3)
Level(2)
D‐Unlikely
Recommended Action (Improve existing controls / implement new controls) Including reference to procedures Blue highlight denotes Contractor procedures
3‐Moderate
Likelihood(2)
Existing Controls
Consequence(2)
Rank(1)
Level(1)
Un-wanted Event
Likelihood(1)
Hazard
Consequence(1)
Task
Revision No. 0
Residual Risk
Inherent Risk
Item
Company : Saudi Electrical Company Contract Number :
Comments
Location Work Area:
PP-13
SEC-PP13 COMBINED CYCLE PLANT PROJECT
Date of this Revision:
11-Nov-2015
MECHANICAL | I&C | ELECTRICAL WORKS
Date of last Revision:
New
RISK ASSESSMENT RISK REDUCTION PLAN
RISK ASSESSMENT RECORD
STATUS Percent Complete
0%
25
0%
Low
24
0%
Low
28
0%
Low
29
0%
Low
20
0%
Lo
23
0%
INSTALLATION AND ERECTION HRSG AND GTG While moving loads by crane, tag lines must be tied at both ends to minimize oscillation of the load. All the loads shall be secured properly during transportation. Reversing of equipments and vehicles shall be performed with reversing alarm in the presence of an assigned, trained Flagman. Inspect vehicles before operation. Never operate a defective vehicle. A proper route plan shall be developed for transporting heavy equipment.
Visitors, workmen could suffer injury from collision, Visitors, workmen could suffer injury from collision,
Extreme
Collision
C‐Possible
Movement of vehicles
5‐Catasrophic
10
4
Sufficient support shall be provided to prevent pitching or rolling of the load. Only authorized personnel to operate vehicles and with a valid license and permission to drive in the refinery. Drive carefully, especially on bumpy areas and roads. Never carry extra passengers in the vehicles not designated fort them. Follow road traffic / site safety rules.
Back injuries, severe pains in the hands, wrist, arm or neck
High
Strain of lifting material
C‐Possible
Manual handling
3‐Moderate
11
follow client site speed limits. Use a mechanical device like pulley blocks, etc to minimize manual handling, if required.; do not lift a load if you have doubt about the weight or adequacy of the equipment. Ensure there are enough crew members before lifting the load.
10 Check for any obstructions before lifting. Check out the area where the load will be placed before lifting the load. If additional support is required make sure it’s adequate to support the load. Proper maintenance must be done regularly.
High Medium High Extreme
4‐M
D‐Un
Hi
Injury material damage
4‐Major
Bursting of compressed Hose
20
C‐Possible
Injury due to Trip, fall & damage to hose
D‐Unlikely
Poor management of Compressor Hose
20 personnel to noise .
3‐Moderate
Compressor
E‐Rare
12
Asphyxia / Injury
3‐Moderate
Compressed air
Temporary deafness, headache
D‐Unlikely
Noise
Suffocation, Sickness.
3‐Moderate
Toxic Gases, (Carbon Mono Oxide) Smoke, Fumes
Compressors must be inspected and tagged by the competent person.
15
It Should be placed in well ventilated area. Compressors shall never be kept in enclosed places except when there is no other alternative, but in that case forced ventilation must be ensured. Compressors must be kept at a distance or sound barriers shall be placed to prevent exposure of
If it is not possible then the ear protection must be used. Never try to clean the body or face with compressed air horseplay with it and crew must always wear PPE while working with compressed air. The coupling of the hose must be secured with locking wire. Besides this, if possible whip back arrestor shall be used to secure/ hold the hose to avoid hitting the personnel in case of accidental disconnection from
5
The hose of the compressor shall not cross the walk ways. The hose shall be arranged in a good order to avoid trip and fall and damage to the hose Damaged / cut hoses shall not be used.
8
Preventive maintenance should be done periodically
Continual monitoring required , tool box talk on good hose management
16 Continual monitoring required TBT
All employees
Completion Date
Rank(3) 20
Low
E‐R
Low
Med
Target Date
Level(3)
D‐Un
2‐M
Medium
E‐Rare
D‐Unlikely
All employees
2‐Minor
Medium
3‐Moderate 3‐M
E‐Rare
D‐Unlikely
All employees
2‐Minor
Medium
3‐Moderate
E‐Rare
E‐Rare
All employees
2‐Minor
Medium
3‐Moderate
15
E‐Rare
D‐Unlikely
25 Toolbox talk
Technician
2‐Minor
Medium
3‐Moderate
22 Toolbox talk
E‐Rare
D‐Unlikely
20
All employees
2‐Minor
Medium
3‐Moderate
18 Conduct toolbox talk prior to start job
Site Engineer / supervisor
E‐Rare
D‐Unlikely
Continual monitoring required , Conduct tool box talk periodically ,
2‐Minor
Rank(2)
3‐Moderate
12
By Whom Person To Action
Likelihood(3)
Level(2)
Recommended Action (Improve existing controls / implement new controls) Including reference to procedures Blue highlight denotes Contractor procedures
Consequence(3)
Likelihood(2)
Existing Controls
Final Risk
Consequence(2)
Rank(1)
Level(1)
Un-wanted Event
Likelihood(1)
Hazard
Consequence(1)
Task
Revision No. 0
Residual Risk
Inherent Risk
Item
Company : Saudi Electrical Company Contract Number :
Comments
Location Work Area:
PP-13
SEC-PP13 COMBINED CYCLE PLANT PROJECT
Date of this Revision:
11-Nov-2015
MECHANICAL | I&C | ELECTRICAL WORKS
Date of last Revision:
New
RISK ASSESSMENT RISK REDUCTION PLAN
RISK ASSESSMENT RECORD
2‐Minor
E‐Rare
2‐Minor
E‐Rare
2‐Minor 2‐Minor
E‐Rare
2‐Minor
E‐Rare
Medium
3‐Moderate
D‐Unlikely
Medium
3‐Moderate
D‐Unlikely
Medium
3‐Moderate
D‐Unlikely
Medium
3‐Moderate
D‐Unlikely
Medium
3‐Moderate
D‐Unlikely
Medium
3‐Moderate 3‐Moderate
D‐Unlikely
Medium
18
D‐Unlikely
Medium
15
3‐
D
0%
22
0%
24
0%
All traffic rules and regulations must be followed as per client requriment. Proper maintenance must be done regularly.
High
Low Low
Carry out visual inspection equipment prior to use equipment , preventive maintenance should be done on routine basis
All employees
Low
22
Toolbox talk
All employees
Low
23
Monitoring should be done by competent person
Site Engineer / supervisor
E‐Rare
Low
0%
Low
Low
0%
21
2‐Minor
0%
Ensure employee competency , on prior to towing equipment check all fitting is done properly and acceptable
E‐Rare
0%
22
2‐Minor
0%
Continual monitoring required , TBT
E‐Rare
Speed must be very slow and utmost care to be taken on turnings. All traffic and site rules and regulations must be followed
0%
2‐Minor
High
The generators must be properly connected with the towing vehicle.
0%
23
E‐Rare
High
All generator cables must be arranged properly and should not be crossing the walk way. Cables must not be crossing roads or paths that are used by vehicles/ forklifts to avoid any damage to the cables.
26
2‐Minor
High
7
All cables must be checked that it is not damaged or cut. Appropriate ground earth connection should be provided.
Preventive maintenance should be done periodically
E‐Rare
Medium
6
C‐Possible
Disengagement, overturning, accident
6
3‐Moderate
Towing of Generators
must be used.
C‐Possible
Trip & Fall , Cable damage
Generators must be kept at a distance to avoid
18 exposure of personnel to noise or ear protection
3‐Moderate
Electrical Cables
Generators
Generators must be inspected and tagged by the competent person. Generators Should be placed in well ventilated area ,Forced ventilation must be provided in enclosed place.
4‐Major
Electrical shock
17
D‐Unlikely
Electricity
D‐Unlikely
Temporary deafness, headache
3‐Moderate
Noise
4‐Major
Death ,Suffocation, Sickness.
D‐Unlikely
13
Toxic Gases, (Carbon Mono Oxide) Smoke, Fumes
21
Preventive maintenance shall be done regularly
High
4‐Major
Loss of Equipment, property and injury to men
D‐Unlikely
Fire due to Overheating of Generators
Fire extinguishers must be placed nearby to immediately extinguish the fire.
10 The generators shall be kept away from other flammable and combustible materials. The generators must be put off before going on break or when it is not in use.
High
4‐Major
High
Slips, trips & stress
15
D‐Unlikely
Improper storage of tools & spare parts .
C‐Possible
Injuries
3‐Moderate
Defective & Greasy Tools
10
Check all tools and don't use defective tools. Keep the tools clean and free from any lubricants like oil grease
All tools and equipment must be properly stored. All spare parts must be identified, marked and stored correctly. Gas Cylinders must be stored under shaded and ventilated place, secured in vertical position.
Completion Date
E‐Rare
Medium
D‐Unlikely
15
Percent Complete
2‐Minor
Medium
3‐Moderate
16
Rank(3)
Rare
Driver
16
20
Low
Minor
All employees
15 Toolbox talk
0%
Low
Likelihood(3)
All employees
22 Toolbox talk
23
Low
Consequence(3)
All employees
20
Target Date
ow
Rank(2)
dium
All employees
Ensure employee competency , on prior to 15 towing equipment check all fitting is done properly and acceptable
By Whom Person To Action
Level(3)
Level(2)
Driver
D‐Unlikely
6
Carry out visual inspection equipment prior to 13 use equipment , preventive maintenance should be done on routine basis
3‐Moderate
High
4‐Major
D‐Unlikely
The compressor must be properly connected with the towing vehicle. Speed must be very slow and utmost care to be taken on turnings.
All employees
D‐Unlikely
Fire extinguishers must be placed nearby to immediately extinguish the fire. The compressor shall be kept away from other flammable and combustible materials. The compressors must be put off before going on break or when it is not in use.
All employees
3‐Moderate
4‐Major
Towing of Compressors
Disengagement, overturning ,accident
D‐Unlikely
Injury to personnel & damage to property
16 Continual monitoring required , TBT
Recommended Action (Improve existing controls / implement new controls) Including reference to procedures Blue highlight denotes Contractor procedures
odera
Preventive maintenance shall be done regularly. Fire due to Overheating of Compressors
STATUS Final Risk
nlikely
High
10
No vehicle shall pass over compressed hose.
Likelihood(2)
gh
8
Existing Controls
Consequence(2)
Rank(1)
Injury , material damage
nlikely
Bursting of compressed Hose
Major
INSTALLATION AND ERECTION HRSG AND GTG
Level(1)
Un-wanted Event
Likelihood(1)
Hazard
Consequence(1)
Task
Revision No. 0
Residual Risk
Inherent Risk
Item
Company : Saudi Electrical Company Contract Number :
Comments
Location Work Area:
PP-13
SEC-PP13 COMBINED CYCLE PLANT PROJECT
Date of this Revision:
11-Nov-2015
MECHANICAL | I&C | ELECTRICAL WORKS
Date of last Revision:
New
RISK ASSESSMENT RISK REDUCTION PLAN
RISK ASSESSMENT RECORD
Percent Complete
2‐Minor
20
0%
Horseplay is strictly not allowed in the work area.
High
Employees shall ensure that their tools are in good replaced.
Toolbox talk
0%
24
0%
20
0%
Low
High
10 condition and if a defect is observed then it must be
Drive slowly and give necessary signals extra attention must be given while driving on all areas of the company
E‐Rare
Extreme
C‐Possible
Injury
6
3‐Moderate
Using defective tools.
All vehicles entering and exiting the Workshop, garage shall be driven as slow as possible.
4‐Major
Injuries, Fatalities, Property damage.
All slippery surfaces shall be cleaned immediately
12 using sawdust or sand.
C‐Possible
Speed
General
C‐Possible
Slips and falls
3‐Moderate
14
Slippery surface
26
Low
Employees are not allowed to leave their job without informing the immediate supervisor Employees are to be in their work area only, and have to take prior permission of the supervisor to leave their job area.
Low
9
Low
High
C‐Possible
Injury
3‐Moderate
Horse play & loitering, unsafe acts
Sleeping is strictly not allowed on operational areas regardless of circumstances.
22
0%
Supervisor shall ensure that required proper tools are available and they are in good condition. Mushroom head tools shall be rectified or replaced.
All employees
E‐Rare
15
barricate the area
All employees
2‐Min
E‐Rar
0%
20
0%
Low
Visual inspection to be done before use any ladder , if found defect immediately change it .
26
Low
Site Engineer / supervisor
Low
Conduct toolbox talk prior to start job , Conduct gas test if required , assign job watcher
2‐Minor
Brass hammers shall be used as applicable and shall be frequently checked as it has high failure rates Flogging spanners shall be kept clean and in congested area hammering shall be done with extreme care.
E‐Rare
8
2‐Minor
High
C‐Possible
Injuries
3‐Moderate
Opening man ways and other flanges
All hammers heads shall be fitted firmly to the wooden handles.
20
0%
Penetrating liquids shall be used for unbolting process. Tools shall be also checked, during the work for any defects
High
6
Ensure that, there are no cables, pipes or any obstructions on the ladder rungs, or near it. Ensure ladder rungs are free from any slippery substance.
High
C‐Possi
3‐Mode
Injuries
C‐Possible
Rotating equipments
Injuries
3‐Moderate
Using ladders
Ensure ladders are in good condition and secured or fixed in a correct angle.
9
Ensure that the rotary movement of equipment has come to a complete halt and power supply disconnected before carrying out any activities like inspection, repairs, cleaning.
Completion Date
Rank(3)
Low
E‐Rare
Low
Level(3)
2‐Minor
Mediu
E‐Rare
D‐Unlik
2‐Minor
Medium
E‐Rare
Medium
3‐Mode
2‐Minor
Medium
13
Target Date
E‐Rare
Medium
D‐Unlikely
2‐Minor
Medium
15
3‐Moderate
E‐Rare
Medium
D‐Unlikely
2‐Minor
Medium
15 Toolbox talk
3‐Moderate
Likelihood(3)
Rank(2)
Medium
D‐Unlikely
Consequence(3)
Level(2)
12
3‐Moderate
All employees
D‐Unlikely
Driver
16 Monitoring should be done by competent person
3‐Moderate
All employees
D‐Unlikely
All employees
18
3‐Moderate
Toolbox talk
D‐Unlikely
Ensure the work and resting area kept neat and clean and all rubbish is put into the waste and it is regularly emptied.
All employees
15
3‐Moderate
8
Continual improvement of housekeeping required
Monitoring should be done by competent person
D‐Unlikely
Medium
3‐Moderate
Contaminate disease
D‐Unlikely
Bad housekeeping
0%
18
3‐Moderate
There must be 20 ' distance from Oxygen to Acetylene , Propane or other flammable Gas Cylinders.
25
‐Moderate
Gas Cylinders must be segregated and kept separately ie Full Oxygen, CO2, Empty, Acetylene etc.
Site Engineer / supervisor
Recommended Action (Improve existing controls / implement new controls) Including reference to procedures Blue highlight denotes Contractor procedures
D‐Unlikely
Explosion, Fire
By Whom Person To Action
Likelihood(2)
Rank(1)
High
6
Existing Controls
INSTALLATION AND ERECTION HRSG AND GTG Improper storage of Gas Cylinders
STATUS Final Risk
Consequence(2)
Level(1)
4‐Major
D‐Unlikely
Un-wanted Event
Likelihood(1)
Hazard
Consequence(1)
Task
Revision No. 0
Residual Risk
Inherent Risk
Item
Company : Saudi Electrical Company Contract Number :
Comments
Location Work Area:
PP-13
SEC-PP13 COMBINED CYCLE PLANT PROJECT
Date of this Revision:
11-Nov-2015
MECHANICAL | I&C | ELECTRICAL WORKS
Date of last Revision:
New
RISK ASSESSMENT RISK REDUCTION PLAN
RISK ASSESSMENT RECORD
STATUS
Low Low Low Low Low
26
Provide good supervision. Don’t use sudden force. Ensure working platforms used are in firm and in good condition.
Personnel Injury, Loss to Property
Extreme
Slip, Trip ,fall , finger trap
4‐Major
Unbolting Bolting
C‐Possible
15
Maintain good housekeeping.
5
Don’t keep the free nuts/bolts on platform plank or on platform grating. Store in steel bucket or at ground level to minimize falling hazards.
Conduct toolbox talk prior to start job ,
Site Engineer / supervisor
Conduct toolbox talk prior to start job
Site Engineer / supervisor
Conduct toolbox talk prior to start job .
Site Engineer / supervisor
Conduct toolbox talk prior to start job
Site Engineer / supervisor
Obtain necessary valid work permit
Site Engineer / supervisor
Always use the correct and inspected tools required for the job. Avoid placing hands and fingers between flanges to avoid pinch points. Wear proper gloves. Clear all non essential people.
Fall / tripping / injury
Floor openings shall be barricaded or protected by hard barricades and proper signage to be provided. High
Unprotected floor opening
4‐Major
Walking on higher elevated /platform
C‐Possible
16
7
Employees shall check the area before walking on the platforms and always be very alert while working at height. Use safety harness where required. Use only tested & approved chain blocks only. Assure that all lifting equipment meets the current company color code. Secure the chain block firmly. Don’t exceed the chain block safe working load. Employees must be well trained to operate the chain blocks.
Personnel and property damage.
High
Failure of equipment
C‐Possible
Pulling of equipment by using chain blocks or liver block
3‐Moderate
17
6
Users must stay in view of the chain block at all time to ensure the following: Do not operate a damaged or malfunctioning chain block. Do not remove or obscure warning labels if provided. Make sure the chain is clean and well maintained. Keep personnel away while pulling . Do not use hands to guide the chain onto the chain blocks while pulling . Avoid jerking of chain blocks. Never use or operate a damaged chain block. Secure the chain blocks properly before leaving it unattended. Provide personnel barrier in the area a chain block is being used.
High
C‐Possible
3‐Moderate
Exposure to flammable liquids Irritation to respiratory system, ,toxic gases and dust particles eyes and skin
Use suitable respiratory protection. 8
Use goggles. Use proper PPE.
Medium
Internal cleaning
D‐Unlikely
18
Sprains and strains
3‐Moderate
Restricted space
Allow only experienced workers to go inside. Follow company procedure for entering in confined
18 spaces. Job rotation of workers.
2
C‐
3‐M
Job fit for purpose All scrap material and unnecessary items have to be removed from the working area as soon as possible to secure the area
Completion Date
w
Percent Complete
Level(3)
Rank(3)
E‐Rare
M
22
2‐Minor
D‐
E‐Rare
Medium
3‐M
21
2‐Minor
D‐Unlikely
E‐Rare
Medium
3‐Moderate
20
2‐Minor
D‐Unlikely
0%
E‐Rare
Medium
3‐Moderate
0%
21
2‐Minor
D‐Unlikely
0%
E‐Rare
Medium
3‐Moderate
0%
2‐Minor
D‐Unlikely
0%
or
Medium
3‐Moderate
15
Target Date
e
D‐Unlikely
13
By Whom Person To Action
Likelihood(3)
um
3‐Moderate
13
Recommended Action (Improve existing controls / implement new controls) Including reference to procedures Blue highlight denotes Contractor procedures
Consequence(3)
kely
13
Rank(2)
Level(2)
erate
h Keep portable grinders on the ground only after the wheel has complete stopped rotating.
Likelihood(2)
Existing Controls
Final Risk
Consequence(2)
Rank(1)
Level(1)
ible
INSTALLATION AND ERECTION HRSG AND GTG
erate
Un-wanted Event
Likelihood(1)
Hazard
Consequence(1)
Task
Revision No. 0
Residual Risk
Inherent Risk
Item
Company : Saudi Electrical Company Contract Number :
Comments
Location Work Area:
PP-13
SEC-PP13 COMBINED CYCLE PLANT PROJECT
Date of this Revision:
11-Nov-2015
MECHANICAL | I&C | ELECTRICAL WORKS
Date of last Revision:
New
RISK ASSESSMENT RISK REDUCTION PLAN
RISK ASSESSMENT RECORD
Percent Complete
22
0%
21
0%
25
0%
25
0%
21
0%
Low
27
0%
Low
26
0%
Low
22
0%
Low
24
0%
All employees shall wear appropriate PPE. Provide proper ventilation.
Extreme
6
High
Follow confined space procedures.
19
Conducts gas test before enter in confine space Use suitable PPE. Ensure all final checks have been performed before entry. Entry after clearance, Plan and schedule the job correctly. Provide plenty of water at job location. Provide ventilation.
Medium
C‐Possible
15
Use suitable PPE. Toolbox talk about how to use ear plugs. Carryout gas test if required
High
Poisoning, fainting, major fatality, fire and explosion.
3‐Moderate
Confined Space
Exposure to flammable and toxic gases
D‐Unlikely
19
Stress & deafness
3‐Moderate
Noise
7
Provide enough ventilation. Follow correct procedures. Use only tested & inspected equipments
High
4‐Major
Electrocution
D‐Unlikely
Electrical equipment
10
Use ELCB. se only 24/110 volts equipments. Maintain proper cable management to avoid slip and trip
High
C‐Possible
Injury
3‐Moderate
Obstructions
12
Be aware of surroundings. Be vigilant.
High
C‐Possible
Darkness , collision with equipment
3‐Moderate
Poor lighting
Ensure proper lighting before entering confine space 5
wear clear safety glass Work in a team while handling or lifting any office items. Medium
D‐Unlikely
Back pain
3‐Moderate
Manual handling of office equipments
15
Trolley to be used to handle heavy equipment or carried out the handling activity with the help from team member. Before Handling Ensure you are fit for task.
Medium
C‐Possible
Discomfort posture , injuries , head ache
3‐Moderate
Display screen equipments
Maintain good posture to avoid unwanted glare and reflection falling on screen. 16
Plan your work task accordingly to avoid Back pain by working continuous on computer. Follow with interval breaks. Switch off the power source when not in use and before leaving the office .
C‐Possible
Medium
9
Injuries
3‐Moderate
C‐Possible
Medium
Slip, trip and falls
Stress
3‐Moderate
Lack of job control
6
Always work within design or environmental limits. Always address abnormal conditions and never let them become accepted as normal .if Doubt ask to your senior. Maintain good housekeeping All area well lit . Including stair and walkways. Keep the assess free from to avoid from Slip & Trip.
Completion Date
Rank(3)
0%
Low
E‐Rare
23
Low
2‐Minor
0%
Low
E‐Rare
All employees
22
Low
2‐Minor
Toolbox talk , countinual improvemetn in housekeeping required.
0%
Low
E‐Rare
All employees
22
Low
2‐Minor
Toolbox talk
Target Date
Low
All employees
By Whom Person To Action
Low
Toolbox talk
Recommended Action (Improve existing controls / implement new controls) Including reference to procedures Blue highlight denotes Contractor procedures
Level(3)
All employees
E‐Rare
Medium
Access load before handle
2‐Minor
D‐Unlikely
All employees
E‐Rare
Medium
3‐Moderate
Toolbox talk , Routine inspection
2‐Minor
D‐Unlikely
All employees
E‐Rare
Medium
3‐Moderate
Toolbox talk
2‐Minor
D‐Unlikely
All employees
E‐Rare
Medium
3‐Moderate
Visual inspection to be done before using any electical equipment , if found defect immediately change it .
2‐Minor
D‐Unlikely
All employees
E‐Rare
Medium
3‐Moderate
Employees should familiar of emergency procedure
2‐Minor
D‐Unlikely
16
Site Engineer / supervisor
E‐Rare
Medium
3‐Moderate
16
Ensure employees are using ear protection device
2‐Minor
D‐Unlikely
21
Site Engineer / supervisor
E‐Rare
Medium
3‐Moderate
19
Obtain necessary valid work permit . Conduct toolbox talk prior to start job
2‐Minor
D‐Unlikely
13
Site Engineer / supervisor
E‐Rare
Medium
3‐Moderate
19
Obtain necessary valid work permit . Conduct toolbox talk prior to start job
2‐Minor
Medium
D‐Unlikely
16
All employees
E‐Rare
Medium
3‐Moderate
15
Continual improvement of housekeeping required
‐Minor
Medium
D‐Unlikely
20
Likelihood(3)
Rank(2)
Medium
22
Consequence(3)
Level(2)
13
D‐Unlikely
C-Possible
16
3‐Moderate 3‐Moderate
3-Moderate
Ensure that working tools and items are kept in a secure container.
D‐Unlikely
C‐Possible
Giddiness, unsteadiness
Falling objects
3‐Moderate
High
5‐Catasrophic
High temperature
INSTALLATION AND ERECTION HRSG AND GTG
Unlikely
Rank(1)
Possible
Fire, explosion / fatality
Existing Controls
Moderate
Level(1)
Moderate
Oxygen deficient / enriched atmosphere
Un-wanted Event
Likelihood(2)
Likelihood(1)
9
Hazard
STATUS Final Risk
Consequence(2)
Consequence(1)
Personnel injury and property damage
Task
Revision No. 0
Residual Risk
Inherent Risk
Item
Company : Saudi Electrical Company Contract Number :
Comments
Location Work Area:
PP-13
SEC-PP13 COMBINED CYCLE PLANT PROJECT
Date of this Revision:
11-Nov-2015
MECHANICAL | I&C | ELECTRICAL WORKS
Date of last Revision:
New
RISK ASSESSMENT RISK REDUCTION PLAN
RISK ASSESSMENT RECORD
STATUS Percent Complete
22
0%
21
0%
22
0%
Low
23
0%
Low
22
0%
Low
21
0%
INSTALLATION AND ERECTION HRSG AND GTG
20
Ensure all office equipment’s are CE marked.
Office activities
Ensure all office equipment well maintained.
Extreme
C‐Possible
Fire , Electric shock
4‐Major
Electricity
Avoid wet hand before touching electrical equipment 5 Avoid of misuse or overload any electrical equipment Ensure isolation of energy before doing any repair work of office equipment Maintain proper cable routing to avoid from shocks especially from water Dispenser or from Electric stove in case of such facilities provided in working office. Emergency procedure and assembly point Emergency escape route marked and clear
High
C‐Possible
Burn , Property damage
3‐Moderate
Fire
Ensure all electrical equipment in well maintained 5 Provision of fire extinguisher and training Ensure Fire alarm systems well maintained Conduct mock drills
4‐Major
D‐Unlikely
Electricity
Electrical shock
C‐Possible
Security staff check all area before locking the offices
10
Ensure machinery is stopped and electrically isolated during maintenance.
Extreme
C‐Possible
Entanglement
5
High
3‐Moderate
Rotating machinery
High
Suffer injury
4‐Major
Lone working
6
Electrical fault finding or safety testing with live equipment only done by qualified or competent person Vices and other suitable fixtures for holding/clamping work‐pieces are provided.
High
C‐Possible
21
Cuts/abrasions, stabbing, impact ,small projectiles , dust
3‐Moderate
Damage of tools
Tools are kept in good condition and are maintained by workshop staff as required. 9
Maintenance activities
Eye protection, boiler suits /lab coats, gloves, safety shoes and dust masks are provided and used as appropriate. Workbenches are sited away from machine tools and other activities.
Inspect tool before using , replace if found defect.
Conduct toolbox talk prior to start job
Use inspected tools Guards are either permanent fixtures, or are available to be fitted to
Entanglement Friction
Prepared by ,
Reviewed by
Extreme
Stabbing/Puncturing,
4‐Major
Cutting, Shearing,
C‐Possible
Abrasion, Powered machinery
6
Machines as necessary. They are correctly adjusted and used Work‐pieces are securely held with vices, chucks, fixtures and clamps. Emergency stop/brake Abrasive wheels are mounted and dressed by trained competent persons. Rests on bench/pedestal grinders are set by trained competent persons.
Impact, Crushing,
Machine operators wear suitable protective
Drawing in, and Ejection.
Machinery is kept in good working order through regular maintenance and cleaning.
Approved by
Completion Date
Rank(3)
0%
Low
E‐Rare
23
Low
Target Date
Low
By Whom Person To Action
Low
13
Recommended Action (Improve existing controls / implement new controls) Including reference to procedures Blue highlight denotes Contractor procedures
Level(3)
Site Engineer / supervisor
2‐Minor
Medium
E‐Rare
D‐Unlikely
Technician
2‐Minor
Medium
16
3‐Moderate
E‐Rare
D‐Unlikely
Technician
2‐Minor
Medium
13 Toolbox talk
3‐Moderate
E‐Rare
Medium
15 Ensure employees competency
D‐Unlikely
Technician
2‐Minor
D‐Unlikely
All employees
E‐Rare
Medium
13
3‐Moderate 3‐Moderate
Complete task in time . And leave the office if you are alone
2‐Minor
D‐Unlikely
Site Engineer / supervisor
E‐Rare
Medium
16
3‐Moderate
Refresh emergecy procedure in toolbox talk
2‐Minor
D‐Unlikely
All employees
E‐Rare
Medium
14
3‐Moderate
Toolbox talk
2‐Minor
Rank(2)
D‐Unlikely
Likelihood(3)
Level(2)
3‐Moderate
Consequence(3)
Likelihood(2)
Existing Controls
Final Risk
Consequence(2)
Rank(1)
Level(1)
Un-wanted Event
Likelihood(1)
Hazard
Consequence(1)
Task
Revision No. 0
Residual Risk
Inherent Risk
Item
Company : Saudi Electrical Company Contract Number :
Comments
Location Work Area:
PP-13
SEC-PP13 COMBINED CYCLE PLANT PROJECT
Date of this Revision:
11-Nov-2015
MECHANICAL | I&C | ELECTRICAL WORKS
Date of last Revision:
New
RISK ASSESSMENT RISK REDUCTION PLAN
RISK ASSESSMENT RECORD
Completion Date
Percent Complete
Level(3)
Target Date
Rank(3)
By Whom Person To Action
Likelihood(3)
GAMA
Recommended Action (Improve existing controls / implement new controls) Including reference to procedures Blue highlight denotes Contractor procedures
Consequence(3)
NIS Project Manager
STATUS Final Risk
Rank(2)
NIS HSE Dept .
Level(2)
INSTALLATION AND ERECTION HRSG AND GTG
Likelihood(2)
Existing Controls
Consequence(2)
Rank(1)
Level(1)
Un-wanted Event
Likelihood(1)
Hazard
Consequence(1)
Task
Revision No. 0
Residual Risk
Inherent Risk
Item
Company : Saudi Electrical Company Contract Number :
Comments
OHS_Risk_Matrix
RISK MATRIX 1. Identify the credible consequence for each unwanted event using the table below. If a combination of harm, loss or damage could result then the greater of the consequences should be used.
ALL INCIDENT CLASSIFICATION MATRIX High Potential
Insignificant
Minor
Moderate
Major
Catastrophic
First Aid Treatment
Medical Treatment Lost time injury (LTI) required - no lost time injury
Multiple LTI’s Permanent disabling injury
Fatality
Environment
No Impact on baseline environment. Localised to point source. No recovery required. Non compliance event. No prosecution.
Localised within site boundaries. Recovery measurable within 1 month of impact.
Moderate harm with possible wider effect. Recovery in 1 year. Failure to follow internal clearing requirements.
Significant harm with local effect. Recovery longer than 1 year. Ground disturbance with no approvals in place. Rare or endangered species or heritage site impacted but recoverable. Repeat legal non compliance / internal breach. Prosecution.
Significant Impact that is widespread, unconfined impact, requiring long-term recovery, leaving major residual damage. Unauthorised clearing resulting in damage to a rare and/or endangered species habitat and/or has damaged heritage sites. The site and species cannot be recovered.
Asset Damage &
Up to $5k
Up to $15K
Up to 16- 30K
Up to 31-50K
>500K
Reputation
Localised temporary impact
Localised, short term impact
Localised, long term impact but manageable
Localised, long term impact with unmanageable outcomes
Long term regional impact
OHS Injury OHS Illness
2. Determine the likelihood of the event occurring and it resulting in the consequence selected above using the table below.
Description Incident is expected to occur on this project, possibly several times Evidence of common or repeated occurrence
Likelihood Rating Almost Certain 95%
Occurs more than once a year. Incident may easily occur on this project
Likely 75%
Occurs at least once in a year
Possible 50%
Incident has occurred on a similar project
Unlikely 25%
Incident unlikely to occur during this project
Rare 5%
Incident highly unlikely to occur on this project
May occur at least once in a year Not likely to occur in 10-100 years.
Not likely to occur in 100-1000 years
3. Utilise the risk matrix below to identify the risk and risk rating Likelihood Description
Insignificant
Minor
Moderate
Major
Catastrophic
%
1
2
3
4
5
95%
HIGH
HIGH
EXTREME
EXTREME
EXTREME
A
Almost Certain
Incident is expected to occur on this project, possibly several times
B
Likely
Incident may easily occur on this project
75%
MEDIUM
HIGH
HIGH
EXTREME
EXTREME
C
Possible
Incident has occurred on a similar project
50%
LOW
MEDIUM
HIGH
EXTREME
EXTREME
D
Unlikely
Incident unlikely to occur during this project
25%
LOW
LOW
MEDIUM
HIGH
EXTREME
E
Rare
Incident highly unlikely to occur on this project
5%
LOW
LOW
MEDIUM
HIGH
HIGH
E: Extreme risk, immediate action required H: High risk, senior management attention required M: Moderate risk, management responsibility required L: Low risk, manage by routine procedures
E:\Amit Kumar\sarkar\HRSG\Risk Assessment.xlsx
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