ms panel and equipment installation for signaling system works rev 0

8/13/2019 MS Panel and Equipment Installation for Signaling System Works Rev 0

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Railway Electrification and Double-Double Tracking of Java Main Line Project

Package B1 : Railway Facility Construction for BEKASI to CIKARANG

METHOD STATEMENT

Panel and EquipmentFor Signaling System Works

PROJECT Checked by Checked by Approved by

TitleInterface and Engineering

Manager

Deputy General

Superintendent

General Superintendent

Name H. Houan / Y.Nonaka A.H. Desfiansyah Y. Kameda

Signature

Date

SECTION Written by Checked by Checked by

Name Nurhalim/T.Ikenaga N. Fukuta M. Adachi

Signature

Date December 14th, 2013

Contractor Mitsubishi-Sumitomo Joint Operation


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RAILWAY ELECTRIFICATION AND DOUBLE-DOUBLE TRACKING OF JAVA MAIN LINE PROJECT

PACKAGE B1: RAILWAY FACILITY CONSTRUCTION FOR BEKASI TO CIKARANG

Revision History

Rev. DateSection Project

Written by Checked by Approved by Written by Checked by Approved by

0

Dec 14th, 2013 Signed on Cover Page

Description:

1

Signed on Cover Page

Description:

2 Description:

3 Description:

4Description:

5 Description:


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Table of Contents1 Purpose ............................................................................................... 1

1.1 Introduction ....................................................................................................... 11.2 Objective .......................................................................................................... 1

2 Scope Of Work .................................................................................... 13 Reference Documents ........................................................................ 24 Organization ........................................................................................ 2

4.1 Site Works Organization (Signal & Telecom Works) .................................... 24.2 Support Project Organizations ......................................................................... 3

5 Materials ............................................................................................. 36 Tools and Equipment .......................................................................... 57 Work Procedure .................................................................................. 6

7.1 Preparation ....................................................................................................... 67.2 Transferring Panel and Equipment .................................................................. 67.3 Materials Delivery and Arrangement ................................................................ 67.4 Preparation to Install ........................................................................................ 77.5 Unloading Handling Panel and Equipment at Site ........................................... 77.6 Storage ............................................................................................................. 77.7 Recommended Inspection ............................................................................... 77.8 Installation ........................................................................................................ 8

7.8.1 Installation Procedure for Panel ...................................................................................... 87.8.2 Installation Procedure for Equipment .............................................................................. 9

8 Safety, Environmental and Hazard Mitigation ................................... 128.1 Preparation ..................................................................................................... 128.2 Toolbox Talk ................................................................................................... 138.3 Train Watchers (Safety Supervision) ............................................................. 148.4 Accident Prevention Arrangement ................................................................ 158.5 Initial Response and Reporting ...................................................................... 16


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Table of Figure

Figure 5-1. Panel at inside Signal Cabin ................................................................................. 4Figure 5-2. Panel at Wayside/Outside .................................................................................... 4Figure 5-3. Equipment ............................................................................................................ 5Figure 7-1. Transferred by Truck ............................................................................................ 6Figure 7-2. Hand pallet ........................................................................................................... 7Figure 8-1.Personal Protective Equipment (PPE) ................................................................. 12Figure 8-2.Tool Box Talk ....................................................................................................... 13Figure 8-3.The Position of Train Watchers ........................................................................... 14Figure 8-4.The Standard Outfit of Train Watchers ................................................................ 14Figure 8-5.Accident Incident No. 1 ........................................................................................ 15Figure 8-6 Accident Incident No. 2 ........................................................................................ 15Figure 8-7.Reporting System for Minor Accident .................................................................. 16Figure 8-8.Reporting System for Major Accident .................................................................. 17

Table of Attachment

MSJO Construction Organization Chart. ...................................................................... A 1 of 1


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1 Purpose

1.1 Introduction

The project Railway Electrification and Double-Double Tracking of Java Main Line

Project, Package B1 is an operating line that needs to be upgraded and expanded to

accommodate the increasing train traffic which is attributable to the increase in public

patronage.

This Statement describes transferring, placement, inspecting and installing for panel and

equipment for signaling system works.

So as to realize the indicated general project goals, panel and equipment for signaling

system will be designed and installed. This Signaling facilities upgrade will improve the

transporting capability of the train system, improve or upgrade the safety level of the

operating system and in a relative sense, reduce pollution and elevate riding comfort.

1.2 Objective

This proposed Method Statement is intended to detail the work procedures and

requirements that will be implemented or used during the panel and equipment

installation for Signaling System works of the Railway Electrification and Double-Double

Tracking of Java Main Line Project, Package B1.

The method statement is prepared in such a way to ensure:

- Safety and punctuality of the installation process;

- Quality of the installation works;

- Minimum affect to the train operation;

- Minimum or no delay to the installation or to the construction works.

2 Scope Of Work

This work shall consist of transferring, placement, inspecting and installing for panel and

equipment for signaling system works. The works shall be performed in accordance with the

specification and as shown on the drawing unless otherwise directed by engineer.

I t ll ti k f l & i t t h ll b i d t ithi t ti t


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3 Reference Documents

The following documents are considered for the development of this Method Statement:

Technical Specification and Tender Drawings of RAILWAY FACILITY CONSTRUCTION

FOR BEKASI TO CIKARANG-PACKAGE B1;

Project Management Plan B1/PLN/GEN/0008;

Basic Design Section 8 : Signaling Systems Works B1IN/PLN/GEN/0004;

Construction Management and Organization Plan B1/PLN/GEN/0012;

Site Health and Safety Plan B1/GEN/PLN/0015;

Permit and Work Procedure in an Operating Railway B1/PLN/GEN/0024; Quality Management Program B1/PLN/GEN/0013;

Quantity Management Program B1/PLN/GEN/0014;

4 Organization

MSJO, through the General Superintendent, has the overall responsibility to manage all

works under the DDT project. The Panel and Equipment installation for Signaling Systemworks will be performed under Construction Management and Organization for Electrical &

Mechanical Works.A proposed site organization chart specific for the supervision of the

works is included in the detailed Method Statement, as shown in Attachment

The Site Supervisor will be responsible for the execution of the Works, and will report to

MSJO Engineer-in-Charge on all progress issues, and shall perform supervise of material,

tools equipment, and quality control also of the performed works and Other issues as defined

by MSJO Engineer-in-Charge.

4.1 Site Works Organization (Signal & Telecom Works)

A work team for the The Panel and Equipment Installation for Signaling System will be

organized to perform the installation works

The work team will consist of the following.

1) Foreman or Site Supervisor;

2) Drivers;

3) Technicians;

4) Laborers;

5) Train watchers.

The team or each team will be monitored / supervised by Site Supervisor who will record or

document the Panel and Equipment Installation and will be assisted by the HSE ( Health


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4.2 Support Project Organizations

Support project organizations are shown in the following attachments:

1. Attachment 1MSJO and PT. Len Construction Organization Chart

5 Materials

The following materials will be utilized for panel and equipment installation by signalling worksare following below:

Panel1. Inside Signal Cabin:

- OT/FT Rack- TC Device Rack- Relay Rack- Logic Rack- UPS- MDPD

- SDDP- Control Console- MTC (Maintenance Terminal Console)

2. Outside/Wayside Railway:- JB (Junction Boxes) / CB (Connection Boxes)- Location Cases (LOC)

Equipment

- Signal & Marker- Point Machine- Automatic Block Signal- Level Crossing


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Control Console

MTC:

MaintenanceConsole

Logic Rack

(K5B) Relay Rack

OT Rack

(Control Room)

Signal Device Room

TC Device Rack

InsulationTransformer

(for PM)

Insulation

Transformer

(for ABS)

InsulationTransformer

(for TC)

Insulation Trans-former

(for EI)

InsulationTrans-former

(for LT)

Insulation

Trans.

(OPC)

Insulation Trans-former

(for EI)

Transformer Rack FT Rack

Opticalfiber Cable

Relay I/FBetween EI / Field Equipments

OutsideEquipments

Figure 5-1. Panel at inside Signal Cabin


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Point Machine Signal Indicator

Level Crossing Track Circuit With IRJ

6 Tools and Equipment

The tools and equipment listed below will be utilized for panel & equipment installationfor signalling works:

Picks and shovels;

Crow bars and Digger bars;

Measuring tapes;

Hammers and sledge hammers;

Cutting tools;

Hand tools, assorted;

Termination tools;

Multi tester;

Toolkit;

Figure 5-3. Equipment


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7 Work Procedure

7.1 Preparation

Work management for Critical Path (Coordination with other panel and equipmentworks) in implementing new installation or modification of panels and equipment setsystem must be finished in accordance with the available work window time and cannotdisturb the train operation. To achieve the work target, the following are the items mustbe considered:

Preparation work to be well arranged.

Good coordination with site staff. Material preparation and equipment to be used.

Sufficient manpower preparation.

Qualified site staff/person in charge preparation who fully qualified understandswith the work to be done.

Construct the foundation correcly in accordance with drawing or the outlinedrawing before the arrival of panel and equipment.

7.2 Transferr ing Panel and Equipment

Arrangement for transportation

Distribution panel and equipment can be shipped complete in standard shippingcontainer.

Weather-proof blanking plates are provided where necessary.

7.3 Materials Delivery and ArrangementIn Panel and Equipment installation, there are two (2) delivery conditions that possible:

Panels and Equipment from the Port / factory directly taken to the substation.

This condition can be done if the current equipment that will be brought alreadyarrived in the port, the condition of civil works allows for placement of goods fora while.

Panels and Equipment will be taken to a substation of the MHI warehouse. Thiscondition is performed if at the time the equipment arrived in the port, civilbuilding conditions or foundation construction have not allowed for layingequipment for a while.


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Figure 7- 2 Hand Pallet

7.4 Preparation to Install

Determining location for installation of Panel and Equipment

The location in which the Panel & Equipment is to be installed must be accuratelydetermined and preparations for which such as the concrete foundation, base, anchor,

etc. (if its wayside location for example panel: LOC) and such as placement on thefloor according to shop drawing that is approved by engineer & PT. KAI (if its insideSignal Cabin) should be completed prior to the arrival of the Panel & Equipment.

7.5 Unloading Handling Panel and Equipment at Site

The Panel and Equipment should be unloaded by suitable lifting device of sufficient.Always use lifting mechanisms of adequate capacity. Use of any under capacity liftingmechanism or accessories could result in severe damage to the Equipment, liftingequipment and possibly personnel involved in handling the Equipment.

7.6 Storage

Accessories / Fittings dispatched separately from main consignment are usuallypacked in case/crate, although certain items are sometimes dispatched withoutpacking. All items as received should be stored in a dry and covered place providedthere are no signs of damage or rough handling.

Indoor type Equipment must be protected from the weather. Outdoor units may bestored outside, in a warm area, if possible, protected from the prevailing weather.

7.7 Recommended Inspection


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Dents / cracks

Damage to protruding Loose bolts / screws / clamps.

Check the packages with the packing list and also investigate damages ofthe components

It is preferable to store the accessories inside a building, however wherethey are outdoors, cover them with a suitable sheets. Dont expose them tothe weather.

The various packages should be checked against the advice notes. Anydiscrepancy from the advice notes should be immediately reported to the InsuranceUnderwriters, and to the Transport Contractors, used for transportation by theSupplier, particularly where damage has occurred in transportation. Claims can thenbe lodged with transport contractor and / or insurance underwriters as required.

After the Equipment has arrived at site, the Equipment should be stored on theEquipment foundation pad until the installation work will be started. The Equipmentmain body and its parts should be stored as follows.

7.8 Installation

7.8.1 Installation Procedure for Panel

Installation Procedure for Panel at ins ide Signal Cabin:

Coordination with PT.KAI before doing installation to avoid obstruction to the existingtrain operation in the area specified herein

Placement at a position in accordance drawings panels and wiring route that have

been approved by Engineer and PT. KAI After the placement is determined, the panel can be placed in a position in accordance

with the marking of each panel

In the marking that has been made, holes for the panel should also available.

After marking and holes have been completed, the panel can be placed in a positionin accordance with the marking of each panel. Then the panel shall be fixed with boltsand shall be installed upright in signal cabin

Clearance spaces for maintenance work on the panel shall be not less than one (1)meter in front of panel and to any passageway and not less than 0.6 meters to rear ofpanel as necessary.

For protecting the panel from lighting surges and any electromagnetic interference,the following shall also be taken into consideration:

a. Grounding facilities inclusive of suitable arrester shall be provideb. Isolation transformer for surge protection type shall be provided against

lightning surge from power supply equipment to electronic at inside the panel


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Installation Procedure Point Machine Equipment:

1. Close Coordination with track works for location of long sleepers and stabilization ofthis sleepers,

2. All point machine shall be robustly installed outside of construction gauge on longwooden sleepers.

3. Fitting such as throw rods and detection rods including fitting brackets, if required,shall be robustly connected between electrical point machine and track structure. Asrequired tongue rails may be strengthened by the approved materials for connectionof these fittings

4. Lead-up cable to electrical point machine shall be protected by conduits approved bythe Engineer

5. Steel point number plates shall be fixed to point machines or to sleepers.

6. Terminal Boxes shall be installed on concrete foundation,

7. Steel guard structure against any accident to point machine shall be robustly installedsame as existing one

8. Installation of electric point machines shall include provision of insulated gauge tieplates and insulated point machines installation plate.

9. Point machine shall operate sequentially as follow:

a. Open detection contacts,

b. Unlock point,

c. Lock point,

d. Close detection contact.

Installation Procedure Track Circuit Equipment:

1. Track transformers, track resistors, repeating transformers and track relays shall beprovided in signal cabin or apparatus cases

2. Impedance bonds housing shall be protected by concrete frame at sides and shall be1.7m or more from track centre, except when installed between other tracks.

3. Impedance bonds shall be connected with suitable bolts to web of rails by strandedaluminium cables with terminals. Cables shall be protected with PVC conduitapproved by the engineer. Impedance bond exclusive use for return current tosubstation, if required, shall be installed as same method as others.

4. Rail bonds shall be connected with bolts to web rail. For main tracks bonds shall beduplicated.

5. Signal bonds shall be welded and duplicated to each rail joint to permit signal current.

6. Jumper wires and cross bonds shall be welded to rails with terminals protected byconduit approved by the Engineer.

7. Resonance condensers or impedances fixed in cases shall be connected to tertiarycoils of impedance bonds installed independently near substation Cases shall be


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10. Rail connector between cases or boxes and rails shall be fixed with bolts to web of

rails with terminals protected with conduit approved by the Engineer11. To permit traction return current where track circuits are not installed, cross bonds

with terminals protected with conduit, or rail bonds shall be welded to rail.

Installation Procedure Automatic Block Signal (ABS) Equipment:

1. Location of signals shown in the Drawings is approximate and exact locationaccording by approved the Engineer.

2. All Signals shall be installed so that they keep the clearance with construction gauge

as shown in the Drawings.

3. Signal posts shall be erected vertical on the base fixed with bolts to concretefoundation. Top surface of concrete foundation shall be at rail level where this ispracticable and otherwise not less than 150mm above the surrounding ground level

4. Concrete foundations shall have a cable entry approximately 800mm belowsurrounding ground level

Installation Procedure Level Crossing Protection System Equipment:

1. Alarm control table at each level crossing shall be submitted to the Engineer for hisapproval, conforming to typical alarm control diagrams as shown in the Drawings.

2. During installation or modification works any train operation in service shall not beinterrupted.

3. Warning alarm signals shall be installed on a concrete foundation and distanceLocation from centre track shall be approximately 3 meters to consider the visibilityfrom pedestrians and road traffic drivers. Precaution signal shall be installed minimum

five meters in front of level crossing along traffic road on a concrete foundation.4. Closing barriers shall be installed on a concrete foundation and distance from center

of track shall be approximately 3 meters to consider right angle to road traffic orparallel to track layout.

5. Track Circuit shall be installed outside of construction gauge, nearby watchmansshed and shall not obstruct visibility of approaching trains to passers-by, vehicledrivers or suitable operation including batteries power supply.

6. Power supply shall be checked to ensure that level crossing protection equipment

shall be suitable operation including batteries power supply.


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8 Safety, Environmental and Hazard Mitigation

8.1 Preparation

MSJO will be responsible in fulfilling and maintaining the following traffic control duties

and the construction safety management:

- Keeping any existing railway facilities and safe for regular traffic.

- Maintaining train movement as per regular operation and maintaining safe train traffic

condition- Safe and convenient use of station facilities and protection of railway passengers.

MSJO will be fully responsible for the control and management of all the site works so

as to ensure train operation safety, including the erection and maintenance of any train

traffic control facilities.

PPE

Personal Protective Equipment (PPE) must be worn by all people or personnel at the

work sites. Nobody can enter the work sites without PPE.

Figure 8-1.Personal Protective Equipment (PPE)


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8.2 Toolbox Talk

The toolbox talk is a very important safety briefing for all the members of the work party.

The toolbox talk always needs to be done before work.

For the DDT project, the coverage or topics of a typical toolbox session are the

following;

1. Permit to work;

2. Attendance list of all members;

3. Personal protective equipment;

4. Safety hazard evaluation at the worksite;

5. Competence and authorized persons;

6. Method of work and tools to be used;

7. Worksite boundaries and protection;

8. Emergency evacuation points and other safety related matters.

Figure 8-2.Tool Box Talk


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8.3 Train Watchers (Safety Supervis ion)

Train watchers are mandatory for working in an operating track system. Work groups

must prepare 2 train watchers who will be posted at both boundary ends of the worksite.

Train watcher will do only the train watching job and will not be utilized in supporting

work group jobs. Train watchers are only to watch train operations and the related jobs

for train running. Train watchers are to render train warnings to the workers who are to

be protected from accidents due to train operations.

Figure 8-3.The Position of Train Watchers


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8.4 Accident Prevention Arrangement

1. Train watchers have to run at least the minimum of 600 meters from the work areaaccident location.

Fig.6.2.3 Accident happen No.1

2. Signal an approaching train to stop by using materials that emits smoke. If notavailable, the Train Watcher must do as below;

Wave Red Flag Wave Jacket W H d B

600m

Figure 8-5Figure 8-5.Accident Incident No. 1


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8.5 Initial Response and Reporting

Initial response and reporting for minor and major accidents will be in accordance withthe shown Flow Chart in Figure 8-7 and Figure 8-8.

Critical injuries or fatalities will be reported in accordance with the local laws andregulations of Indonesia.

Report Accident data to

Aministration Manager andHealth Safety Enviromental

Manager


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Page A - 1 of 1

B1/CON/PWD/0001 Rev.0 MITSUBISHI-SUMITOMO JOINT OPERATION

N

MAIN CONTRACTOR

MITSUBISHI SUMITOMO

E&M CONSTRUCTION MANAGER

M.ADACHI

SIGNAL & TELECOM ENGINEER

S. NAKAMURA

SBS & PWD ENGINEER

H. SEKI

TELECOM SUPERVISOR

FAESAYUSLI

TELECOM SUPERVISOR

FUADIL KIROM

SIGNAL SUPERVISOR

EKO SULISTTIONO

SIGNAL SUPERVISOR

NURHALIM

SBS & PWD SUPERVISOR

SOEPANGATSBS & PWD SUPERVISOR

F. RACHMAN

SUB CONTRACTOR

PT. Len Industri

SIG & TEL PROJECT MANAGER

BENI.R

SBS & PWD PROJECT MANAGER

M. SINAGA

SIG & TEL SITE MANAGER

DEDE.A.B

SBS & PWD SITE MANAGER

ADANG .K

HEALTH,SAFETY,ENVIROMENTALMANAGER

Mrs. CINDERAWATI

SIG & TEL ENGINEER

ENJANG

SBS & PWD ENGINEER

IRFAN

SIG & TEL STAFF SBS & PWD STAFF

HEALTH,SAFETY,ENVIROMENTALMANAGER

RIO SAPTO HIDAYAT