Method Statement For HRSG Works PDF

METHOD STATEMENT FOR HRSG WORKS
Page: 1/32 Doc. No: NIS/626/M Date: 20-12-2015

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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 HSE Manager QA/QC Manager Site Manager
Superintendent
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
Dok. No: PR-004-T05, Rev. No: 1


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ii) entitle him to a variation under the Contract or an adjustment to the Contract Price.
SUBCONTRACTOR
Rev. Prepared HSE QA/QC Site Project
Date Description*
No. by Manager Manager Manager Manager
DOCUMENT HISTORY:
Rev. Remarks
Date
No. (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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1.0 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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5.0 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.

applicable.

applicable.
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.


S/001_Rev
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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.


S/001_Rev
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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.


S/001_Rev
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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.


S/001_Rev
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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.
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:


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1) HSE Manager
Mr.Edwin Suganob
Qualification:
Diploma in Safety Engineering with 14+ years of Experience
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.


S/001_Rev
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14.0 RISK ASSESSMENTS

Hazard Identification & Risk Assessment Procedure attached.
15.0 REFERENCES
PP1314-00-Y-UP-WP-003 Project Quality Plan
GEMSS-G-05 Quality Control & Quality Assurance Plan.
16.0 TECHNICAL APPENDICES

NIS/GAMA/ITP/626-01 Quality Plan & Inspection & Test Program.
QCP-34 Non Conformance Procedure.
17.0 ATTACHMENTS
Attachment-1 Planned Manpower Distribution Histogram.
Attachment-2 Equipment Histogram (Subcontractor & GAMA)
Attachment-3 Detailed Schedule
Attachment-4 Quality Assurance Plan & Inspection Test Plan
Attachment-5 CV of the QA/QC Manager
Attachment-6 Non-Conformities Procedure
Attachment-7 List of the Control and Test Equipment & Tools attached. Calibration
Certificate shall be submitted progressively after mobilizing to site.
Attachment-8 HSE Plan
Attachment-9 Hazard Identification & Risk Assessment Procedure.

Attachment No.: 01
Planned Manpower
Distribution Histogram

ANNEXURE‐I
NASS INDUSTRIAL SERVICES
SEC POWER PLANT PP‐13 PROJECT
MANPOWER HISTOGRAM
SL.NO CATEGORY (INDIRECT) Month 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 Resident Project Manager COMMON FOR HRSG & GTG

2 Unit Incharge 1 1 1 1 1 1 1 1 1 1 1 1 1 1
3 QA/QC Manager COMMON FOR HRSG & GTG
4 HSE Manager COMMON FOR HRSG & GTG
5 Planning Dept 1 2 2 2 2 2 2 2 2 2 2 2 2 1
6 Administative Officer COMMON FOR HRSG & GTG
7 Accountant COMMON FOR HRSG & GTG
8 Stores Incharge COMMON FOR HRSG & GTG
9 QA/QC Engineer/Supervisor 1 1 1 1 1 1 1 1 1 1 1 1 1
10 QC Inspector & NDT Technician 1 1 1 1 1 1 1 1 1 1 1 1
11 Execution Engineer 1 1 1 1 1 1 1 1 1 1 1 1 1
12 Execution Supervisor 1 2 2 2 2 2 2 2 2 2 2 2 2 1
13 Safety Officer/Supervisor 1
14 Survey Team 1 1 1 1 1 1 1 1 1 1 1 1 1 1
15 Lifting Supervisor/Rigger-1 1 1 1 1 1 1 1 1 1 1 1 1 1
16 Foremen 1 2 2 3 3 3 3 3 3 3 3 3 2 1
17 Store Keeper COMMON FOR HRSG & GTG
18 Time Keeper COMMON FOR HRSG & GTG
19 Data Operator COMMON FOR HRSG & GTG
TOTAL 0 6 11 12 13 13 13 13 13 13 13 13 13 12 9
SL.NO CATEGORY (DIRECT) Month 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 STRUCTURE FITTER 2 6 10 14 14 14 14 14 14 14 14 14 10 5
2 PRESSURE PARTS / PIPING FITTER 1 2 3 5 5 5 5 5 5 4 3 2
3 MILL WT FITTER 1 2 3 3 3 3 3 3 3 3 3 3 2
5 TIG WELDER 1 4 4 5 5 5 5 5 4 4 2
6 STUCTURE & OTHER WELDER 2 5 12 15 15 15 15 15 15 15 15 15 15 10
7 GRINDER/GAS CUTTER 1 5 10 15 15 15 15 15 15 15 15 15 15 8
8 ERECTOR/RIGGER 2 10 15 20 25 25 25 25 25 25 25 25 20 12
11 PAINTER 1 2 2 2 4 4 4 4 4 4 4 4 2
12 HIAB/TRAILOR/FORLIFT OPERATOR COMMON FOR BOTH HRSG & GTG
13 ELECTRICIANS/MAINTENANCE COMMON FOR BOTH HRSG & GTG
14 WATCHMAN/OFFICE BOY COMMON FOR BOTH HRSG & GTG
15 HELPERS/OTHERS 10 40 50 95 125 125 125 125 125 125 125 125 80 60
TOTAL 0 17 68 102 167 206 210 211 211 211 211 211 209 154 103
DURMA PROJECT 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. 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
1 600 MT. CRANE 1 1 1 1 1 1 1
6
2 300 MT. CRANE 1 1 1 1 1 1 1 1 1
8
3 150MT. CRANE 2 1 2 2 2 2 2 1 1 1 1
15
4 90 MT. CRANE 2 1 1 2 2 2 2 2 2 2 2 1 1 1
21
4 50MT. CRANE 2 1 2 2 2 2 2 2 2 2 2 2 1 1 1
24
5 30 MT. CRANE 3 2 2 3 3 3 3 3 3 3 2 1 1 1
30
6 AIR COMPRESSOR 2 1 2 2 2 2 2 2 2 2 2 1 1
21
7 20 MT. TRAILOR 2 1 2 2 2 2 2 2 2 2 2 2 1 1 1
24
8 40 MT. TRAILOR 2 1 2 2 2 2 2 2 2 2 2 1 1
21
9 FORKLIFT (5/7/10) 3 2 3 3 3 3 3 3 3 3 3 2 2 1
34
10 5/7‐ HIAB 2 1 2 2 2 2 2 2 2 2 2 2 2 1 1
25
11 DIESEL GENERATOR MOUNTING LIGHT 8 2 6 8 8 8 8 8 8 8 8 8 5 5 5
95
12 SPREADER BEAM 3 1 2 3 3 3 3 3 3 3 3 3 2 2 1
35
13 WELDING MACHINE 37 6 15 21 34 37 37 37 37 37 37 37 37 26 16
414
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 <<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<< AS PER REQUIREMENT >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
** NOTE: CLIENT HAS TO PROVIDE DETIALS REGARDING AVAILABILITY OF MATERIALS/EQUIPMENT AT SITE.

Attachment No.: 03
Detailed Schedule

GAMA-GTG HRSG Activities/Activity Usage Spreadsheet 19-Dec-15 14:56
# Activity ID Activity Name Start Finish Original 2016 2017
Duration ar
Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb
1 GAMA GAMA-GTG & HRSG
HRS 10-Nov-15 18-Jan-17 374d 18-Jan-17, GA
2 GAMA.2 HRSG INSTALLATION

INSTALLA SCHEDULE 10-Nov-15 18-Jan-17 374d 18-Jan-17, GA
3 GAMA.2.3 Milestone 10-Nov-15 26-Nov-15 15d 26-Nov-15, GAMA.2.3 Milestone
4 const9550 Award of Contract 10-Nov-15 10-Nov-15 0d 10-Nov-15,
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 * 26-Nov-15,
8 GAMA.2.1 CONSTRUCTION 01-Dec-15 18-Jan-17 356d 18-Jan-17, GA
9 GAMA.2.1.1 NMC MOBILIZATION
MOBILIZATIO 01-Dec-15 29-Dec-15 25d 29-Dec-15, GAMA.2.1.1 NMC MOBILIZATION
10 GAMA.2.1.1.1 Mechanical W
Works 01-Dec-15 29-Dec-15 25d 29-Dec-15, GAMA.2.1.1.1 Mechanical Works
11 const6530 HRSG Mobilzation 01-Dec-15* 29-Dec-15 25dc-15* 29-Dec-15,
12 GAMA.2.1.2 Block 20 04-Jan-16 18-Jan-17 326d 18-Jan-17, GA
13 GAMA.2.1.2.1 Unit 23 04-Jan-16 13-Nov-16 269d 13-Nov-16, GAMA.2.1.2.1 Unit 23
14 GAMA.2.1.2.1.1 HRSG-23 04-Jan-16 13-Nov-16 269d 13-Nov-16, GAMA.2.1.2.1.1 HRSG
15 GAMA.2.1.2.1.1.1 By Pass
P Stack 04-Jan-16 09-Jul-16 160d 09-Jul-16, GAMA.2.1.2.1.1.1 By Pass Stack
16 const6540 by pass stack foundation preparation 04-Jan-16 18-Jan-16 12d 04-Jan-16 18-Jan-16,
17 const6550 erection of bypass stack steel structure 19-Jan-16 17-Feb-16 25d 19-Jan-16 17-Feb-16,
18 const6560 installation of diverter box 18-Feb-16* 13-Mar-16 20d 18-Feb-16* 13-Mar-16,
19 const6570 installation of upper steel structure 14-Mar-16* 31-Mar-16 15d 14-Mar-16* 31-Mar-16,
20 const6580 pre-assembly of stack section1 (round reducer ,silencer ,square to round transition 02-Apr-16* 10-Apr-16 7d 02-Apr-16* 10-Apr-16,
21 const6590 installation of stack section 1 11-Apr-16* 12-Apr-16 1d 11-Apr-16* 12-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* 19-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* 28-Apr-16,
25 const6630 installation of stack section 3 30-Apr-16* 01-May-16 1d 30-Apr-16* 01-May-16,
26 const6640 installation of CEMS Unit 01-May-16* 15-May-16 12d 01-May-16* 15-May-16,
27 const6641 installation of OUT LET duct 15-May-16 21-May-16 5d 15-May-16 21-May-16,
28 const6642 installation of bellow 21-May-16 23-May-16 2d 21-May-16 23-May-16,
29 const6650 By Pass Stack Precommissioning 23-May-16* 09-Jul-16 40d 23-May-16* 09-Jul-16,
30 GAMA.2.1.2.1.1.2 HRS
HRSG Steel Structure & Casing Erection 16-Jan-16 30-Apr-16 90d 30-Apr-16, GAMA.2.1.2.1.1.2 HRSG Steel Structure & Casing Erection
31 const6660 foundation preparation 16-Jan-16 24-Jan-16 7d 16-Jan-16 24-Jan-16,
32 const6670 Crane available at site 24-Jan-16 0d Crane available at site
33 const6680 Main stair tower &platform pre-assembly 25-Jan-16 10-Feb-16 14d 25-Jan-16 10-Feb-16,
34 const6690 Casing Panel Installation 26-Jan-16 13-Feb-16 15d 26-Jan-16 13-Feb-16,
35 const6700 bottom plate installation 13-Feb-16 18-Feb-16 5d 13-Feb-16 18-Feb-16,
36 const6710 vertical side panels 20-Feb-16 24-Feb-16 4d 20-Feb-16 24-Feb-16,
37 const6720 Main stair tower and platform erection 01-Feb-16* 16-Feb-16 14d 01-Feb-16* 16-Feb-16,
38 const6730 Lower front panel casing 17-Feb-16* 20-Feb-16 3d 17-Feb-16* 20-Feb-16,
39 const6740 Installation of field casing plates 21-Feb-16* 23-Feb-16 3d 21-Feb-16* 23-Feb-16,
40 const6750 Erection of side platform 13-Feb-16 07-Mar-16 20d 13-Feb-16 07-Mar-16,
41 const6751 installation of liner system 24-Feb-16 27-Feb-16 3d 24-Feb-16 27-Feb-16,
42 const6752 installation of insulation & lining at junction of casing & duct 28-Feb-16 29-Feb-16 2d 28-Feb-16 29-Feb-16,
43 const6753 installation of Backstays and header spacers 01-Mar-16 02-Mar-16 2d 01-Mar-16 02-Mar-16,
44 const6754 installation of connecting plates (external stiffners to casing panels ) 03-Mar-16 07-Mar-16 4d 03-Mar-16 07-Mar-16,
45 const6762 execution of final allignment ,levelling & verticality of casing structure 08-Mar-16 12-Mar-16 4d 08-Mar-16 12-Mar-16,
46 const6771 Bumper Installation 22-Feb-16* 15-Mar-16 20d 22-Feb-16* 15-Mar-16,
47 const6772 final bolt tightening of main columns 17-Mar-16* 19-Mar-16 2d 17-Mar-16* 19-Mar-16,
48 const6790 Installation of CEMS skid 22-Mar-16* 02-Apr-16 10d 22-Mar-16* 02-Apr-16,
49 const6800 HRSG block 20 Elevator structure installation 14-Feb-16* 30-Apr-16 65d 14-Feb-16* 30-Apr-16,
50 GAMA.2.1.2.1.1.3 Module
Mod & Drum 20-Mar-16 25-Jun-16 84d 25-Jun-16, GAMA.2.1.2.1.1.3 Module & Drum
51 const6820 Drum supporting Structure preparation / Installation 04-May-16* 09-May-16 5d 04-May-16* 09-May-16,
52 GAMA.2.1.2.1.1.3.4 Module Erection 20-Mar-16 10-May-16 45d 10-May-16, GAMA.2.1.2.1.1.3.4 Module Erection
53 const10000 installation of module 1A&1B 20-Mar-16 23-Mar-16 4d 20-Mar-16 23-Mar-16,
54 const10010 installation of module 2A &2 B 24-Mar-16 29-Mar-16 5d 24-Mar-16 29-Mar-16,
55 const10020 installation of module of 3A & 3B 30-Mar-16 05-Apr-16 6d 30-Mar-16 05-Apr-16,
56 const10030 installation of module 4A & 4B 06-Apr-16 11-Apr-16 5d 06-Apr-16 11-Apr-16,
57 const10040 restoration of insulation and liner between modules 26-Apr-16 28-Apr-16 3d 26-Apr-16 28-Apr-16,
Remaining Work Milestone Page 1 of 8 TASK filter: All Activities
Critical Remaining Work summary © Oracle Corporation

Duration ar
58 const10050 installation of nozzle connection & piping 30-Apr-16 10-May-16 10d 30-Apr-16 10-May-16,
59 GAMA.2.1.2.1.1.3.
GAMA.2.1.2.1.1.3.4.1 Installation of trusses 12-Apr-16 25-Apr-16 12d 25-Apr-16, GAMA.2.1.2.1.1.3.4.1 Installation of trusses
60 const10060 installation of upper trusses 12-Apr-16 16-Apr-16 4d 12-Apr-16 16-Apr-16,
61 const10070 installation of intermediate trusses 17-Apr-16 20-Apr-16 4d 17-Apr-16 20-Apr-16,
62 const10080 installation of lower trusses 21-Apr-16 25-Apr-16 4d 21-Apr-16 25-Apr-16,
63 GAMA.2.1.2.1.1.3.1 HP drum 10-May-16 21-Jun-16 37d 21-Jun-16, GAMA.2.1.2.1.1.3.1 HP drum
64 const9280 HP drum erection 10-May-16 10-May-16 1d 10-May-16 10-May-16,
65 const9290 HP down comer piping 18-May-16 21-Jun-16 30d 18-May-16 21-Jun-16,
66 GAMA.2.1.2.1.1.3.2 IP drum 11-May-16 15-Jun-16 31d 15-Jun-16, GAMA.2.1.2.1.1.3.2 IP drum
67 const9300 IP drum erection 11-May-16 11-May-16 1d 11-May-16 11-May-16,
68 const9310 IP down comer piping 24-May-16 15-Jun-16 20d 24-May-16 15-Jun-16,
69 GAMA.2.1.2.1.1.3.3 LP drum 14-May-16 25-Jun-16 37d 25-Jun-16, GAMA.2.1.2.1.1.3.3 LP drum
70 const9320 LP drum erection 14-May-16 15-May-16 2d 14-May-16 15-May-16,
71 const9330 LP down comer piping 28-May-16 25-Jun-16 25d 28-May-16 25-Jun-16,
72 GAMA.2.1.2.1.1.4 Pipin
Piping & Instruments 16-May-16 06-Sep-16 98d 06-Sep-16, GAMA.2.1.2.1.1.4 Piping & Instruments
73 const6850 install blow down tank 18-May-16* 23-May-16 5d 18-May-16* 23-May-16,
74 const6860 Valves & Instruments Installation 25-May-16* 31-Aug-16 85d 25-May-16* 31-Aug-16,
75 const6870 Piping test preparation 21-Aug-16* 06-Sep-16 15d 21-Aug-16* 06-Sep-16,
76 GAMA.2.1.2.1.1.4.1 Large Bore Piping 16-May-16 29-Aug-16 91d 29-Aug-16, GAMA.2.1.2.1.1.4.1 Large Bore Piping
77 const6880 LP Feedwater 16-May-16* 30-Jun-16 40d 16-May-16* 30-Jun-16,
78 const6890 HP Feedwater 30-May-16* 14-Jul-16 40d 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* 01-Aug-16,
81 const6920 LP Eva- Sh-Eco 28-May-16* 16-Aug-16 70d 28-May-16* 16-Aug-16,
82 const6930 IP-Eva-Sh-Eco 09-Jun-16* 29-Aug-16 70d 09-Jun-16* 29-Aug-16,
83 const6940 HP-Eva-Sh-Eco 31-May-16* 20-Aug-16 70d 31-May-16* 20-Aug-16,
84 GAMA.2.1.2.1.1.4.2 Small Bore Piping 14-Jun-16 01-Sep-16 69d 01-Sep-16, GAMA.2.1.2.1.1.4.2 Small Bore Piping
85 const6950 LP Feedwater 14-Jun-16* 04-Aug-16 45d 14-Jun-16* 04-Aug-16,
86 const6960 HP Feedwater 28-Jun-16* 07-Aug-16 35d 28-Jun-16* 07-Aug-16,
87 const6970 IP Feedwater 28-Jun-16* 30-Aug-16 55d 28-Jun-16* 30-Aug-16,
88 const6980 RH 28-Jun-16* 23-Aug-16 49d 28-Jun-16* 23-Aug-16,
89 const6990 LP Eva- Sh-Eco 26-Jun-16* 16-Aug-16 45d 26-Jun-16* 16-Aug-16,
90 const7000 IP-Eva-Sh-Eco 12-Jul-16* 01-Sep-16 45d 12-Jul-16* 01-Sep-16,
91 const7010 HP-Eva-Sh-Eco 03-Jul-16* 23-Aug-16 45d 03-Jul-16* 23-Aug-16,
92 GAMA.2.1.2.1.1.5 Auxillary
Auxi Steel Structure 16-May-16 30-Jun-16 40d 30-Jun-16, GAMA.2.1.2.1.1.5 Auxillary Steel Structure
93 const7020 silencer support structure installation 16-May-16* 07-Jun-16 20d 16-May-16* 07-Jun-16,
94 const7030 Silencer Installation 09-Jun-16* 15-Jun-16 6d 09-Jun-16* 15-Jun-16,
95 const7040 Spring Hangers 20-Jun-16* 30-Jun-16 10d 20-Jun-16* 30-Jun-16,
96 GAMA.2.1.2.1.1.6 Inlet Duct Steel Structure 08-Mar-16 04-May-16 50d 04-May-16, GAMA.2.1.2.1.1.6 Inlet Duct Steel Structure
97 const7050 Inlet duct foundation preparation 08-Mar-16* 09-Mar-16 2d 08-Mar-16* 09-Mar-16,
98 const7060 inlet duct support structure erection 12-Mar-16* 22-Mar-16 10d 12-Mar-16* 22-Mar-16,
99 const7070 inlet duct floor casing alignment & welding 26-Mar-16* 05-Apr-16 10d 26-Mar-16* 05-Apr-16,
100 const7080 inlet duct left side casing alignment & welding 31-Mar-16 11-Apr-16 10d 31-Mar-16 11-Apr-16,
101 const7090 inlet duct right side casing alignment & welding 07-Apr-16 18-Apr-16 10d 07-Apr-16 18-Apr-16,
102 const7100 inlet duct roof side casing alignment & welding 13-Apr-16 24-Apr-16 10d 13-Apr-16 24-Apr-16,
103 const7110 Inlet duct front casing & expansion joint alignment & welding 20-Apr-16 01-May-16 10d 20-Apr-16 01-May-16,
104 const7170 installation & insulation of connecting pieces b/n exhaust & duct 02-May-16 04-May-16 3d 02-May-16 04-May-16,
105 GAMA.2.1.2.1.1.7 Stack 14-Feb-16 16-Aug-16 159d 16-Aug-16, GAMA.2.1.2.1.1.7 Stack
106 GAMA.2.1.2.1.1.7.1 STACK section 1 14-Feb-16 22-Mar-16 33d 22-Mar-16, GAMA.2.1.2.1.1.7.1 STACK section 1
107 const9020 pre assembly shell no1 14-Feb-16* 17-Feb-16 4d 14-Feb-16* 17-Feb-16,
108 const9021 installation of ladders ,platforms and inspection doors 18-Feb-16 21-Feb-16 3d 18-Feb-16 21-Feb-16,
109 const9030 inspection and welding vertical joint 22-Feb-16* 27-Feb-16 5d 22-Feb-16* 27-Feb-16,
110 const9040 erection and allingment no 1 28-Feb-16* 02-Mar-16 4d 28-Feb-16* 02-Mar-16,
111 const9050 shell no 1 joint welding (circum) 03-Mar-16* 08-Mar-16 5d 03-Mar-16* 08-Mar-16,
112 const9060 Stack section 1 installation 09-Mar-16* 20-Mar-16 10d 09-Mar-16* 20-Mar-16,
113 const9120 anchor bolt tightening 21-Mar-16 22-Mar-16 2d 21-Mar-16 22-Mar-16,
114 GAMA.2.1.2.1.1.7.2 STACK section 2 09-Mar-16 13-Apr-16 31d 13-Apr-16, GAMA.2.1.2.1.1.7.2 STACK section 2
115 const9070 pre assembly shell no2 09-Mar-16* 13-Mar-16 4d 09-Mar-16* 13-Mar-16,

Duration ar
116 const9072 installation of ladders ,platforms and inspection doors 14-Mar-16 16-Mar-16 3d 14-Mar-16 16-Mar-16,
117 const9080 inspection and welding vertical joint 17-Mar-16* 22-Mar-16 5d 17-Mar-16* 22-Mar-16,
118 const9090 erection and allingment no 2 23-Mar-16* 27-Mar-16 4d 23-Mar-16* 27-Mar-16,
119 const9100 shell no 2 joint welding (circum) 28-Mar-16* 02-Apr-16 5d 28-Mar-16* 02-Apr-16,
120 const9110 Stack section 2 Installation 03-Apr-16* 13-Apr-16 10d 03-Apr-16* 13-Apr-16,
121 GAMA.2.1.2.1.1.7.3 STACK section 3 AND DAMPER 03-Apr-16 15-May-16 37d 15-May-16, GAMA.2.1.2.1.1.7.3 STACK section 3 AND DAMPER
122 const9130 pre assembly shell no3 03-Apr-16* 06-Apr-16 4d 03-Apr-16* 06-Apr-16,
123 const9131 installation of ladders ,platforms and inspection doors 07-Apr-16 10-Apr-16 3d 07-Apr-16 10-Apr-16,
124 const9140 inspection and welding vertical joint 11-Apr-16* 16-Apr-16 5d 11-Apr-16* 16-Apr-16,
125 const9145 pre assembly of damper 17-Apr-16* 20-Apr-16 4d 17-Apr-16* 20-Apr-16,
126 const9147 inspection and welding joint circum 20-Apr-16* 24-Apr-16 4d 20-Apr-16* 24-Apr-16,
127 const9150 erection and allingment no 3 with damper 24-Apr-16* 27-Apr-16 4d 24-Apr-16* 27-Apr-16,
128 const9160 shell no2 to 3 joint welding (circum) 28-Apr-16* 03-May-16 5d 28-Apr-16* 03-May-16,
129 const9170 Stack section 3 Installation 04-May-16* 15-May-16 10d 04-May-16* 15-May-16,
130 GAMA.2.1.2.1.1.7.4 STACK section 4 04-May-16 23-Jul-16 69d 23-Jul-16, GAMA.2.1.2.1.1.7.4 STACK section 4
131 const9180 pre assembly shell no4 04-May-16* 08-May-16 4d 04-May-16* 08-May-16,
132 const9181 installation of ladders ,platforms and inspection doors 09-May-16 11-May-16 3d 09-May-16 11-May-16,
133 const9190 inspection and welding vertical joint 12-May-16* 17-May-16 5d 12-May-16* 17-May-16,
134 const9200 erection and allingment no 4 02-Jul-16* 05-Jul-16 4d 02-Jul-16* 05-Jul-16,
135 const9210 shell no 4 joint welding (circum) 06-Jul-16* 11-Jul-16 5d 06-Jul-16* 11-Jul-16,
136 const9220 Stack section 4 installation 12-Jul-16* 23-Jul-16 10d 12-Jul-16* 23-Jul-16,
137 GAMA.2.1.2.1.1.7.5 STACK section 5 11-May-16 16-Aug-16 84d 16-Aug-16, GAMA.2.1.2.1.1.7.5 STACK section 5
141 const9250 erection and allingment no 5 24-Jul-16* 27-Jul-16 4d 24-Jul-16* 27-Jul-16,
142 const9260 shell no 5 joint welding (circum) 28-Jul-16* 02-Aug-16 5d 28-Jul-16* 02-Aug-16,
143 const9261 installation of silencer 03-Aug-16 04-Aug-16 2d 03-Aug-16 04-Aug-16,
144 const9270 Stack section 5 installation 06-Aug-16* 16-Aug-16 10d 06-Aug-16* 16-Aug-16,
145 GAMA.2.1.2.1.1.8 Precomissioning
Prec & Tests 25-Feb-16 13-Nov-16 225d 13-Nov-16, GAMA.2.1.2.1.1.8 Prec
146 const7210 Hydrotest 11-Sep-16* 03-Oct-16 20d 11-Sep-16* 03-Oct-16,
147 const7220 ReInstatement 04-Oct-16* 20-Oct-16 15d 04-Oct-16* 20-Oct-16,
148 const7230 Chemical cleaning & Restore (by others ) 05-Oct-16* 02-Nov-16 25d 05-Oct-16* 02-Nov-16,
149 const7240 Insulation 06-Oct-16* 12-Nov-16 32d 06-Oct-16* 12-Nov-16,
150 const7510 final touch up painting 25-Feb-16 13-Nov-16 225d 25-Feb-16 13-Nov-16,
151 GAMA.2.1.2.9 Unit 22 21-Jan-16 14-Dec-16 281d 14-Dec-16, GAMA.2.1.2.9
152 GAMA.2.1.2.9.1 HRSG 22 21-Jan-16 14-Dec-16 281d 14-Dec-16, GAMA.2.1.2.9
153 GAMA.2.1.2.9.1.1 By Pass
P Stack 21-Jan-16 16-Jul-16 151d 16-Jul-16, GAMA.2.1.2.9.1.1 By Pass Stack
154 const7250 by pass stack foundation preparation 21-Jan-16* 04-Feb-16 12d 21-Jan-16* 04-Feb-16,
155 const7260 erection of bypass stack steel structure 06-Feb-16* 06-Mar-16 25d 06-Feb-16* 06-Mar-16,
156 const7270 installation of diverter box 06-Mar-16* 29-Mar-16 20d 06-Mar-16* 29-Mar-16,
157 const7280 installation of upper steel structure 29-Mar-16* 16-Apr-16 15d 29-Mar-16* 16-Apr-16,
158 const7290 pre-assembly of stack section1 (round reducer ,silencer ,square to round transition 16-Apr-16* 24-Apr-16 7d 16-Apr-16* 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* 04-May-16,
161 const7320 installation of stack section 2 05-May-16* 07-May-16 1d 05-May-16* 07-May-16,
162 const7330 pre-assembly of slack section 3(round reducer,silencer,square to round transition e 07-May-16* 15-May-16 7d 07-May-16* 15-May-16,
164 const7350 installation of CEMS Unit 16-May-16* 30-May-16 12d 16-May-16* 30-May-16,
165 const7351 installation of out let duct 30-May-16 05-Jun-16 5d 30-May-16 05-Jun-16,
166 const7352 installation of bellow 05-Jun-16 07-Jun-16 2d 05-Jun-16 07-Jun-16,
167 const7360 By Pass Stack Precommissioning 30-May-16* 16-Jul-16 40d 30-May-16* 16-Jul-16,
168 GAMA.2.1.2.9.1.2 HRS
HRSG Steel Structure & Casing Erection 14-Feb-16 16-Jun-16 106d 16-Jun-16, GAMA.2.1.2.9.1.2 HRSG Steel Structure & Casing Erection
169 const7370 foundation preparation 14-Feb-16* 22-Feb-16 7d 14-Feb-16* 22-Feb-16,
170 const7380 Crane available at site 23-Feb-16* 0d Crane available at site
171 const7390 Main stair tower &platform pre-assembly 24-Feb-16* 10-Mar-16 14d 24-Feb-16* 10-Mar-16,
172 const7400 Casing Panel Installation 27-Feb-16* 14-Mar-16 15d 27-Feb-16* 14-Mar-16,

Duration ar
173 const7410 bottom plate installation 15-Mar-16* 20-Mar-16 5d 15-Mar-16* 20-Mar-16,
174 const7420 vertical side panels 22-Mar-16* 26-Mar-16 4d 22-Mar-16* 26-Mar-16,
175 const7430 Main stair tower and platform erection 07-Mar-16* 22-Mar-16 14d 07-Mar-16* 22-Mar-16,
176 const7440 Lower front panel casing 23-Mar-16* 26-Mar-16 3d 23-Mar-16* 26-Mar-16,
177 const7450 Installation of field casing plates 27-Mar-16* 29-Mar-16 3d 27-Mar-16* 29-Mar-16,
178 const7460 Erection of side platform 14-Mar-16* 05-Apr-16 20d 14-Mar-16* 05-Apr-16,
179 const7461 installation of liner system 06-Apr-16 09-Apr-16 3d 06-Apr-16 09-Apr-16,
180 const7462 installation of insulation & lining at junction of casing & duct 10-Apr-16 11-Apr-16 2d 10-Apr-16 11-Apr-16,
181 const7463 installation of Backstays and header spacers 12-Apr-16 13-Apr-16 2d 12-Apr-16 13-Apr-16,
182 const7464 installation of connecting plates (external stiffners to casing panels ) 14-Apr-16 18-Apr-16 4d 14-Apr-16 18-Apr-16,
183 const7465 execution of final allignment ,levelling & verticality of casing structure 19-Apr-16 23-Apr-16 4d 19-Apr-16 23-Apr-16,
184 const7480 final bolt tightening of main columns 24-Apr-16* 28-Apr-16 5d 24-Apr-16* 28-Apr-16,
185 const7490 Bumper Installation 29-Mar-16* 20-Apr-16 20d 29-Mar-16* 20-Apr-16,
186 const7500 Installation of CEMS skid 06-Jun-16* 16-Jun-16 10d 06-Jun-16* 16-Jun-16,
187 GAMA.2.1.2.9.1.3 Module
Mod & DRum 30-Apr-16 31-Jul-16 80d 31-Jul-16, GAMA.2.1.2.9.1.3 Module & DRum
188 const7530 Drum supporting Structure preparation / Installation 09-Jun-16* 14-Jun-16 5d 09-Jun-16* 14-Jun-16,
189 GAMA.2.1.2.9.1.3.4 module erection 30-Apr-16 20-Jun-16 45d 20-Jun-16, GAMA.2.1.2.9.1.3.4 module erection
190 const10090 installation of module 1A&1B 30-Apr-16 03-May-16 4d 30-Apr-16 03-May-16,
191 const10100 installation of module 2A &2 B 04-May-16 09-May-16 5d 04-May-16 09-May-16,
192 const10110 installation of module of 3A & 3B 10-May-16 16-May-16 6d 10-May-16 16-May-16,
193 const10120 installation of module 4A & 4B 17-May-16 22-May-16 5d 17-May-16 22-May-16,
194 const10130 restoration of insulation and liner between modules 06-Jun-16 08-Jun-16 3d 06-Jun-16 08-Jun-16,
195 const10140 installation of nozzle connection & piping 09-Jun-16 20-Jun-16 10d 09-Jun-16 20-Jun-16,
196 GAMA.2.1.2.9.1.3.
GAMA.2.1.2.9.1.3.4.1 installation of trusses 23-May-16 05-Jun-16 12d 05-Jun-16, GAMA.2.1.2.9.1.3.4.1 installation of trusses
197 const10150 installation of upper trusses 23-May-16 26-May-16 4d 23-May-16 26-May-16,
198 const10160 installation of intermediate trusses 28-May-16 31-May-16 4d 28-May-16 31-May-16,
199 const10170 installation of lower trusses 01-Jun-16 05-Jun-16 4d 01-Jun-16 05-Jun-16,
200 GAMA.2.1.2.9.1.3.1 HP drum 15-Jun-16 27-Jul-16 37d 27-Jul-16, GAMA.2.1.2.9.1.3.1 HP drum
201 const9340 HP drum erection 15-Jun-16 15-Jun-16 1d 15-Jun-16 15-Jun-16,
202 const9350 HP down comer piping 23-Jun-16 27-Jul-16 30d 23-Jun-16 27-Jul-16,
203 GAMA.2.1.2.9.1.3.2 IP drum 16-Jun-16 21-Jul-16 31d 21-Jul-16, GAMA.2.1.2.9.1.3.2 IP drum
204 const9360 IP drum erection 16-Jun-16 16-Jun-16 1d 16-Jun-16 16-Jun-16,
205 const9370 IP down comer piping 29-Jun-16 21-Jul-16 20d 29-Jun-16 21-Jul-16,
206 GAMA.2.1.2.9.1.3.3 LP drum 19-Jun-16 31-Jul-16 37d 31-Jul-16, GAMA.2.1.2.9.1.3.3 LP drum
207 const9380 LP drum erection 19-Jun-16 20-Jun-16 2d 19-Jun-16 20-Jun-16,
208 const9390 LP down comer piping 03-Jul-16 31-Jul-16 25d 03-Jul-16 31-Jul-16,
209 GAMA.2.1.2.9.1.4 Pipin
Piping & Instruments 21-Jun-16 04-Oct-16 91d 04-Oct-16, GAMA.2.1.2.9.1.4 Piping & Instrume
210 const7560 install blow down tank 22-Jun-16* 27-Jun-16 5d 22-Jun-16* 27-Jun-16,
211 const7570 Valves & Instruments Installation 28-Jun-16* 28-Sep-16 80d 28-Jun-16* 28-Sep-16,
212 const7580 Piping test preparation 18-Sep-16* 04-Oct-16 15d 18-Sep-16* 04-Oct-16,
213 GAMA.2.1.2.9.1.4.1 Large Bore Piping 21-Jun-16 21-Sep-16 80d 21-Sep-16, GAMA.2.1.2.9.1.4.1 Large Bore Piping
214 const7590 LP Feedwater 21-Jun-16* 06-Aug-16 40d 21-Jun-16* 06-Aug-16,
215 const7600 HP Feedwater 03-Jul-16* 17-Aug-16 40d 03-Jul-16* 17-Aug-16,
216 const7610 IP Feedwater 28-Jun-16* 13-Aug-16 40d 28-Jun-16* 13-Aug-16,
217 const7620 RH 05-Jul-16* 06-Sep-16 55d 05-Jul-16* 06-Sep-16,
218 const7630 LP Eva- Sh-Eco 30-Jun-16* 13-Sep-16 65d 30-Jun-16* 13-Sep-16,
219 const7640 IP-Eva-Sh-Eco 04-Jul-16* 17-Sep-16 65d 04-Jul-16* 17-Sep-16,
220 const7650 HP-Eva-Sh-Eco 05-Jul-16* 21-Sep-16 68d 05-Jul-16* 21-Sep-16,
221 GAMA.2.1.2.9.1.4.2 Small Bore Piping 20-Jul-16 25-Sep-16 58d 25-Sep-16, GAMA.2.1.2.9.1.4.2 Small Bore Piping
222 const7660 LP Feedwater 20-Jul-16* 10-Sep-16 45d 20-Jul-16* 10-Sep-16,
223 const7670 HP Feedwater 26-Jul-16* 04-Sep-16 35d 26-Jul-16* 04-Sep-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,
Auxi Steel Structure 21-Jun-16 08-Aug-16 42d 08-Aug-16, GAMA.2.1.2.9.1.5 Auxillary Steel Structure
230 const7730 silencer support structure installation 21-Jun-16* 13-Jul-16 20d 21-Jun-16* 13-Jul-16,

Duration ar
231 const7740 Silencer Installation 17-Jul-16* 23-Jul-16 6d 17-Jul-16* 23-Jul-16,
232 const7750 Spring Hangers 28-Jul-16* 08-Aug-16 10d 28-Jul-16* 08-Aug-16,
233 GAMA.2.1.2.9.1.6 Inlet Duct Steel Structure 22-Mar-16 23-May-16 54d 23-May-16, GAMA.2.1.2.9.1.6 Inlet Duct Steel Structure
234 const7760 Inlet duct foundation preparation 22-Mar-16* 23-Mar-16 2d 22-Mar-16* 23-Mar-16,
235 const7770 inlet duct support structure erection 26-Mar-16* 30-Mar-16 5d 26-Mar-16* 30-Mar-16,
236 const7780 inlet duct floor casing alignment & welding 31-Mar-16 11-Apr-16 10d 31-Mar-16 11-Apr-16,
237 const7790 inlet duct left side casing alignment & welding 18-Apr-16 28-Apr-16 10d 18-Apr-16 28-Apr-16,
238 const7800 inlet duct right side casing alignment & welding 24-Apr-16 04-May-16 10d 24-Apr-16 04-May-16,
239 const7810 inlet duct roof side casing alignment & welding 30-Apr-16 10-May-16 10d 30-Apr-16 10-May-16,
240 const7820 Inlet duct front casing & expansion joint alignment & welding 09-May-16 19-May-16 10d 09-May-16 19-May-16,
241 const7821 installation & insulation of connecting pieces b/n exhaust & duct 21-May-16 23-May-16 3d 21-May-16 23-May-16,
242 GAMA.2.1.2.9.1.7 Stack 10-Mar-16 26-Sep-16 172d 26-Sep-16, GAMA.2.1.2.9.1.7 Stack
243 GAMA.2.1.2.9.1.7.1 STACK section 1 10-Mar-16 11-Apr-16 28d 11-Apr-16, GAMA.2.1.2.9.1.7.1 STACK section 1
244 const9400 pre assembly shell no1 10-Mar-16* 14-Mar-16 4d 10-Mar-16* 14-Mar-16,
245 const9401 installation of ladders ,platforms and inspection doors 15-Mar-16 17-Mar-16 3d 15-Mar-16 17-Mar-16,
246 const9410 inspection and welding vertical joint 15-Mar-16* 20-Mar-16 5d 15-Mar-16* 20-Mar-16,
247 const9420 erection and allingment no 1 21-Mar-16* 24-Mar-16 4d 21-Mar-16* 24-Mar-16,
248 const9430 shell no 1 joint welding (circum) 26-Mar-16* 30-Mar-16 5d 26-Mar-16* 30-Mar-16,
249 const9480 Stack section 1 installation 31-Mar-16* 11-Apr-16 10d 31-Mar-16* 11-Apr-16,
250 GAMA.2.1.2.9.1.7.2 STACK section 2 31-Mar-16 02-May-16 28d 02-May-16, GAMA.2.1.2.9.1.7.2 STACK section 2
251 const9440 pre assembly shell no2 31-Mar-16* 04-Apr-16 4d 31-Mar-16* 04-Apr-16,
254 const9460 erection and allingment no 2 11-Apr-16* 14-Apr-16 4d 11-Apr-16* 14-Apr-16,
255 const9470 shell no 2 joint welding (circum) 16-Apr-16* 20-Apr-16 5d 16-Apr-16* 20-Apr-16,
256 const9490 Stack section 2 Installation 21-Apr-16* 02-May-16 10d 21-Apr-16* 02-May-16,
257 GAMA.2.1.2.9.1.7.3 STACK section 3 AND DAMPER 05-Apr-16 16-May-16 36d 16-May-16, GAMA.2.1.2.9.1.7.3 STACK section 3 AND DAMPER
261 const9511 pre assembly of damper 16-Apr-16* 19-Apr-16 4d 16-Apr-16* 19-Apr-16,
262 const9512 inspection and welding joint circum 20-Apr-16* 24-Apr-16 4d 20-Apr-16* 24-Apr-16,
263 const9520 erection and allingment no 3 with damper 25-Apr-16* 28-Apr-16 4d 25-Apr-16* 28-Apr-16,
264 const9530 shell no2 to 3 joint welding (circum) 30-Apr-16* 04-May-16 5d 30-Apr-16* 04-May-16,
266 GAMA.2.1.2.9.1.7.4 STACK section 4 05-May-16 30-Aug-16 101d 30-Aug-16, GAMA.2.1.2.9.1.7.4 STACK section 4
270 const9590 erection and allingment no 4 09-Aug-16* 13-Aug-16 4d 09-Aug-16* 13-Aug-16,
271 const9600 shell no 4 joint welding (circum) 14-Aug-16* 18-Aug-16 5d 14-Aug-16* 18-Aug-16,
272 const9610 Stack section 4 installation 20-Aug-16* 30-Aug-16 10d 20-Aug-16* 30-Aug-16,
273 GAMA.2.1.2.9.1.7.5 STACK section 5 10-May-16 26-Sep-16 120d 26-Sep-16, GAMA.2.1.2.9.1.7.5 STACK section 5
277 const9640 erection and allingment no 5 31-Aug-16* 04-Sep-16 4d 31-Aug-16* 04-Sep-16,
278 const9650 shell no 5 joint welding (circum) 05-Sep-16* 10-Sep-16 5d 05-Sep-16* 10-Sep-16,
279 const9651 installation of silencer 11-Sep-16 14-Sep-16 4d 11-Sep-16 14-Sep-16,
280 const9660 Stack section 5 installation 15-Sep-16* 26-Sep-16 10d 15-Sep-16* 26-Sep-16,
281 GAMA.2.1.2.9.1.8 Precommissiong
Prec & Test 07-Apr-16 14-Dec-16 216d 14-Dec-16, GAMA.2.1.2.9
282 const7920 Hydrotest 09-Oct-16* 01-Nov-16 21d 09-Oct-16* 01-Nov-16,
283 const7930 ReInstatement 02-Nov-16* 19-Nov-16 15d 02-Nov-16* 19-Nov-16,
284 const7940 Chemical cleaning & Restore (by others ) 02-Nov-16* 06-Dec-16 30d 02-Nov-16* 06-Dec-16,
285 const7950 Insulation 02-Nov-16* 12-Dec-16 35d 02-Nov-16* 12-Dec-16,
286 const8220 final touch up painting 07-Apr-16 14-Dec-16 216d 07-Apr-16 14-Dec-16,
287 GAMA.2.1.2.2 Unit 21 02-Feb-16 18-Jan-17 301d 18-Jan-17, GA

Duration ar
288 GAMA.2.1.2.2.1 HRSG 21 02-Feb-16 18-Jan-17 301d 18-Jan-17, GA
289 GAMA.2.1.2.2.1.1 By Pass
P Stack 02-Feb-16 21-Jul-16 146d 21-Jul-16, GAMA.2.1.2.2.1.1 By Pass Stack
290 const7960 by pass stack foundation preparation 02-Feb-16* 16-Feb-16 12d 02-Feb-16* 16-Feb-16,
291 const7970 erection of bypass stack steel structure 16-Feb-16* 16-Mar-16 25d 16-Feb-16* 16-Mar-16,
292 const7980 installation of diverter box 16-Mar-16* 09-Apr-16 20d 16-Mar-16* 09-Apr-16,
293 const7990 installation of upper steel structure 09-Apr-16* 26-Apr-16 15d 09-Apr-16* 26-Apr-16,
294 const8000 pre-assembly of stack section1 (round reducer ,silencer ,square to round transition 26-Apr-16* 04-May-16 7d 26-Apr-16* 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* 12-May-16,
298 const8040 pre-assembly of slack section 3(round reducer,silencer,square to round transition e 12-May-16* 19-May-16 6d 12-May-16* 19-May-16,
300 const8060 installation of CEMS Unit 21-May-16* 04-Jun-16 12d 21-May-16* 04-Jun-16,
301 const8061 installation of outlet duct 04-Jun-16 09-Jun-16 5d 04-Jun-16 09-Jun-16,
302 const8062 installation of bellow 09-Jun-16 12-Jun-16 2d 09-Jun-16 12-Jun-16,
303 const8070 By Pass Stack Precommissioning 05-Jun-16* 21-Jul-16 40d 05-Jun-16* 21-Jul-16,
304 GAMA.2.1.2.2.1.2 HRS
HRSG Steel Structure & Casing Erection 16-Mar-16 16-Jun-16 79d 16-Jun-16, GAMA.2.1.2.2.1.2 HRSG Steel Structure & Casing Erection
305 const8080 foundation preparation 16-Mar-16* 24-Mar-16 7d 16-Mar-16* 24-Mar-16,
306 const8090 Crane available at site 26-Mar-16* 0d Crane available at site
307 const8100 Main stair tower &platform pre-assembly 28-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 16-Apr-16* 20-Apr-16,
310 const8130 vertical side panels 21-Apr-16* 25-Apr-16 4d 21-Apr-16* 25-Apr-16,
311 const8140 Main stair tower and platform erection 06-Apr-16* 21-Apr-16 14d 06-Apr-16* 21-Apr-16,
312 const8150 Lower front panel casing 23-Apr-16* 25-Apr-16 3d 23-Apr-16* 25-Apr-16,
313 const8160 Installation of field casing plates 26-Apr-16* 28-Apr-16 3d 26-Apr-16* 28-Apr-16,
314 const8170 Erection of side platform 13-Apr-16* 05-May-16 20d 13-Apr-16* 05-May-16,
315 const8171 installation of liner system 07-May-16 09-May-16 3d 07-May-16 09-May-16,
316 const8172 installation of insulation & lining at junction of casing & duct 10-May-16 11-May-16 2d 10-May-16 11-May-16,
317 const8173 installation of Backstays and header spacers 12-May-16 14-May-16 2d 12-May-16 14-May-16,
318 const8174 installation of connecting plates (external stiffners to casing panels ) 15-May-16 18-May-16 4d 15-May-16 18-May-16,
319 const8175 execution of final allignment ,levelling & verticality of casing structure 19-May-16 23-May-16 4d 19-May-16 23-May-16,
320 const8190 final bolt tightening of main columns 24-May-16* 25-May-16 2d 24-May-16* 25-May-16,
321 const8200 Bumper Installation 26-Apr-16* 16-May-16 18d 26-Apr-16* 16-May-16,
322 const8210 Installation of CEMS skid 04-Jun-16* 16-Jun-16 12d 04-Jun-16* 16-Jun-16,
323 GAMA.2.1.2.2.1.3 Mdu
Mdule & Drum 26-May-16 23-Aug-16 77d 23-Aug-16, GAMA.2.1.2.2.1.3 Mdule & Drum
324 const8240 Drum supporting Structure preparation/ Installation 03-Jul-16* 07-Jul-16 5d 03-Jul-16* 07-Jul-16,
325 GAMA.2.1.2.2.1.3.4 module erection 26-May-16 17-Jul-16 45d 17-Jul-16, GAMA.2.1.2.2.1.3.4 module erection
326 const10200 installation of module 1A&1B 26-May-16 30-May-16 4d 26-May-16 30-May-16,

327 const10210 installation of module 2A &2 B 31-May-16 05-Jun-16 5d 31-May-16 05-Jun-16,
328 const10220 installation of module of 3A & 3B 06-Jun-16 12-Jun-16 6d 06-Jun-16 12-Jun-16,
329 const10230 installation of module 4A & 4B 13-Jun-16 18-Jun-16 5d 13-Jun-16 18-Jun-16,
330 const10240 restoration of insulation and liner between modules 03-Jul-16 05-Jul-16 3d 03-Jul-16 05-Jul-16,
331 const10250 installation of nozzle connection & piping 06-Jul-16 17-Jul-16 10d 06-Jul-16 17-Jul-16,
332 GAMA.2.1.2.2.1.3.
GAMA.2.1.2.2.1.3.4.1 installation of trusses 19-Jun-16 02-Jul-16 12d 02-Jul-16, GAMA.2.1.2.2.1.3.4.1 installation of trusses
333 const10260 installation of upper trusses 19-Jun-16 22-Jun-16 4d 19-Jun-16 22-Jun-16,
334 const10270 installation of intermediate trusses 23-Jun-16 27-Jun-16 4d 23-Jun-16 27-Jun-16,
335 const10280 installation of lower trusses 28-Jun-16 02-Jul-16 4d 28-Jun-16 02-Jul-16,
336 GAMA.2.1.2.2.1.3.1 HP drum 09-Jul-16 20-Aug-16 37d 20-Aug-16, GAMA.2.1.2.2.1.3.1 HP drum
337 const9670 HP drum erection 09-Jul-16 09-Jul-16 1d 09-Jul-16 09-Jul-16,
338 const9680 HP down comer piping 17-Jul-16 20-Aug-16 30d 17-Jul-16 20-Aug-16,
339 GAMA.2.1.2.2.1.3.2 IP drum 10-Jul-16 14-Aug-16 31d 14-Aug-16, GAMA.2.1.2.2.1.3.2 IP drum
340 const9690 IP drum erection 10-Jul-16 10-Jul-16 1d 10-Jul-16 10-Jul-16,
341 const9700 IP down comer piping 23-Jul-16 14-Aug-16 20d 23-Jul-16 14-Aug-16,
342 GAMA.2.1.2.2.1.3.3 LP drum 12-Jul-16 23-Aug-16 37d 23-Aug-16, GAMA.2.1.2.2.1.3.3 LP drum
343 const9710 LP drum erection 12-Jul-16 13-Jul-16 2d 12-Jul-16 13-Jul-16,
344 const9720 LP down comer piping 26-Jul-16 23-Aug-16 25d 26-Jul-16 23-Aug-16,

Duration ar
345 GAMA.2.1.2.2.1.4 Pipin
Piping & Instruments) 14-Jul-16 07-Nov-16 100d 07-Nov-16, GAMA.2.1.2.2.1.4 Piping
346 const8270 install blow down tank 14-Jul-16* 19-Jul-16 5d 14-Jul-16* 19-Jul-16,
347 const8280 Valves & Instruments Installation 20-Jul-16* 01-Nov-16 90d 20-Jul-16* 01-Nov-16,
348 const8290 Piping test preparation 22-Oct-16* 07-Nov-16 15d 22-Oct-16* 07-Nov-16,
349 GAMA.2.1.2.2.1.4.1 Large Bore Piping 16-Jul-16 18-Oct-16 82d 18-Oct-16, GAMA.2.1.2.2.1.4.1 Large Bore
350 const8300 LP Feedwater 16-Jul-16* 30-Aug-16 40d 16-Jul-16* 30-Aug-16,
351 const8310 HP Feedwater 26-Jul-16* 10-Sep-16 40d 26-Jul-16* 10-Sep-16,
352 const8320 IP Feedwater 23-Jul-16* 06-Sep-16 40d 23-Jul-16* 06-Sep-16,
353 const8330 RH 02-Aug-16* 04-Oct-16 55d 02-Aug-16* 04-Oct-16,
354 const8340 LP Eva- Sh-Eco 27-Jul-16* 10-Oct-16 65d 27-Jul-16* 10-Oct-16,
355 const8350 IP-Eva-Sh-Eco 01-Aug-16* 15-Oct-16 65d 01-Aug-16* 15-Oct-16,
356 const8360 HP-Eva-Sh-Eco 04-Aug-16* 18-Oct-16 65d 04-Aug-16* 18-Oct-16,
357 GAMA.2.1.2.2.1.4.2 Small Bore Piping 08-Aug-16 18-Oct-16 62d 18-Oct-16, GAMA.2.1.2.2.1.4.2 Small Bore
358 const8370 LP Feedwater 08-Aug-16* 28-Sep-16 45d 08-Aug-16* 28-Sep-16,
359 const8380 HP Feedwater 18-Aug-16* 27-Sep-16 35d 18-Aug-16* 27-Sep-16,
360 const8390 IP Feedwater 15-Aug-16* 17-Oct-16 55d 15-Aug-16* 17-Oct-16,
361 const8400 RH 25-Aug-16* 06-Oct-16 37d 25-Aug-16* 06-Oct-16,
362 const8410 LP Eva- Sh-Eco 14-Aug-16* 10-Oct-16 50d 14-Aug-16* 10-Oct-16,
363 const8420 IP-Eva-Sh-Eco 22-Aug-16* 12-Oct-16 45d 22-Aug-16* 12-Oct-16,
364 const8430 HP-Eva-Sh-Eco 28-Aug-16* 18-Oct-16 45d 28-Aug-16* 18-Oct-16,
Auxi Steel Structure 07-Jul-16 17-Aug-16 36d 17-Aug-16, GAMA.2.1.2.2.1.5 Auxillary Steel Structure
366 const8440 silencer support structure installation 07-Jul-16* 30-Jul-16 20d 07-Jul-16* 30-Jul-16,
367 const8450 Silencer Installation 31-Jul-16* 06-Aug-16 6d 31-Jul-16* 06-Aug-16,
368 const8460 Spring Hangers 07-Aug-16* 17-Aug-16 10d 07-Aug-16* 17-Aug-16,
369 GAMA.2.1.2.2.1.6 Inlet Duct Steel Structure 04-Apr-16 23-Jun-16 70d 23-Jun-16, GAMA.2.1.2.2.1.6 Inlet Duct Steel Structure
370 const8470 Inlet duct foundation preparation 04-Apr-16* 05-Apr-16 2d 04-Apr-16* 05-Apr-16,
371 const8480 inlet duct support structure erection 07-Apr-16* 12-Apr-16 5d 07-Apr-16* 12-Apr-16,
372 const8490 inlet duct floor casing alignment & welding 01-May-16* 11-May-16 10d 01-May-16* 11-May-16,
373 const8500 inlet duct left side casing alignment & welding 12-May-16 23-May-16 10d 12-May-16 23-May-16,
374 const8510 inlet duct right side casing alignment & welding 18-May-16 29-May-16 10d 18-May-16 29-May-16,
375 const8520 inlet duct roof side casing alignment & welding 28-May-16 07-Jun-16 10d 28-May-16 07-Jun-16,
376 const8530 Inlet duct front casing & expansion joint alignment & welding 08-Jun-16 19-Jun-16 10d 08-Jun-16 19-Jun-16,
377 const8540 installation & insulation of connecting pieces b/n exhaust & duct 20-Jun-16 23-Jun-16 4d 20-Jun-16 23-Jun-16,
378 GAMA.2.1.2.2.1.7 Stack 04-Apr-16 05-Oct-16 159d 05-Oct-16, GAMA.2.1.2.2.1.7 Stack
379 GAMA.2.1.2.2.1.7.1 STACK section 1 04-Apr-16 12-May-16 34d 12-May-16, GAMA.2.1.2.2.1.7.1 STACK section 1
381 const9731 installation of ladders,platforms and inspection doors. 09-Apr-16 12-Apr-16 4d 09-Apr-16 12-Apr-16,
383 const9750 erection and allingment no 1 19-Apr-16* 23-Apr-16 4d 19-Apr-16* 23-Apr-16,
384 const9760 shell no 1 joint welding (circum) 24-Apr-16* 28-Apr-16 5d 24-Apr-16* 28-Apr-16,
385 const9810 Stack section 1 installation 30-Apr-16* 10-May-16 10d 30-Apr-16* 10-May-16,
386 const9880 anchor bolt tightnening 11-May-16 12-May-16 2d 11-May-16 12-May-16,
387 GAMA.2.1.2.2.1.7.2 STACK section 2 30-Apr-16 31-May-16 28d 31-May-16, GAMA.2.1.2.2.1.7.2 STACK section 2
388 const9770 pre assembly shell no2 30-Apr-16* 03-May-16 4d 30-Apr-16* 03-May-16,
389 const9771 installation of ladders,platforms&inspection doors. 04-May-16 08-May-16 4d 04-May-16 08-May-16,
391 const9790 erection and allingment no 2 10-May-16* 14-May-16 4d 10-May-16* 14-May-16,
392 const9800 shell no 2 joint welding (circum) 15-May-16* 19-May-16 5d 15-May-16* 19-May-16,
394 GAMA.2.1.2.2.1.7.3 STACK section 3 AND DAMPER 04-May-16 19-Jun-16 40d 19-Jun-16, GAMA.2.1.2.2.1.7.3 STACK section 3 AND DAMPER
398 const9841 pre assembly of damper 19-May-16* 23-May-16 4d 19-May-16* 23-May-16,
399 const9842 inspection and welding joint circum 24-May-16* 28-May-16 4d 24-May-16* 28-May-16,
400 const9850 erection and allingment no 3 with damper 29-May-16* 01-Jun-16 4d 29-May-16* 01-Jun-16,
401 const9860 shell no2 to 3 joint welding (circum) 02-Jun-16* 07-Jun-16 5d 02-Jun-16* 07-Jun-16,

Duration ar
402 const9870 Stack section 3 Installation 08-Jun-16* 19-Jun-16 10d 08-Jun-16* 19-Jun-16,
403 GAMA.2.1.2.2.1.7.4 STACK section 4 09-May-16 08-Sep-16 106d 08-Sep-16, GAMA.2.1.2.2.1.7.4 STACK section 4
407 const9920 erection and allingment no 4 18-Aug-16* 22-Aug-16 4d 18-Aug-16* 22-Aug-16,
408 const9930 shell no 4 joint welding (circum) 23-Aug-16* 28-Aug-16 5d 23-Aug-16* 28-Aug-16,
409 const9940 Stack section 4 installation 29-Aug-16* 08-Sep-16 10d 29-Aug-16* 08-Sep-16,
410 GAMA.2.1.2.2.1.7.5 STACK section 5 14-May-16 05-Oct-16 125d 05-Oct-16, GAMA.2.1.2.2.1.7.5 STACK section
414 const9970 erection and allingment no 5 10-Sep-16* 13-Sep-16 4d 10-Sep-16* 13-Sep-16,
415 const9980 shell no 5 joint welding (circum) 14-Sep-16* 19-Sep-16 5d 14-Sep-16* 19-Sep-16,
416 const9981 installation of silencer 20-Sep-16 24-Sep-16 4d 20-Sep-16 24-Sep-16,
417 const9990 Stack section 5 installation 25-Sep-16* 05-Oct-16 10d 25-Sep-16* 05-Oct-16,
418 GAMA.2.1.2.2.1.8 Precommissioning
Prec & Tests 14-May-16 18-Jan-17 215d 18-Jan-17, GA
419 const8630 Hydrotest 13-Nov-16* 06-Dec-16 21d 13-Nov-16* 06-Dec-16,
420 const8640 ReInstatement 07-Dec-16* 22-Dec-16 14d 07-Dec-16* 22-Dec-16,
421 const8650 Chemical cleaning & Restore (by others ) 07-Dec-16* 10-Jan-17 30d 07-Dec-16* 10-Jan-17,
422 const8660 Insulation 07-Dec-16* 16-Jan-17 35d 07-Dec-16* 16-Jan-17,
423 const8670 final touch up painting 14-May-16 18-Jan-17 215d 14-May-16 18-Jan-17,

Detailed Schedule
ID Name Duration Start Finish

1 HRSG INSTALLATION SCHEDULE 374 days 11/10/2015 0:00 1/18/2017
2 Milestone 15 days 11/10/2015 11/26/2015
3 Signing of Sub‐Contract Agreement 7 days 11/19/2015 11/26/2015
4 Award of Contract 0 days 11/10/2015 11/10/2015
5 Issuance & Signing of LOI 7 days 11/11/2015 11/18/2015
6 Kick off meeting 0 days 11/18/2015 11/18/2015
7 CONSTRUCTION 356 days 12/1/2015 1/18/2017
8 NMC MOBILIZATION 25 days 12/1/2015 12/29/2015
9 Mechanical Works 25 days 12/1/2015 12/29/2015
10 HRSG Mobilzation 25 days 12/1/2015 12/29/2015
11 Block 20 326 days 1/5/2016 1/18/2017
12 Unit 23 269 days 1/5/2016 11/13/2016
13 HRSG‐23 269 days 1/5/2016 11/13/2016
14 By Pass Stack 160 days 1/5/2016 7/9/2016
15 by pass stack foundation preparation 12 days 1/5/2016 1/18/2016
16 erection of bypass stack steel structure 25 days 1/20/2016 2/17/2016
17 installation of diverter box 20 days 2/20/2016 3/13/2016
18 installation of upper steel structure 15 days 3/15/2016 3/31/2016
19 pre‐assembly of stack section1 (round reducer ,silencer ,square to round transition element 7 days 4/3/2016 4/10/2016
20 installation of stack section 1 1 day 4/12/2016 4/12/2016
21 pre‐assembly of slack section 2 (round reducer,silencer,square to round transition element ) 7 days 4/12/2016 4/19/2016
23 pre‐assembly of slack section 3(round reducer,silencer,square to round transition element ) 7 days 4/21/2016 4/28/2016
25 installation of CEMS Unit 12 days 5/2/2016 5/15/2016
26 By Pass Stack Precommissioning 40 days 5/24/2016 7/9/2016
27 installation of OUT LET duct 5 days 5/16/2016 5/21/2016
28 installation of bellow 2 days 5/22/2016 5/23/2016
29 HRSG Steel Structure & Casing Erection 90 days 1/17/2016 4/30/2016
30 foundation preparation 7 days 1/17/2016 1/24/2016
31 Crane available at site 0 days 1/24/2016 1/24/2016
32 Main stair tower &platform pre‐assembly 14 days 1/26/2016 2/10/2016
33 Casing Panel Installation 15 days 1/27/2016 2/13/2016
34 bottom plate installation 5 days 2/14/2016 2/18/2016
35 vertical side panels 4 days 2/21/2016 2/24/2016
36 Main stair tower and platform erection 14 days 2/1/2016 2/16/2016
37 Lower front panel casing 3 days 2/17/2016 2/20/2016
38 Installation of field casing plates 3 days 2/21/2016 2/23/2016
39 Erection of side platform 20 days 2/14/2016 3/7/2016
40 final bolt tightening of main columns 2 days 3/17/2016 3/19/2016
41 Bumper Installation 20 days 2/22/2016 3/15/2016
42 Installation of CEMS skid 10 days 3/22/2016 4/2/2016
43 HRSG block 20 Elevator structure installation 65 days 2/15/2016 4/30/2016
44 execution of final allignment ,levelling & verticality of casing structure 4 days 3/8/2016 3/12/2016
45 installation of liner system 3 days 2/24/2016 2/27/2016
46 installation of insulation & lining at junction of casing & duct 2 days 2/28/2016 2/29/2016
47 installation of Backstays and header spacers 2 days 3/1/2016 3/2/2016
48 installation of connecting plates (external stiffners to casing panels ) 4 days 3/3/2016 3/7/2016
Detailed Schedule
49 Module & Drum 84 days 3/20/2016 6/25/2016

50 Drum supporting Structure preparation / Installation 5 days 5/4/2016 5/9/2016
51 Module Erection 45 days 3/20/2016 5/10/2016
52 installation of module 1A&1B 4 days 3/20/2016 3/23/2016
53 installation of module 2A &2 B 5 days 3/24/2016 3/29/2016
54 installation of module of 3A & 3B 6 days 3/30/2016 4/5/2016
55 installation of module 4A & 4B 5 days 4/6/2016 4/11/2016
56 restoration of insulation and liner between modules 3 days 4/26/2016 4/28/2016
57 installation of nozzle connection & piping 10 days 4/30/2016 5/10/2016
58 Installation of trusses 12 days 4/12/2016 4/25/2016
59 installation of upper trusses 4 days 4/12/2016 4/16/2016
60 installation of intermediate trusses 4 days 4/17/2016 4/20/2016
61 installation of lower trusses 4 days 4/21/2016 4/25/2016
62 HP drum 37 days 5/10/2016 6/21/2016
63 HP drum erection 1 day 5/10/2016 5/10/2016
64 HP down comer piping 30 days 5/18/2016 6/21/2016
65 IP drum 31 days 5/11/2016 6/15/2016
66 IP drum erection 1 day 5/11/2016 5/11/2016
67 IP down comer piping 20 days 5/24/2016 6/15/2016
68 LP drum 37 days 5/14/2016 6/25/2016
69 LP drum erection 2 days 5/14/2016 5/15/2016
70 LP down comer piping 25 days 5/28/2016 6/25/2016
71 Piping & Instruments 98 days 5/16/2016 9/6/2016
72 install blow down tank 5 days 5/18/2016 5/23/2016
73 Valves & Instruments Installation 85 days 5/25/2016 8/31/2016
74 Piping test preparation 15 days 8/21/2016 9/6/2016
75 Large Bore Piping 91 days 5/16/2016 8/29/2016
76 LP Feedwater 40 days 5/16/2016 6/30/2016
77 HP Feedwater 40 days 5/30/2016 7/14/2016
78 IP Feedwater 40 days 5/29/2016 7/13/2016
79 RH 55 days 5/30/2016 8/1/2016
80 LP Eva‐ Sh‐Eco 70 days 5/28/2016 8/16/2016
81 IP‐Eva‐Sh‐Eco 70 days 6/9/2016 8/29/2016
82 HP‐Eva‐Sh‐Eco 70 days 5/31/2016 8/20/2016
83 Small Bore Piping 69 days 6/14/2016 9/1/2016
87 RH 49 days 6/28/2016 8/23/2016
88 LP Eva‐ Sh‐Eco 45 days 6/26/2016 8/16/2016
89 IP‐Eva‐Sh‐Eco 45 days 7/12/2016 9/1/2016
90 HP‐Eva‐Sh‐Eco 45 days 7/3/2016 8/23/2016
91 Auxillary Steel Structure 40 days 5/16/2016 6/30/2016
92 silencer support structure installation 20 days 5/16/2016 6/7/2016
93 Silencer Installation 6 days 6/9/2016 6/15/2016
94 Spring Hangers 10 days 6/20/2016 6/30/2016
95 Inlet Duct Steel Structure 50 days 3/8/2016 5/4/2016
96 Inlet duct foundation preparation 2 days 3/8/2016 3/9/2016
97 inlet duct support structure erection 10 days 3/12/2016 3/22/2016
98 inlet duct floor casing alignment & welding 10 days 3/26/2016 4/5/2016
Detailed Schedule
99 inlet duct left side casing alignment & welding 10 days 3/31/2016 4/11/2016

100 inlet duct right side casing alignment & welding 10 days 4/7/2016 4/18/2016
101 inlet duct roof side casing alignment & welding 10 days 4/13/2016 4/24/2016
102 Inlet duct front casing & expansion joint alignment & welding 10 days 4/20/2016 5/1/2016
103 installation & insulation of connecting pieces b/n exhaust & duct 3 days 5/2/2016 5/4/2016
104 Stack 159 days 2/14/2016 8/16/2016
105 STACK section 1 33 days 2/14/2016 3/22/2016
106 pre assembly shell no1 4 days 2/14/2016 2/17/2016
107 Inspection and welding vertical joint 5 days 2/22/2016 2/27/2016
108 erection and allingment no 1 4 days 2/28/2016 3/2/2016
109 shell no 1 joint welding (circum) 5 days 3/3/2016 3/8/2016
110 Stack section 1 installation 10 days 3/9/2016 3/20/2016
111 anchor bolt tightening 2 days 3/21/2016 3/22/2016
112 installation of ladders ,platforms and inspection doors 3 days 2/18/2016 2/21/2016
118 Stack section 2 Installation 10 days 4/3/2016 4/13/2016
120 STACK section 3 AND DAMPER 37 days 4/3/2016 5/15/2016
123 erection and allingment no 3 with damper 4 days 4/24/2016 4/27/2016
124 shell no2 to 3 joint welding (circum) 5 days 4/28/2016 5/3/2016
126 pre assembly of damper 4 days 4/17/2016 4/20/2016
127 inspection and welding joint circum 4 days 4/20/2016 4/24/2016
131 inspection and welding vertical joint 5 days 5/12/2016 5/17/2016
143 installation of silencer 2 days 8/3/2016 8/4/2016
144 Precomissioning & Tests 225 days 2/25/2016 11/13/2016
145 Hydrotest 20 days 9/11/2016 10/3/2016
146 ReInstatement 15 days 10/4/2016 10/20/2016
147 Chemical cleaning & Restore (by others ) 25 days 10/5/2016 11/2/2016
148 Insulation 32 days 10/6/2016 11/12/2016
Detailed Schedule
149 final touch up painting 225 days 2/25/2016 11/13/2016

150 Unit 22 281 days 1/23/2016 12/14/2016
151 HRSG 22 281 days 1/23/2016 12/14/2016
165 installation of out let duct 5 days 5/31/2016 6/5/2016
186 Module & DRum 80 days 4/30/2016 7/31/2016
187 Drum supporting Structure preparation / Installation 5 days 6/9/2016 6/14/2016
188 module erection 45 days 4/30/2016 6/20/2016
195 installation of trusses 12 days 5/23/2016 6/5/2016
Detailed Schedule
199 HP drum 37 days 6/15/2016 7/27/2016

202 IP drum 31 days 6/16/2016 7/21/2016
205 LP drum 37 days 6/19/2016 7/31/2016
208 Piping & Instruments 91 days 6/21/2016 10/4/2016
216 RH 55 days 7/5/2016 9/6/2016
217 LP Eva‐ Sh‐Eco 65 days 6/30/2016 9/13/2016
218 IP‐Eva‐Sh‐Eco 65 days 7/4/2016 9/17/2016
219 HP‐Eva‐Sh‐Eco 68 days 7/5/2016 9/21/2016
224 RH 50 days 7/28/2016 9/24/2016
225 LP Eva‐ Sh‐Eco 50 days 7/27/2016 9/22/2016
226 IP‐Eva‐Sh‐Eco 45 days 8/2/2016 9/22/2016
227 HP‐Eva‐Sh‐Eco 46 days 7/31/2016 9/21/2016
241 Stack 172 days 3/10/2016 9/26/2016
Detailed Schedule

280 Precommissiong & Test 216 days 4/7/2016 12/14/2016
281 Hydrotest 21 days 10/9/2016 11/1/2016
284 Insulation 35 days 11/2/2016 12/12/2016
286 Unit 21 301 days 2/3/2016 1/18/2017
287 HRSG 21 301 days 2/3/2016 1/18/2017
Detailed Schedule

301 installation of outlet duct 5 days 6/5/2016 6/9/2016
322 Mdule & Drum 77 days 5/26/2016 8/23/2016
323 Drum supporting Structure preparation/ Installation 5 days 7/3/2016 7/7/2016
324 module erection 45 days 5/26/2016 7/17/2016
331 installation of trusses 12 days 6/19/2016 7/2/2016
335 HP drum 37 days 7/9/2016 8/20/2016
338 IP drum 31 days 7/10/2016 8/14/2016
341 LP drum 37 days 7/12/2016 8/23/2016
344 Piping & Instruments) 100 days 7/14/2016 11/7/2016
Detailed Schedule

352 RH 55 days 8/2/2016 10/4/2016
353 LP Eva‐ Sh‐Eco 65 days 7/27/2016 10/10/2016
354 IP‐Eva‐Sh‐Eco 65 days 8/1/2016 10/15/2016
355 HP‐Eva‐Sh‐Eco 65 days 8/4/2016 10/18/2016
360 RH 37 days 8/25/2016 10/6/2016
361 LP Eva‐ Sh‐Eco 50 days 8/14/2016 10/10/2016
362 IP‐Eva‐Sh‐Eco 45 days 8/22/2016 10/12/2016
363 HP‐Eva‐Sh‐Eco 45 days 8/28/2016 10/18/2016
377 Stack 159 days 4/4/2016 10/5/2016
384 installation of ladders,platforms and inspection doors. 4 days 4/9/2016 4/12/2016
385 anchor bolt tightnening 2 days 5/11/2016 5/12/2016
392 installation of ladders,platforms&inspection doors. 4 days 5/4/2016 5/8/2016
Detailed Schedule

417 Precommissioning & Tests 215 days 5/14/2016 1/18/2017
418 Hydrotest 21 days 11/13/2016 12/6/2016
421 Insulation 35 days 12/7/2016 1/16/2017

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: Yahiyamadan@hotmail.com
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
Page 1 of 4

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)
1. 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
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.
Page 2 of 4

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, co-
ordination 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, inter-
connecting 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
Page 3 of 4

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
Page 4 of 4

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

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 1 of 23
NIS SITE HSE PLAN

FOR POWER ISLAND ME&I AND
EQUIPMENT INSTALLTION WORKS
FOR SEC POWER PLANT PP-13, KSA.
VALIDATION
Prepared by NIS Reviewed by NIS Approved by GAMA
DEPT HSE DEPT PROJECT MANAGER
SIGNATURE
GAMA PROJECT IN KSA
HSE Plan
TABLE OF CONTENTS
SECTION DESCRIPTION
1) Project Policy Statement

a) HSE Policy
b) Environmental Policy
c) Alcohol and Drug Policy
d) Smoking Policy
2) Duty and responsibilities of the Project`s Officer(s)

a) Project Manager
b) Site / Construction Manager
c) HSE Manager
d) Safety Supervisor
e) Field Superintendent/Supervisor
f) Security Officer
g) Employee(Worker)
3) Formal Inspection of Construction site

a) The Purpose of HSE Inspections
b) Scope of Inspection and Audit
c) HSE Audit Items
d) HSE Inspection Items
4) HSE Meeting(s)
a) Weekly HSE Coordination Meeting
b) Monthly HSE Committee Meeting
5) Accident & Investigation

a) Investigation
b) Accident Reporting
c) Monthly Safety Health and Fire Report
6) EQUIPMENT SAFETY
a) Housekeeping
7) Job Safety Analysis & Risk Assessment(s)

GAMA PROJECT IN KSA
8) Medical Facilities and Procedure

8.1 General
9) Safety Training
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 .
GAMA PROJECT IN KSA
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.
GAMA PROJECT IN KSA
b) 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.
c) Any possible impact which activities have on the environment will be identified and suitable
precautions taken to reduce the impact.
d) Procedures are developed and implemented to ensure that risk of spillages or discharges of
chemicals, paint or other environmentally hazardous materials are minimized.
e) Where spillages or discharges occur, procedures exist for dealing with them quickly and
Effectively.
f) 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.
g) Disposal of waste products is in a controlled and proper manner using registered carriers.
h) 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
GAMA PROJECT IN KSA
 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.
GAMA PROJECT IN KSA
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.
GAMA PROJECT IN KSA
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.

GAMA PROJECT IN KSA
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
GAMA PROJECT IN KSA
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.
GAMA PROJECT IN KSA
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.
GAMA PROJECT IN KSA
 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-Information-

monitoring-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.
GAMA PROJECT IN KSA
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.
GAMA PROJECT IN KSA
 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 TYPES AND REQUIREMENTS OF HSE TRAINING
9.1.1 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.)
6) 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
GAMA PROJECT IN KSA
 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).
GAMA PROJECT IN KSA
 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

GAMA PROJECT IN KSA
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.
GAMA PROJECT IN KSA
 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.
GAMA PROJECT IN KSA
 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. No fuelling to take place within 30 meters of any hot work including grinding, welding etc.
2. No equipment will be refueled while the engine is running.
3. No smoking.
4. Discharge nozzles on fuel bowsers shall be fitted with an automatic shut off valve.
5. Dip trays shall be placed under all portable equipment to contain any leaks.
6. 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.
GAMA PROJECT IN KSA
 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
 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:
1. Periodic water spraying of bare surfaces

2. Proper maintenance of road surfaces.
3. Regular maintenance of equipment and vehicles to reduce exhaust emissions.
4. Use of tarpaulins over transported earth/sand loads.
5. 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.
GAMA PROJECT IN KSA
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 Generator Risk Assessment Record and Risk Reduction Plan
OH&S Risk Matrix Measures of Consequence and Likelihood for OH&S Risks
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
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Location Work Area: PP-13 SEC-PP13 COMBINED CYCLE PLANT PROJECT Company : Saudi Electrical Company
Date of this Revision: 11-Nov-2015 MECHANICAL | I&C | ELECTRICAL WORKS Contract Number :
Date of last Revision: New RISK ASSESSMENT Revision No. 0

RISK REDUCTION PLAN STATUS
RISK ASSESSMENT RECORD
Inherent Risk Residual Risk Final Risk
Percent Complete
Consequence(1)
Consequence(2)
Consequence(3)
Likelihood(2)
Likelihood(1)
Likelihood(3)
Recommended Action
Completion
Level(2)
Rank(3)
Level(1)
Level(3)
Rank(1)
Rank(2)
(Improve existing controls
Date
By Whom
Item Task Hazard Un-wanted Event Existing Controls / implement new controls) Target Date Comments
Person To Action
Including reference to procedures
Blue highlight denotes Contractor procedures
INSTALLATION AND ERECTION HRSG AND GTG
3‐Moderate
3‐Moderate
D‐Unlikely
Medium
2‐Minor
B‐Likely
E‐Rare
Site Engineer /
High
Low
Sharp edges Hand Injury , cut 13 Use Leather Hand gloves. 15 Conduct toolbox talk prior to start job 23 0%
supervisor
Use double insulated or properly grounded
Electrical Shock Fatal, serious injuries
equipment.
3‐Moderate
D‐Unlikely
C‐Possible
Medium
Extreme
4‐Major
2‐Minor
E‐Rare
Use only inspected and Tagged tools and cables. 8 Carry out visual inspection of equipment All employees
Low
5 20 0%
prior to use .
Use Rubber Hand gloves with adequate PPE’S.
Ensure all safety guards are present before start of
Moving parts Major Injuries
Mechanical Cutting of Steel any operation.
1 Materials.
Use a push stick while using a cutting machine.
3‐Moderate
3‐Moderate
C‐Possible
D‐Unlikely
Medium
2‐Minor
E‐Rare
Preventive maintenance should be carried
High
Low
15 All electrical equipment, appliances, cables shall be 18 22 0%
maintained (inspected, repaired and tested) to out periodically. Technician
eliminate any unsafe conditions.
Only a competent person shall carryout maintenance.
3‐Moderate
3‐Moderate
D‐Unlikely
D‐Unlikely
Flying metals particles Injuries to the Eye Use safety Glasses.
Medium
2‐Minor
E‐Rare
Site Engineer /
High
Low
8 12 Conduct toolbox talk prior to start job 20 0%
Face shield must be used while using portable supervisor
cutting tools.
Use flash back arresters, regulator and ensure it is
regularly maintained.
Fabricator should check the cutting set before each
use.
3‐Moderate
D‐Unlikely
D‐Unlikely
Medium
2‐Minor
4‐Major
E‐Rare
Necessary work permit should be valid Site Engineer /
High
Low
Gas cylinder / cutting set Major fire, explosion 8 13 20 0%
Use only flint sparking device to start flame. obtained before start work supervisor
Regular checks on condition of hoses.
Proper PPE precaution during torch heating of
component.
Maintain good hose management
Transport gas cylinders in trolley. Inspect the trolley
3‐Moderate 3‐Moderate
D‐Unlikely
D‐Unlikely
Medium
before in use.
4‐Major
2‐Minor
E‐Rare
Monitoring should be done by competent Site Engineer /
Low
High
Unsecured / unprotected gas Gas cylinders must be kept in vertical position and
cylinders
Fire, explosion & injury 10 15 22 0%
secured to avoid falling. It must have protective cap. person supervisor
D‐Unlikely
C‐Possible
Medium
Medium
2‐Minor
2‐Minor
E‐Rare
Site Engineer /
Low
Use adequate hand gloves and personnel protective supervisor
2 Gas cutting operation High temperature Burn clothing
Area must be clean of flammable materials.
3‐Moderate
3‐Moderate
Use PPE appropriately so that the molten metals do
D‐Unlikely
D‐Unlikely
Medium
Medium
2‐Minor
not enter inside coveralls, boots etc
E‐Rare
Area to be barricated while work , use fire
Low
Hot molten metals Fire, burns 17 20 All employees 25 0%
Make sure to cover the sewer manhole without fail. blanket if required .
Ensure drains are flushed and have a water seal
3‐Mo
3‐Mo
C‐Po
D‐U
Me
2‐M
Use safety glasses.
E‐
Inspect equipment before using ensure
H
L

Percent Complete
Consequence(1)
Consequence(2)
Consequence(3)
Likelihood(2)
Likelihood(1)
Likelihood(3)
Recommended Action
Completion
Level(2)
Rank(3)
Level(1)
Level(3)
Rank(1)
Rank(2)
Date
By Whom
Person To Action
Unlikely
Inspect equipment before using , ensure
High
Low
edium
Minor
‐Rare
oderate 3‐Moderate
oderate 3‐Moderate
ossible
Flying metals, sparks Injuries to eyes 15 Face shield must be worn while using portable tools. 18 All employees 22 0%
safety guard in place
D‐Unlikely
D‐Unlikely
Medium
Medium
2‐Minor
E‐Rare
Continual monitoring required , if found any Site Engineer /
Low
16 19 20 0%
damage of equipment immediately replace supervisor
Gas leakage Suffocation 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
3‐Moderate
D‐Unlikely
D‐Unlikely
Medium
4‐Major
2‐Minor
shielded from direct sunlight or other heat source.
E‐Rare
Site Engineer /
Low
High
Explosion / combustion of Temporary overlay plates installed.
Outbreak of fire
flammable material
7 16 Assign job watcher 22 0%
supervisor
Fire extinguisher available and hoses connected to
the hydrants
Face shield and safety glasses to be used.
3‐Moderate
3‐Moderate
D‐Unlikely
C‐Possible
Medium
2‐Minor
E‐Rare
Grinding carried out such that spark travel away from Machine guard to be checked and ensure it
Low
High
Injuries to eye / fire / combustion
Flying metals, spark
of materials
10 personnel. 16 All employees 21 0%
is in its place
Remove all combustible material from the area.
Check that disk guard is secured and validity of
grinder disk
Follow manufacturer instructions.
3‐Moderate
D‐Unlikely
D‐Unlikely
Trial run machine before use.
Medium
2‐Minor
4‐Major
E‐Rare
Site Engineer /
High
Low
Grinding disk (if broken) Injury to person 13 Use appropriate PPE. 16 Ensure employee competency 20 0%
supervisor
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.
5‐Catasrophic
Check that equipment is in good condition and
3‐Moderate
D‐Unlikely
Medium
tagged.
2‐Minor
E‐Rare
E‐Rare
Carry out visual inspection equipment prior to
Low
High
Electric shock Fatality 5 Check extension cables check for damage, replace if 12 All employees 20 0%

use equipment
necessary.
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.
3‐Moderate
3‐Moderate
Hand gloves must be fitting to the hand / fingers.
D‐Unlikely
C‐Possible
Medium
2‐Minor
E‐Rare
Site Engineer /
Low
High
Moving parts Major Injuries 18 Loose gloves may come in contact with the rotating 20 Ensure employee competency 25

supervisor
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.
3-Moderate
3‐Moderate
D‐Unlikely
D‐Unlikely
Medium
Medium
2‐Minor
E‐Rare
Site Engineer /
Low
Noise Temporary deafness, stress 20 Use Hearing protection. 25 Conduct toolbox talk prior to start job 28
supervisor

Percent Complete
Consequence(1)
Consequence(2)
Consequence(3)
Likelihood(2)
Likelihood(1)
Likelihood(3)
Recommended Action
Completion
Level(2)
Rank(3)
Level(1)
Level(3)
Rank(1)
Rank(2)
Date
By Whom
Person To Action
3‐Moderate
3‐Moderate
D‐Unlikely
C‐Possible
Medium
2‐Minor
E‐Rare
Site Engineer /
Low
High
Sharp edges Injury 15 Use hand gloves. 20 Conduct toolbox talk prior to start job 23 0%
supervisor
Use appropriate PPE.
3‐Moderate
3‐Moderate
D‐Unlikely
D‐Unlikely
Medium
Medium
2‐Minor
E‐Rare
Restrict personnel in vicinity of welding operations. Site Engineer /
Low
“Arc flash” and hot metal “Arc eye” skin burn 6 16 Conduct toolbox talk prior to start job 20 0%
supervisor
Use “anti flash” safety glasses.
Welding helmets fitted with correct UV lenses.
While working, crew must place themselves up wind,
3‐Moderate if possible, so that fumes and gases are blown away
3‐Moderate
D‐Unlikely
C‐Possible
Medium
Medium
2‐Minor
from them.
E‐Rare
Site Engineer /
Low
Generation of toxic gases and Metal fume fever, dizziness,
fumes nausea
10 15 Continual monitoring required 21 0%
Use respiratory mask 3M‐8214 if required. supervisor
Use forced ventilation when required.
Local exhaust ventilation to be used.
3‐Moderate
B‐Likely
Loose welding rods / stubs Personnel tripping, fall and injury Used electrode pieces must be collected / kept in
3‐Moderate
D‐Unlikely
bucket or bin containers.
Medium
2‐Minor
E‐Rare
Site Engineer /
High
Low
Keep the area clean. supervisor
Use inspected cables
Welding earth shall be connected at work piece
5‐Catasrophic
3‐Moderate
only
D‐Unlikely
C‐Possible
Medium
Extreme
2‐Minor
E‐Rare
Continual monitoring required , if found any Site Engineer /
Low
Electric, welding cables and Grounding shall be connected at plant permanent
Earthing /Grounding
Fire / electric shock /Fatality 5 16 20 0%
earth connector only damage of equipment immediately replace supervisor
Maintain good cable management
4 Welding operations
Use fire extinguisher , fire blanket and fire watcher
Metal fume Use ventilation or exhaust to keep area as air‐
breathing zone clear and comfortable.
3‐Moderate
3‐Moderate
D‐Unlikely
D‐Unlikely
Crew, while working must place them self in the up
Medium
2‐Minor
E‐Rare
fever, dizziness, nausea Site Engineer /
High
Low
wind direction, so that the fumes and gases are
Toxic Fumes 18 20 Continual monitoring required 24 0%
blown away from them. supervisor
Use suitable Respirators especially when working in
confine space
Use 3M 8524 while welding on aluminum, galvanized
and Stainless steel.
3‐Moderate 3‐Moderate 3‐Moderate 3‐Moderate
Use correct filter lens and always use welding hood /
Medium
4‐Major
2‐Minor
E‐Rare
E‐Rare
E‐Rare
helmet. Site Engineer /
Low
High
Ultra violet radiation. Damage to eyes and skin. 20 22 Ensure employee competency 23 0%

Wear cotton coverall and provide non‐flammable supervisor
shielding to protect others.
Use hand gloves and avoid getting in contact with hot
3‐Moderate 3‐Moderate 3‐Moderate
C‐Possible
D‐Unlikely
Medium
2‐Minor
metal.
E‐Rare
High
Low
Hot Metal Burns 12 Warn others from getting in contact with hot metal or 18 Area to be barricated while working All employees 24 0%
post sign boards.
D‐Unlikely D‐Unlikely
C‐Possible
All cables, hoses and other portable equipment
Medium
2‐Minor
E‐Rare
Low
High
should be placed in a safe area and cables; hose lines
Tripping Hazards Injuries 10 must be laid in one side of the pathway and recoiled 15 Toolbox talk , Routine inspection All employees 20 0%
after completion of the job.
Medium
Used Electrode pieces must be collected / kept in
2‐Minor
B‐Likely
E‐Rare
Low
High
Bad House ‐keeping Injury, Trip 6 bucket or a tin container. 16 Continual Housekeeping All employees 22 0%

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
3‐Mod
D‐Unl
D‐Unl
work will be performed during the night time or
Obtain necessary valid safe work permit if
Med
2‐Mi
4‐Ma
E‐Ra
other than normal working hours. Site Engineer /
Hig
Low
Radiations burns and sickness
5 Radiography Radiation 5 12 required ,Area to be barricated while working , 20 0%

Percent Complete
Consequence(1)
Consequence(2)
Consequence(3)
Likelihood(2)
Likelihood(1)
Likelihood(3)
Recommended Action
Completion
Level(2)
Rank(3)
Level(1)
Level(3)
Rank(1)
Rank(2)
Date
By Whom
Person To Action

5 Radiography Radiation 5 12 required ,Area to be barricated while working , 20 0%
derate
gh
are
ajor
w
ium
caused due to exposure supervisor
ikely
ikely
nor
Any area where radiography work is to be
performed, must be barricaded with yellow and
Sign board required , Job watcher assigned ,
black stripe rope or tape.
Ensure all non‐classified personnel are away from any
test area.
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
5‐Catasrophic scrap materials.
3‐Moderate
D‐Unlikely
Substandard platforms,
Medium
Extreme
2‐Minor
B‐Likely
Collapse of platform, major
E‐Rare
Continual monitoring required , Conduct tool box Site Engineer /
Low
unsecured platform, fall Never carry any materials by hand while ascending or
6 Working at height
objects, unauthorized
injuries, and damage to crew and 4 15 21 0%
equipment. descending ladders. Maintain proper good talk prior to starts job at height supervisor
alterations. housekeeping at work location.
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
3‐Moderate
D‐Unlikely
D‐Unlikely
on the hydro test pump.
Medium
2‐Minor
4‐Major
E‐Rare
High
Low
Hydro testing and pressure Leakage, sudden release of The pressure source supply hose shall be
7 testing pressure
Personnel and property damage 5 16 22 0%
disconnected or isolated after test pressure is talk prior to starts job. supervisor
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.

Percent Complete
Consequence(1)
Consequence(2)
Consequence(3)
Likelihood(2)
Likelihood(1)
Likelihood(3)
Recommended Action
Completion
Level(2)
Rank(3)
Level(1)
Level(3)
Rank(1)
Rank(2)
Date
By Whom
Person To Action
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.
Ensure out riggers are fully extended, ground is
Obtain necessary valid safe work permit if
3‐Moderate
compacted and level. Always use blocks under
D‐Unlikely
Failure of slings, lifting gear, Injury to crew and other required ,Area to be barricated while working , project Manager
Medium
Extreme
2‐Minor
4‐Major
B‐Likely
E‐Rare
outrigger floats.
Low
hoisting and unstable crane, operatives in and around the job
8 Lifting / Rigging
failure of rope and hydraulic site damage to plant and
3 15 Display Lifting Sign board in lifting area .Lifting /Site Engineer / 21 0%
Specify equipment to rigging supervisor to ensure
system equipment. that the crane is suitable. shall be carried out only as per Approved Rigging supervisor
plan .
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.
3‐Moderate
C‐Possible
D‐Unlikely
Medium
Extreme
2‐Minor
4‐Major
Loading , unloading ,
E‐Rare
The lifting / loading / unloading area shall be Site Engineer /
Low
Injury to personnel, damage to
9 transporting& storage of Dropping of load
equipment and materials.
4 cordoned off to ensure that no person is under or 15 Ensure employee competency . 22 0%
materials supervisor
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.

Percent Complete
Consequence(1)
Consequence(2)
Consequence(3)
Likelihood(2)
Likelihood(1)
Likelihood(3)
Recommended Action
Completion
Level(2)
Rank(3)
Level(1)
Level(3)
Rank(1)
Rank(2)
Date
By Whom
Person To Action

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.
Sufficient support shall be provided to prevent
5‐Catasrophic
pitching or rolling of the load.
3‐Moderate
C‐Possible
D‐Unlikely
Visitors, workmen could suffer Only authorized personnel to operate vehicles and
Medium
Extreme
2‐Minor
E‐Rare
Low
injury from collision, Visitors, with a valid license and permission to drive in the
10 Movement of vehicles Collision
workmen could suffer injury from
4 12 20 0%
refinery. talk periodically , supervisor
collision,
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.
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.
3‐Moderate
3‐Moderate
Ensure there are enough crew members before
C‐Possible
D‐Unlikely
Medium
2‐Minor
lifting the load.
E‐Rare
High
Low
Back injuries, severe pains in the
11 Manual handling Strain of lifting material
hands, wrist, arm or neck
10 Check for any obstructions before lifting. 18 Conduct toolbox talk prior to start job All employees 25 0%
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.
Compressors must be inspected and tagged by the
3‐Moderate
3‐Moderate
D‐Unlikely
D‐Unlikely
competent person.
Medium
2‐Minor
E‐Rare
Preventive maintenance should be done
Low
High
Toxic Gases, (Carbon Mono
Suffocation, Sickness. 15 It Should be placed in well ventilated area. 20 Technician 24 0%
Oxide) Smoke, Fumes periodically
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
3‐Moderate
3‐Moderate
Medium
Medium
2‐Minor
barriers shall be placed to prevent exposure of
E‐Rare
E‐Rare
E‐Rare
Low
Noise Temporary deafness, headache 20 personnel to noise . 22 Toolbox talk All employees 28 0%
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
3‐Moderate
3‐Moderate
while working with compressed air.
D‐Unlikely
D‐Unlikely
Medium
2‐Minor
E‐Rare
The coupling of the hose must be secured with
High
Low
Compressed air Asphyxia / Injury 20 locking wire. 25 Toolbox talk All employees 29 0%
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
3‐Moderate 3‐M
12 Compressor
D‐Unlikely
C‐Possible
The hose of the compressor shall not cross the walk
Medium
Extreme
4‐Major
2‐Minor
E‐Rare
Continual monitoring required , tool box talk on
Low
Poor management of Injury due to Trip, fall & damage ways.
Compressor Hose to hose
5 15 All employees 20 0%
good hose management
The hose shall be arranged in a good order to avoid
trip and fall and damage to the hose
D‐Un
D‐Un
Med
2‐M
4‐M
Damaged / cut hoses shall not be used.
E‐R
Hi
Lo
Bursting of compressed Hose Injury material damage 8 16 Continual monitoring required TBT All employees 23 0%

Percent Complete
Consequence(1)
Consequence(2)
Consequence(3)
Likelihood(2)
Likelihood(1)
Likelihood(3)
Recommended Action
Completion
Level(2)
Rank(3)
Level(1)
Level(3)
Rank(1)
Rank(2)
Date
By Whom
Person To Action
Minor
Major
Rare
ow
8 16 Continual monitoring required , TBT All employees 23 0%
dium
Bursting of compressed Hose Injury , material damage
nlikely
nlikely
odera
gh
No vehicle shall pass over compressed hose.
Preventive maintenance shall be done regularly.
3‐Moderate
D‐Unlikely
D‐Unlikely
Medium
2‐Minor
4‐Major
Fire extinguishers must be placed nearby to
E‐Rare
High
Low
Fire due to Overheating of Injury to personnel & damage to
Compressors property
10 immediately extinguish the fire. 13 use equipment , preventive maintenance should All employees 20 0%
The compressor shall be kept away from other be done on routine basis
flammable and combustible materials.
The compressors must be put off before going on
break or when it is not in use.
The compressor must be properly connected with the
towing vehicle.
3‐Moderate
D‐Unlikely
D‐Unlikely
Ensure employee competency , on prior to
Medium
2‐Minor
4‐Major
E‐Rare
High
Low
Disengagement, overturning Speed must be very slow and utmost care to be taken
Towing of Compressors
,accident
6 on turnings.
15 towing equipment check all fitting is done Driver 22 0%
properly and acceptable
All traffic rules and regulations must be followed as
per client requriment.
Proper maintenance must be done regularly.
3‐Moderate
D‐Unlikely
D‐Unlikely
Medium
4‐Major
2‐Minor
Generators must be inspected and tagged by the
Preventive maintenance should be
E‐Rare
Low
High
Toxic Gases, (Carbon Mono competent person.
Oxide) Smoke, Fumes
Death ,Suffocation, Sickness. 17 20 All employees 24 0%
Generators Should be placed in well ventilated area done periodically
,Forced ventilation must be provided in enclosed
place.
3‐Moderate
3‐Moderate
D‐Unlikely
D‐Unlikely
Medium
Medium
2‐Minor
Generators must be kept at a distance to avoid
E‐Rare
Low
Noise Temporary deafness, headache 18 exposure of personnel to noise or ear protection 22 Toolbox talk All employees 26 0%
must be used.
3‐Moderate
D‐Unlikely
D‐Unlikely
Medium
2‐Minor
4‐Major
E‐Rare
High
Low
Electricity Electrical shock 6 All cables must be checked that it is not damaged or 15 Toolbox talk All employees 23 0%
cut. Appropriate ground earth connection should be
provided.
13 Generators All generator cables must be arranged properly and
3‐Moderate
3‐Moderate
D‐Unlikely
C‐Possible
Medium
2‐Minor
should not be crossing the walk way.
E‐Rare
Low
High
Electrical Cables Trip & Fall , Cable damage 6 16 Continual monitoring required , TBT All employees 22 0%

Cables must not be crossing roads or paths that are
used by vehicles/ forklifts to avoid any damage to the
cables.
The generators must be properly connected with the
3‐Moderate
3‐Moderate
D‐Unlikely
towing vehicle.
C‐Possible
Medium
Ensure employee competency , on prior to
2‐Minor
E‐Rare
Low
Disengagement, overturning,
High
Towing of Generators 7 Speed must be very slow and utmost care to be 16 towing equipment check all fitting is done Driver 21 0%

accident taken on turnings.
properly and acceptable
All traffic and site rules and regulations must be
followed
Preventive maintenance shall be done regularly
3‐Moderate
Fire extinguishers must be placed nearby to
D‐Unlikely
D‐Unlikely
Medium
2‐Minor
4‐Major
immediately extinguish the fire.
E‐Rare
Low
Fire due to Overheating of Loss of Equipment, property and
High
Generators injury to men
10 The generators shall be kept away from other 15 use equipment , preventive maintenance should All employees 22 0%
flammable and combustible materials. be done on routine basis
The generators must be put off before going on
break or when it is not in use.
D‐Unlikely
3‐Moderate
Check all tools and don't use defective tools.
C‐Possible
Medium
2‐Minor
E‐Rare
Low
High
Defective & Greasy Tools Injuries 15
Keep the tools clean and free from any lubricants like
18 Toolbox talk All employees 23 0%
oil grease
D‐Unlikely
D‐Unlikely
Medium
2‐Minor
4‐Major
All tools and equipment must be properly stored.
E‐Rare
Low
Improper storage of tools & Site Engineer /
High
spare parts .
Slips, trips & stress 10 15 Monitoring should be done by competent person supervisor
21 0%
All spare parts must be identified, marked and stored
correctly.
Gas Cylinders must be stored under shaded and
ventilated place, secured in vertical position.
3‐
D

Percent Complete
Consequence(1)
Consequence(2)
Consequence(3)
Likelihood(2)
Likelihood(1)
Likelihood(3)
Recommended Action
Completion
Level(2)
Rank(3)
Level(1)
Level(3)
Rank(1)
Rank(2)
Date
By Whom
Person To Action
D‐Unlikely
‐Moderate
D‐Unlikely
Medium
2‐Minor
4‐Major
E‐Rare
Low
Improper storage of Gas Site Engineer /
High
Cylinders
Explosion, Fire 6 Gas Cylinders must be segregated and kept separately 18 Monitoring should be done by competent person supervisor
25 0%
ie Full Oxygen, CO2, Empty, Acetylene etc.
There must be 20 ' distance from Oxygen to
Acetylene , Propane or other flammable Gas
Cylinders.
3‐Moderate
D‐Unlikely
D‐Unlikely
3‐Moderate
Medium
Medium
2‐Minor
Ensure the work and resting area kept neat and clean
E‐Rare
Continual improvement of housekeeping
Low
Bad housekeeping Contaminate disease 8 and all rubbish is put into the waste and it is regularly 15 All employees 20 0%
emptied. required
Horseplay is strictly not allowed in the work area.
Sleeping is strictly not allowed on operational areas
3‐Moderate
3‐Moderate
D‐Unlikely
C‐Possible
regardless of circumstances.
Medium
2‐Minor
E‐Rare
Low
Horse play & loitering, unsafe
High
acts
Injury 9 Employees are not allowed to leave their job without 18 Toolbox talk All employees 26 0%
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.
3‐Moderate
3‐Moderate
D‐Unlikely
C‐Possible
Medium
2‐Minor
E‐Rare
Low
High
All slippery surfaces shall be cleaned immediately
Slippery surface Slips and falls 12 using sawdust or sand. 16 Monitoring should be done by competent person All employees 24 0%
All vehicles entering and exiting the Workshop,
3‐Moderate
D‐Unlikely
C‐Possible
Medium
garage shall be driven as slow as possible.
2‐Minor
Extreme
4‐Major
14 General
E‐Rare
Low
Injuries, Fatalities, Property
Speed
damage.
6 Drive slowly and give necessary signals extra 12 Toolbox talk Driver 20 0%
attention must be given while driving on all areas of
the company
3‐Moderate
3‐Moderate
D‐Unlikely
C‐Possible
Medium
2‐Minor
Employees shall ensure that their tools are in good
E‐Rare
Low
High
Using defective tools. Injury 10 condition and if a defect is observed then it must be 15 Toolbox talk All employees 22 0%

replaced.
Supervisor shall ensure that required proper tools
are available and they are in good condition.
Mushroom head tools shall be rectified or replaced.
All hammers heads shall be fitted firmly to the
wooden handles.
3‐Moderate
3‐Moderate
D‐Unlikely
C‐Possible
Medium
2‐Minor
E‐Rare
Conduct toolbox talk prior to start job , Conduct
Low
Opening man ways and other Site Engineer /
High
Injuries 8 Brass hammers shall be used as applicable and shall 15 26 0%
flanges be frequently checked as it has high failure rates gas test if required , assign job watcher supervisor
Flogging spanners shall be kept clean and in
congested area hammering shall be done with
extreme care.
Penetrating liquids shall be used for unbolting
process.
Tools shall be also checked, during the work for any
defects
Ensure ladders are in good condition and secured or
3‐Moderate
fixed in a correct angle.
3‐Moderate
D‐Unlikely
C‐Possible
Medium
2‐Minor
E‐Rare
Visual inspection to be done before use any
Low
High
Ensure that, there are no cables, pipes or any
Using ladders Injuries 6 13 All employees 20 0%
obstructions on the ladder rungs, or near it. ladder , if found defect immediately change it .
Ensure ladder rungs are free from any slippery
substance.
Ensure that the rotary movement of equipment has
come to a complete halt and power supply
3‐Mode
3‐Mode
D‐Unlik
C‐Possi
Mediu
2‐Min
disconnected before carrying out any activities like
E‐Rar
Low
High
Rotating equipments Injuries 9 inspection, repairs, cleaning. 15 barricate the area All employees 20 0%


Percent Complete
Consequence(1)
Consequence(2)
Consequence(3)
Likelihood(2)
Likelihood(1)
Likelihood(3)
Recommended Action
Completion
Level(2)
Rank(3)
Level(1)
Level(3)
Rank(1)
Rank(2)
Date
By Whom
Person To Action
w
erate
erate
h
um
kely
ible
e
or
Keep portable grinders on the ground only after the
wheel has complete stopped rotating.
Provide good supervision.
Don’t use sudden force.
Ensure working platforms used are in firm and in
good condition.
3‐Moderate
D‐Unlikely
Maintain good housekeeping.
C‐Possible
Medium
2‐Minor
Extreme
4‐Major
E‐Rare
Low
Site Engineer /
15 Unbolting Bolting Slip, Trip ,fall , finger trap Personnel Injury, Loss to Property 5 Don’t keep the free nuts/bolts on platform plank or 13 Conduct toolbox talk prior to start job , supervisor
21 0%
on platform grating. Store in steel bucket or at
ground level to minimize falling hazards.
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.
Floor openings shall be barricaded or protected by
3‐Moderate
D‐Unlikely
C‐Possible
Medium
hard barricades and proper signage to be provided.
2‐Minor
4‐Major
E‐Rare
Low
Walking on higher elevated Site Engineer /
High
16 /platform
Unprotected floor opening Fall / tripping / injury 7 Employees shall check the area before walking on the 13 Conduct toolbox talk prior to start job supervisor
20 0%
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.
Users must stay in view of the chain block at all time
3‐Moderate
D‐Unlikely
3‐Moderate
to ensure the following:
C‐Possible
Medium
2‐Minor
E‐Rare
Low
Pulling of equipment by using Do not operate a damaged or malfunctioning chain Site Engineer /
High
17 chain blocks or liver block
Failure of equipment Personnel and property damage. 6 13 Conduct toolbox talk prior to start job . supervisor
21 0%
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.
3‐Moderate
D‐Unlikely
3‐Moderate
C‐Possible
Medium
2‐Minor
Use suitable respiratory protection.
E‐Rare
Low
Exposure to flammable liquids Irritation to respiratory system, Site Engineer /
High
,toxic gases and dust particles eyes and skin
8 Use goggles. 15 Conduct toolbox talk prior to start job supervisor
22 0%
Use proper PPE.
3‐Moderate
Allow only experienced workers to go inside.
3‐Moderate
D‐Unlikely
D‐Unlikely
Medium
2‐Minor
Medium
Follow company procedure for entering in confined
E‐Rare
Low
Site Engineer /
Restricted space Sprains and strains 18 spaces. Obtain necessary valid work permit supervisor
26 0%
18 Internal cleaning Job rotation of workers.
Job fit for purpose
All scrap material and unnecessary items have to be
removed from the working area as soon as possible
3‐M
3‐M
D‐
to secure the area
C‐
2

Percent Complete
Consequence(1)
Consequence(2)
Consequence(3)
Likelihood(2)
Likelihood(1)
Likelihood(3)
Recommended Action
Completion
Level(2)
Rank(3)
Level(1)
Level(3)
Rank(1)
Rank(2)
Date
By Whom
Person To Action
Medium
Moderate
Moderate
Possible
Unlikely
‐Minor
E‐Rare
Continual improvement of housekeeping
Low
Personnel injury and property
High
Falling objects
damage
9 Ensure that working tools and items are kept in a 16 All employees 22 0%
required
secure container.
All employees shall wear appropriate PPE.
Provide proper ventilation.
5‐Catasrophic
3‐Moderate
D‐Unlikely
C‐Possible
Follow confined space procedures.
Medium
2‐Minor
Extreme
E‐Rare
Obtain necessary valid work permit . Conduct
Low
Oxygen deficient / enriched Conducts gas test before enter in confine space Site Engineer /
atmosphere
Fire, explosion / fatality 6 13
supervisor
22 0%
Use suitable PPE.
toolbox talk prior to start job
Ensure all final checks have been performed before
entry.
3-Moderate
C-Possible
Entry after clearance,
D‐Unlikely
Medium
2‐Minor
E‐Rare
Obtain necessary valid work permit . Conduct
Low
Plan and schedule the job correctly. Site Engineer /
High
High temperature Giddiness, unsteadiness 19 22
supervisor
23 0%
Provide plenty of water at job location. toolbox talk prior to start job
Provide ventilation.
D‐Unlikely
3‐Moderate
D‐Unlikely
Medium
2‐Minor
Medium
E‐Rare
Ensure employees are using ear protection
Low
Site Engineer /
Noise Stress & deafness 15 Use suitable PPE. 20
supervisor
22 0%
device
Toolbox talk about how to use ear plugs.
Carryout gas test if required
3‐Moderate
D‐Unlikely
3‐Moderate
C‐Possible
Medium
2‐Minor
E‐Rare
Employees should familiar of emergency
Low
Exposure to flammable and Poisoning, fainting, major fatality,
High
toxic gases fire and explosion.
7 Provide enough ventilation. 15 All employees 21 0%
19 Confined Space procedure
Follow correct procedures.
3‐Moderate
Use only tested & inspected equipments
D‐Unlikely
D‐Unlikely
Visual inspection to be done before using any
Medium
2‐Minor
4‐Major
E‐Rare
Use ELCB.
Low
High
Electrical equipment Electrocution 10
se only 24/110 volts equipments.
16 electical equipment , if found defect All employees 25 0%
immediately change it .
Maintain proper cable management to avoid slip
and trip
3‐Moderate
D‐Unlikely
3‐Moderate
C‐Possible
Medium
2‐Minor
E‐Rare
Low
High
Be aware of surroundings.
Obstructions Injury 12 19 Toolbox talk All employees 25 0%
Be vigilant.
3‐Moderate
D‐Unlikely
3‐Moderate
C‐Possible
Medium
2‐Minor
Ensure proper lighting before entering confine space
E‐Rare
Low
Darkness , collision with
High
Poor lighting
equipment
5 13 Toolbox talk , Routine inspection All employees 21 0%
wear clear safety glass

Work in a team while handling or lifting any office
3‐Moderate
items.
D‐Unlikely
3‐Moderate
D‐Unlikely
Medium
2‐Minor
Medium
E‐Rare
Trolley to be used to handle heavy equipment or
Low
Manual handling of office
equipments
Back pain 15 carried out the handling activity with the help from 19 Access load before handle All employees 27 0%
team member.
Before Handling Ensure you are fit for task.
Maintain good posture to avoid unwanted glare and
reflection falling on screen.
3‐Moderate
3‐Moderate
D‐Unlikely
C‐Possible
Medium
2‐Minor
Medium
Plan your work task accordingly to avoid Back pain by
E‐Rare
Low
Discomfort posture , injuries ,
Display screen equipments
head ache
16 working continuous on computer. Follow with 21 Toolbox talk All employees 26 0%
interval breaks.
Switch off the power source when not in use and
before leaving the office .
3‐Moderate
D‐Unlikely
3‐Moderate
C‐Possible
Medium
2‐Minor
Medium
Always work within design or environmental limits.
E‐Rare
Low
Lack of job control Stress 9
Always address abnormal conditions and never let
16 Toolbox talk All employees 22 0%
them become accepted as normal .if Doubt ask to
your senior.
3‐Moderate
D‐Unlikely
Maintain good housekeeping
3‐Moderate
C‐Possible
Medium
2‐Minor
Medium
E‐Rare
Toolbox talk , countinual improvemetn in
Low
Slip, trip and falls Injuries 6 All area well lit . Including stair and walkways. 16 All employees 24 0%
housekeeping required.
Keep the assess free from to avoid from Slip & Trip.

Percent Complete
Consequence(1)
Consequence(2)
Consequence(3)
Likelihood(2)
Likelihood(1)
Likelihood(3)
Recommended Action
Completion
Level(2)
Rank(3)
Level(1)
Level(3)
Rank(1)
Rank(2)
Date
By Whom
Person To Action
20 Office activities Ensure all office equipment’s are CE marked.
Ensure all office equipment well maintained.
Avoid wet hand before touching electrical
3‐Moderate
D‐Unlikely
C‐Possible
Medium
2‐Minor
Extreme
equipment
4‐Major
E‐Rare
Low
Electricity Fire , Electric shock 5 14 Toolbox talk All employees 23 0%
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
3‐Moderate
D‐Unlikely
3‐Moderate
C‐Possible
Medium
2‐Minor
Ensure all electrical equipment in well maintained
E‐Rare
Low
Site Engineer /
High
Fire Burn , Property damage 5 16 Refresh emergecy procedure in toolbox talk supervisor
22 0%
Provision of fire extinguisher and training
Ensure Fire alarm systems well maintained
Conduct mock drills
3‐Moderate
D‐Unlikely
3‐Moderate
C‐Possible
Medium
2‐Minor
E‐Rare
Complete task in time . And leave the office if
Low
High
Lone working Suffer injury 5 Security staff check all area before locking the offices 13 All employees 21 0%

you are alone
D‐Unlikely
D‐Unlikely
Medium
2‐Minor
4‐Major
E‐Rare
Low
Ensure machinery is stopped and electrically isolated
High
Rotating machinery Entanglement 10
during maintenance.
15 Ensure employees competency Technician 22 0%
D‐Unlikely
C‐Possible
Medium
Extreme
2‐Minor
4‐Major
E‐Rare
Low
Electricity Electrical shock 6 Electrical fault finding or safety testing with live 13 Toolbox talk Technician 23 0%
equipment only done by qualified or competent
person
Vices and other suitable fixtures for
holding/clamping work‐pieces are provided.
Tools are kept in good condition and are maintained
3‐Moderate
D‐Unlikely
by workshop staff as required.
3‐Moderate
C‐Possible
Medium
2‐Minor
E‐Rare
Inspect tool before using , replace if found
Low
Cuts/abrasions, stabbing, impact
High
Damage of tools
,small projectiles , dust
9 Eye protection, boiler suits /lab coats, gloves, safety 16 Technician 22 0%
shoes and dust masks are provided and used as defect.
appropriate.
21 Maintenance activities Workbenches are sited away from machine tools
and other activities.
Use inspected tools
Guards are either permanent fixtures, or are
Entanglement available to be fitted to
Machines as necessary. They are correctly adjusted
Friction and used
Work‐pieces are securely held with vices, chucks,
3‐Moderate
D‐Unlikely
C‐Possible
Medium
Abrasion, fixtures and clamps. Emergency stop/brake
2‐Minor
Extreme
4‐Major
E‐Rare
Low
Abrasive wheels are mounted and dressed by trained Site Engineer /
Powered machinery 6 13 Conduct toolbox talk prior to start job supervisor
21 0%
Cutting, Shearing, competent persons.
Rests on bench/pedestal grinders are set by trained
Stabbing/Puncturing, competent persons.
Impact, Crushing, Machine operators wear suitable protective
Machinery is kept in good working order through
Drawing in, and Ejection. regular maintenance and cleaning.
Prepared by , Reviewed by Approved by


Percent Complete
Consequence(1)
Consequence(2)
Consequence(3)
Likelihood(2)
Likelihood(1)
Likelihood(3)
Recommended Action
Completion
Level(2)
Rank(3)
Level(1)
Level(3)
Rank(1)
Rank(2)
Date
By Whom
Person To Action
NIS HSE Dept . NIS Project Manager GAMA

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

OHS Injury First Aid Treatment Medical Treatment Lost time injury (LTI) Multiple LTI’s Fatality
required - no lost time Permanent disabling
OHS Illness injury injury
Environment No Impact on baseline Localised within site Moderate harm with Significant harm with Significant Impact
environment. Localised to boundaries. Recovery possible wider effect. local effect. that is widespread,
point source. measurable within 1 Recovery in 1 year. Recovery longer than unconfined impact,
No recovery required. month of impact. Failure to follow 1 year. requiring long-term
Non compliance event. No internal clearing Ground disturbance recovery, leaving
prosecution. requirements. with no approvals in major residual
place. Rare or damage.
endangered species Unauthorised clearing
or heritage site resulting in damage to
impacted but a rare and/or
recoverable. endangered species
Repeat legal non habitat and/or has
compliance / internal damaged heritage
breach. Prosecution. 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 Localised, long term Localised, long term Long term regional
impact impact but impact with impact
manageable unmanageable
outcomes
2. Determine the likelihood of the event occurring and it resulting in the consequence selected above using the table below.
Likelihood Rating Description
Incident is expected to occur on this project, possibly several times
Almost Certain Evidence of common or repeated occurrence
95%
Occurs more than once a year.
Likely Incident may easily occur on this project

75% Occurs at least once in a year
Possible Incident has occurred on a similar project

50% May occur at least once in a year
Unlikely Incident unlikely to occur during this project
25% Not likely to occur in 10-100 years.
Incident highly unlikely to occur on this project
Rare
5% Not likely to occur in 100-1000 years
3. Utilise the risk matrix below to identify the risk and risk rating
Likelihood Insignificant Minor Moderate Major Catastrophic
Description % 1 2 3 4 5
Incident is
expected to occur
A Almost Certain on this project, 95% HIGH HIGH EXTREME EXTREME EXTREME
possibly several
times
Incident may
B Likely easily occur on 75% MEDIUM HIGH HIGH EXTREME EXTREME
this project
Incident has
C Possible occurred on a 50% LOW MEDIUM HIGH EXTREME EXTREME
similar project
Incident unlikely
D Unlikely to occur during 25% LOW LOW MEDIUM HIGH EXTREME
this project
Incident highly
E Rare unlikely to occur 5% LOW LOW MEDIUM HIGH HIGH
on this project
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 Page 1 of 1

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METHOD STATEMENT FOR HRSG WORKS

Page: 1/32 Doc. No: NIS/626/M Date: 20-12-2015

SEC POWER PLANT PP-13 PROJECT

METHOD STATEMENT FOR ERECTION OF HSRG

Dok. No: PR-004-T05, Rev. No: 1

Page: 2/32 Doc. No: NIS/626/M Date: 20-12-2015

Dok. No: PR-004-T05, Rev. No: 1

Page: 3/32 Doc. No: NIS/626/M Date: 20-12-2015

1.0 PURPOSE ..................................................................................................................................... 4

Dok. No: PR-004-T05, Rev. No: 1

Page: 4/32 Doc. No: NIS/626/M Date: 20-12-2015

2.0 SCOPE OF WORK

4.0 DEFINITIONS / ABBREVIATIONS

Dok. No: PR-004-T05, Rev. No: 1

Page: 5/32 Doc. No: NIS/626/M Date: 20-12-2015

Planned Manpower Distribution Histogram attached.

8.0 SUBCONTRACTORS’ SUB-TIER CONTRACTORS

b) Unloading & Storage

Daily Material Receipt (DMR)

Dok. No: PR-004-T05, Rev. No: 1

Page: 6/32 Doc. No: NIS/626/M Date: 20-12-2015

9.2 Planning & Construction

a) Sequence of Erection of HRSG Components.

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

6) Installation of Stack Section-1.

7) Pre-Assembly of Stack Section-2 along with platform,ladder,gratings and other accessories if

8) Installation of Stack Section-2.

9) Pre-Assembly of Stack Section-3 along with platform,ladder,gratings and other accessories if

10) Installation of Stack Section-3.

11) Installation of CEMS Unit.

9.3 Erection of HRSG.

a) HRSG Casing erection Sequence:

Dok. No: PR-004-T05, Rev. No: 1

Page: 7/32 Doc. No: NIS/626/M Date: 20-12-2015

HRSG Casing Module shall be erected from Grid G to Grid N as follows:

1) Suitable Shimming shall be provided and Installed as required.

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;

1) Installation of bottom panels to be levelled,aligned to the HRSG main longitudinal and

3) Installation of front and rear panel.

Dok. No: PR-004-T05, Rev. No: 1

Page: 8/32 Doc. No: NIS/626/M Date: 20-12-2015

verticality of casing structures have to be recorded in a dedicated form to be arranged at site

7) Execution of final connections and welding of the truss guide beams.

13. Installation and bolting of buckstays to the main columns.

Dok. No: PR-004-T05, Rev. No: 1

Page: 9/32 Doc. No: NIS/626/M Date: 20-12-2015

Dok. No: PR-004-T05, Rev. No: 1

Page: 10/32 Doc. No: NIS/626/M Date: 20-12-2015

Dok. No: PR-004-T05, Rev. No: 1

Page: 11/32 Doc. No: NIS/626/M Date: 20-12-2015

9.4 Inlet Duct

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;