Railway Electrification and Double-Double Tracking of Java Main Line Project Package B1 : Railway Facility Construction for BEKASI

to CIKARANG

METHOD STATEMENT Panel and Equipment For Signaling System Works

PROJECT Title Name Signature Date SECTION Name Signature Date Contractor Originator

Checked by Interface and Engineering Manager H. Houan / Y.Nonaka

Checked by Deputy General Superintendent A.H. Desfiansyah

Approved by General Superintendent Y. Kameda

Written by Nurhalim/T.Ikenaga

Checked by N. Fukuta

Checked by M. Adachi

December 14th, 2013

Mitsubishi-Sumitomo Joint Operation Mitsubishi Heavy Industries, Ltd. B1/CON/SIG/0001

R001P-EG43-00002 Revision:

Document No.

Internal Ref. No. (Form B1IN/GEN/PLN/0001 Rev. 0)

RAILWAY ELECTRIFICATION AND DOUBLE-DOUBLE TRACKING OF JAVA MAIN LINE PROJECT PACKAGE B1: RAILWAY FACILITY CONSTRUCTION FOR BEKASI TO CIKARANG

Revision History
Section
Written by Checked by Approved by Written by Signed on Cover Page

Rev.

Date
Dec 14th, 2013

Project
Checked by Approved by

Description:
Signed on Cover Page

Description:

Description:

Description:

Description:

Description:

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Table of Contents

1 Purpose...............................................................................................1
1.1 Introduction....................................................................................................... 1 1.2 Objective .......................................................................................................... 1

2 Scope Of Work....................................................................................1 3 Reference Documents ........................................................................2 4 Organization........................................................................................2

4.1 Site Works Organization (Signal & Telecom Works) .................................... 2 4.2 Support Project Organizations ......................................................................... 3

5 Materials .............................................................................................3 6 Tools and Equipment ..........................................................................5 7 Work Procedure ..................................................................................6

7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 Preparation ....................................................................................................... 6 Transferring Panel and Equipment .................................................................. 6 Materials Delivery and Arrangement................................................................ 6 Preparation to Install ........................................................................................ 7 Unloading Handling Panel and Equipment at Site ........................................... 7 Storage ............................................................................................................. 7 Recommended Inspection ............................................................................... 7 Installation ........................................................................................................ 8
Installation Procedure for Panel ...................................................................................... 8 Installation Procedure for Equipment .............................................................................. 9

8 Safety, Environmental and Hazard Mitigation ...................................12

8.1 8.2 8.3 8.4 8.5 Preparation ..................................................................................................... 12 Toolbox Talk ................................................................................................... 13 Train Watchers (Safety Supervision) ............................................................. 14 Accident Prevention Arrangement ................................................................ 15 Initial Response and Reporting ...................................................................... 16

7.8.1 7.8.2

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

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

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1 Purpose 1.1 Introduction The project Railway Electrification and Double-Double Tracking of Java Main Line Project, Package B1 is an operating line that needs to be upgraded and expanded to accommodate the increasing train traffic which is attributable to the increase in public patronage. This Statement describes transferring, placement, inspecting and installing for panel and equipment for signaling system works. So as to realize the indicated general project goals, panel and equipment for signaling system will be designed and installed. This Signaling facilities upgrade will improve the transporting capability of the train system, improve or upgrade the safety level of the operating system and in a relative sense, reduce pollution and elevate riding comfort.

1.2

Objective This proposed Method Statement is intended to detail the work procedures and requirements that will be implemented or used during the panel and equipment installation for Signaling System works of the Railway Electrification and Double-Double Tracking of Java Main Line Project, Package B1. The method statement is prepared in such a way to ensure: Safety and punctuality of the installation process; Quality of the installation works; Minimum affect to the train operation; Minimum or no delay to the installation or to the construction works.

Scope Of Work

This work shall consist of transferring, placement, inspecting and installing for panel and equipment for signaling system works. The works shall be performed in accordance with the specification and as shown on the drawing unless otherwise directed by engineer. Installation work of new panel & equipment system shall be carried out within station at Manggarai, Jatinegara, Bekasi, which controls Cakung, and Cikarang, which control Tambun, including related system between stations and Cipinang depot.

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Reference Documents The following documents are considered for the development of this Method Statement: Technical Specification and Tender Drawings of RAILWAY FACILITY CONSTRUCTION
FOR BEKASI TO CIKARANG-PACKAGE B1;

Project Management Plan B1/PLN/GEN/0008; Basic Design Section 8 : Signaling Systems Works B1IN/PLN/GEN/0004; Construction Management and Organization Plan B1/PLN/GEN/0012; Site Health and Safety Plan B1/GEN/PLN/0015; Permit and Work Procedure in an Operating Railway B1/PLN/GEN/0024; Quality Management Program B1/PLN/GEN/0013; Quantity Management Program B1/PLN/GEN/0014;

Organization

MSJO, through the General Superintendent, has the overall responsibility to manage all works under the DDT project. The Panel and Equipment installation for Signaling System works will be performed under Construction Management and Organization for Electrical & Mechanical Works. A proposed site organization chart specific for the supervision of the works is included in the detailed Method Statement, as shown in Attachment The Site Supervisor will be responsible for the execution of the Works, and will report to MSJO Engineer-in-Charge on all progress issues, and shall perform supervise of material, tools equipment, and quality control also of the performed works and Other issues as defined by MSJO Engineer-in-Charge.

4.1

Site Works Organization (Signal & Telecom Works)

A work team for the The Panel and Equipment Installation for Signaling System will be organized to perform the installation works The work team will consist of the following. 1) Foreman or Site Supervisor; 2) Drivers; 3) Technicians; 4) Laborers; 5) Train watchers. The team or each team will be monitored / supervised by Site Supervisor who will record or document the Panel and Equipment Installation and will be assisted by the HSE ( Health Safety Enviromental ) Manager or any of his designate.

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4.2

Support Project Organizations

Support project organizations are shown in the following attachments: 1. Attachment 1MSJO and PT. Len Construction Organization Chart

Materials

The following materials will be utilized for panel and equipment installation by signalling works are following below: Panel 1. Inside Signal Cabin : - OT/FT Rack - TC Device Rack - Relay Rack - Logic Rack - UPS - MDPD - SDDP - Control Console - MTC (Maintenance Terminal Console) 2. Outside/Wayside Railway: - JB (Junction Boxes) / CB (Connection Boxes) - Location Cases (LOC) Equipment - Signal & Marker - Point Machine - Automatic Block Signal - Level Crossing

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(Control Room) Control Console

Optical fiber Cable

MTC: Maintenance Console

Logic Rack (K5B) Relay Rack

Signal Device Room TC Device Rack

Relay I/F Between EI / Field Equipments

Transformer Rack
Insulati on Trans. Insulation Transformer (for ABS) (OPC) Insulation Transformer (for LT)

FT Rack

OT Rack

Insulatio n Transformer (for EI)

Insulatio n Transformer (for EI)

Outside Equipments

Insulation Transformer (for PM)

Insulation Transformer (for TC)

Figure 5-1. Panel at inside Signal Cabin

Location Case

Figure 5-2. Panel at Wayside/Outside

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Point Machine

Signal Indicator

Level Crossing

Track Circuit With IRJ

Figure 5-3. Equipment 6 Tools and Equipment The tools and equipment listed below will be utilized for panel & equipment installation for signalling works: Picks and shovels; Crow bars and Digger bars; Measuring tapes; Hammers and sledge hammers; Cutting tools; Hand tools, assorted; Termination tools; Multi tester; Toolkit; Hand pallet; Transferred by Truck.

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7 7.1

Work Procedure Preparation Work management for Critical Path (Coordination with other panel and equipment works) in implementing new installation or modification of panels and equipment set system must be finished in accordance with the available work window time and cannot disturb the train operation. To achieve the work target, the following are the items must be considered: Preparation work to be well arranged. Good coordination with site staff. Material preparation and equipment to be used. Sufficient manpower preparation. Qualified site staff/person in charge preparation who fully qualified understands with the work to be done. Construct the foundation correcly in accordance with drawing or the outline drawing before the arrival of panel and equipment.

7.2

Transferring Panel and Equipment

Arrangement for transportation Distribution panel and equipment can be shipped complete in standard shipping container. Weather-proof blanking plates are provided where necessary.

7.3

Materials Delivery and Arrangement

In Panel and Equipment installation, there are two (2) delivery conditions that possible: Panels and Equipment from the Port / factory directly taken to the substation. This condition can be done if the current equipment that will be brought already arrived in the port, the condition of civil works allows for placement of goods for a while. Panels and Equipment will be taken to a substation of the MHI warehouse. This condition is performed if at the time the equipment arrived in the port, civil building conditions or foundation construction have not allowed for laying equipment for a while.

Figure 7- 1. Transferred by Truck

For Panels and Equipment will be taken from the truck using Hand Pallet to be positioned in the space that provided.

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Figure 7- 2 Hand Pallet

7.4

Preparation to Install
Determining location for installation of Panel and Equipment The location in which the Panel & Equipment is to be installed must be accurately determined and preparations for which such as the concrete foundation, base, anchor, etc. (if its wayside location for example panel: LOC) and such as placement on the floor according to shop drawing that is approved by engineer & PT. KAI (if its inside Signal Cabin) should be completed prior to the arrival of the Panel & Equipment.

7.5

Unloading Handling Panel and Equipment at Site

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

7.6

Storage
Accessories / Fittings dispatched separately from main consignment are usually packed in case/crate, although certain items are sometimes dispatched without packing. All items as received should be stored in a dry and covered place provided there are no signs of damage or rough handling. Indoor type Equipment must be protected from the weather. Outdoor units may be stored outside, in a warm area, if possible, protected from the prevailing weather.

7.7

Recommended Inspection
Panel & Equipment are properly packed and dispatched by suitable transport up to destination. In spite of all care being taken during dispatch, the panel & equipment can get damaged during transit and any consignment should be checked after delivery at site. Immediately on arrival at site, any Panel and Equipment should be examined for any sign of external damage in transit with particular attention to;
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Dents / cracks Damage to protruding Loose bolts / screws / clamps. Check the packages with the packing list and also investigate damages of the components It is preferable to store the accessories inside a building, however where they are outdoors, cover them with a suitable sheets. Dont expose them to the weather.

The various packages should be checked against the advice notes. Any discrepancy from the advice notes should be immediately reported to the Insurance Underwriters, and to the Transport Contractors, used for transportation by the Supplier, particularly where damage has occurred in transportation. Claims can then be lodged with transport contractor and / or insurance underwriters as required. After the Equipment has arrived at site, the Equipment should be stored on the Equipment foundation pad until the installation work will be started. The Equipment main body and its parts should be stored as follows.

7.8

Installation

7.8.1 Installation Procedure for Panel

Installation Procedure for Panel at inside Signal Cabin: Coordination with PT.KAI before doing installation to avoid obstruction to the existing train operation in the area specified herein Placement at a position in accordance drawings panels and wiring route that have been approved by Engineer and PT. KAI After the placement is determined, the panel can be placed in a position in accordance with the marking of each panel In the marking that has been made, holes for the panel should also available. After marking and holes have been completed, the panel can be placed in a position in accordance with the marking of each panel. Then the panel shall be fixed with bolts and shall be installed upright in signal cabin Clearance spaces for maintenance work on the panel shall be not less than one (1) meter in front of panel and to any passageway and not less than 0.6 meters to rear of panel as necessary. For protecting the panel from lighting surges and any electromagnetic interference, the following shall also be taken into consideration: a. Grounding facilities inclusive of suitable arrester shall be provide b. Isolation transformer for surge protection type shall be provided against lightning surge from power supply equipment to electronic at inside the panel c. High quality insulated frame with suitable dimension shall be provided d. If cable trays or ducts of steel are used, they shall be isolated by adequate insulators such as vinyl sheets from ceilings and/or walls of building structure e. Indoor cable and wires connected between signal devices in the signal cabin or equipment buildings shall be isolated from outdoor cables terminated on external cable racks and laid in under-floor ducts or overhead cable tray.

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Installation Procedure for Panel at Wayside Railway: Coordination with PT.KAI before doing installation to avoid obstruction to the existing train operation in the area specified herein Placement at a position in accordance drawings panels that have been approved by Engineer and PT. KAI The panel (ex. Location cases) shall be installed on concrete foundation with maintenance work space and top of concrete foundation shall be same level as top of rail. In case of narrow space on width of ballast shoulder, sheathing shall be provided. The panel (ex. Connection Boxes/Junction Boxes) shall be provided at places where tail cables will be connected with wayside equipment such as signals, point machines or track circuit devices. These connection boxes shall be fixed on to concrete foundations the lower parts of which shall be provided with PVC pipe cable inlet. In the marking that has been made, anchor holes for the panel should also available. After marking and anchor holes have been completed, the panel can be placed in a position in accordance with the marking of each panel. Once the panel is in position in accordance with the marking, then the panel pedestal anchor bolts in accordance with the marking holes that have been made. Then the panel shall be fixed with anchor bolts. For protecting the panel from lighting surges and any electromagnetic interference shall be installed grounding facilities, isolation transformer for surge protection type shall be provided against lightning surge from power supply equipment to electronic at inside the panel

7.8.2 Installation Procedure for Equipment

Coordination with PT.KAI before doing installation to avoid obstruction to the existing train operation in the area specified herein Placement at a position in accordance drawings that have been approved by the Engineer and PT. KAI When the Equipment has been arrived site, check the appearance for any damage

Installation Procedure Signal & Marker Equipment: 1. All signals and markers shall be installed so that they keep the clearance with construction gauge as shown in the Drawings. 2. Existing signal head with conventional lamp within project area which will not be removed shall be replaced with new signal head LED type as same as the newly installing signals. 3. Signal lanterns shall be positioned to provide best visibility to a train driver 4. Signal posts shall be erected vertical on the base fixed with bolts to concrete foundation. Top surface of concrete foundation shall be at rail level where this is practicable and otherwise not less than 150mm above the surrounding ground level 5. Base of steel posts shall be grounded wires and rods 6. Concrete foundations shall have a cable entry approximately 800mm below surrounding ground level 7. Gantry assemblies for running and shunting signal shall be provided

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Installation Procedure Point Machine Equipment: 1. Close Coordination with track works for location of long sleepers and stabilization of this sleepers, 2. All point machine shall be robustly installed outside of construction gauge on long wooden sleepers. 3. Fitting such as throw rods and detection rods including fitting brackets, if required, shall be robustly connected between electrical point machine and track structure. As required tongue rails may be strengthened by the approved materials for connection of these fittings 4. Lead-up cable to electrical point machine shall be protected by conduits approved by the Engineer 5. Steel point number plates shall be fixed to point machines or to sleepers. 6. Terminal Boxes shall be installed on concrete foundation, 7. Steel guard structure against any accident to point machine shall be robustly installed same as existing one 8. Installation of electric point machines shall include provision of insulated gauge tie plates and insulated point machines installation plate. 9. Point machine shall operate sequentially as follow: a. Open detection contacts, b. Unlock point, c. Lock point, d. Close detection contact. Installation Procedure Track Circuit Equipment: 1. Track transformers, track resistors, repeating transformers and track relays shall be provided in signal cabin or apparatus cases 2. Impedance bonds housing shall be protected by concrete frame at sides and shall be 1.7m or more from track centre, except when installed between other tracks. 3. Impedance bonds shall be connected with suitable bolts to web of rails by stranded aluminium cables with terminals. Cables shall be protected with PVC conduit approved by the engineer. Impedance bond exclusive use for return current to substation, if required, shall be installed as same method as others. 4. Rail bonds shall be connected with bolts to web rail. For main tracks bonds shall be duplicated. 5. Signal bonds shall be welded and duplicated to each rail joint to permit signal current. 6. Jumper wires and cross bonds shall be welded to rails with terminals protected by conduit approved by the Engineer. 7. Resonance condensers or impedances fixed in cases shall be connected to tertiary coils of impedance bonds installed independently near substation. Cases shall be fixed to concrete foundations with cable inlets. 8. Apparatus cases and terminal Boxes shall be installed on concrete cable with cable inlets. Bases of these housings shall from a close fit top of concrete foundation such that there is no space in which vermin, gravel, grass or undesirable materials may enter. 9. Connection boxes shall be provides adjacent to track connection and fixed to concrete foundation with cable inlets.
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10. Rail connector between cases or boxes and rails shall be fixed with bolts to web of rails with terminals protected with conduit approved by the Engineer 11. To permit traction return current where track circuits are not installed, cross bonds with terminals protected with conduit, or rail bonds shall be welded to rail. Installation Procedure Automatic Block Signal (ABS) Equipment: 1. Location of signals shown in the Drawings is approximate and exact location according by approved the Engineer. 2. All Signals shall be installed so that they keep the clearance with construction gauge as shown in the Drawings. 3. Signal posts shall be erected vertical on the base fixed with bolts to concrete foundation. Top surface of concrete foundation shall be at rail level where this is practicable and otherwise not less than 150mm above the surrounding ground level 4. Concrete foundations shall have a cable entry approximately 800mm below surrounding ground level Installation Procedure Level Crossing Protection System Equipment: 1. Alarm control table at each level crossing shall be submitted to the Engineer for his approval, conforming to typical alarm control diagrams as shown in the Drawings. 2. During installation or modification works any train operation in service shall not be interrupted. 3. Warning alarm signals shall be installed on a concrete foundation and distance Location from centre track shall be approximately 3 meters to consider the visibility from pedestrians and road traffic drivers. Precaution signal shall be installed minimum five meters in front of level crossing along traffic road on a concrete foundation. 4. Closing barriers shall be installed on a concrete foundation and distance from center of track shall be approximately 3 meters to consider right angle to road traffic or parallel to track layout. 5. Track Circuit shall be installed outside of construction gauge, nearby watchmans shed and shall not obstruct visibility of approaching trains to passers-by, vehicle drivers or suitable operation including batteries power supply. 6. Power supply shall be checked to ensure that level crossing protection equipment shall be suitable operation including batteries power supply.

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Safety, Environmental and Hazard Mitigation

8.1

Preparation MSJO will be responsible in fulfilling and maintaining the following traffic control duties and the construction safety management: - Keeping any existing railway facilities and safe for regular traffic. - Maintaining train movement as per regular operation and maintaining safe train traffic condition - Safe and convenient use of station facilities and protection of railway passengers. MSJO will be fully responsible for the control and management of all the site works so as to ensure train operation safety, including the erection and maintenance of any train traffic control facilities.

PPE Personal Protective Equipment (PPE) must be worn by all people or personnel at the work sites. Nobody can enter the work sites without PPE.

Figure 8-1.Personal Protective Equipment (PPE)

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8.2

Toolbox Talk The toolbox talk is a very important safety briefing for all the members of the work party. The toolbox talk always needs to be done before work. For the DDT project, the coverage or topics of a typical toolbox session are the following;

1. 2. 3. 4. 5. 6. 7. 8.

Permit to work; Attendance list of all members; Personal protective equipment; Safety hazard evaluation at the worksite; Competence and authorized persons; Method of work and tools to be used; Worksite boundaries and protection; Emergency evacuation points and other safety related matters.

Figure 8-2.Tool Box Talk

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8.3

Train Watchers (Safety Supervision) Train watchers are mandatory for working in an operating track system. Work groups must prepare 2 train watchers who will be posted at both boundary ends of the worksite. Train watcher will do only the train watching job and will not be utilized in supporting work group jobs. Train watchers are only to watch train operations and the related jobs for train running. Train watchers are to render train warnings to the workers who are to be protected from accidents due to train operations.

Figure 8-3.The Position of Train Watchers

Figure 8-4.The Standard Outfit of Train Watchers

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8.4

Accident Prevention Arrangement 1. Train watchers have to run at least the minimum of 600 meters from the work area accident location.

600m
Fig.6.2.3 Accident happen No.1
Figure 8-5 Figure 8-5.Accident Incident No. 1

2. Signal an approaching train to stop by using materials that emits smoke. If not available, the Train Watcher must do as below;

Wave Red Flag

Wave Jacket

Wave Hand

Burn paper

Figure 8-6 Accident Incident No. 2

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8.5

Initial Response and Reporting Initial response and reporting for minor and major accidents will be in accordance with the shown Flow Chart in Figure 8-7 and Figure 8-8. Critical injuries or fatalities will be reported in accordance with the local laws and regulations of Indonesia.

Report Accident data to Aministration Manager and Health Safety Enviromental Manager

Figure 8-7.Reporting System for Minor Accident

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Figure 8-8.Reporting System for Major Accident

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N
E&M CONSTRUCTION MANAGER HEALTH,SAFETY,ENVIROMENTAL MANAGER

MAIN CONTRACTOR MITSUBISHI SUMITOMO

M.ADACHI

RIO SAPTO HIDAYAT

SBS & PWD ENGINEER

H. SEKI

SIGNAL & TELECOM ENGINEER

SBS & PWD SUPERVISOR

SBS & PWD SUPERVISOR

S. NAKAMURA

SOEPANGAT

F. RACHMAN

TELECOM SUPERVISOR

TELECOM SUPERVISOR

SIGNAL SUPERVISOR

SIGNAL SUPERVISOR

FAESAYUSLI

FUADIL KIROM

EKO SULISTTIONO

NURHALIM

SIG & TEL PROJECT MANAGER

SBS & PWD PROJECT MANAGER HEALTH,SAFETY,ENVIROMENTAL MANAGER

BENI.R

M. SINAGA

SUB CONTRACTOR

PT. Len Industri

Mrs. CINDERAWATI
SIG & TEL SITE MANAGER SBS & PWD SITE MANAGER

DEDE.A.B

ADANG .K

SIG & TEL ENGINEER

SBS & PWD ENGINEER

ENJANG

IRFAN

SIG & TEL STAFF

SBS & PWD STAFF

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