PROJEK LEBUHRAYA USAHASAMA BERHAD

SSL DEV SDN. BHD.

PROPOSED ENHACEMENT OF EXISTING MAIN SWITCHBOARD

(MSB) (MSB) AT SELECTED TOLL PLAZAS OF NORTH-SOUTH
EXPRESSWAY

MATERIAL SUBMISSION & METHOD STATEMENT

SUPPLY, DELIVERY, INSTALLATION, TESTING AND COMMISIONING OF
MAIN SWITCHBOARD (MSB)

Reference No. : SSL/PLUSMSB/2023/001

Rev. No. :
Date Issued : 26/05/2023

Prepared By Approved By

Engineer Project Manager

MOHD YUSRI BIN MOHD YASSIM MUHAMMAD IZZUDDIN BIN MUSTAPA
761213-03-5255 981007-15-5031
 PROPOSED ENHACEMENT OF EXISTING MAIN SWITCHBOARD
(MSB) AT SELECTED TOLL PLAZAS OF NORTH-SOUTH EXPRESSWAY

Document No.
Revision No. 00 Rev. Date 19/05/2023

REVISION HISTORY

Rev. No. Revision Details Rev. Date

00 First Issue 19/05/2023

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TABLE OF CONTENTS

1. SCOPE OF WORK ....................................................................................................................... 4

1.1 GENERAL DESCRIPTION ................................................................................................... 4

1.2 REFERENCES .................................................................................................................... 4
1.3 MATERIAL ....................................................................................................................... 4
1.4 PLANT AND EQUIPMENT .................................................................................................. 4
1.5 MAN POWER REQUIREMENT ........................................................................................... 5
1.6 CONSTRUCTION PROCEDURES ......................................................................................... 6
2. SAFETY AND HEALTH REQUIREMENT ............................................................................ 14

2.1 JOB SAFETY & HEALTH ANALYSIS................................................................................ 16

2.2 INFORMATION TO PERSONNEL ....................................................................................... 16
2.3 EMERGENCY ARRANGEMENTS ...................................................................................... 16
2.4 PERMIT TO WORK .......................................................................................................... 17
3. ENVIRONMENTAL ASPECTS, IMPACTS & CONTROL MEASURES .......................... 18

3.1 ENVIRONMENTAL ASPECTS, IMPACTS & CONTROL MEASURES ................................... 18

3.2 AIR QUALITY CONTROL ................................................................................................ 19
3.3 NOISE AND VIBRATION CONTROL ................................................................................. 19
3.4 WATER QUALITY ........................................................................................................... 19
3.5 WASTE MANAGEMENT .................................................................................................. 19
4. QUALITY ASSURANCE & QUALITY CONTROL .............................................................. 20

4.1 CONTRACTUAL REQUIREMENTS .................................................................................... 20

4.2 INSPECTION & TESTING ................................................................................................. 20
4.3 FOLLOW UP & EVALUATION.......................................................................................... 20
5. APPENDICES ............................................................................................................................. 20

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1. SCOPE OF WORK

1.1 General Description

1.1.1 The purpose of generating this method statement is to define the procedure step by step to
implement the correct practices for Main Switchboard (MSB) Installation through the
guidelines contained herein so as to ensure that the job execution complies with specification
and serves the intended function to satisfactory level where applicable in the building of the
project.

1.1.2 This method statement covers all processes related Installation of Main Switchboard (MSB).
This procedure is to be read in conjunction with the relevant ITP, outlining the responsibility
and the quality verification to be performed by various parties.

1.2 References

Referring to drawing and documentation in Table 1:

No Description Document Ref. No.

1. Drawing As per attached

Table 1
1.3 Material
The supply, delivery, installation, testing and commissioning of Main Switchboard (MSB)
involve all of its accessories that in table 3. Table 3 indicate list of material in each Main
Switchboard (MSB).

No Type of Material Qty MSA No

1 Main Switch Board (MSB) 1

Table 2

1.4 Plant and Equipment

1.4.1 Plant and Equipment: The following Machineries and Equipment will be deployed for each
work, as detail in Table 6.

No Type of Equipment Qty. Purpose

Safety Equipment
1 TBA Safety P.P.E
• Safety helmets

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• Safety shoes
• Eyes Goggles
• Hand gloves
• Ears shield
• Danger signage
Crane or Lorry Crane of suitable capacity &
2 arrangement in line with the manufacturer’s TBA Installation
recommendations and as required at site
3 Forklift of suitable capacity TBA Installation
4 Chain pulley block TBA Installation
5 Portable hand tools TBA Installation
6 Portable Drilling Machine TBA Installation
7 Grinding Machine TBA Installation
8 Angle Cutter TBA Installation
9 Sprit Level TBA Installation
10 Crimping Tool TBA Installation
11 Load bank TBA Installation
12 Merger / Multimeter TBA Installation
13 Clamp meter TBA Installation

Table 6 Machineries and Equipment

1.5 Manpower Requirement

No. of
No Description Brief Roles and Responsibilities
person
Responsible for overall commercial,
As contractual, & technical performances
1 Project Manager
Required associated with specific projects.
Responsible to report to the Project Director.
As Planning, Manage, coordinating and
2 Project Engineer
Required supervising the dedicated utilities team
Project Executive As To assist the M&E Manager in his functions
3
QA/QC Required and to attend to all submissions
As Supervising and Coordination all site
4 Project Supervisor
Required activities
Machinery and Plant As
5 Operating the plant and machinery
Operators Required
As
6 Chargeman Perform cable jointing and termination
Required
As
7 General Workers Conduct general works at site
Required

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As To control and ensure the Safety, Health and

8 Safety Supervisor
Required Environmental is adhering at site

Table 7: Manpower Responsibility

PROJECT MANAGER

PROJECT ENGINEER PROJECT EXECUTIVE

PROJECT QA/QC

SAFETY SUPERVISOR PROJECT SUPERVISOR

CHARGEMAN MACHINERY AND

PLANT OPERATORS

i) SKILLED WIREMAN
ii) SEMISKILLED
iii) UNSKILLED WIREMAN

Chart 1: Manpower Line of Communication

1.6 Construction Procedures

1.6.1 Work Sequence and Methodology

a) Check all material delivered to site is inspected properly by QA/QC Engineer and check if
it is stored properly as per manufacturer’s recommendations.

b) MIR shall be raised for the inspection of materials received at site by MEP QA/QC
Engineer to the Main contractor/Company Engineer.

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c) All the work for the installation must be under supervision of the system manufacturer’s local
dealer and he must attend the installation stage.

d) Work shall be carried out by the site staff under strict supervision and guidance of the concerned
Supervisors/ Foremen/ Engineers.

e) The MEP QA/QC Engineer shall check all the installations as per the installation checklist.

f) WIR shall be prepared by MEP QA/QC Engineer and will be submitted to Company for their
inspection and approval with attendance of system manufacturer’s local dealer.

g) MEP QA/QC Engineer shall coordinate with other contractors and arrange inspection for
installations to the Company Engineer after confirming the installation and requirements from
the system manufacturer’s local dealer

h) MEP QA/QC Engineer is responsible for all installation activities for getting the work inspected
and approved by Company Engineer.
1.6.2 Site Visit

a) Apply permit to user for visiting. The application include the purpose of site visit, time, date
and location.

b) Familiarize the site location, layout, and any relevant background information before site
visit.

c) Make a checklist of things to bring, such as a notebook, camera, measuring tools, safety gear,
and any necessary documents.

d) Bring a proper checklist based on the purpose of site visit.

e) Observe the site carefully, taking notes and photograph as needed. Pay attention to details
related to objectives.

f) Document observation, measurements and any discussion in the checklist.

g) Create a report summarizing the site visit, include key findings, observations, and
recommendations.

1.6.3 Manufacturing Process

a) Design the switchboard layout, determining the arrangement of component, wiring and
dimension based on site suitability. The layout design and single line diagram must be endorsed
by client.

b) Component installation. Circuit breaker, switches, meters and other electrical components
are installed to the panel based on JKR specification.

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c) Wire the components using copper conductor based on schematics and safety
guideline.

d) Assemble the panels and door to create the complete switchboard enclosure. This
might involve hinges, locks, and mounting brackets

e) Labels and marks the components, wires and panel for identification, making
maintenance and troubleshooting easier.

f) The switchboard is often painted or coated with protective finishes to prevent

corrosion and enhance its appearance.

g) The assembled switchboard undergoes various tests, including insulation resistance

tests, continuity tests, and functional tests to ensure everything works as intended

h) A thorough quality check is performed to verify that the switchboard meets safety
standards and performance requirements.
.

1.6.4 Handling and Storage

On receipt of the Main Switchboard (MSB) at site, necessary precautions shall be taken for
unloading, shifting and storage, as follows:

a) Material shall be stored in a covered/ dry space at all time.

b) All materials received at site shall be inspected and ensured that the materials are as per
approved material submittal.

c) Any discrepancies, damage etc., found will be notified and reported for further action.

d) Site Engineer (Electrical) has to ensure that all equipment used at site are free from any
damage or deformity of any kind. Any minor damages observed shall be repaired suitably
and in case if the repairs could not be done properly, the Equipment are to be removed
from site.
1.6.5 Engagement with Tenaga Nasional Berhad (TNB)

a) Get in touch with TNB well in advance of the planned shutdown. Reach out through
customer service channels or designated contact points.

b) Furnish TNB with all the relevant information about the planned shutdown. This includes
date, time, and duration of the shutdown, as well as the reason for the shutdown
c) Obtain permits and approvals from regulatory bodies before proceeding.

1.6.6 Before installation of Main Switchboard (MSB)

a) Ensure that Drawings for Installation are approved & coordinated with other services.
b) Check the material to be used is inspected and MIR approved.

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c) Check if the work location/area is ready without any obstruction.

d) Perform breaker inspection and test the mechanical functions.
e) Ensure that all Cables / Wires are tested for Insulation and Continuity before
Glanding and Termination.
f) Before starting the work, check that all safety precautions are in place.

1.6.7 Factory Acceptance Test

a) The Main Switchboard (MSB) functionality is tested to ensure that it operates as per the
design specifications. This could involve simulating various scenarios and inputs to verify
that the board responds correctly.
b) The performance of the Main Switchboard (MSB) under different load conditions is assessed
to ensure that it can handle the intended tasks without issues.
c) The electrical characteristics of the Main Switchboard (MSB), such as voltage levels, current
draw, and power consumption, are measured and compared against the specifications.
d) The Main Switchboard (MSB) is inspected for compliance with safety standards and
regulations. This includes checking for proper grounding, insulation, and protection against
electrical hazards.
e) The documentation related to the Main Switchboard (MSB), including schematics, user
manuals, and technical specifications, is reviewed to ensure accuracy and completeness.
f) The Main Switchboard (MSB) is inspected for any defects in manufacturing, such as
soldering issues, loose connections, or physical damage.

1.6.8 Temporary Power Supplies

a) Generator Rental: One of the most common solutions is to rent or deploy a generator to
provide temporary electrical power. A generator can be sized based on the power
requirements of the facility and can provide a stable power source throughout the
switchboard replacement.
b) Temporary Connection Points: Temporary electrical panels and distribution boards can be
installed to create interim power distribution points. These panels are connected to the
existing electrical infrastructure and provide power to essential circuits.
c) Cable and Connection Management: Proper cable management is crucial to ensure safety and
reliability. Temporary power cables and connections should be properly sized and installed
to handle the load and prevent hazards.
d) Monitoring and Maintenance: Regular monitoring of the temporary power supply is necessary
to ensure that it's functioning correctly. Additionally, maintenance tasks should be carried
out as needed to prevent any issues during the switchboard replacement period.
e) Transition Plan: Develop a clear plan for transitioning back to the permanent power supply
once the main switchboard replacement is complete. This includes testing, inspections, and
any necessary adjustments.
1.6.9 Installation of Main Switchboard (MSB)

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a) To carryout installation activities for Main Switchboard (MSB) below mentioned

procedures are recommended to follow up step in the sequential manner.

b) Pre-delivery inspection shall be performed by the system manufacturer’s local dealer at

dealer’s facility to ensure no damage is occurred in transit to all Main Switchboard (MSB)
components. This has been done after factory test per approved specs.

c) Prior to start installation, Site Engineer (Electrical) should ensure that approved shop
drawings related to the installation area are referred and that required materials are available
at site as per approved material submittals.

d) Site Engineer (Electrical) has to ensure that all the materials are received at site as per
approved material submittal and verify the ratings.

e) The nameplate will be checked against equipment data sheet to confirm conformity with the
approval.

f) MIR request should be raised for materials verification upon delivery at site.

g) Ensure all civil works are completed for the area including painting to carry out the
installation, and clearance is obtained from respective authorities to proceed further for the
installation of Main Switchboard (MSB).

h) Installation procedures are to be followed as per manufacturer’s recommendations attached.

i) Installation works shall be carried out only with respect to approved shop drawings of latest
revision.

j) Move the panels from the storage area to the designated electrical room. Panels shipped on a
timber sub-base shall be lifted under the sub-base by forklift. Unpack and remove the panels
from its timber base. Care must be

k) Move-in the panels using roller to its final location. Care must be taken to ensure that the
panel does not overbalance while being move to its final location.

l) Align the panel horizontally and vertically. And fix the panel to floor using anchor bolts.
Clearance between panels and walls shall be following Approved shop drawing / Approved
Installation details.

m) Ensure that the panels are installed properly in its designated location as shown in the shop
drawings.

n) Remove all unused bolts, nuts, washers and clean the panel. Panel side covers and doors
shall be put back ensuring that they are properly tightened

o) Ensure tightness of all terminals using calibrated torque wrench before closing the shroud
Remove all unused bolts, nuts, washers and clean the panel. Panel side covers and doors
shall be put back ensuring that they are properly tightened.

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p) Ensure that the load schedule/wiring diagram is provided inside the panel.

q) Installation and commissioning shall be as per manufacturer recommendation.

r) Cover or protect all installed switchboard to prevent the accumulation of dust and debris
during construction.

s) Ensure that workmanship in neat and clean and compiling to good construction practices.

1.6.10 WORK METHODOLOGY

1.6.10.1 MAIN SWITCHBOARD (MSB) INSTALLATION

Step 1
The installation works shall be referred to the approved shop drawing where the arrangement
of the equipment need to be positioned accordingly.

Step 2: Unloading of the Main Switchboard (MSB)

When lifting Main Switchboard (MSB), special lifting equipment is required. It is
recommended that a spreader lifting beam of the correct lifting load capacity is used and that
the lifting chains, hooks, shackles, eye bolts, etc are checked and within the safety working
loads. The load should be secured, stable and balanced when lifting, therefore and assessment
of the position of its center of gravity must be determined to ensure that the lifting point is
over it. The lifting chains, etc. must be firmly secured to the load by means of hooks on the
purpose-designed lifting points, and that the rated included angle is not exceeded.

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Figure 1

Step 4
Position the MSB onto the strong flat surface. Then use machine skate below the Main
Switchboard (MSB) to easily move and position the Main Switchboard (MSB) in the MSB
room

Figure 2

Step 5
Using the machine skate, move the board to the place as shown in the shop drawing

Figure 3

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1.6.10.2 TESTING AND COMMISIONING

1.6.10.2.1Purpose
The purpose of generating this method statement is to define the procedure step by step to
implement the correct practices for Main Switchboard (MSB) Testing and Commissioning
through the guidelines contained herein so as to ensure that the job execution complies with
specification and serves the intended function to satisfactory level where applicable in the
building of the project

1.6.10.2.2Scope
This method statement covers all processes related to Main Switchboard (MSB) Testing and
Commissioning the following:

• Main Switchboard (MSB) Testing and Commissioning as per Manufacturer

recommendation and specs.
• This procedure is to be read in conjunction with the relevant ITP, outlining the
responsibility and the quality verification to be performed by various parties

1.6.10.2.3Testing and Commissioning of Main Switchboard (MSB)

Testing and commissioning for the MSB will be done as per manufacturer recommendation
mentioned in point 7.2.1 and 7.2.2 and approves specs

1.6.4.4.3.1Pre Start-Up Inspection:

A pre- check shall be carried out by the concerned engineer before energize the system, in
order to ensure that all parts have been installed as per the procedure.

S/N VISUAL INSPECTION / ACTION Yes No Remarks

1 Walk around inspection

2 Check the layout of fitted components

3 Check dimension of switchboard

4 Check size of busbars

5 Check the cables

6 Check earthing conductors

7 Check the components installed

8 Check the labels, name plate and phase identification

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9 Check circuit breaker

10 Emergency trip in On position

Table 8
S/N MECHANICAL INSPECTION / ACTION Yes No Remarks

1 All apparatus mounting plates are securely fastened

2 All components on mounting plates are securely fastened

3 All switches handles mounted on front panel operate

correctly

4 All front panels and doors close properly with necessary

lock

5 All side cover/back cover and doors are fitted with gasket

6 All brackets supporting heavy apparatus are securely

fastened

7 All live part with securely fastened

Type text here

Table 9

S/N ELECTRICAL INSPECTION / ACTION Yes No Remarks

1 All apparatus mounted on front panel or mounting plate are

securely fastened and not damaged

2 All instrument such as Vm, Am, KWH, KW, Hz, PF, etc are
of correct rating/setting

3 Protection relays such as E/F, O/C, ELR and ELCB are of

correct rating/setting

4 Busbar are securely fastened with insulated support &

clearly marked in RED, YELLOW, BLUE, and BLACK
colour,

5 Earth bar is securely fastened into the body to the

switchboard

6 All electrical wiring are securely and correctly fastened

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7 All starters c/w overload are correct range as per drawing

8 All name plates are positioned correctly as per drawing

Table 10

S/N GENERAL FUNTIONAL REST Indication Remarks

1 Voltmeter c/ selector switch

2 Ammeter c/w selector switch

3 Frequency meter

4 KW meter

5 KWH meter

6 Power Factor Meter

7 Hour run meter

8 R,Y,B Phase indicating light

9 Incoming ACB/MCCB with Shunt Trip

10 Incoming ACB/MCCB with Under Voltage Trip

11 Incoming isolator

12 Incoming change-over switch

13 Outgoing isolator

14 Outgoing change-over switch

15 Change-over contractor

16 Outgoing ACB/MCCB with Shunt Trip

17 Outgoing ACB/MCCB with Under Voltage Trip

18 Earth Fault Relay

19 Over Current Relay

20 Earth Leakage Relay

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21 Earth Leakage Circuit Breaker (ELCB)

22 Protection C.T

23 Metering C.T

24 Panel Light

25 Panel Heater

26 Time Switch/ By Pass Switch

27 Capacitor bank (MCCB, Fuse, Contactor & Capacitor)

28 Power Factor correctly set and scaled

29 Transducer

Table 11

2. SAFETY AND HEALTH REQUIREMENT

2.1 Job Safety & Health Analysis

2.1.1 The Job Safety and Health Analysis (JSA) is a safety management tools in which the risk or
hazards of a specific job in the workplace are identified and measures to eliminate or control
those hazards are determined and implemented. It is systematic process in evaluating certain
jobs, tasks, processes, or procedures and eliminating or reducing the risk or hazards to as low
as reasonably practical in order to protect workers from injury or illness. The JSA process is
documented and is used in the workplace as a guide to work safety environment. Please refer
to Appendix 5.2 for details Job Safety Analysis for Installation, Testing and Commissioning
of MSB.

2.2 Information to Personnel

2.2.1 All site personnel must have completed and attended the Green Card / NIOSH –
Safety Passport prior of start work at site. Only the managers, engineers, supervisors
and workers who have successfully completed the training for their role will be
allowed working on site.

2.2.2 All workers and site personnel employed in the project site must have valid CIDB
Green Card.

2.2.3 All new workers and staff to attend the Safety Induction before commencing works at
site and attendances shall be recorded in an induction record.

2.2.4 All site personnel shall wear approved Personnel Protective Equipment (PPE).

2.3 Emergency Arrangements

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2.3.1 An emergency Response and Communication Team shall be informed for the potential
emergency such as fire explosion, evacuation, structure collapse, major injury or fatality
from accidents, major chemical spillage, road Accident / vehicle breakdown, flooding and
heavy machinery breakdown, protest/riot, food poisoning and unstable person has been
specified in Emergency Response Plan.

2.3.2 The organization chart, list of emergency contact person and relevant authorities with
their contact numbers shall be posted on the Notice Board.

2.3.3 In the event of emergency, the site management staff must evaluate the situation and
commence the necessary procedures as follow: -
• Raise the alarm
• Stop work
• Remain composed
• Notification of emergency or evacuation to surroundings
• Prepare the aid kit at the assembly point
• Ensure all workers assemble at designated assembly point
• Ensure all workers not to leave the assembly point until clear signed issued
• Headcount
• Assessment reports

2.4 Permit to Work

To Control High Risk tasks need to apply the Permit to Work (PTW) system for the
authorization before to do work. High-risk task following activities:

No Description Remarks

1. Working at Height For work above 2 meter

2. Hot Work Validity

3. Confined Space Validity

4 Lifting Work For all lifting activity

5 Excavation Work For work 1.2 metres deep and above

6 Permit to Move and Permit to Operate Valid for 3 days

7 Night Work Daily (after 7pm and if necessary)

8 Transportation Daily Permit

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9 For lockout/tag out of equipment or

Lockout/Tag out (LOTO)
machinery

Table 12

3. ENVIRONMENTAL ASPECTS, IMPACTS & CONTROL MEASURES

3.1 Environmental Aspects, Impacts & Control Measures

3.1.1 Smoking Regulation

3.1.1.1 There is smoking area that prepared for smoker. Besides that, smoking is totally
prohibited in the plant

3.1.1.2 No matchers or lighters (including vehicle’s cigarette lighter) are allowed to be

brought in to the process area.

3.1.1.3 Failure to deposit matchers or lighters is considered as a serious offense and can result
in suspend or dismissal from work immediately due to internal law and requirement in
plant.

3.1.2 Illegal Use of Drug, Alcohol, Explosives, Fire Arms and Hazardous Material

3.1.2.1 Using, transportation or showing signs of the use of alcoholic beverages drugs or
controlled substance; any possession or transportation of fire arm, explosive
incendiary devices or hazardous substance are absolutely prohibited while in the
client work area and can result in disciplinary action (i.e. removal of security pass/
instant dismissal).

3.1.2.2 Client site management that relevant and management reserved the right to conduct
search or inspection of effects and bags, if suspected. Personnel are also subjected to
body search prior to entering or leaving the site or yard area.

3.1.3 Housekeeping

3.1.3.1 All personnelare responsible to maintain a high standard of cleanliness at workplace.

Workplaces shall be kept in a clean, tidy and orderly condition at all times. At the end
of working period, all equipment, scaffolding pipe and material shall be kept and
placed at proper area.All personnel are required to use only the designated sanitary
facilities and Eating places provided by Client’s management. (in clients plant)

3.1.4 Environmental Control During Project or Maintenance

3.1.4.1 Environmental control shall comply with the approved Waste Management System.
Environmental Monitoring Daily inspection carried out by the project organization
personnel shall include environmental monitoring. Site draining

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• Any line draining should be routed to the appropriate drain system. No

hydrocarbon/chemicals shall be allowed into the open monsoon drain.
• Should the above instruction is impossible, Client to be notified.
• Dedicated wash bays area will be agreed with Client’s management for
decontaminations of equipment.

3.1.5 Toxic/hazardous Material and Scheduled Waste

3.1.5.1 All containers containing toxic and hazardous brought in or used in the plant shall be
labelled and the Chemical Safety Data Sheet (CSDS) made available. One copy of
CSDS shall be sent to Client’s HSE department if available.

3.1.5.2 Special PPE gloves and safety goggles shall be worn when handling the substance as
stated in the permit to work and CSDS.

3.1.5.3 Empty drums used to contain toxic material shall be punctured prior to sending scrap.

3.1.5.4 Scheduled waste will be labelled and stored in drums and sent to temporary yard for
disposal in accordance with Client’s Waste Management Procedure

3.2 Air Quality Control

3.2.1 Site clearance and earthwork shall be carried out in stages to minimize the exposed soil.

3.2.2 Vehicle washing facilities shall be provided at site exit. Public roads shall be kept clear of soil
and cleaned.

3.2.3 Traffic control such as speed limit and traffic volume restrictions to be implemented
especially at sensitive areas.

3.2.4 Open burning is prohibited at site.

3.3 Noise and Vibration Control

3.3.1 Movement of heavy vehicles shall be restricted to daytime working hours and minimized
during nigh time. Construction work during nigh time shall get the approval from PDP and
local authorities.

3.3.2 Noise generating equipment and machinery shall be inspected regularly and maintained in
good working condition. Noise and vibration emitting from equipment shall be placed away
from sensitive receptors.

3.4 Water Quality

3.4.1 Water treatment plant shall be cleaned / maintained at least weekly depend on site activity.

3.5 Waste Management

3.5.1 Waste shall be disposed of at an approved disposal site.

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3.5.2 Waste containers and storage areas shall be sufficient capacity to contain all waste generated.

4. QUALITY ASSURANCE & QUALITY CONTROL

4.1 Contractual Requirements

4.1.1 The general requirements for supply, delivery, installation, testing and
commissioning of MSB shall accordance to Project Quality Plan and Procedures
.
4.2 Inspection & Testing
4.2.1 All inspection and testing involved shall be in accordance to the Inspection and
Test Planand Inspection Checklist. Refer to appendix 5.4 and 5.5.

4.3 Follow up & Evaluation

4.3.1 Detail implementations for checklist mentioned in the Inspection Checklist and Test
Plan attached.

5. APPENDICES
5.1 Construction Sequence
5.2 Job Safety & Health Analysis (JSA)
5.3 Environmental Aspect Impact Register (EAIR)
5.4 Inspection Test Plan (ITP)
5.5 Quality Control Inspection Forms and Checklist

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Appendix 5.1
Construction Sequence

SUPPLY, DELIVERY, INSTALLATION, TESTING AND COMMISIONING OF MAIN

SWITCHBOARD (MSB)

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SEQUENCE OF WORK
METHOD OF STATEMENT REPLACEMENT MAIN SWITCHBOARD (MSB)

TIME
NO. LOCATION DATE DESCRIPTION
START FINISH

1.
Parking Area To load Rental Genset (2 Nos Rental Genset: 1 Nos Running & 1 Nos Standby).

2. Outside MSB
To load Temporary Switchboard & Cables. To deliver new MSB at site.
Room

To lay and terminate Temporary Cables from Rental Genset to Temporary

Switchboard. 1 Nos Rental Genset on RUNNING MODE, 1 Nos Rental Genset
3. MSB Room
on STANDBY MODE. Transfer load to Temporary Sub Switchboard (Phase by
Phase)

4. TNB Room DAY 1 5.00 pm 6.00 pm Shutdown TNB Power Supply.

5. MSB Room DAY 1 6.00 pm 2.00 am Disconnect Existing Incoming Cable from MSB to TNB. Dismantle Existing MSB.

6. MSB Room DAY 2 2.00 am 10.00 am Install New MSB. Terminate Existing Incoming Cable and TNB Power Energise.

Transfer load of Existing SSB to New MSB (Phase by Phase)

7. MSB Room DAY 2 10.00 am 3.00 pm

Testing & Commissioning. Rental Genset on STOP MODE

8. MSB Room DAY 2 3.00 pm 5.00 pm

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Refer Table Sequence of Work: -

1 Switchboard
4 Room
Rental Genset
5 (Running)
Temporary Cables
TNB

Existing MSB Temporary

Switchboard
Rental Genset
PLUS
Genset (Standby) 2 3

DB Room

Existing Cables

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Refer Table Sequence of Work: -

Switchboard
Room
Rental Genset
6 8
(Running)
Temporary Cables
TNB

New MSB Temporary

Switchboard
Rental Genset
PLUS
Genset (Standby) 7

DB Room

Existing Cables

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TEMPORARY POWER SUPPLIES ARRANGEMENT

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Type text here

S Appendix 5.2
Job Safety & Health Analysis (JSA)

SUPPLY, DELIVERY, INSTALLATION, TESTING AND COMMISIONING OF

MAIN SWITCHBOARD (MSB)

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ACTIVITY ANALYSIS HAZARD IDENTIFICATION AND RISK ASSESSMENT DETERMINATION OF CONTROLS

No. Job Steps RESPONSIBLE Ha zard Cons equence Current Control s Mea sures S L R Propos ed Control Mea s ures S L
Fa cil i ty Work Reques t 0.00
ATTENDED SAFETY BRIEFING, CONDUCTED
TECHNICIAN/GENERAL TOOLBOX TALK PRIOR TO START WORK BY
1 MOBILIZATION OF MANPOWER - - 1 1 1
WORKER SUPERVISOR AND OBTAIN VALID WORK
PERMIT

MANUAL EGRONOMIC - USE TROLLEY FOR TRANSFERRING

PM/SV 2 2 4
HANDLING BACK PAIN MATERIALS

PPE : SAFETY HELMET, INSULATED RUBBER

SLIP, TRIP & BODILY
PM/SV GLOVE, SAFETY GLASS WITH UV 2 2 4
FALL INJURY
PROTECTION, SAFETY SHOE
PREPARATION & MOBILIZATION OF MATERIALS &
2
TOOLS TO WORK AREA
ELECTRICAL
PM/SV 3 4 12
SHOCK
ELECTRICAL INSPECTION OF ELECTRICAL / POWER
HAZARD UTILITY DB TOOLS PRIOR TO USE & USE ELCB
PANEL TRIP
PM/SV 2 2 4
DUE TO
FAULTY
ISOLATION BY PLUS CHARGEMAN, LOTO
ELECTRICAL ELECTRICAL PROCEDURE
3 VERIFY '0' VOLT PRIOR TO EXECUTE WORK CHARGEMAN 3 4 12
HAZARD SHOCK PPE : ELECTRICAL GLOVE (CAT.8) & SAFETY
GLASS

ELECTRIC
CHECK SUPPLY & GROUNDING FIRST
EXPOSE TO SHOCK,
4 SWITCHING (OFF/ ON SUPPLY) CHARGEMAN (PROVE DEAD) THEN BARRICADE AREA HAS 1 1 1
FLASHOVER EXPOLSION
SUPPLY
FLAMES

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EXPOSE TO
SUPPLY FROM
ELECTRICAL
5 CLEANING PANEL TECNICIAN ESSENTIAL USED GLOVE & MULTIMETER TEST PEN 2 2 2
SHOCK
BOARD OR
GENSET
EXPOSE TO
SHARP /STUCK CHECK USING LONG SCREWDRIVER AND
6 MECHANICAL CHECK TECHNICIAN HAND INJURY 2 2 2
GEAR & PLIER
MECHANICAL
PPE : SAFETY HELMET, INSULATED RUBBER
EXPOSE TO ELECTRICAL
7 Pick up heavy object GENERAL WORKER GLOVE, SAFETY GLASS WITH UV 3 4 12
FALL DOWN SHOCK
PROTECTION, SAFETY SHOE

CHECKING TEMPERATURE USING THERMAL GUN OF INSPECTION SURROUND ROOM, UPS AND
8 SURROUND AREA INCLUDING BATTERY TECHNICIAN - - BATTERY TEMPERATURE WITH CALIBRATED 3 4 12
TEMPERATURE TOOLS

VERIFY WITH PLUS CHARGEMAN AND SSL PIC ONCE

TECHNICIAN/CHARGEM 2 MAN VERIFICATION - TELEWIRING AND
9 INSTALLATION DONE BEFORE PROCEEDING WITH - - 1 1 1
AN PLUS CHARGEMAN
HOUSEKEEPING

MANUAL
HANDLING /
BODY PAIN / PPE : SAFETY HELMET & SAFETY SHOE /
10 HOUSEKEEPING / PERFORM 5S PM/SV EGRONOMIC / 2 1 2
BODY INJURY SAFETY GLOVES
SLIP, TRIP &
FALL

MANUAL EGRONOMIC - USE TROLLEY FOR TRANSFERRING

PM 3 1 3
HANDLING BACK PAIN MATERIALS
PREPARATION & MOBILIZATION OF MATERIALS &
11
TOOLS AFTER WORK COMPLETED
PPE : SAFETY HELMET, INSULATED RUBBER
SLIP, TRIP & BODILY
PM GLOVE, SAFETY GLASS WITH UV 3 1 3
FALL INJURY
PROTECTION, SAFETY SHOE

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Risk Assessment Matrix.

Severity Negligible Minor Serious Fatal Catastrophic
No injury or Disabling Non-fatal One single fatality, Numerous
minimal health but not injury, partially disability, non fatalities, total
effect, minor permanent partially -reversible minor disability, non-
abrasions, injury disability, health effect, major reversible major
Description bruises, cuts, first lost time property damage health effect,
aid type injury injury or irrecoverable
illness 4 property damage
days max and productivity

LIKELIHOOD DESCRIPTION 1 2 3 4 5
The most likely
result of the
Most likely 5 5 10 15 20 25
hazard / event
being realized
Has a good
chance of
Possible 4 4 8 12 16 20
occurring and
is not unusual
Might be occur
Conceivable at sometime in 3 3 6 9 12 15
future
Has not been
known to occur
Remote 2 2 4 6 8 10
after many
years
Is practically
impossible and
Inconceivable 1 1 2 3 4 5
has never
occurred

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Risk Action

RISK RATING DESCRIPTION RISK DESCRIPTION AND NECESSARY ACTION

HIGH RISK :
UNACCEPTABLE.
Prompt senior management attention needed. Task must not proceed until risk reduced to ACCEPTABLE
15-25 HIGH level through further risk reduction measures and with Top Management approval.
Task needs to be redefined or further control measures put in place to reduce risk within a specified time
period.
Actions taken must be documented in the HIRAC form.
MEDIUM RISK :
MODERATELY ACCEPTABLE.
5-14 MEDIUM
Requires a planned approach to controlling the hazard and applies temporary measure if required.
Actions taken must be documented on the HIRAC form.
LOW RISK :
ACCEPTABLE.
1-4 LOW A risk identified as LOW may be considered as acceptable and further reduction may not be necessary.

However, if the risk can be resolved quickly and efficiently, control measures should be implemented and
recorded.

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Appendix 5.3
Environmental Aspect Impact Register (EAIR)

SUPPLY, DELIVERY, INSTALLATION, TESTING AND COMMISIONING OF

MAIN SWITCHBOARD (MSB)

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ENVIRONMENTAL ASPECT AND IMPACT REGISTER

No. Activity & Env Aspect Env Impact Conditions Risk Rating Signific Risk/Opportunity Management
Work Area ant Measures
(Rate
≥10
N A E L S Rate Ye N
(LxS) s o
1 Vehicular/ma Noise Public √ 1 3 3 √ Notice and Working hours is
chinery generation transport compound from from 7am-7pm
authority
Dust/smoke Air pollution √ 3 1 3 √ Notice and Control of speed
compound from limit and traffic
authority volume to reduce
dust churned up by
vehicles
Oil and diesel Land √ 2 1 2 √ Notice and Proper and regular
spillage pollution compound from maintenance of
authority machineries and
vehicles at site
2 Dewatering Surface runoff Water √ 2 3 6 √ Notice and Silted run-off shall
pollution compound from be channel into
authority earth drain and
contain it in silt trap
prior discharge

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3 Material Noise and dust Air pollution √ 3 1 3 √ Notice and Proper and regular
cutting and compound from maintenance of
drilling authority machineries at site

Waste Air and land √ 2 3 6 √ Notice and Adequate waste bin

generation contaminati compound from shall be provided
on authority prior disposal to
authority landfill

N = Normal
A = Abnormal
E = Emergency
L = Likelihood (Refer to appendix 2)
S = Severity (Refer to appendix 2)
Risk Rating Calculation shown at appendix 2

Prepared by Reviewed by Approved by

Name :
Muhammad Izzuddin Mustapa Nur Azizi Bin Ibrahim
Signature : (Site Safety Supervisor)

Date : 11 October 2023 11 October 2023

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Appendix 5.4
Inspection & Test Plan (ITP)

SUPPLY, DELIVERY, INSTALLATION, TESTING AND COMMISIONING OF

MAIN SWITCHBOARD (MSB)

Type text here

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INSPECTION & TEST PLAN

ACTIVITY PROPOSED ENHANCEMENT OF EXISTING MAIN SWITCHBOARD (MSB) AT SELECTED TOLL PLAZAS OF NORTH-SOUTH EXPRESSWAY

AREA/LOCATION SELECTED TOLL PLAZAS OF NORTH-SOUTH EXPRESSWAY

ITP approved by Contractor’s QA/QC : ITP Approved by consultant :

Signature : Signature :
Date : Date :
S/N DESCRIPTION FREQUENCY SPECIFICATION INSPECTION LEVEL VERIFICATION RECORD
ITL CONTRA CONSULTA
CTOR NT
1 DOCUMENTATION
1.1 Shop drawing approval Each drawing Project specification - R R
shop and drawings
1.2 Material approval Each MAR( prior Project specification - H H
to order the and drawings
material)
1.3 Method statement Once (approval Project specification - H H
approval prior to start of and drawings
activity)
2 MATERIAL INSPECTION
2.1 Check the material as per Each delivery Project - H H
approved submittal specifications and
drawings
3 TESTING AND
COMMISSIONING
3.1 Pre-testing and MSB ROOM Project specification - H H
commissioning and drawings

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3.2 Testing and MSB ROOM Project specification - H H

commissioning for MSB and drawings
LEGEND : H: HOLD W : WITNESS S : SURVEILLANCE R : REVIEW
CONTRACTOR APPROVAL : CONSULTANT APPROVAL :

NAME : Muhammad Izzuddin Mustapa NAME :

SIGN : SIGN :
DATE : 11 October 2023 DATE :

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Appendix 5.5
Quality Control Site Inspection Checklist

SUPPLY, DELIVERY, INSTALLATION, TESTING AND COMMISIONING OF

MAIN SWTCHBOARD

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Risk Rating
Hazards Identified Risks Involved Residual
Serial No. Sub-Activities Initial Control Measures
(Generic & Task) (People & Property) Severity Probability Risk
Risk
• TBT/DSTI to be conducted by the
foreman/ safety officer prior to work
commencement Low
1. Prepare work area Unauthorized, • Cuts 2 A L ( R )
untrained • abrasions • Task specific safety training to be
workers provided
• Authorized personnel to undertake the
job
• Daily safety inspection should be carried

• Any lifting tasks shall be

carried out by persons
physically capable to do
• Incorrect lifting of • Back Injuries so
loads • Cut to finger • No employee should be asked to Low
2. Manual Handling • Sharp edges. 3 C M carry loads (ALARP)
• Strain
• Placing the object • above his capacity and in any case
while fingers • Musculos no load shall exceed 30kg per man.
keletal • Mass of the load is more then to
underneath.
Injuries be equally shared
• Slip/trip/fall (same
level) • Deploy enough number of
• Unsafe posture personnel for lifting shall be
appointed to the task depending
upon the type of load to be lifted.
• Use easy modes of transport like
trolley etc
.

• Load not to be lifted above

your shoulder height
• Keep your fingers away from
pinch point While placing the
load
• Area to be illuminated with

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Serial Risk Rating

No. Hazards Identified Risks Involved Residual
Sub-Activities Initial Control Measures
(Generic & Task) (People & Property) Severity Probability Risk
Risk

• Prior to start obtain all relevant approval

from traffic department in connection to the
use of road.
• Trained and experienced operator/ driver
and banks men to be appointed for the
• Collision with vehicles/ activity.
fixed installations. • Fatality • Restricted to unauthorized and public to
Poor identification • Property damage Enter the area. Low
3. Traffic and road • Fracture 4 B M • Public vehicles and transport to be restrict
• Unauthorized/ untrained • Penalty/ to enter the work area and proper
(ALARP)
management Operator/ driver, banks compensation alternative way to be provided.
men • Warning sign boards to be placed and area
Poor access for vehicle To be well barricaded.
Public movement • High visibility vest to be provided to flagman
to increase visibility.
• Flagman to be positioned to the areas
Wherever required.
• Close supervision to be done at all times.

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• Ensure the crane and forklift engaged is tested

• Unauthorized, Untrained and having valid license and the operator has
Workers • Fatality valid license and approved 3rd party certificate.
Unloading, shifting Failure of lifting • Fractures • Engage trained and certified banks man. M
4. and placing load bank equipment • Property damage 4 C H • Barricade and warning signs in to the (ALARP)
by forklift or crane Failure of lifting tools & • Injury to personal Area where lifting operation is carried out and
tackles. • Sprain and strain restrict the entry.
Unsafe lifting. • Check list should be carried out to their
• Swinging of material vehicles by the operator prior to start any
• Damaged sling/wire rope
work.
Or a chain
• Use tagline for control of swing and alignment.
• Poor maintenance of
vehicle
• All lifting equipment’s and gear shall be
having third party certified.

• Speedy operation • The crane must be stopped when the

• Overturn • speed exceeds 38km/hr.
• Overload • SWL should be clearly marked on the
crane and should be check that is
• functioning.
The crane and trucks shall be
periodically maintained and a
periodical check has been done by the
• maintenance
Vehicle not toteam.
be left unattended at site
(ie,to be switch off mode if required and
• keysworking
Safe removed) load should be carry by
crane and trucks and Secure the load
before it is travelling.
• Operators and rigger must worn high
level of reflecting vest and adequate PPE
(Shoe, helmet, leather gloves, goggles,
• over
Vehicleall routes
) kept free of obstructions
(with spillages being cleaned up
• Any reversing that is necessary
should be overseen by a trained
• flagman
Operator /should
Banksfollow
man. the site speed
limit and obey the traffic rules.

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• Color coded system to be implemented

• All lifting equipments as per the
month.

Risk Rating
Serial Hazards Identified Risks Involved Residual
Sub-Activities Initial Control Measures
No. (Generic & Task) (People & Property) Severity Probability Risk
Risk
• Defective tools should not be issued or used
to perform the task, to be checked by
storekeeper.
• Slip, trip and fall • Don’t extend the spanner by using a pipe as
Working with Hand • Damaged warn out hand • Fatigue an extension bar Low
5. tools tools • Trigger finger 3 C M Hand tools shall be free from oil, grease & etc. (ALARP)
• Flying objects • Cuts and abrasions • Chisel’s head shall have safety cap to avoid
 Mushroom Heads finger injury.
Never use a file as a lever
• Using incorrect type
Never use a screwdriver as a chisel
• Use eye/ face protection when there is flying
materials hazard, wear gloves while required to
protect the hands.
• Use right tools for the job

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 Trained person only to do the testing.

• PTW to be applied and obtained prior to
start work.
• Unauthorized/ untrained
• Electric shock and • Ensure that the circuit is not live before
Testing & Person Low
6. Burns 3 B M using the instrument.
commissioning using Faulty Instrument (ALARP)
• Calibrated / certified instrument only shall be
by multi meter, Improper identification •Cut and abrasion
megger, clamp meter Electrocution used.
• Warning boards should be provided and
Barricaded.
• Lock out tag out (LOTO) procedure to be
followed during testing & commissioning.
• Emergency evacuation plan shall be readily
available according to site condition and
briefed to the workforce prior to start.
• Trained first aider, fire warden and emergency
vehicle to be available at the site during the
activity.

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Risk Rating
Hazards Identified Risks Involved Residual
Serial No. Sub-Activities Initial Control Measures
(Generic & Task) (People & Property) Severity Probability Risk
Risk
Electricity • Electrocution or • Only those persons who have been adequately
• SS
Conductors (water, metal, death trained and experienced in the work of
Working with concrete) • Burns and shocks electricity to allow for the same.
7. electricity (load bank ) Broken wires 4 B M • Electrical work shall not carry out in wet Low
• Muscle contraction
Improper plug, case • Heart, lung Conditions. (ALARP)
• Overloading Paralysis • Lock out tag out (LOTO) procedure to be
•Fire followed during testing & commissioning.
• Do not overload the circuits.
• Communicate to all personnel about testing
& commissioning.
• Don’t use homemade electrical accessories and
use industrial type only.
• Disconnect main supply before commencing
of work.
• Defective tools and equipment should not be
used, report it and replaced it immediately.
• Barricade the location and signage to be
placed where circuits and equipments are
energized.
• PPE should worn at all time where working in
energized circuits. (Insulated gloves, Electric
resistivity shoe)
• Temporary power supply shall be taken
through standard rated MCBs & RCBs.
• Temporary power supply cables shall not
Have joints.

• Proper illumination to be provided Low

8.  Poor illumination  Fatality 3 B M • Light post to be secured from fall
While working at night (ALARP)
  Cuts
shift Slip/trip/fall • Proper cable management system to
be Followed
• All materials to be staged in proper
manner without obstacles

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Risk Rating
Hazards Identified Risks Involved Residual
Serial No. Sub-Activities Initial Control Measures
(Generic & Task) (People & Property) Severity Probability Risk
Risk
• Emergency procedure to be briefed to all
personnel prior to the start of the activity.
• Emergency evacuation plan shall be readily
available according to site condition and
briefed to the workforce prior to start.
• Trained first aider, fire warden and
Emergency vehicle to be available at all times
while during night work.

• Drink plenty of water

Low
• Dehydration 2 B M • Employees shall be trained about heat
• Heat Stress • Sunburn stress symptoms & first aid measures.
9. Working in hot
weather • Skin Cancer • Avoid highly physical tasks during the
hottest part of the day
• Isotonic drinks to be provided
• Provide sufficient rest breaks based on
the humidity& temperature
conditions.
• Heat stress management plan
shall developed and implement
during the activity.

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 PROPOSED ENHACEMENT OF EXISTING MAIN SWITCHBOARD
(MSB) AT SELECTED TOLL PLAZAS OF NORTH-SOUTH EXPRESSWAY

Document No.
Revision No. 00 Rev. Date 19/05/2023

• Low
• Poor housekeeping Fire • General housekeeping, Remove all
10. Work Completion 2 A L
• Slip/trip/fall surface, unwanted waste materials
from the building
• All necessary precautions will be adopted
to prevent fire.

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