METHOD STATEMENT

for the

INSTALLATION

of

2 NO. TRANSFORMERS

at

FARSHA SUBSTATION,
KINGDOM OF SAUDI ARABIA.

Project Number AA5373.09

Project FARSHA SUBSTATION, KSA

Client GE

Document number AA5373.09-MS002

0 29/01/2018 For Approval SK SI FB

Revision Date Description Prepared Checked Approved Approved
ALE Saudi Arabian Limited Company Client

Doc. SWF14 Rev. 1.1 Date: 01/10 Page 1 of 14

Client: GE Doc Number: AA5373.09-MS-002 Rev 0
Project: Farsha Substation Revision Status: For Approval

CONTENTS

1. INTRODUCTION ......................................................................................................................... 3
1.1. SCOPE OF DOCUMENT .......................................................................................................... 3
1.2. PARTIES .................................................................................................................................. 4
2. MANAGEMENT OF OPERATIONS ............................................................................................. 5
2.1. THE ALE ENGINEER & PROJECT MANAGER......................................................................... 5
2.2. THE ALE OPERATIONS SUPERVISOR ................................................................................... 5
2.3. MANAGEMENT OF CHANGE .................................................................................................. 5
2.4. SITE SAFETY ........................................................................................................................... 6
2.5. TOOLBOX TALK RECORD....................................................................................................... 7
3. PREREQUISITES AND INITIAL CONDITIONS ........................................................................... 8
3.1. GENERAL ................................................................................................................................ 8
3.2. RESPONSIBILITIES ................................................................................................................. 8
3.3. CONTROL OF OPERATION ..................................................................................................... 8
3.4. ORGANOGRAM ....................................................................................................................... 9
4. OPERATIONAL PROCEDURE ................................................................................................. 10
4.1. PRE-OPERATION PREPARATORY WORKS......................................................................... 11
4.2. OPERATIONAL PROCEDURE – INSTALLATION OF 2 NO. TRANSFORMERS AT FARSHA
SUBSTATION, KSA.......................................................................................................................... 11
4.3. DEMOBILISATION OF ALE EQUIPMENT .............................................................................. 12
5. PROJECT DRAWINGS AND REFERENCE DOCUMENTS ...................................................... 13
APPENDICES ..................................................................................................................................... 14
5.1. APPENDIX ‘A’ – PROJECT DRAWINGS
5.2. APPENDIX ‘B’ – RISK ASSESSMENTS
5.3. APPENDIX ‘C’ – TOOLBOX TALK PROFORMA

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Client: GE Doc Number: AA5373.09-MS-002 Rev 0
Project: Farsha Substation Revision Status: For Approval

1. INTRODUCTION

1.1. SCOPE OF DOCUMENT

This method statement covers the Installation procedure for 2 No. Transformers at Farsha
Substation via jacking and skidding operations.

The initial characteristics of the Transformer are as follows:

Quantity Item Description Length (m) Width (m) Height (m) Weight (t)
2 Transformer 7.300 2.800 4.000 75.00

This method statement represents the procedure to be followed, drawings, back up engineering
and risk assessments to ensure the safe installation of the Transformers.

This document may be updated and revised upon receipt of further information, Client comments
and revisions.

All operations are subject to our standard terms and conditions of carriage.

Included in the preliminary scope of work for the project is:

• Supply of installation equipment for the Installation of Transformer at Farsha

Substation, KSA.

• Supply of engineering support for all relevant operations and procedures.

It is the aim of this Method Statement to define and describe the equipment and safe procedures,
which are to be employed by ALE Saudi Arabian LLC to conduct the operations in compliance
with the following legislative and guidance documentation:

LEGISLATION
Ministerial Order No (32) Year 1982.
Federal Law No (24) of 1999 Protection & development of Environment

APPROVED CODES OF PRACTICE

AISC ASD 14th Edition

OTHER
ALE Middle East LLC General Conditions
ALE Middle East LLC HSE & Q Procedures

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Client: GE Doc Number: AA5373.09-MS-002 Rev 0
Project: Farsha Substation Revision Status: For Approval

1.2. PARTIES

The relevant parties involved with the Installation are listed below:

- GE - Client

- Abnormal Load Engineering LLC Saudi Arabia - Subcontractor for Installation

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Client: GE Doc Number: AA5373.09-MS-002 Rev 0
Project: Farsha Substation Revision Status: For Approval

2. MANAGEMENT OF OPERATIONS

Outlined below are the responsibilities of ALE personnel. This section also details the procedures to
follow if a deviation from the original operations procedure occurs.

2.1. THE ALE ENGINEER & PROJECT MANAGER

The ALE Engineer will prepare the method statement along with all drawings and calculations, which
will be checked by the ALE authorised Manager. It is the responsibility of the ALE Project Manager to
ensure that the on-site Operations Supervisor is adequately briefed on the content of this method
statement.

2.2. THE ALE OPERATIONS SUPERVISOR

Prior to the commencement of the works the supervisor must ensure that all site personnel are
adequately briefed on the contents of this method statement. This briefing shall take the form of a
short ‘toolbox talk’. The supervisor must liaise with the ALE manager should site circumstances require
material change to the methods to be employed during the operation and follow the ‘ALE management
of change procedure’ provided within this document. It is the responsibility of the supervisor to have
completed all safety checklists and briefings as identified within this scope of works.

2.3. MANAGEMENT OF CHANGE

This procedure has been prepared to categorise and authorise any intended deviation from the
intended scope of works outlined within this safe system of work. The ALE Operations Supervisor on
site is responsible for the work being conducted in accordance with the current approved method
statement. Any deviation from that approved method is categorised as follows:
2.3.1. Category 1 – (Minor) Deviation
The ALE Operations Supervisor on site considers a deviation from the intended scope of work to be a
small adjustment to meet local site conditions. They must bring this matter to the attention of the
clients’ on-site representative. Where the client agrees that the adjustment is minor and would not
introduce any risk to personnel or the integrity and safe operation of the equipment, authorisation to
proceed may be approved by both parties concerned by signing of the changes to the method
statement in the record of changes box provided within the method statement.
Any changes must be communicated back to the ALE Engineer / Project Manager and communicated
to the work force by means of a toolbox talk, which must also be recorded. The work may then
proceed.

Any change from the intended scope of work must comply with the manufacturer’s recommendations
for the use of the equipment and any associated procedural documentation, i.e. ALE and client
procedures and / or requirements. Where there is any doubt as to the implications changes may have
on the safety and / or integrity of the system/equipment or any conflict from the client’s representative
on site, for whatever reason, this change will become a category 2 – Major and the appropriate
category 2 action will apply.
2.3.2. Category 2 – (Major) Deviation
Category 2 deviations are those that the ALE Operations Supervisor or the client’s nominated
representative considers to be significant or deviations from category 1 that become category 2 as
identified in 2.3.1 above. Any proposed deviations / changes to the intended scope of work under this
category shall be communicated to the ALE Engineer / Project Manager who will revise the method
statement and liaise with the client representative to agree any changes for approval prior to
commencement of work.
Where necessary, engineering deviations / changes will be approved by the client or nominated third
party. On approval, any changes in the method statement and / or intended scope of work affecting the
safe system of work will be communicated to the work force by means of a recorded toolbox talk. All

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Client: GE Doc Number: AA5373.09-MS-002 Rev 0
Project: Farsha Substation Revision Status: For Approval

deviations and / or changes will be recorded and authorised within the record box provided within this
method statement.
A record of authorised changes during scope of work is available within the template of any
Method Statement devised for the erection and/or operation of any (ALE) equipment. An example
is provided below:

Client’s
ALE ALE
Cat Date Change to MS Action Responsible
Engineer Supervisor
Person

Example of a record of authorised changes during the execution of work within an ALE method statement

2.4. SITE SAFETY

When at the site there is a situation or area that is considered unsafe but beyond the abilities of
ALE personnel to make safe. All ALE work activities in that area will cease and the unsafe
situation or activity will be reported to the site supervisor for action.

The unsafe situation / activities / area will be reported to the client for the client to take measures
to make it safe again for the activities to continue.

No ALE activities will be performed until the situation or area is again made safe for working by
the client or the client’s agent. Should the measures taken by the client prove inadequate, the
works can and will be stopped until adequate steps have been taken. ALE cannot be held
responsible for any delays resulting from works being stopped due to unsafe situations.

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Client: GE Doc Number: AA5373.09-MS-002 Rev 0
Project: Farsha Substation Revision Status: For Approval

2.5. TOOLBOX TALK RECORD

A toolbox talk record is provided for the purpose of recording the initial toolbox talk on
commencement of the works under the scope of this method statement. A toolbox talk record
sheet is also provided within the appendix of this document and should be used to record any
future toolbox talks conducted on site. A minimum of one daily toolbox talk should be conducted
at the earliest opportunity prior to commencement of works.

The record is to be completed by all ALE and subcontracted labour personnel employed within the
scope work and working to this Method Statement and associated Risk Assessment.

Prior to commencing the operation all site personnel are to sign the toolbox talk sheet to confirm
that a clear briefing explaining the job has been given and is understood:

‘I am satisfied that I understand the work to be carried out. All known hazards have been
identified to me and I have been made fully aware of the control measures in place to reduce any
risk to both myself and others’.

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Client: GE Doc Number: AA5373.09-MS-002 Rev 0
Project: Farsha Substation Revision Status: For Approval

3. PREREQUISITES AND INITIAL CONDITIONS

3.1. GENERAL

1. Method Statement is subject to approval prior to the commencement of work.

2. Method Statement to be read in conjunction with the attached Risk Assessment
Documentation.
3. Minimum Personnel Protective Equipment (PPE) to be worn on site is as follows:
• Overalls,
• Hard Hat,
• Safety Footwear,
• Eye Protection,
• Gloves,
• Full Safety Harnesses (where necessary).
• High visibility vest

3.2. RESPONSIBILITIES

1. Clear area for working afforded at all times by client.

2. SJA (Safe Job Analysis), if necessary, to be carried out prior to work starting.
3. Ground preparatory work on site is to be carried out prior to arrival of transport and to be able
to withstand the loadings imposed during this operation.
4. Centre of gravity to be clearly marked on the Transformer, or advised by the client.
5. Centre lines to be clearly marked on the foundation and in front of the foundation, by client.
6. Client to supply mechanical handling equipment (i.e. crane age and forklift truck [if required])
for the sole use of ALE on-site activities.

3.3. CONTROL OF OPERATION

Outlined below are the responsibilities of ALE personnel associated with ALE’s on-site operations.

1. The ALE site supervisor is responsible for the performance of the operational disciplines,
which can be divided into two main areas, namely on-site operations and equipment
maintenance.
2. All operations associated with the Installation of the Items are under the direct control of the
ALE site supervisor.
3. After any break in the operational procedure, a walk round and visual inspection will be made
of the equipment in its current set-up to check that nothing has changed since leaving the
work place.
4. The ALE operators are capable of fixing most problems that can occur during the operations.
5. Other maintenance engineers are available on call to assist in rectifying any equipment
malfunction in the shortest possible time.

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Client: GE Doc Number: AA5373.09-MS-002 Rev 0
Project: Farsha Substation Revision Status: For Approval

3.4. ORGANOGRAM

GE

ALE HSQE Officer

Kennedy West
+966505639206

ALE Operations Manager

Maxwell Sampson
+966555348685

ALE Project Engineer

Said Khatib
+966555001948

Project Coordinator
Munawar Khan
+966581991088

ALE Installation
Operatives

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Client: GE Doc Number: AA5373.09-MS-002 Rev 0
Project: Farsha Substation Revision Status: For Approval

4. OPERATIONAL PROCEDURE

On the days that preparation of equipment will take place there will be a ‘toolbox’ meeting prior to
the start of activities that will review the following items:

a) Procedures, requirements and details specified in the work plans and drawings.
b) Review of safety items such as weather concerns, plant activity, escape routes,
contingency plans, locations of fire-fighting and personal safety equipment etc.
c) Designate key personnel, such as signalmen, tagline handlers etc.
d) Complete and sign off all appropriate checklists and safety permits.
e) Check the placement of all banners and barricades that define the safety boundaries of the
work areas.
Discuss and give due consideration to any additional appropriate steps that any participant
feels, is necessary to perform a safe and timely operation.
Note: Weather forecasts will be obtained prior to the operation. If the forecasts, in conjunction with
the actual wind speed-readings taken, do not give a sufficient window a suitable window a
suitable weather then the lift programme will be re-assessed.

Limits Go No go
Wind speed ≤ 20 Knots (10.3m/s) > 20 Knots (10.3m/s)
24hr weather forecast (wind) Dropping Increasing
Visibility ≥ 30m < 30m

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Client: GE Doc Number: AA5373.09-MS-002 Rev 0
Project: Farsha Substation Revision Status: For Approval

4.1. PRE-OPERATION PREPARATORY WORKS

4.1.1 Structural integrity of the Transformer is the responsibility of Client, during the entire operation.

4.1.2 Areas around the relevant plinth are to be suitably prepared by others and must be confirmed
that the plinth is capable of withstanding the loads imposed during the entire operations.

4.1.3 Centre of gravity to be clearly marked on the Transformers, or advised by client.

4.1.4 Centre line to be clearly marked on the foundation and in front of the foundation, by the client.

4.2. OPERATIONAL PROCEDURE – INSTALLATION OF 2 NO. TRANSFORMER AT

FARSHA SUBSTATION SITE, KSA.

4.2.1 On a designated date, the installation equipment is mobilized to Farsha Substation. The
equipment is offloaded in suitable areas near the foundation using a mobile crane and/or fork-lift
provided by others.

Note A: The operation area will be cordoned off with red and white tape. Instructions to
be given by site to other site contractors to inform about the removal operations,
and to keep clear of the operation area.
Non-essential personnel are to keep clear of the area.
Essential personnel are to request permission from ALE supervisor or site
engineer prior to entering cordoned off area.
Whole jacking and skidding equipment must be carefully examined for any
leakage or damage, prior to start of operation.

4.2.2 The Transformer arrives at the installation area and is offloaded onto support stillages with the
COG of the Transformer positioned in line with the centerline of the foundation as shown in
Drawings.

Note B: The route on site and approaching the Installation Area is to be cleared of
any obstructions and is to be suitably prepared for the expected loads during
transportation of the Transformer.

4.2.3 The transport lashings are removed from between Transformer and trailer, the trailer continues
to lower until the Transformer rests on the support stillages completely, the trailer is then
removed from beneath the Transformer.

4.2.4 Hydraulic Jacks used in this operation are following:

2 No. 100.00t Capacity Hydraulic Jacks will be used through end to end jacking; while inserting
and removing skid beams, skates for jacking and skidding operation.

4.2.5 Once in storage position the Transformer is jacked up, support stillages removed, and skid
beams are inserted beneath the Transformer.

4.2.6 2 No. Parallel skid tracks, support mats & timber packing (as required) are positioned beneath
the Transformer and skid tracks continued to the foundation. Packing to be used to keep the
tracks level. The skates and hydraulic propelling system are positioned beneath the
Transformer.

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Client: GE Doc Number: AA5373.09-MS-002 Rev 0
Project: Farsha Substation Revision Status: For Approval

4.2.7 The Transformer is then jacked down onto 4 No. skates on the skid track.

4.2.8 The Transformer is skated along the skid tracks, powered by the hydraulic propelling system,
until the Transformer’s COG is centered with the foundation.

4.2.9 Once above final position, the Transformer is jacked up off the beams, skates and skid tracks,
which are removed from beneath the Transformer.

4.2.10 The Transformer is jacked down onto the final position on the foundation as per client
confirmation.

4.2.11 Once over the final position, client to confirm the alignment of the Transformer before removal of
ALE equipment.

4.2.12 The above procedure is repeated for the next Transformer.

4.3. DEMOBILISATION OF ALE EQUIPMENT

4.3.1 Once all operations are completed, all ALE equipment is demobilised from the site.

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Client: GE Doc Number: AA5373.09-MS-002 Rev 0
Project: Farsha Substation Revision Status: For Approval

5. PROJECT DRAWINGS AND REFERENCE DOCUMENTS

DRAWING
REV DESCRIPTION
NUMBER

AA5373.09-IN01 0 Preliminary Installation Arrangement for 75.00t Transformer.

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Client: GE Doc Number: AA5373.09-MS-002 Rev 0
Project: Farsha Substation Revision Status: For Approval

APPENDICES

5.1. APPENDIX ‘A’ – PROJECT DRAWINGS

5.2. APPENDIX ‘B’ – RISK ASSESSMENTS

5.3. APPENDIX ‘C’ – TOOLBOX TALK PROFORMA

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5.1 APPENDIX “A” - PROJECT DRAWINGS
5.3 APPENDIX “C” – RISK ASSESSMENTS
 Risk Assessment
for the

Farsha Substation Project

Project number: AA5373.09

Project: Farsha Substation Project

Client: GE

Document number : RA-AA5373.09-002

A 29 January 2018 Risk SK SI FB

assessment
is created
Revision Risk assessment Description Prepared Checked Approved Accepted
date
ALE Client

RA-AA5373.09-002 A This document is uncontrolled if printed. Page 1 of 17

CONTENTS

1. INTRODUCTION 1
2. PROCESS 2
3. RISK ASSESSMENT MATRIX 3
4. Assessment description: Installation of 75.00t Transformer 4

RA-AA5373.09-002 A This document is uncontrolled if printed. Page 2 of 17

 1. INTRODUCTION

This risk assessment is conducted according the ALE-IMS-01-HSQE-PRO-017 (Risk Assessment

Procedure), which is part of the ALE management system.
Within this risk assessment all occupational health, safety and environmental hazards relevant to the
project scope are included.
All risks which are liable and realistic to the project are assessed by a team of competent team
members from disciplines relevant to the project scope.
The risk assessment is reviewed by the Engineering manager and approved by the HSQE
manager/advisor.
The assessment team was:
- Said Khatib
- Firas Bawazir
- Kennedy West
- Samar Iqbal

2. PROCESS

The team has followed the risk management protocol as listed below:
• Identify hazards
• Establish possible consequences from the hazard
• Assess the risk
• Identify suitable measures to eliminate or control unacceptable consequence the hazard poses
• Implement control measures
• Ensure that residual risks are As Low As Reasonably Practicable (ALARP)
• Reappraise residual risk
The risks are assessed according to the risk matrix under chapter 3.
The control measures will be verified by the responsible persons and were required instructions and
toolbox talks will be given.

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3. RISK ASSESSMENT MATRIX

RA-AA5373.09-002 A This document is uncontrolled if printed. Page 4 of 17

Health, Safety & Environmental Risk Assessment Author: : Checked: Approved:
SK SI FB
Assessment description: Installation of 75.00t Transformer Area and/or activity: Farsha, KSA
Document number : RA-AA5373.09-002 Document revision: A Revision date: 29 January 2018 Review date: 29 January 2018

N Sub- Potential Hazard / Potential Consequence Initial Risk Control measures Responsi Residual Risk Note / Additional
o. activities Activity S L R ble S L R measure
1 Installatio Ground surface giving way Excessive settlement. 6 2 12 Maximum settlement to be Client 6 1 6
n during jack-up Increase likelihood of other communicated with client.
hazards Client will confirm that
(stability/overloading) maximum settlement will not
be exceeded.
During initial pick-up
settlement will be monitored.
Minor settlement 4 2 8 Shimming will be applied. Client 4 1 4
2 Jack instability Multiple fatalities due 10 2 20 Calculations to be made by Engineer, 10 1 10 Site emergency response
uncontrolled movemement project engineer to prove Operator plan to be adhered to.
of Module sufficient stability. &
Environmental limits not to Supervis
be exceeded (See Method or
Statement).

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N Sub- Potential Hazard / Potential Consequence Initial Risk Control measures Responsi Residual Risk Note / Additional
o. activities Activity S L R ble S L R measure
3 Hydraulic power pack Delay of operation 2 4 8 Carry out preventive Worksho 2 2 4
failure maintenance. p Team
Testing of equipment prior to &
project. Supervis
Only qualified personnel to or
work with pressurized
systems or under the direct
supervision of experienced
personnel.
4 Failure of power pack due Delay of operation 2 4 8 Specifications to be send to Worksho 2 2 4 Sufficient spare parts
to low quality of diesel / client p Team available on site
hydraulic oil &
Supervis
or
5 Failure of power pack due Delay of operation 2 4 8 Required quantity of Worksho 2 2 4 If insufficient use additional
insufficient quantity of hydraulic oil to be calculated. p Team hydraulic oil tank.
hydraulic oil Verify the available amount &
of hydraulic oil in power Supervis
pack. or
6 Emission: Exhaust fumes Environmental air pollution 2 4 8 Use DPF (Diesel Particle Safety 2 2 4
from engines and power Filter) in exhaust lines. Officer
packs. Use engines according to
ALARP (As Low As
Reasonably Practical)
principle.
Exhaust gasses can cause 4 2 8 Sufficient ventilation to be Safety 4 1 4 Possible repositioning of
respiratory problems or supplied. Officer exhaust line.
asphyxiation

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N Sub- Potential Hazard / Potential Consequence Initial Risk Control measures Responsi Residual Risk Note / Additional
o. activities Activity S L R ble S L R measure
7 Collapsing of Loss of Module (structure) 6 2 12 Third Party Inspection of Project 6 1 6
dunnage/Support Stool and Injury to Personnel Skidding Arrangement will be Team
done including thorough
inspection of support
arrangements.
8 Teflon pads being pushed Damage to equipment, 2 2 4 During installation of skidding Supervis 2 1 2
along with the skid delay of the operation. equipment and prior to or
beam/skid shoe/bridge skidding operation all teflon
pads to be visually checked.
Teflon pads to be cleaned
and lubricated prior to
loading.
9 Ground surface giving way Skid shoe instability 2 2 4 Client to check the ground Client 2 1 2 Consider load spreading.
during skidding operations resulting in possible bearing pressure indicated in Supervis
damage to equipment and Method Statement. or
structure
Instability of skid shoe 4 2 8 Client to check the ground Client 4 1 4 Consider load spreading
resulting in module bearing pressure indicated in Supervis and/or extra quantity.
instability Method Statement. or
Injury to personnel 4 2 8 Place barriers and allow only Client 4 1 4 Site emergency response
authorised personnel within Supervis plan to be adhered to.
the operating area. or

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N Sub- Potential Hazard / Potential Consequence Initial Risk Control measures Responsi Residual Risk Note / Additional
o. activities Activity S L R ble S L R measure
10 Skid shoe instability during Damage to equipment due 4 2 8 Skid shoes need to be in a Project 4 1 4
installation to overturning of skid shoe transport frames till Team
installation in the skid track.
Use the push / pull
connection pin for installation
of the skid shoe. Skid shoe
lifting lugs not to be used for
installation. Pull skid shoe in
a straight line during
installation.
Injury to personnel due to 4 2 8 Skid shoes need to be in a Project 4 1 4 Site emergency response
overturning of skid shoe transport frames till Team plan to be adhered to.
installation in the skid track.
Personnel not to be located
on the side of the skid shoe
during installation. Use the
push / pull connection pin for
installation of the skid shoe.
Skid shoe lifting lugs not to
be used for installation. Pull
skid shoe in a straight line
during installation.

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N Sub- Potential Hazard / Potential Consequence Initial Risk Control measures Responsi Residual Risk Note / Additional
o. activities Activity S L R ble S L R measure
11 Loss of electrical power Delay of operation 2 4 8 Spare power supply will be Worksho 2 2 4
during operation available for critical p Team,
operations (eg. UPS and/or Supervis
spare generator). or
Spare cables to power
supply will be available for
critical operations.
Where possible, electrical
cables will be positioned in
cable trays and protected
from crossing vehicles.
12 Improperly aligned path of Misalignment of Skid 4 2 8 Skid path to be marked prior Supervis 4 1 4
skidding shoes/Hitting to operation. Dimension or,
corner/Damage to control to be inplace by Operator
Equipment/Structure Dumpy level/Total Station
13 Shoes running off track Misalignment of Skid 4 2 8 Shoes movement along the Supervis 4 1 4
shoes/Hitting track to be monitored. or,
corner/Damage to Dimension control to be Operator
Equipment/Structure inplace by Dumpy level/Total
Station
14 PPU not moved before break of Hoses, Loss of 4 2 8 PPU to be mounted on skid Supervis 4 1 4
hose slack runs out pressure, Damage to beam. Alternatively enough or,
Structure slack of hoses to be provided Operator
during skidding.
15 Manual Slips, trips and falls Injury to personnel, cuts, 4 4 16 Good house keeping Project 4 2 8 Site emergency response
Handling bruises potential broken Keep walkways free of Team plan to be adhered to.
bones, strain injuries. obstacles
All personnel to keep to
established walkways were
possible

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N Sub- Potential Hazard / Potential Consequence Initial Risk Control measures Responsi Residual Risk Note / Additional
o. activities Activity S L R ble S L R measure
16 Hydraulic hose or pipe Equipment damage 4 4 16 Carry out preventive Project 4 2 8
rupture maintenance. Team
Testing of equipment,
function test at low
pressures.
Only qualified personnel to
work with pressurized
systems or under the direct
supervision of experienced
personnel.
Limit maximum pressure of
system.
Injury (direct contact with 2 4 8 Wear correct PPE (gloves, Project 2 2 4 Check Safety Data Sheet
oil e.g. skin, eyes) long sleeves, safety Team
goggles).
Take care of personal
hygiene (washing of hands).
Environmental pollution 2 2 4 Carry out preventive Project 2 1 2 Content of oilspill kit to be
maintenance. Team determined (water and/or
Testing of equipment, soil).
function test at low See also ALE-IMS-01-
pressures. HSQE-GUI-029 Spill
Only qualified personnel to Management.
work with pressurized
systems or under the direct
supervision of experienced
personnel.
Oilspill kit available.
Couplings equipped with self
sealing couplings.

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N Sub- Potential Hazard / Potential Consequence Initial Risk Control measures Responsi Residual Risk Note / Additional
o. activities Activity S L R ble S L R measure
17 Manual handling Injury to personnel (eg. 2 4 8 Where possible operators Project 2 2 4 Site emergency response
Strain injuries, pinched should try and employ a Team plan to be adhered to.
fingers) mechanical means of moving
heavy items such as using a
crane, Telehandler or FLT.
No single operator should
attempt to lift more than 25
kg on their own.
Any other lifts that must be
done manually should be
done using team lifting.
All operators must be
competent in manual
handling in accordance with
ALE-IMS-01-HSQE-PRO-
021.
18 Hazardous substances (eg. Effect on health of 2 4 8 Measurements will be taken Project 2 2 4 Site emergency response
oils, (de)greases, fumes) personnel (eg. headache, according MSDS. Team plan to be adhered to.
irritation, nauseous) Diesel Particulate Filters will
be used in all exhausts.
Appropriate PPE (eg.
Respirators) will be used for
the type of work.

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N Sub- Potential Hazard / Potential Consequence Initial Risk Control measures Responsi Residual Risk Note / Additional
o. activities Activity S L R ble S L R measure
Environmental pollution 2 2 4 Measurements will be taken Project 2 1 2
according MSDS. Team
Diesel Particulate Filters will
be used in all exhausts.
Appropriate PPE (eg.
Respirators) will be used for
the type of work.
Oil spill kit will be available
(consider land and/or water
spill)
19 Insufficient Hygiene due to Physical, microbiological, 4 2 8 Client to provide sufficient Client 4 1 4 Site emergency response
poor facilities biological or chemical types and proper sanitary facilities Site plan to be adhered to.
of disease and excreta management. Supervis
ALE will bring a disposal unit or
to contribute to the solid
waste management.
20 Use of electrical equipment Injury to personnel due to 4 2 8 Carry out preventive Project 4 1 4 Site emergency response
and associated cabling and electrification, cuts, bruises, maintenance. Supervis plan to be adhered to.
generators potential broken bones, Carry out inspections on a or
strain injuries. regular basis.
For safe working with
electricity see ALE-IMS-01-
HSQE-PRO-38 SAFETY
WITH ELECTRICITY.

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N Sub- Potential Hazard / Potential Consequence Initial Risk Control measures Responsi Residual Risk Note / Additional
o. activities Activity S L R ble S L R measure
Fatality due to 6 2 12 Carry out preventive Project 6 1 6 Site emergency response
electrocution. maintenance on electrical Supervis plan to be adhered to.
equipment. or
Carry out inspections on a
regular basis on electrical
equipment.
For safe working with
electricity see ALE-IMS-01-
HSQE-PRO-38 SAFETY
WITH ELECTRICITY.
21 All Noise Short Term Hearing Loss 2 2 4 Relocate source if possible Supervis 2 1 2
Activities Non essential personnel to or, Safety
be kept away from source. Officer
Wear hearing protection
according ALE-IMS-01-
HSQE-PRO-034
22 High ambient temperature Effect on Health of 4 2 8 Provision of clean drinking Client & 4 1 4
and/ or high humidity Personnel (eg. Heat stroke, water ALE
Dehydration, Sun burn) Provision of Air Supervis
conditioned/Shaded rest or
area for Personnel
Provision of sun cream/ sun
block
23 Moving vehicles (e.g. fork Delay of operation. 2 4 8 Ban vehicles which are not Project 2 2 4
lifts, cherry pickers, buses, part of the operation. Supervis
bicycles, passenger cars, Vehicles to make use of or
cranes) segregated driving routes.

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N Sub- Potential Hazard / Potential Consequence Initial Risk Control measures Responsi Residual Risk Note / Additional
o. activities Activity S L R ble S L R measure
Injury to personnel. 4 2 8 Ban vehicles which are not Project 4 1 4 Site emergency response
part of the operation. Supervis plan to be adhered to.
Vehicles to make use of or
segregated driving routes
where possible.
Qualified operators to be
used for operating site
machinery.
Vehicles to drive with limited
speed.
Vehicles with limited
overview to make use of
banksman.
24 Loss of communication or Likelihood of injury or 6 2 12 Function test of radios prior Project 6 1 6 Everybody need to
miscommunication (e.g. damage to equipment from to operation. Supervis understand the
broken radios, language any other hazard drastically Spare batteries to be or commands/instructions.
barrier, etc.) increased available when necessary. Use radio communication
Language for communication protocol.
to be agreed on.
Delay of operation 2 4 8 Function test of radios prior Project 2 2 4 Everybody need to
to operation. Supervis understand the
Spare batteries to be or commands/instructions.
available when necessary. Use radio communication
Language for communication protocol.
to be agreed on.
25 Simultaneous operations in Likelihood of injury or 4 4 16 SIMOPS meeting to be held Project 4 2 8 SIMOPS to be organised
the area damage to equipment from prior to operation . Team by client.
any other hazard drastically TAKE 5 to be carried out.
increases.

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N Sub- Potential Hazard / Potential Consequence Initial Risk Control measures Responsi Residual Risk Note / Additional
o. activities Activity S L R ble S L R measure
26 Oil spillage Environmental pollution 2 4 8 Spil kits to be available at Supervis 2 2 4 Content of oil spill kit to be
e.g. land or sea suitable locations. or determined (water and/or
soil)
See also ALE-IMS-01-
HSQE-GUI-029 SPILL
MANAGEMENT
27 Insufficient structural Damage to equipment 4 4 16 Client to specify Not To Client & 4 2 8
integrity of Module Exceed loads per point and Project
Not To Exceed combined Team
loads for Module.
Client will confirm that the
Module consists of sufficient
structural resistance for the
imposed loads.
Multiple fatalities 10 2 20 Client to specify Not To Client & 10 1 10 Site emergency response
Exceed loads per point and Project plan to be adhered to.
Not To Exceed combined Team
loads for Module.
Client will confirm that the
Module consists of sufficient
structural resistance for the
imposed loads.
Injury to personnel 6 2 12 Client to specify Not To Client & 6 1 6 Site emergency response
Exceed loads per point and Project plan to be adhered to.
Not To Exceed combined Team
loads for Module.
Client will confirm that the
Module consists of sufficient
structural resistance for the
imposed loads.

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N Sub- Potential Hazard / Potential Consequence Initial Risk Control measures Responsi Residual Risk Note / Additional
o. activities Activity S L R ble S L R measure
28 Extreme cold Malfunction of equipment 2 4 8 Add additives. Worksho 2 2 4 Equipment used are to run
caused by changing p Team, idle to make sure the
characteristics of hydraulic Supervis engines and components
oil, fuel and greases or are on temperature that no
break-downs will occur.

RA-AA5373.09-002 A This document is uncontrolled if printed. Page 16 of 17

RA-AA5373.09-002 A This document is uncontrolled if printed. Page 17 of 17
 COSHH ASSESSMENT 004 – Diesel Fuel, Gas Oil

Assessment By: P Cox. Review Date: Jan 2010 Next Review: As required
Material: Diesel Fuel, Gas Oil Supplier: Any Manufacturer: Any
Hazardous contents:

Polycyclic aromatic 100ppm, Route: Skin

Hydrocarbons 5mg/m3, Route: Inhalation
Oil Mist

Description and form of substance: Clear Liquid, Diesel is pale yellowish colour, Gas Oil is red
Normal Use: Fuel for compression-ignition engines
Hazards in normal use: Dermatitis due to prolonged/repeated exposure
Inhalation of mist/vapours – aspiration into lungs
Normal Control Measures:
Protective clothing to be worn where prolonged/repeated contact is likely
Impermeable gloves to be worn during handling/pumping ( EN 420 )
Adequate ventilation, avoid frequent/prolonged skin contact
Avoid prolonged inhalation of mist/vapours use HSE approved respiratory when significant vapours occur
Avoid wearing clothing/footwear soaked in oil
Avoid skin contact, wash thoroughly with plenty of soap and water
Avoid splash filling at high flow rates to prevent electrostatic charges being generated
Storage:
Fuel to be stored in 5 litre approved container and kept inside the jacking box AT ALL TIMES

First Aid:
Skin: Remove contaminated clothing, Wash skin thoroughly with plenty of soap and water. Seek
medical attention if irritation persists
Eyes: Rinse IMMEDIATELY with plenty of water until irritation subsides (at least 15 minutes) if
irritation persists seek medical advice.
Inhalation:
Remove immediately from exposure, using safe and proper rescue precautions, administer
Ingestion: artificial respiration if necessary, get prompt medical attention.
Do not induce vomiting because of dangers of aspiration. Get medical advice IMMEDIATELY
Fire: Use - Powder - Foam - Carbon Dioxide (CO2).
Do not use water.
Toxic fumes are produced when substance is involved in a fire.

Spillage: Ventilate area. Vapour heavier than air so particular attention to adjacent pits/basements.
Eliminate all sources of ignition.
Shut off at source.
Absorb in sand or inert absorbent material.
Collect into a container, close lid.
Suitable hand protection must be worn.
Wear respiratory equipment when spillage is in confined space.
Wear protective overalls and chemical / safety footwear.
Do not allow spillage to enter the drain / sewers / water courses.
Dispose of in accordance with Local Authority Regulations
Risk Assessment in Normal Use: LOW
 COSHH ASSESSMENT 004 – Transmission / Hydraulic Oil

Assessment By: P Cox. Review Date: Jan 2010 Next Review: As required
Material: Liquimatic Transmission Oils, Hydraulic Oil Supplier: Any Manufacturer: Any
Hazardous contents: On Heating.
Carbon Monoxide
Carbon Dioxide
Oxides of Nitrogen & Sulphur

Description and form of substance: Mobile Liquid Oil

Normal Use: Hydraulic & Transmission Lubricant
Hazards in normal use: Dermatitis due to prolonged/repeated exposure
Inhalation of mist/vapours – aspiration into lungs
Normal Control Measures:
Protective clothing to be worn where prolonged/repeated contact is likely
Impermeable gloves to be worn during handling/pumping ( EN 420 )
Eye protection when handling heated product
Adequate ventilation, avoid frequent/prolonged skin contact
Avoid prolonged inhalation of mist/vapours use HSE approved respiratory when significant vapours occur
Avoid wearing clothing/footwear soaked in oil
Avoid skin contact, wash thoroughly with plenty of soap and water
Avoid splash filling at high flow rates to prevent electrostatic charges being generated
Storage:
Fuel to be stored in 5 litre approved container and kept inside the jacking box AT ALL TIMES

First Aid:
Skin: Remove contaminated clothing, Wash skin thoroughly with plenty of soap and water. Do not use
solvents or thinners. Seek medical attention if irritation persists
Eyes: Rinse IMMEDIATELY with plenty of water until irritation subsides (at least 15 minutes) if irritation
persists seek medical advice.
Inhalation: Remove immediately from exposure, using safe and proper rescue precautions, administer artificial
respiration if necessary, get prompt medical attention.
Ingestion: Do not induce vomiting because of dangers of aspiration. Get medical advice IMMEDIATELY
Fire: Use - Powder - Foam - Carbon Dioxide (CO2).
Do not use water.
Toxic fumes are produced when substance is involved in a fire.

Spillage: Ventilate area.

Eliminate all sources of ignition.
Shut off at source.
Absorb in sand or inert absorbent material.
Collect into a container, close lid.
Suitable hand protection must be worn.
Wear respiratory equipment when spillage is in confined space.
Wear protective overalls and chemical / safety footwear.
Do not allow spillage to enter the drain / sewers / water courses.
Dispose of in accordance with Local Authority Regulations
Risk Assessment in Normal Use: LOW
 COSHH ASSESSMENT 006 – PTFE & White Grease

Assessment By: T Ellson Review Date: Feb 2010 Next Review: As required
Material: PTFE & White Grease Supplier: Any Manufacturer: Any
Hazardous contents:
Petroleum Distillate

Description and form of substance: Aerosol canister of Spray Grease, compressed liquid form.
Normal Use: Spray on Grease for Lubrication
Hazards in normal use: Aerosols can contain highly flammable asphyxiating gas. Inhalation of vapours
– aspiration into lungsRepeated exposure may cause skin dryness or cracking.
If there is a source of ignition fire or explosion may occur.
Normal Control Measures:
Avoid skin contact - protective clothing to be worn where prolonged/repeated contact is likely. Impermeable gloves
to be worn during handling. DO NOT SMOKE, EAT OR DRINK WHILST HANDLING. In case of skin contact, wash
thoroughly with plenty of soap and water
Ensure adequate ventilation, avoid inhalation of mist/vapour, use HSE approved respiratory protection (RPE) if
necessary when significant vapours occur
KEEP AWAY FROM NAKED FLAMES AND SOURCES OF IGNITION.
Storage:
Store in original canister out of direct sunlight and away from other heat sources.

First Aid: Eyes: Immediately flush eyes with plenty of cold water for at least 15 minutes, holding eye lids
open. Get IMMEDIATE medical attention
If skin or hair contact occurs, IMMEDIATELY remove contaminated clothing and wash skin
Skin:
with running water. A component of this product can absorbed through the skin with toxic
effects. Seek medical assistance IMMEDIATELY.
Inhalation: IMMEDIATELY remove patient to uncontaminated area. Keep warm and at rest. If breathing
has stopped or is showing signs of stopping, commence artificial respiration. Seek medical
assistance IMMEDIATELY.
Ingestion: If swallowed do NOT induce vomiting. Seek medical assistance IMMEDIATELY.
Fire: Use – Foam, carbon dioxide, dry chemical powder. Do not use water and remove only if safe
to do so.
Toxic fumes are produced when substance is involved in a fire.

Spillage: Shut off at source, ventilate area & eliminate all sources of ignition.
Use cover to slow spread of vapours.
Absorb in sand or inert absorbent material.
Close container where possible, close lid.
Wear respiratory equipment when spillage is in confined space.
Suitable hand protection must be worn.
Wear protective overalls and chemical / safety footwear.
Do not allow spillage to enter the drain / sewers / water courses.
Dispose of in accordance with Local Authority Regulations
Risk Assessment in Normal Use: LOW
5.4 APPENDIX “D” – TOOLBOX TALK PROFORMA
 ALE Integrated Management System

ALE-IMS-01-HSQE-TEM-013Z
TOOLBOX TALK RECORD SHEET

Date Location

Person delivering Talk Signature person delivering Talk

Content of the toolbox talk (include details of any documents you have made reference to)

No Attendee’s Name Signature Company

10

11

12

13

14

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