Method Statement and Risk

Assessment

METHODE STATEMENT
FOR AC & DC WIRING

Revision #: 01 Document Number: CRS-2306-MS-01

Prepared by: RSW Reviewed by: KSG
Date 01 April 2024 Date 01 April 2024
Signature Signature

Project TOTAL ENERGIES PT PERUSAHAAN INDUSTRI CERES 2163 kWP

Customer TOTAL ENERGIES
Client/Facility owner PT PERUSAHAAN INDUSTRI CERES
EPC PT SURYA ENERGI INDOTAMA
Subcontractors

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 Method Statement and Risk
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Approvals Submittal Date Revision Date Comment

- Oke, All reference documents will be in approved
condition and available at site while performing work
EPC 01/04/2024 - the steps related to string testing and continuity test has
been added
- the steps related to IR and Continuity Test has been added
- All reference documents should be in approved condition
and available at site while performing work
- Please add the steps related to string testing and continuity
test. Result should be noted down, results should not be
Total Solar 18/03/2024
abnormal
- Please add the steps related to IR and Continuity Test.
result should be noted down, result should not be
abnormal
Client

1) Purpose:
The purpose of this document is made, namely:

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a) As a guideline for the implementation of Alternating Current (AC), Low Loltage (LV) and DC (Direct
Current) cable installation work in the Total Energies area of PT Perusahaan Industri Ceres 2163
kWp.
b) To ensure technical conformity between drawings and specifications with actual field.

2) Scope:
a) Work must comply with safety standards.
b) All work must be in accordance with the approved drawing documents, please use the latest
revised drawings as a reference.

3) Definitions and abbreviations:

LV = Low Voltage
AC = Alternating Current
DC = Direct Current
PLTS = Pembangkit Listrik Tenaga Surya
PV = Photovoltaic
K3 = Kesehatan dan Keselamatan Kerja
PUIL = Persyaratan Umum Instalasi Listrik

4) Applicable regulations
This activity refers to several applicable regulations including:
a. PUIL 2011

5) Reference documents:
a. CRS-2306-TS-03 DC Cables
b. CRS-2306-TS-04 AC Power Cables
c. CRS-2306-EM-01 Master Single Line Diagram
d. CRS-2306-EM-03 AC/DC Cable Trays and Routing Details
e. CRS-2306-EM-05 Equipment Layout Overall Plant & Electrical Control Room
f. CRS-2306-EM-06 Stringing Layout
g. CRS-2306-CE-04 Inverter Station and Foundation Details
h. CRS-2306-EM-04 Communication and Monitoring System Configuration
i. CRS-2306-TS-06 Solar Cable Connectors
j. CRS-2306-TS-08 Conduit, Conduit Fitting and Accessories
k. CRS-2306-TS-13 Cable Lugs, Glands and Other Accessories
6) Personal involved (responsibilities and supervision):
a. Project Manager

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 Method Statement and Risk
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In the case of projects, the Project Manager is tasked with managing project activities from the
beginning to The project ends, and the main tasks are as follows:
1. Responsible for all project activities;
2. Drawing up a project budget;
3. Create a schedule for the execution of work;
4. Monitor and supervise the project work plan whether it is running on schedule;
5. Ensure that the work safety program runs properly;
6. Report project activities to company leaders or directors;
7. Deal directly with the giver or project owner.
The Project Manager has the ability to give direct instructions to the team in fields such as
ExecutorTechnique, Civil Execution, Electrical Mechanical Executor, Technician, Helper,
Administration Personnel

b. Civil Engineer
In the case of projects, the Civil Engineering Executor is in Preparing letters related to this work;
charge of ensuring all forms of construction work civil in accordance with the specifications
specified in the contract, in this case the Civil Executor have the following tree tasks :
1. Conduct a plan determination survey;
2. Supporting materials are available such as PV module support, inverter support and AC panel
support;
3. Supervise civil servants;
4. Checking the quality of the foundation.

c. Electrical Engineer
In the structure of the Executor's work, Electrical Engineering is responsible in all fields
engineering in electrical engineering side work,

d. Executor K3 Construction
In the structure of the work, the Executor of K3 Construction in the project is the responsible
leader, Responsible for all K3 fields in this work and supervise K3 in the field.

e. Administration Personnel
Administration personnel in terms of PLTS installation work has the main duties include:
1. Prepare documents related to this job;
2. Create weekly reports and monthly reports;
3. Helps Project Managers to control project budgets or finances
f. Field Superintendent

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Field Supervisors are in charge of supervising the PLTS Construction work process from beginning
to end, hard barricade installation, temporary safety line installation, PV Mounting installation,
walkway installation, etc. Commissioning and other work work. As well as taking photos / videos of
documentation of all stages / processes of work.

7) Machinery and tools:

Work Material : Work Tools :
a. Heatshring a. Measuring Tape
b. Bolt & nut b. Hydraulic Crimping
c. Schoen Cable c. Cutter
d. DC Cable d. Multimeter
e. AC Cable e. Megger Tester
f. MC4 Connector f. Torque Wrench
g. Wrench
h. Saw/Grind
i. Heat Gun
j. Diagonal Pliers
k. Screwdriver
l. MC4 Crimping
m. Electric drill
n. Hole Saw Drill

8) Chemical substances used:

No hazardous chemicals were used.

9) Environment of work:
The work location is at PT Perusahaan Industri Ceres with Address PT. Perusahaan Industri Ceres, Jl.
Raya Dayeuhkolot No.94 No. 92, Pasawahan, Kec. Dayeuhkolot, Kabupaten Bandung, Jawa Barat
40256.
The company is engaged in food and berages specialized in chocolate processing.
The PV Module installation location is in Garuda Building, and Garuda Building has 4 roofs.
Here are the details of the location of the work area :
a. Raw Material Building Roof
b. Finish Good Building Roof
c. Production Building Roof
d. Packaging Building Roof
e. LVMDP M Room
f. LVMDP PQ Room
g. Transformator 2 Room
h. Transformator 5 Room

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i. All Area connecting to Garuda Building

Work risks related to environmental conditions in the work area are the risk of working at height for
the installation of DC Cable Wiring in the roof area to connections in the LVMDP M and LVMDP PQ
rooms, the risk of electrical work in AC cable installation.

10) PPE required:

The PPE to be used is as follows:
a. Safety Shoes
b. Safety Glasses
c. Safety Gloves
d. Coverall/Rompi
e. Safety Helmet
f. Electrical Gloves

11) Competency certifications:

Each of our personnel involved in this Project has a certificate of competence including: :
a) Engineer : SKTTK Level 5
b) Technician : TKBT 2
c) PIC K3 : General K3 Certificate

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12) Emergency plan:

Figure 1 Emergency Plan

In an emergency, the assembly point area is located in the rear parking area close to LVMDP M and another in front
close to the Company's lobby.

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Duration of Activity:
Description of the Activity (Step by Step)
DC/PV Cable Installation Procedure
A. Pulling DC Cable
1 There are two types of DC wiring, namely leap frog wiring and daisy chain wiring such as figure 2 and figure
3
2 This Pulling DC Cable is done after the PV Module's internal wiring is completed
3 Make sure again before the cable is held cable connector / cable gland has been installed and check all
document reference
4 Cables are placed in a neat order, avoiding crossings and puncturing with other cables, as well as tidying up
in cable tray/trench using cable ties.
5 Ensuring towing equipment (cable roll etc.)
6 Ensure that turns and angles do not exceed the swelling radius of the appropriate cable manufacturer
recommendations
7 After cable pulling, check for mechanical damage to the cable
8 Perform a continuity test on each cable that has been pulled to ensure each pull matches the cable
schedule and record the measurement results on the form provided
9 Next, Insulation Resistance (IR test) to ensure there are no voltage leaks or damage to the cable (minimum
measurement value: working voltage x 1000) and record the measurement results on the form provided
10 Ensure both ends of the cable are marked with the relevant cable number and sealed for
prevent moisture ingress before termination work
11 Record the actual cable path length installed and record the schedule of installed cables
12 Make sure there is no cable connection in this process of pulling cable dc
13 DC cables are not directly exposed to sunlight but through flexible metal conduit
14 No DC cable is exposed to the roof directly, DC cable is tied using clip cables and cable ties
15 Flexible metal conduit leading to cable tray mounted in parallel with straight rail PV so that flexible metal
conduit does not touch the roof see figure 7
B. PV String Connection
1 Make sure all PV modules used are of the same type
2 When stripping the cable insulation “L”, 7mm to 9mm in length should be removed on the end of cable
3 Fix the stripping tool, cutting length to 7mm to 9mm (the length of L should be fixed). See Figure 8
4 Take the cable one hand and take the stripping tool the other hand.
5 Insert cables until the end touches fixed block
6 Squeeze the handle of the stripping tool by hand, then cut and remove the cable insulation see figure 9
7 Insert striped cable into contact barrel and insure all conductor strands are captured in the contact barrel.
Crimp contact barrel by using the corresponding crimping die. See Figure 10
8 Insert the crimped male or female terminal into back of male or female cable connector .A “click” should
be heard or felt when the contact cable assembly is seated in correct position. Contacts cannot be
removed once seated. See figure 11
9 To fixed the gland nut by the open-end wrench of the assembly tool, and to fixed the male cable connector

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or female cable connector by the another assembly tool, then tighten the gland nut with the specified
tightening torque. See figure 11
10 Spin clockwise to fully tighten the gland nut. Clearance between the gland nut and the cable connector
should be 0.8 to 3.0mm
11 Insert the female cable connector into the male cable connector when the gland nut is fully tightened. The
connection of female and male cable connector is complete when an “audible click” is heard.
C. Pulling AC Cable
1 Use cables according to specifications and check all document reference
2 Make sure that when installing all components there is no voltage
3 Open the inverter AC Cable cabinet and remove the supporting accessories and store them properly
4 Choose crimping tools that match the type of AC output cable LV AC cable termination 0.6/1 kV 1R x 3C x
95 sqmm using cable schoen/skun bimetal 95-M12 , for grounding cable used bimetal 50-M8 and crimping
using hydraulic method. Colored heatshrink (adjusting phase color coding) is used to seal the crimping
results on the bimetallic Schoen cable. The connection from the termination of the LV AC cable to the
terminal uses bolt & nut with a torque of 20-30 Nm.
5 Bending AC LV Cable, for laying cable, attention must be paid to the bending radius, in accordance with
conditions below.

6 Make sure again before the cable is held cable connector / cable gland has been installed
7 After cable pulling, check for mechanical damage to the cable
8 Perform a continuity test on each cable that has been pulled to ensure each pull matches the
cableschedule and record the measurement results on the form provided
9 Next, Insulation Resistance (IR) test to ensure there are no voltage leaks or damage to the cable (minimum

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measurement value: working voltage x1000) and record the measurement results on the form
10 Ensure both ends of the cable are marked with the relevant cable number and sealed for
prevent moisture ingress before termination work
11 Record the actual cable path length installed and record the schedule of installed cables
Sketch/drawing if relevant:

Figure 2 Leap Frog Wiring Connection PV Module

Figure 3 Daisy Chain Wiring connection PV Module

Figure 4 Hole saw process for cable connector installation

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Figure 5 Cable Connector Installation

Figure 6 Cable Connector Installation

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Figure 7 Implemetation point 13

Figure 8 L= 7-9 mm

Figure 9 cable Insulation removal

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Figure 10 crimping cable

Figure 11 insert cable crimping to MC4

Figure 12 Finish Installation MC4

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Permits Required:

Which Golden Rules apply?

☐ 1 High-Risk Situations ☒ 5 Work Permits ☐ 9 Excavation Work
☒ 2 Traffic ☐ 6 Lifting Operations ☒ 10 Work at Height
☐ 3 Body Mechanics and Tools ☒ 7 Powered Systems ☐ 11 Change Management
☒ 4 Protective Equipment ☐ 8 Confined Spaces ☐ 12 Simultaneous Operations / Co-Activities

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 Method Statement and Risk
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Risk Assessment
Steps Who might Which controls are already in What further controls/actions What are the PPEs Who is in charge of
be harmed place on site? will be implemented? required? implementation of
and how? controls? (job title /
company)
A.2 Electrical Using electrical safety gloves to All workers attend toobox a. Safety Shoes Electrical Supervisor –
Technician avoid electrical shock meetings to explain the DC Cable PT SEI
b. Safety Glasses
and Helper wiring process briefly to avoid
misunderstandings in the field
c. Electrical Safety
DC Electrical Gloves
shock d. Coverall/Rompi
e. Safety Helmet

A-3 Mechanical Aware of the part to be installed The installation of the Cable a. Safety Shoes Leader Mechanical –
Technician cable connector so that the Connector on the cable tray is PT SEI
b. Safety Glasses
and helper placement of the cable connector done by at least two technicians,
is appropriate, Using appropriate so that someone can make sure
c. Safety Gloves
Hand pinched gloves to use an Electric drill the cable connector is in position d. Coverall/Rompi
by cable and holds the cable tray so that it e. Safety Helmet
connector does not shake.
and injured
hand pierced
by electric
drill
A-4 Electrical All workers wear safety gloves All workers must follow the toolbox a. Safety Shoes Electrical Supervisor –
Technician meeting and technical explanation PT SEI
b. Safety Gloves
and Helper of DC cable withdrawal to avoid

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 Method Statement and Risk
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Steps Who might Which controls are already in What further controls/actions What are the PPEs Who is in charge of
be harmed place on site? will be implemented? required? implementation of
and how? controls? (job title /
company)
misunderstanding in the field c. Coverall/Rompi
Hand injured d. Safety Helmet
due to cable
friction during
DC cable
pulling
B-2 Electrical All workers wear safety gloves All workers must follow the toolbox a. Safety Shoes Electrical Supervisor –
Technician meeting and technical explanation PT SEI
b. Safety Gloves
and Helper of DC cable peeling to avoid
misunderstanding in the field
c. Coverall/Rompi
Hand injured d. Safety Helmet
by cutting e. Safety glasses
pliers while
peeling DC
cable

B-4 Electrical Re-explanation of the use of The Electrical Technician must be a. Safety Shoes Electrical Supervisor –
Technician crimping tools to technicians present at the toolbox meeting for b. Safety Gloves PT SEI
a re-explanation of the hazards c. Coverall/Rompi
d. Safety Helmet
Hand pinched
by crimping e. Safety glasses
tool

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 Method Statement and Risk
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Steps Who might Which controls are already in What further controls/actions What are the PPEs Who is in charge of
be harmed place on site? will be implemented? required? implementation of
and how? controls? (job title /
company)
C-2 Electrical Using electrical safety gloves to All workers attend toobox a. Safety Shoes Electrical Supervisor –
Technician avoid electrical shock meetings to explain the AC Cable b. Electrical Safety PT SEI
wiring process briefly to avoid Gloves
Check with Voltage tester for
misunderstandings in the field c. Coverall/Rompi
Zero Voltage Testing
AC Electrical
shock d. Safety Helmet
e. Safety glasses

TASK HAZARD CONSEQUENCES INITIAL RISK CONTROL MEASURES REDUCED

RISK

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 Method Statement and Risk
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CONSEQUENCES

CONSEQUENCES
LIKELIHOOD

LIKELIHOOD
RISK LEVEL

RISK LEVEL
hit by materials and minor and major - use the right equipment and the right way to use
equipment injuries 2P D M it when mobilizing 1P C L
Preparation of equipment and - briefing and toolbox meeting before mobilization
materials manual handling Low Back Pain - do it safely and pay attention to proper manual
(LBP), minor injury 2P D M handling steps 1P C L
- do it with ergonomic body position
Installing support tray and cable tray
Major injury - make sure workers have had a medical check-up
- do according to manual handling work procedures
- pay attention to footsteps when working and do not
Falling or tripping 3P D M rush 1P D L
- use the road access that is already available
- the number of manpower is adjusted to the weight of
Manual handling
the material to be lifted
pinched or crushed - avoid pinch points on the object/material to be lifted
- position the body properly, ergonomically when
Major Injury 3P D M working 1P D L
- make sure the area is safe when lifting and installed
barricades / safety signs
- Ensure scaffolding is inspected and tagged 1P D L
- use safe access to get on and off personnel
worker falls from - use standard PPE and full body harness double layer
Installing support tray and cable tray Major injury 3P D M
height with hook hooked (100% tie off) (absorber used at
height > 5.5 m)
- make sure not to carry materials when going up/down

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 Method Statement and Risk
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(use ropes as a tool to transfer materials and

equipment)
- area is isolated with barricades and safety signage
installed
- use assistive devices (if required)
- maintain a safe distance when unloading
pinched hands, back materials/equipment
injuries, crushed Major injury 3P D M - protection of pointed material parts 1P D L
materials/equipment - good coordination when working
- ensure manual lifting with ergonomic body positioning
- avoid pinch points on the object to be held
- good coordination when working
materials fall and hit
Property damage 3A D M - protection of facilities in the installation area 1A D L
the facility
- use toolboxes to store small tools/materials
AC and DC cable pulling
- use gloves when installing cables
hand pinched and - good coordination when working
pierced by the end of Minor injury 2P C L - the distance between people when pulling the cable 1P C L
the wire with other teams is 1.5 to 15 meters (adjusting to the
size of the cable)
AC and DC cable pulling - if using a cable roller, make sure the cable stays in the
cable roller path, and make sure the cable roller is
material/cable damage Minor injury 2P C L 1P C L
functioning properly and does not scratch the puller
- make sure the cable route is free of sharp objects
fatigue, dehydration, - people management and placement as needed
Minor injury 2P C L 1P C L
and heat stress - ensure there is enough drinking water
- make sure to use secure access
- make sure workers have had a health check
AC and DC cable pulling falling from a height Major Injury 3P D L - make sure the scaffolding has been inspected and 1P C L
tagged by the safety team inspector (if using
scaffolding)
Housekeeping

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 Method Statement and Risk
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- use gloves
clean up leftover materials and clean - make sure the remaining material is collected in the
hand injured Minor Injury 2P C L 1P C L
up tools when finished working place provided
- make sure the room is clean before the start-up process

RISK ASSESSMENT MATRIX

CONSEQUENCE INCREASING LIKELIHOOD

Severity People (Health Assets (Economics) Environment Reputation A B C D E
& Safety)

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 Method Statement and Risk
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Slight injury /
1 health effect Slight damage < 5K US$ Slight effect Slight Impact Improbable >20yrs 4 – 20 yrs 0,5 – 4 yrs 0 – 0,5 yrs
(first aid)
Minor injury /
Minor damage, 1 – 10K Limited
2 Health effect Minor effect
US$ Impact
(MTA)
Major Injury /
Local damage, 0,1 – 1M Considerable
3 Health effect Localised Happens
US$ Impact Incident has Happens several
(LTA) Never heard Heard of in several times
occured in times per year in
Permanent of in industry Industry per year in our
hour company our location
Total Disability Major damage, 100K-1M National company
4 Major effect
(PTD) or 1-3 US$ Impact
fatalities
Multiple Major damage > 1M US$ Massive effect International
5
Fatalities Impact

RISK MATRIX
L L L L L
L L L M M
L L M M H
L M M H H
M M H H H

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