Railway Electrification and Cable Installation Project

Railway Electrification and Double-Double Tracking of Java Main Line Project
Package B1 : Railway Facility Construction for BEKASI to CIKARANG
METHOD STATEMENT
Cable Installation Works
For Signalling System
PROJECT Checked by Checked by Approved by

Interface and Deputy General General
Title
Engineering Manager Superintendent Superintendent
Name H. Houan / Y.Nonaka A.H. Desfiansyah Y. Kameda
Signature
Date
SECTION Written by Checked by Checked by

Name F. Rachman M. Adachi T.Ikenaga
Signature
Date January 20th, 2013
Contractor Mitsubishi-Sumitomo Joint Operation
Originator Mitsubishi Heavy Industries, Ltd.
Document No. B1/CON/SIG/0002 Revision: 2
Internal Ref. No. R001P-S043-10003

RAILWAY ELECTRIFICATION AND DOUBLE-DOUBLE TRACKING OF JAVA MAIN LINE PROJECT
PACKAGE B1: RAILWAY FACILITY CONSTRUCTION FOR BEKASI TO CIKARANG
(Form – B1IN/GEN/PLN/0004 Rev. 1)
Page 1 of 38
MITSUBISHI-SUMITOMO JOINT OPERATION
XXXX-XXXXX-XXXXX Rev.0
Revision History
Section Project
Rev. Date
Written by Checked by Approved by Written by Checked by Approved by
31 Oct. 2013 Signed on Cover Page

0 Description:
First Issue
20 Jan. 2014 Signed on Cover Page
Description:
- PT.Len Quality Manual instruction has been revised with MSJO Quality
Management Program ( See Contractor’s Response )
- Clarify work management item by MSJO organization, don’t permit PT.Len ownway
has been modified the sentence with independent expression of MSJO
- Potition Name PT. Len compare With Org Chart Has Noted
- Responsibility for testing by MSJO has revised
- MSS for splicing closure has been prepared
- Clarify planned locations stock yard for telecom cables has noted
- Permit work and procedure in operating railway has noted
1
- Orderlines ( 7.1.4 b,c,d )incase these work will not be finished before cable laying
has noted
- Cable containment installtion shall be presentation to PT.KAI has noted
- PVC pipe should be changed galvanized pipe has been revised
- Dinstance center line of track to center trench sould be changed to 4000mm ,has been
revised
- Underground cable will be laid at minimum depth of 0.8 m, sould be 1 meter has
been revised
- Cable installation has been revised per comments
Train watcher shall have handy talky tools between station operation area and work area has
noted
2 Description:
- Contractor will submit MSS HDPE 8 mm thickness
- Contractor will submit shop drawing bridge crossing method for each bridge
3 Description:
4 Description:
5 Description:
Page i
B1/CON/SIG/0002 Rev.2 MITSUBISHI-SUMITOMO JOINT OPERATION
Table of Contents
1 Purpose...........................................................................................................................................1
1.1 Introduction.............................................................................................................................1
1.2 Objective.................................................................................................................................1
2 Scope Of Work...............................................................................................................................1
2.1 Metallic Cables........................................................................................................................1
2.2 Signal Equipment and Temporary use of Cables.....................................................................1
3 Reference Document......................................................................................................................2
4 Organization...................................................................................................................................2
5 Materials.........................................................................................................................................3
6 Tools and Equipment......................................................................................................................3
7 Working Method............................................................................................................................4
7.1 Materials Delivery and Arrangement......................................................................................4
7.1.1 Cable Storage...................................................................................................................4
7.1.2 Cable Delivery by Land...................................................................................................4
7.1.3 Cable Delivery by Rail.....................................................................................................6
7.1.4 Orderliness.......................................................................................................................6
7.2 Cable Installation Work Preparation.......................................................................................7
7.3 Cable Installation Work...........................................................................................................7
7.3.1 Cable containment installation before cable installation..................................................7
7.3.2 Underground/Buried Cable Installation..........................................................................13
7.4 Work Sequence.....................................................................................................................21
7.5 Flow Chart.............................................................................................................................22
8 Safety, Environmental and Hazard Mitigation..............................................................................24
8.1 Preparation............................................................................................................................24
8.2 Toolbox Talk.........................................................................................................................25
8.3 Train Watchers (Safety Supervision).....................................................................................26
8.4 Accident Prevention Arrangement.......................................................................................27
8.5 Initial Response and Reporting..............................................................................................28
Page ii
Table of Figure
Figure 7-1 Cable Drum Unloading Unto Temporary Storage Facility...................................................5
Figure 7-2 Delivery of Cable Drum from Temporary Storage to Site....................................................5
Figure 7-3 Cable Drum Unloading From Lorry.....................................................................................6
Figure 7-4.Cable duct installation on river crossing..............................................................................8
Figure 7-5.Photo of existing cable duct on river crossing......................................................................8
Figure 7-6.Photo of exposed pipe with bridge.......................................................................................9
Figure 7-7.Photo of cable duct with bridge............................................................................................9
Figure 7-8.Boring under the ditch........................................................................................................10
Figure 7-9.Boring under the river........................................................................................................10
Figure 7-10.Boring under the tracks....................................................................................................11
Figure 7-11.Overhead catenary wiring................................................................................................12
Figure 7-12.Photo of concrete pole for Overhead catenary wiring......................................................12
Figure 7-13.Photo of Overhead catenary wiring..................................................................................12
Figure 7-14 Cable Installation.............................................................................................................14
Figure 7-15 Cables order for the case of one side (standard in wayside).............................................16
Figure 7-16 Cables order for the case of both sides (standard in wayside)..........................................16
Figure 7-17 Cable Installation Standard..............................................................................................17
Figure 7-18.Cable Installtion Detail.....................................................................................................18
Figure 7-19 Cable Route Marker Standard Installation.......................................................................19
Figure 7-20 Detail Cable Route Marker...............................................................................................19
Figure 7-21 Installation of cable containment......................................................................................22
Figure 7-22.Installation of Cables........................................................................................................23
Figure 8-1 Train Watcher Position......................................................................................................24
Figure 8-2 Tool Box Talk....................................................................................................................25
Figure 8-3 Train Watcher Position......................................................................................................26
Figure 8-4.Train Watcher Facility.......................................................................................................26
Figure 8-6 Accident Happened No 1...................................................................................................27
Figure 8-7 Accident Happened No 2...................................................................................................27
Figure 8-7.Reporting System for Minor Accident...............................................................................28
Figure 8-8.Reporting System for Major Accident................................................................................29
Table of Attachment
MSJO Construction Organization Chart. For E & M ........................................................Attachment 1
Page iii
1 Purpose
1.1 Introduction
The project “Railway Electrification and Double-Double Tracking of Java Main Line
Project, Package B1” is an operating railway system that needs to be upgraded and
expanded to accommodate the increasing train traffic, which is attributable to the increase
in public patronage.
For MSJO to be able to meet the indicated general project goals, new cables for the
Signaling system will be designed and installed. This upgrade will improve the present
Signaling system of the line, improve or upgrade the safety level of the operating system
and in general improve the operating efficiency of the rail system in terms of train running
and maintenance.
Due to the similarity in the scope, the work under the guidance of this Method Statement
will also be performed in conjunction with the Cable Installation Works for Signaling
System which is covered under the document B1/CON/SIG/0002.
1.2 Objective
This proposed Method Statement is intended to detail the work procedures and requirements that
will be implemented or used during the Signaling cable Installation works for the Signaling
system of the Railway Electrification and Double-Double Tracking of Java Main Line Project,
Package B1.
The method Statement is prepared in such a way to ensure:

- Safety and punctuality of the cable installation process;
- Quality of the cable installation;
- Minimum affect to the train operation;
- Minimum or no delay to the construction works.
2 Scope Of Work
Cables with termination equipment and raceway system will be installed between Manggarai and
Cikarang stations so as to accommodate the increased train and thus signal traffic consequential
to the double – double tracking and electrification of the railways system between Bekasi-
Cikarang stations.
2.1 Metallic Cables
Main metallic cables will be installed at the required locations between Manggarai and Cikarang
stations areas. Main Metaalic cable are signaling control cables. Cable crossing the track or
waterways will be provided with manhole sand pipes to protect the metallic cables.
2.2 Signal Equipment and Temporary use of Cables
The works consist of installing and constructing signal facilities and pre-installed signal facilities
for temporary use such as equipments, components and materials which will not be used in
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permanent facilities, this beingin order to maintain the existing signaling system, train operation
and other related systems. This work will be done at wayside and all station located between
Manggarai-Cikarang including both station yards.
3 Reference Document
The following documents are considered for the development of this Method Statement:
 Technical Specification and Tender Drawings of “RAILWAY FACILITY CONSTRUCTION
FOR BEKASI TO CIKARANG-PACKAGE B1”;
 Project Management Plan – B1/PLN/GEN/0008;
 Interface Management Plan Between SC and MHI – B1/PLN/GEN/0009;
 Construction Management and Organization Plan – B1/PLN/GEN/0012;
 Site Health and Safety Plan – B1/GEN/PLN/0015;
 Permit and Work Procedure in an Operating Railway – B1/PLN/GEN/0024;
 Quality Management Program – B1/PLN/GEN/0013;
 Quantity Management Program – B1/PLN/GEN/0014;
 Shop Drawings for wayside detail layout
Wayside Cable Route Drawings;
B1/DSN/GEN/MRICKR/001 Rev.1
B1/DSN/GEN/MRIJNG/001 Rev.1
B1/DSN/GEN/JNGBUR/001 Rev.1
B1/DSN/GEN/BURCAK/001 Rev.1
B1/DSN/GEN/CAKBKS/001 Rev.1
B1/DSN/GEN/BKSBKT/001 Rev.1
B1/DSN/GEN/BKTTMB/001 Rev.1
B1/DSN/GEN/TMBCIT/001 Rev.1
B1/DSN/GEN/CITCKR/001 Rev.1
4 Organization
MSJO, through the General Superintendent, has the overall responsibility to manage all works under
the DDT project. The Cable Installation for Signalling System works will be performed under
Construction Management and Organization for Electrical & Mechanical Works. A proposed site
organization chart specific for the supervision of the works is included in the detailed Method
Statement, as shown in Attachment
The Supervisor will be responsible for the execution of the Works, start from preparation,
execution,testing and will report to MSJO Engineer-in-Charge on all progress issues, and shall
perform supervise of material, tools equipment, and quality control also of the performed works and
Other issues as defined by MSJO Engineer-in-Charge. A work team for Cable Installation will be
organized to perform the installation works which include tests of Cable where necessary.
The work team will consist of the following.

1) Foreman or Supervisor;
2) Drivers;
3) Technicians;
4) Laborers;
5) Train watchers.
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The team or each team will be monitored / supervised by Supervisor who will record or document
the Cable Installation and will be assisted by the HSE ( Health Safety Environmental ) Manager or
any of his designate.
5 Materials
The following materials will be utilized for the Signaling cable installation work:
● Metallic cables;
● Metallic closures;
● Fibre Optical Cables;
● FO Splice closures;
● Rigid steel conduits and PVC conduit;
● Cable ties and cap;
● Electric tapes and self-bonding tape
● Cable lubricants;
● Plastic sheets;
● Sand;
● Marker and warning tapes;
● Cable protector plates or materials;
● Barricades and bollards.
6 Tools and Equipment
The tools and equipment listed below will be utilized for the Signaling cables installation work:
● Picks and shovels;

● Drum Jacks;
● Measuring tapes;
● Hammers and sledge hammers;
● Pipe and wire cutting tools;
● Digger bar and Crowbar;
● Miscellaneous Hand tools;
● Cable rollers;
● “A” frames;
● Lever blocks;
Due to the similarities with the requirements for Signalling, these tools and equipment may
also be employed for the said system/subsystem.
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7 Working Method
7.1 Materials Delivery and Arrangement
Materials are delivered at the work site as required using appropriately sized trucks. Use
of trucks will take into consideration the passageways and the parking areas most
especially those near passenger congregation areas.
All delivered materials are removed by forklift or hydraulic pallet or are manually moved
to the work site where feasible.
Other sensitive installation materials are stored and stacked in small lockable store of
appropriate sizes.
7.1.1 Cable Storage
a. Storage place for cable drums is preferably at the manufacturer’s warehouse where the
cable will be manufactured.
b. Temporary storage for the cable drums will only be made when trenching is ongoing.
The temporary cable drum storage place will be located near the trenching areas which
are also nearest to the station and will be posted with security guard/s.
c. Shipping of cable drums from the manufacturer’s warehouse to the work site partially
depends on the cable drum storage plan and on the cable installation schedule.
d. Delivery of cable drums can be done direct to the trenching area or to the nearby
temporary storage place.
e. If there are cable drums that must stay overnight in a trenching area, the cable drums
must be guarded by a security person and properly protected.
7.1.2 Cable Delivery by Land
a. Cable drum delivery to the cable trenching area will make use of an equipment or
method that will allow direct access to the work area, and as well will not affect or
disturb train operations.
b. Such equipment can be a truck, pickup or cable jinker, the choice of use of which
depends on the work area to be accessed.
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c. The weight and volume of the cable drum to be shipped or delivered should not be over
the capacity of the truck or pickup.
d. The pickup or truck that are to deliver the cable drum will be equipped with a system
or equipment that will ensure the safe loading and unloading of the cable drum unto
the work area.
e. Loading of the cable drums onto the truck or pickup from the main ware house will
make use of forklift or crane which are normally available in main ware house.
f. Unloading of cable drums unto the temporary storage place will make use of slide
boards, assisted by available labor.
g. Movement of cable drum near the trenching area will be done by wheeling the cable
drums carefully.
h. Movement of materials around the work area can be done manually using available
labor.
Cable Drum
Sand
Figure 7-1 Cable Drum Unloading Unto Temporary Storage Facility
Figure 7-2 Delivery of Cable Drum from Temporary Storage to Site
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7.1.3 Cable Delivery by Rail
a. The cable drums delivery, as much as possible, will avoid using the rail system. Cable drums
delivery will be carried out using conventional means or land transport.
b. If the land access not possible and that material delivery must use the rail system, this must
be in such a way that there is no effect on train operations or resort to the use of hand trolley
for cable drums delivery.
c. Cable drums delivery utilizing the rail system must be in the window time or in the time
agreed between MSJO and the Train Operator.
d. When using the hand trolley at the trenching area, this will also be coordinated with the
Train Operator.
e. Adequate number of labor will be employed when using the trolley.
f. Cable drums loading and unloading process will be carried on safely, so as to avoid damage
on the cables.
Figure 7-3 Cable Drum Unloading From Lorry
7.1.4 Orderliness
a. Cable installation work area is required be free from interference from other
contractor’s work particularly along the cable route.
b. Track works at the cable installation area must be finished before the cable installation
work is performed.
c. Bridge construction must be finished before the cable installation work is performed
where a bridge is to be crossed by cables.
d. Civil works at a station area which will be crossed by cables must be finished first
before cables are installed in this area. Coordination with the civil subcontractor is
necessary when cable installation and civil work is be done simultaneously or when
cables need a kind of raceway.
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The delivery date of materials which has been already confirmed through the program of
works will be updated.
7.2 Cable Installation Work Preparation

Preparations for cable installation will consist of the following:
a)Tools and Materials preparation

b) Work Permit and scheduling
c) Engineering, which are as per the following:
The designated cable route will be surveyed concurrent with the related works and staking out
will be performed after the result of the survey is approved. Cable route within the right of way
(ROW) will be defined and approved by the Engineer before the commencement of the works.
Checking of the existing facilities and utilities such as PLN, Gas, Telecom, Water and others will
be performed, to avoid unexpected obstruction. When utilities are located, markers or rope line
corresponding to the utility line will be installed before starting the trenching works.
● Approved Shop Drawings.
● Approved Material Sample Sheet .
7.3 Cable Installation Work
7.3.1 Cable containment installation before cable installation
Cable Installation activities starting from cable containment installation, installation of cable
containment will be in accordance with the cable route and work specified in the “Installation
Specification”. Cable containment will be done under supervision of competent and experienced
staff in installation work for Signaling system. In case the cable route is crossing the road (URX),
track (UTX), platform (UPX) and bridge (UBX), installation specification for these will be
developed presented should be presented to the Engineer for approval. Route for the UTX, URX,
UBX, UPX cables and cable joints will be marked in the assigned location by using the specified
marker. Cable containment installation works will have the preparation works as follows:
A-1, Cable Duct on river crossing;
A-2, Rigid Steel Conduit Pipe and Cable Duct on bridge and exposed structure;
A-3, Rigid Steel Conduit Pipe of boring under track crossing, under road crossing,
Under river crossing, under station platforms;
A-4, Manhole between cable routes;
A-5, Overhead Catenary wiring;
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A-1, the sequence of work for cable installation in Cable Duct on river crossing consist of;
 Start;
 Staking out;
 Installation of support foundation for steel structure, H-steel in the ends of river
 Installation of steel structure, H-steel on river crossing;
 Installation of cable duct on the steel structure, H-steel on river crossing;
 Opening of duct cover
 Cable installation
 Closing of duct cover permanently
 Clean up and finish
Figure 7-4.Cable duct installation on river crossing
Figure 7-5.Photo of existing cable duct on river crossing
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A-2, the sequence of work for cable installation in Rigid Steel Conduit Pipe and Cable Duct on
bridge and exposed structure consist of;
 Start;
 Staking out;
 Installation of support bracket on bridge
 Installation of joint box in the ends of bridge underground
 Installation of rigid steel pipe or cable duct on support bracket
 Open the Joint box cover or duct cover
 Cable installation into pipe or duct
 Closing of box cover
 Closing of duct cover by welding
 Clean up and finish;
Figure 7-6.Photo of exposed pipe with bridge
Figure 7-7.Photo of cable duct with bridge
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A-3, the sequence of work for cable installation in Rigid Steel Conduit Pipe of boring
Under track crossing, under road crossing, under river crossing, under station
Platforms consist of;
 Start;
 Staking out;
 Excavation of boring space in the ends of boring route;
 Boring of pipe by water jet or manual between boring route;
 Cleaning of the ends of boring pipe;
 Installation of manhole in the ends of boring route
 Installation of cable between boring route;
 Disposal of pipe entrance with cable;
 Backfilling of boring space;
Figure 7-8.Boring under the ditch
Figure 7-9.Boring under the river
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Figure 7-10.Boring under the tracks
A-4, the sequence of work for cable installation in Manhole between cables routes consist of;
 Start;
 Staking out;
 Excavation of manhole space;
 Installation of wood form;
 Installation of steel rebar and sleeve;
 Installation of concrete
 Installation of HDPE pipe 8mm thickness to sleeve, cable entrance for cable protection ;
 Installation of cable
 Backfilling of space;
A-5, the sequence of work for cable installation in Overhead Catenary wiring consist of;
 Start;
 Staking out;
 Excavation of overhead catenary pole hole;
 Installation of OC poles;
 Installation of messenger wire between OC poles;
 Installation of manholes beside OC poles;
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 Installation of rigid steel conduits from manhole to the top of OC pole ;

 Installation of cable with messenger wire
Figure 7-11.Overhead catenary wiring
Figure 7-12.Photo of concrete pole for Overhead catenary wiring
Figure 7-13.Photo of Overhead catenary wiring
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7.3.2 Underground/Buried Cable Installation
Cable Installation activities starting after cable containment installation, cable installation will be
in accordance with the cable route and work specified in the “Installation Specification”. Cable
installation will be done under supervision of competent and experienced staff in installation
work for Signaling system. Cable installation works will have the work sequence as follows:
B-1, Excavation;
B-2, Setup of Cable Drum and Cables;
B-3, Cable Installation;
B-4, Markers;
B-5, Splice and Termination;
B-6, Testing
B-1, Excavation
All excavation will be as straight as possible guided by an installed rope line. The location of the
cable route will generally be within the right of way (ROW).
The distance between the centerline of the track to the centerline of the trench is at the minimum
of 4000 millimeters. The dimension of the excavated trench will be approximately 300
millimeters at the bottom, tapering to the top where soil condition so dictates. The depth of the
excavated trench is at 1000 millimeters from the bottom of the trench up to existing finished
ground surface.
If the location of the cable route is within the 4000 millimeters center to center of the tracks, all
excavations will be protected with temporary shoring (wood etc.) to prevent the collapse of
trench walls (See Figure 3). Protective covering (plastic sheet) will be placed over the ballast as
required, to prevent contamination.
If the cable is to be installed in a concrete trough, the minimum depth should be 300 millimeters
from the finished ground surface to the top of the cover of the trough.
Clearance between cables and earth electrodes, the poles for overhead contact system or guy
wires, will generally be 1000 millimeters and those between cables and underground metal
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utilities such as gas pipes and water pipes will be not less than 300 millimeters, where not shown
in the drawings.
Where cables are routed and installed vertically, these will be provided with galvanized steel
conduits, with bushing at the top of the conduits. Cable crossing under a road, tracks, or along
bridge will be laid underground or across in HDPE pipes 8 mm thickness, after these has been
installed at the designated location, where not shown in the drawings.
B-2, Setup of Cable Drum and Cables
The installation of cables will start when the excavations are already finished or when the cable
containment is already installed on the assigned section which has the approval of the Engineer.
The Metallic cable length of one section cable run will be approximately 500 meters up to 1000
meters. Fiber Optical cable length of one section cable run will be approximately 500 meters up
to 3000 meters.
The following checks should be carried out before cable installation:

 The condition of cable drum;
 Identification of cables;
 End cover/caps of cables (moisture protector).
Cable drums will be handled and transported using the appropriate equipment to avoid any
damage to the cable. Drum jacks will be used to support the cable drum when pulling or
unwinding the cable before installation. When a section needs a small or short cable, this can be
prepared and cut from the drum at the storage area, then transported and installed without the
cable drum.
Figure 7-14 Cable Installation
B-3, Cable Installation
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Before installation of a new cable labels will be installed, with one label at the sides, one label in
the manhole and one label at each jointing.
Installation will comply strictly with the recommended cable curve radius, this being the
minimum bending radius specified by the cable manufacturer. Cable pulling and installation will
also avoid twist or kinks.
After cable installation and before cutting the cable, a check will be carried out to determine the
adequacy of spare lengths at the ends for jointing and termination purposes. Protection of cable
ends will be through the use of rubber tape.
Cable Installation;
a) Underground cables will generally be laid within the right of-way (ROW).
b) Underground cables will be laid at minimum depth of 1000 meter. For troughs, minimum
depth of earth cover will be 0.3 meter from ground level to the top of troughs.
c) Clearance between a cable and an earth electrode, the pole for overhead contact systems or
guy wires will, in principle, be 1 meter and those between cables and underground metal
utilities such as gas pipes or water pipes, will be not less than 0.3 meter.
d) Wayside Cables will be installed including Signaling cable. Installation of cable

specification is as below;
Signaling cable of standard in wayside;

1, Optical Fiber Cable 24C x 2pcs
2, Metallic Cable 0.9mm – 30pr
3, Metallic Cable 0.9mm – 10pr
Signaling Cable of standard in wayside;
4, Metallic Cable 1.5sq – 40c
5, Metallic Cable 1.5sq – 20c
6, Metallic Cable 6sq – 4c
Cable order of installation is as below;
The rail side is right side and cables will increase in some areas. When cables increase,
cables will arrange according to this order.
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Signaling Cables Signaling Cables
Figure 7-15 Cables order for the case of one side (standard in wayside)
Rail side is center of both routes and cables will increase in some areas.
Up Track, South Bound down Track, North Bound
Figure 7-16 Cables order for the case of both sides (standard in wayside)
e) Cable installation routes, in principle, will be arranged so that cables and Telecom cables can
be laid in the same trench where possible.
f) Cable route markers will be installed at every interface point of road direction change and at
50 meters interval of straight and curve lines, at a depth of 40 centimeters.
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1~5 m
Figure 7-17 Cable Installation Standard
The sequence of work for cable installation consist of;
1) Start
2) Staking out
3) Setup of cable drum
4) Installation of cable/s
5) First backfill
6) Rubber Sheet
7) Second backfill
8) Warning tape
9) Marker
10) Clean up and finish
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600
400
Figure 7-18.Cable Installtion Detail
B-4, Markers
Cable route markers will be provided to show the location of underground cables and will be
made of concrete. Markers will be installed at every interface point between two adjoining routes
or whenever there is a route change and at 50 meters interval on straight and curved routes.
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Figure 7-19 Cable Route Marker Standard Installation
 Cable route markers will be installed at every interface point of road orientation or direction
change and at 50 meters interval at straight and curve routes with a depth 40 centimeters.
 Where cable are installed vertically, these will be protected with galvanized steel conduits.
Cable crossing under roads, tracks or small streams will be laid underground in steel pipes or on
concrete troughs. Manholes at both ends of this crossing will also be constructed.
Figure 7-20 Detail Cable Route Marker
B-5, Splice and Termination
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Splice and Termination will be made when the standard reel length of cable is not enough
for the purpose. Where not specified elsewhere, two meters of spare cables on both ends is
prepared for Splice and Termination work. A cable joint marker of same type as with the
cable route marker, with full painting of the cable direction on top of marker, will be
installed on top, with the marker pointing on the Splice and Termination. A log will also
be generated, showing the type of cable, location, depth, date and name of jointer.
B-6, Testing
a. Have to do inspection and testing of cable which have been laid as according
technical specification.
b. Inspection and testing mentioned as following.
- Visual Inspection
- Testing of insulation and continuity for all cables
c. Result from testing have to be made in the form of test from to be approved by
consultant.
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7.4 Work Sequence
The sequence of work for direct buried cable work is:

1. Preparation
a. Processing and approval of Work Permit;
b. Tools, materials and equipment preparation.
2. Engineering
a. Site survey planning;
b. Existing drawing to be made available;
c. Detailed drawing preparation.
3. Detail Cable Installation

A. Installation of cable containment
a. Checking of Existing Cable Routes
b. Checking of New Cable Routes
c. Staking out of installation area
d. Installation of
1) Cable Duct on river crossing;
2) Rigid Steel Conduit Pipe and Cable Duct on bridge
And exposed structure;
3) Rigid Steel Conduit Pipe of boring under track crossing,
Under road crossing, under river crossing, under station platforms;
4) Manhole between cable routes;
5) Overhead Catenary wiring;
B. Installation of underground/buried cable

a. Checking of Existing Cable Routes
b. Checking of New Cable Routes
c. Checking of cable containment
d. Staking out of installation area
e. Installation of
1) Excavation;
2) Setup of Cable Drum and Cables;
3) Cable Installation;
4) Markers;
5) Splice and Termination;
6) Testing
4. Reporting the finished work to the Station Master.

1) Confirmation of all functions to the Station Master;
2) Checking of the work site and clearing.
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7.5 Flow Chart
Figure 7-21 Installation of cable containment
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Figure 7-22.Installation of Cables
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8 Safety, Environmental and Hazard Mitigation
8.1 Preparation
MSJO is responsible in fulfilling and maintaining the following traffic control duties and the
construction safety management:
- Keeping any existing railway facilities and public roads fit and safe for regular traffic.
- Maintaining train movement as per schedule and maintaining safe train traffic condition
- Safe and convenient use of station facilities and protection of railway passengers.
MSJO will be fully responsible for the control and management of all the site works so as to ensure
train operation safety, including the erection and maintenance of any train traffic control facilities,
temporary arrangement for train operation protection and obtaining of all necessary approvals from
PT. KAI.
PPE
Personal Protective Equipment (PPE) must be taken by all people in the site. Nobody can enter the
site without PPE.
Figure 8-23 Train Watcher Position
Page 24 of 29
8.2 Toolbox Talk

The toolbox talk is a very important safety briefing for all the members of the work party. The
toolbox talk always needs to be done before work.
For the DDT project, the coverage or topics of a typical toolbox session are the following;
1, Permit to work
2, Attendance list of all members
3, Personal protective equipment

4, Safety Hazards at the worksite
5, Competent and authorized persons

6, Method of work and tools to be used,
7, Worksite boundaries and protection,

8, Emergency evacuation points and other safety related matters
Figure 8-24 Tool Box Talk
Page 25 of 29
8.3 Train Watchers (Safety Supervision)

Train watchers are mandatory for working in an operating track system. Work groups must prepare 2
train watchers who will be posted at both boundary ends of the worksite. Train watcher will do only
the train watching job and will not be utilized in supporting work group jobs. Train watchers are only
to watch train operations and the related jobs for train running. Train watchers are to render train
warnings to the workers who are to be protected from accidents due to train operations.
Train Watcher
Figure 8-25 Train Watcher Position
Figure 8-26.Train Watcher Facility
Handy Talky
Page 26 of 29
8.4 Accident Prevention Arrangement
1. Train watchers have to run at least the minimum of 600 meters from the work area accident
location.
600m
a) Stop sign to approaching train using by smoke maker.
Figure 8-27 Accident Happened No 1
2. Signal an approaching train to stop by using materials that emits smoke. If not available,
the Train Watcher must do as below;
Wave Jacket Wave Hand Burn paper

Wave Red Flag
Figure 8-28 Accident Happened No 2
Page 27 of 29
8.5 Initial Response and Reporting
Initial response and reporting for minor and major accidents will be in accordance with
the shown Flow Chart in Figure 8-7 and Figure 8-8.
Critical injuries or fatalities will be reported in accordance with the local laws and
regulations of Indonesia.
Minor Accident
START
Site Engineer Report

to Safety officer
YES NO
Does the Victim need to be
sent to the Hospital
Send Victim to the Safety officer and /

hospital first Aider treat the
victim on the spot
Report Accident Data to

Administration manager and
Health, Safety and enviromental
Manager
FINISH
Figure 8-29.Reporting System for Minor Accident
Page 28 of 29
Major Accident START
Site Engineer Report

to Safety officer and
HSE Manager
HSE Manager Report to

administration manager First Aider / or
First Responder
Administration Manager
handles Accident
Administration
Sent victim to the hospital
Monitor the treatment
Submit Insurance Claim
Settle insurance Claim
Report Accident Data to

Administration manager and
Health, Safety and environmental
Manager
FINISH
Figure 8-30.Reporting System for Major Accident
Page 29 of 29
Attachment - 1 Work Site Organization Chart for E&M Works

HEALTH,SAFETY,ENVIROMENTAL MANAGER
E&M CONSTRUCTION MANAGER
RIO SAPTO HIDAYAT
MAIN CONTRACTOR MITSUBISHI SUMITOMO M.ADACHI
SBS & PWD ENGINEER

QUALITY CONTROLLER H. SEKI
PRASETYO SOEKARNO
SBS & PWD SUPERVISOR SBS & PWD SUPERVISOR

SIGNAL & TELECOM ENGINEER
SOEPANGAT F. RACHMAN
S. NAKAMURA
SIGNAL & TELECOM SUPERVISOR SIGNAL & TELECOM SUPERVISOR SIGNAL & TELECOM SUPERVISOR SIGNAL & TELECOM SUPERVISOR
F.YUSLI E.SULISTIONO F.KIROM N.HALIM
SIG & TEL PROJECT MANAGER SBS & PWD PROJECT MANAGER
BENI.R HEALTH,SAFETY,ENVIROMENTAL MANAGER
M. SINAGA
SUB CONTRACTOR PT. Len Industri Mrs. CINDERAWATI
SIG & TEL SITE MANAGER SBS & PWD SITE MANAGER
DEDE.A.B ADANG .K
SIG & TEL ENGINEER SBS & PWD ENGINEER

ENJANG IRFAN
SIG & TEL STAFF SBS & PWD STAFF
Page A - 1
B1/CON/PWD/0003 Rev.0 MITSUBISHI-SUMITOMO JOINT OPERATION

Railway Electrification and Cable Installation Project

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Railway Electrification and Cable Installation Project

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Railway Electrification and Double-Double Tracking of Java Main Line Project

Package B1 : Railway Facility Construction for BEKASI to CIKARANG

PROJECT Checked by Checked by Approved by

SECTION Written by Checked by Checked by

Date January 20th, 2013

Contractor Mitsubishi-Sumitomo Joint Operation

Originator Mitsubishi Heavy Industries, Ltd.

Document No. B1/CON/SIG/0002 Revision: 2

Internal Ref. No. R001P-S043-10003

(Form – B1IN/GEN/PLN/0004 Rev. 1)

31 Oct. 2013 Signed on Cover Page

The method Statement is prepared in such a way to ensure:

2.1 Metallic Cables

2.2 Signal Equipment and Temporary use of Cables

The work team will consist of the following.

6 Tools and Equipment

● Picks and shovels;

7.1 Materials Delivery and Arrangement

7.1.1 Cable Storage

7.1.2 Cable Delivery by Land

Figure 7-1 Cable Drum Unloading Unto Temporary Storage Facility

Figure 7-2 Delivery of Cable Drum from Temporary Storage to Site

7.1.3 Cable Delivery by Rail

Figure 7-3 Cable Drum Unloading From Lorry

7.2 Cable Installation Work Preparation

a)Tools and Materials preparation

7.3 Cable Installation Work

7.3.1 Cable containment installation before cable installation

Figure 7-4.Cable duct installation on river crossing

Figure 7-5.Photo of existing cable duct on river crossing

Figure 7-6.Photo of exposed pipe with bridge

Figure 7-7.Photo of cable duct with bridge

Figure 7-8.Boring under the ditch

Figure 7-9.Boring under the river

Figure 7-10.Boring under the tracks

 Installation of rigid steel conduits from manhole to the top of OC pole ;

Figure 7-11.Overhead catenary wiring

Figure 7-12.Photo of concrete pole for Overhead catenary wiring

Figure 7-13.Photo of Overhead catenary wiring

7.3.2 Underground/Buried Cable Installation

B-2, Setup of Cable Drum and Cables

The following checks should be carried out before cable installation:

Figure 7-14 Cable Installation

B-3, Cable Installation

d) Wayside Cables will be installed including Signaling cable. Installation of cable

Signaling cable of standard in wayside;

Cable order of installation is as below;

Signaling Cables Signaling Cables

Up Track, South Bound down Track, North Bound

Figure 7-17 Cable Installation Standard

The sequence of work for cable installation consist of;

Figure 7-18.Cable Installtion Detail

Figure 7-19 Cable Route Marker Standard Installation

Figure 7-20 Detail Cable Route Marker

B-5, Splice and Termination

7.4 Work Sequence

The sequence of work for direct buried cable work is:

3. Detail Cable Installation

B. Installation of underground/buried cable

4. Reporting the finished work to the Station Master.

7.5 Flow Chart

Figure 7-21 Installation of cable containment

Figure 7-22.Installation of Cables