METHOD STATEMENT FOR WELDING PIPE

AL SOQOOF10/22/2020METHOD STATEMENTS No comments

1. PURPOSE

The purpose of this methodology is to provide a systematic control and direction for the activity for the fabrication and welding of piping and structure at Safwan. This method statement provides the expectation to execute work in safe, eco-friendly manner and in compliance to the Client HSE and Quality requirements.

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2. SCOPE

This procedure is applicable for fabrication in Safwan yard for the Construction works for All Project.

3. REFERENCES

Specification for material and fabrication requirement for CS piping and equipment in sour service.
Technical specification for piping system.
Specification for welding and welding inspection of shop and field fabricated carbon steel process and utility piping.
ASME B 31.3 Process piping.
DEP 31.38.01.31 Shop and Field fabrication of piping.
AWS D1.1 Structural welding code.
DEP 34.28.00.31A Structural steel works.

4. DEFINITIONS

QHSE Quality, Health, Safety and Environment
QCI Quality Control Inspector
ITP Inspection and Test Plan
WPS Welding Procedure Specification
NDT Non-destructive testing
PWHT Post Weld heat treatment

5. RESPONSIBILITIES

In addition to the regular work as per Job description/ regular practice the following activities shall also be carried out.

5.1. Project / Mechanical engineer

Mechanical engineer is responsible to ensure that this procedure is Understood and is being implemented by his subordinates.

5.2. Supervisor/ Foreman

Ensure that welding equipment, baking oven, quiver is in good condition.
Ensure welding is done as per the approved WPS and approved for Construction drawing.
Ensure that weld maps / spool drawings are available.
Coordinate with QC personnel to study the cause of any reported weld.
Defects and arrange to take corrective and preventive action.
Adhere to the QHSE requirements.
Comply with PTW requirements.

5.3. QC Inspector

Carry out the inspection as per the Inspection and test plan.
Approving/ rejecting the item based on inspection.
Submitting the quality records to the client and getting their approval.
Responsible to keep records of all inspection related activities.
Adhere to the QHSE requirements.

5.4. HSE Officer

Advice the construction crew on HSE aspects and ensure the safety of them.
Arrange through Job performer for tool box talk covering risk assessment in language understandable by workers.
Cross checking certified material devices and equipments are used.
Do weekly, monthly HSE audit.
Ensure appropriate safety measures are taken as per the risk assessment and control document.
Adhere to the HSE plan and HSE requirements.

6. Procedure

6.1. General

Prefabrication will be done at Safwan workshop. Prefabricated spools will be painted with two layers of coating and transported to site for field welding.
Fabricated spools shall be carefully transport to site. The transported spools will be tied down with ample support to prevent any damage. Tie downs shall be nylon straps and chains shall not be used. By this way it is ensured that no damage is done to painting during transportation to site.
Ensure no damage is done to painting during transportation to site.
Whenever the pipes are cut the heat no: shall be transferred to the cut pieces for traceability by paint / permanent marker. Welding shall be done as per the approved procedure, specification and approved for construction drawing.
Welding machine, ovens and etc. shall be maintained in good condition.
Approved welders for the particular WPS shall be used for welding.
Welded surfaces shall be clean and free from grease, oil, paint or other foreign material which are detrimental to welding.
Bevels shall be as per the WPS and cleaned for minimum 1” from the welding.
Peening shall not be performed at any time.
Tack weld not incorporated in the final weld shall be removed by grinding or other mechanical means.
Welding consumables shall be issued, received and handled in accordance with the approved method statement.
All tools used for working on stainless steel shall be those designated for stainless steel work.
All flange face shall be protected with plywood / suitable means from mechanical damages during handling or storage.
End caps of pipes will be kept in place during storage, moving, fabrication and Erection activities, except when the joint end is actually being worked upon. Flanges and open ends shall be protected at all times.
Such protection shall be removed only to permit work to be performed as part of a fabrication or inspection process, after which they shall be again re protected.

6.2. Weather protection:

When the weather does not permit satisfactory workmanship welding shall not be done. On site in windy condition the pipe ends shall be closed to prevent through draughts during welding. Suitable covering using tarpaulin etc. shall be provided. Welding shall not be done when the weld surface is wet / when the area is exposed to rain / strong windy condition.

6.3. Weld Identification:

Each weld shall be uniquely identified with the joint no: and welder number.
After completing the weld, the welder shall mark the joint no: & welder no: near the weld using paint or indelible crayon.
After welding each spool, the line no, spool no & etc shall be marked / tagged on the spool and stocked over wooden sleepers or other suitable material above ground.

6.4. Non Destructive Testing:

Non-destructive testing shall be done as per the approved procedure using approved sub-contractor.

6.5. Alignment Circumferential welds.

Butt weld alignment shall satisfy the requirement of ANSI B 31.3 and conditions stated below.
Internal misalignment of pipe work shall not exceed 1.6 mm in order to facilitate welding of the root pass.
When a GTAW process is to be used maximum misalignment shall not exceed 0.8 mm. If there is excess misalignment tapering of the internal dia of the thicker member to a taper of 1:4 shall be done.
Ensure minimum wall thickness is maintained.
If misalignment up to 3.2 mm exists, internal grinding or machining may be conducted to improve root alignment, provided the taper doses not exceed 1 in 4 maximums and the minimum required wall thickness is maintained.
Misalignment correction shall be done using suitable clamps and heavy hammering or heating of the pipe shall not be done.

6.6. Weld separation

6.6.1. Circumferential welds (Girth welds):

For nominal size of 75mm & above the minimum distance shall be 75 mm. For lesser pipes the minimum distance shall be 4 times of the wall thickness or one pipe dia whichever more is. Welds lesser than the above limit shall be done with the approval of the client and may require PWHT solely at the discretion of the company.

6.6.2. Branch / Nozzle / attachment welds.

Branch / nozzle and other pressure attachment welds shall have minimum 3”.
distance to adjacent pressure welds. Non pressure containing attachment welds shall be separated by 2” from adjacent pressure containing welds.

6.6.3. Longitudinal seams

Longitudinal seams of adjacent pipes shall be separated by at least 4”.

6.7. Pre-heating, Interpass temperature, PWHT:

Preheating shall be done as per the WPS if high pre heat temperature is specified or else minimum preheat for CS upto 19mm thick is 21°C and > 19mm thick CS is 100 °C. When the base material is below 21 deg C, the material shall be heated to 50 deg C prior to welding. The heating shall be done gradually and uniform manner. The preheat temperature shall be held at least five minutes before welding is commenced & shall be checked using temperature indicating crayons.
Preheating shall be done by using propane torches or by electric resistance and the use of oxy-acetylene torch is not allowed. A minimum width of 3” on both side of the joint shall be preheated. Interpass temperature shall be as per the WPS. If any post weld heat treatment is required as per the WPS the same shall be carried out as per the temperature specification in the WPS. Controlled heating and cooling shall be as per the WPS. The temperature recorded chart shall be submitted to the client for approval. PWHT shall be performed on carbon steel piping if the wall thickness exceeds 19.05 mm.

6.8. Weld sequence:

The weld bead sequence shall be as per the approved WPS. The welding shall be cleaned of all flux, slag and spatter by wire brush, grinding and hand chipping after each pass. The welder shall visually check the welding after every pass for any defects and if any defects found it shall be removed or repaired before the next pass. If any crack is found it shall be informed to the inspector and with his knowledge rework shall be done. After completing welding the adjacent surfaces shall be cleaned of all spatters, slag, flux etc.

6.9. Welding interruption:

Welding for each pass shall be continuous without interruption other than changing electrodes or filler wires or allow welder for changing their position. Specifically root run and hot pass shall be done without interruption. If there is interruption the following action shall be taken.

If only 25 % of the weld grove has been deposited, then the weld shall be cutout & recommended for a new preparation. Otherwise the welding shall be recommenced as mentioned below.
The weld shall be allowed to cool slowly to room temperature. This can be done by wrapping the weld with insulation and allowing the joint to cool in still air.
MPI to be carried out prior to welding.
The weld shall be preheated.

7. REPAIR WELDING:

Any defects which require repair shall be entirely removed to sound metal. Metal Shall be removed 1” on both side of the defect without substantial removal of the Base metal.
By grinding, the metal shall be removed and the grove shall be smooth without any undercut. Visual examination and magnetic/dye penetrant test shall be done on the grove.
If repairs are done after hydrotest / PWHT the same shall be repeated after repair. Welding repair shall be done only twice. Even after second repair if the weld is not acceptable the weld shall be removed, re beveled and re welded.
Same NDT technique & acceptance criteria for the original weld shall be done after repair welding.

8. RESOURCES

Welding machine
Grinding machine
Preheating torches with propane gas cylinders
Holding ovens/baking ovens
PWHT equipment
Hiab, Crane
Cutting tools
Generator

9. HSE REQUIREMENTS

Basic PPE.
Fire extinguishers.
First Aider with first aid kit shall be available.

10. QA/QC REQUIREMENT ATTACHEMENTS

Quality shall be maintained by ensuring the systematic implementation of this procedure and ensuring quality records are prepared as per the ITP.

Records:

Piping daily fabrication report P002: MFM 12-M/1-P002
Fabrication control sheet P003: MQM/P3-005
Welding electrode control sheet M15: MFM 12-M/1-M15

11. EMERGENCY CONTACT

The following shall be the contact number in case of any emergency.

Project Manager
Mechanical Engineer

QA/QC Engineer

HSE TRAINING PLAN

AL SOQOOF10/22/2020HSE PROCEDURES/PLAN No comments

HSE TRAINING PLAN

1. PURPOSE AND SCOPE

The aim of this HSE Training Plan is to ensure that Project employees, appointed contractors and all personnel at Operation Phase are provided with the necessary training in health, safety and environmental (HSE) issues based on the needs of the individual, legal requirements, project needs, and industry best practices. This will enable individuals to conduct their work tasks in a way that safeguards the environment and health and safety of themselves and others whilst meeting the requirements of ABC’s integrated quality HSE management system (IMS) and any applicable international standards and guidelines, such as those defined in Section 3 of this plan.

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Key Project personnel whose management roles or job responsibilities/activities may have an impact on the environment will receive specific issue training as appropriate (e.g. in waste management, hazardous material handling etc.). Moreover, a tailor made and job specific Health and Safety Training will be conducted accordingly (e.g. in Welding, Power Actuated Hand Tools etc.).
This plan applies to employees and contractors engaged in operation of Project. A key message in each training programme will be the methods and mechanisms to be employed by relevant staff in the monitoring and audit of environmental and social management. The priority afforded to environmental and social issues will be highlighted both through the content of the training courses and through the day-to-day scrutiny provided by the HSE Manager, and site personnel such as the Operations Manager /Operations HSE Manager.

2. RESPONSIBILITIES

The HSE Manager will develop, implement, and maintain an aggressive safety and health orientation and training program. Employee safety training will be administered in two phases consisting of new employee or reassignment orientation training and regular, refresher or ongoing training. Aside from the formal safety and health related training classes, employees will receive specific guidance and instruction on safe operating procedures of each assigned job or task.
HSE Manager in line with the Operations HSE Manager will develop a HSE Training Programme for the operations personnel.
The Project Manager as well as HSE Manager will be responsible to implement the requirements stated in this Plan.
All contractor HSE Managers are responsible for performing the HSE Training for their personnel, as required by the Project HSE training programme.

3. DOCUMENTATION REFERENCES

QHSE Policy
Environmental Management Plan
IMS Staff Training Procedure

4. HSE TRAINING PROCEDURE

4.1. Identification of HSE Training Needs

The ABC HSE Manager is responsible for ensuring the HSE training needs for d Project employees are identified at least annually and / or when any major change in project activity).The analysis of training needs should incorporate:

Reviewing completed HSE training against previously specified objectives;

Establishing ongoing training objectives.

Environmental training courses will be included in the ABC Project HSE Training Programme which defines the HSE training courses to be provided to ABC employees The HSE Training Programme should include, but are not limited to, those courses specified in Appendix 1.
The ABC HSE Manager will be responsible for developing additional environmental training course and/or materials, as required, should those listed in Appendix 1 be insufficient to meet employee or contractor/ Subcontractor needs.

4.2. Induction Training

All employees will receive HSE induction training to ensure that they fully understand the HSE issues associated with their work tasks and the actions to be taken in the event of an accident or incident e.g., oil or chemical spill.
Induction training programmes for ABC's staff will be managed by the ABC HSE Manager. All contractors and the Operating Company will be responsible for conducting induction training for their personnel.

4.3.Job-Specific Training

When assigned, or transferred, to a work area an employee will be provided with job specific training by his/her immediate line manager. This will include a review of standard operating procedures, HSE risks and precautions, and controls used to manage HSE risks. Guidance and assistance will be sought from the ABC HSE Manager, where necessary.
Where there is a need for specialist HSE training the ABC's HSE Manager is responsible for identifying an appropriate course.
ABC training, including HSE training, is an ongoing commitment; therefore, refresher courses for employees will be given, as appropriate, on at least an annual basis. Toolbox talks shall be one of the daily training tools that can be adopted by ABC's Project.
The need for refresher HSE training for employees will be determined as part of the ABC's employee’s annual performance appraisal. HSE training will be provided at each stage of the Project, from initial establishment of logistical facilities and operation. Training needs and programmes should be reviewed and updated before commencing a new phase of the project, e.g. prior to operation.

4.4. Operations Training Strategy

The operations training strategy will be designed to provide assurance that the ABC Pipeline System can operate its facilities with technical personnel who are safe, well trained, experienced and competent.
The training programme for Operation Phase will have several key components;

Induction and Health, Safety and Environmental Training,
Programme of oil spill response training and drills,
Technical Training,
Discipline specific, specialized skills,
Vendor Training,
On-the-Job Training and Coaching.

4.5. Training Records

A current record of each ABC's employee’s HSE training will be maintained by the ABC's HSE Manager. Operating Company should maintain their own records and make them available to ABC when requested. In addition, a record of all HSE training courses undertaken and a list of attendees, with dates should be kept by ABC the Operating Company and any contractors used on the ABC Project.

4.6. Sub-Contractor Training

ABC Coordinator with support of the ABC HSE Manager will ensure that Subcontractor and employees who work on behalf of ABC are trained in accordance with ABC’s HSE management requirements, HSE risks and controls pertinent to their work task(s).

5. RECORDS

The following records will be retained as specified. Additionally, all these records will be legible, dated and readily identifiable.

HSE Training Records
Record	Person Responsible for Managing the record	Where the Record can be found	Who has Access to the Record	How Long Does the Record Need to kept
HSE Training needs Matrix	HSE Manager	HSE Department	All	5 Year
HSE Training Programme and Materials	HSE Manager	HSE Department	Construction Staff and HSE Manager	5 Year
Employee HSE Training Record (Employee and Training Conducted)	HSE Manager	HSE Department	Only HSE Department	5 Year

6. KEY PERFORMANCE INDICATORS

ABC Project Environmental Plans, contain Key Performance Indicator (KPI) related to training for the topic of interest. Progress against these KPIs will be reported to the HSE Manager on a monthly basis.

7. APPENDIX I– HSE TRAINING PROGRAMMES

HSE Training Programmes
HSE Training Topic	Approximate Duration	To Whom
HSSE Office Induction	I-Hour	All Staff
HSSE Field Induction	I-Hour	All Staff
Contractor HSE Plan	I-Hour	All Staff
Risk Assessment	2-Hour	HSE Team, Site Supervisor and Engineers
Emergancy Response	I-Hour	Rescue Team
Incident Investigation	I-Hour	HSE Team, Site Supervisor and Managers
Basic Firefighting	I-Hour	All Staff
Electricty at Work	I-Hour	HSE and Electrical Team and others
Health and Safety Risks at Excavation	I-Hour	HSE Sup, Site Sup, Workers, Operators
Manual Handling	I-Hour	All Supervisors and Workers
Golden Rule Training	I-Hour	All Staff
Lifting Awareness Training	I-Hour	HSE, Lifting Team
Driving Training (DDT)	I-Hour	All Drivers
Waste Management	I-Hour	HSE EM Team
PTW Training	I-Hour	HSE Team Site Sup, Engineers
HydroTest Water and Effluent Management	I-Hour	HSE team, Hydro Test Team
Crane Operator and Assessment Training	I-Hour	All Operators and Supervisor, Inspector
Hazardous Material Management	I-Hour	All Staff and Workers
Rigging and Slinging Training	I-Hour	All riggers, Lifting team, HSE
Lifting Plan Training	I-Hour	Lifting Team
Line Detection Training	I-Hour	HSE and Civil Team
Athorized Gas Tester	I-Hour	HSE team, Site Sup and Engineers
Confined Space Entry	I-Hour	HSE Team and Confined Space Team
Scaffolding Inspection Supervisor	I-Hour	HSE taem and Scaffolders, supervisors
Lifting operation Supervisor	I-Hour	HSE and Lifting supervisors
Safety and Health administration	I-Hour	HSE Team

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FOUNDATIONS METHOD STATEMENT

AL SOQOOF10/20/2020METHOD STATEMENTS No comments

GENERAL METHOD STATEMENT FOR FOUNDATIONS

1. PURPOSE

The purpose of this general method statement is to describe the construction procedures for the isolated pile cap and pad foundations. Large raft foundations will be covered in specific foundation method statements and are not included in this document.

2. SCOPE

The works will incorporate the procedures necessary to execute the following items: Preparing of Work, Survey and Setting Out, Excavation, Dewatering, Pile (If Applicable), Blinding Concrete, Foundation — Rebar- Formwork — Concrete, Embedded Items, Backfill, Pedestal.

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3. DEFINITIONS

Client = ABC
Contractor = Responsible in the supervision of the sub-contractor who will perform the construction work and all related activities as outlined in this procedure.
Sub-Contractor = Responsible in the execution of the construction work as well as the tests required in accordance to this procedure.

4. RESPONSIBILITIES

4.1. Construction Manager and Senior Engineer

Construction Manager and Senior Engineer responsible in ensuring the implement of construction procedure and method statement, the Quality Control of work, Supervise the work and reporting the progress of work to Site Manager.

4.2. Safety / Environmental Officer

Safety / Environmental Officer responsible in ensuring that all activities are carried out safety patrol at the site, Establishing the site safety plan, conducting continuous safety inspection and stop any work deemed unsafe and a risk to personal, taking action to rectified the unsafe condition and report to project manager and preparing the notes of safety meeting.

4.3. QA / QC Engineer

QA / QC Engineer responsible to monitor the execution and performance of the works in relation to this method statement, approved drawings and material specifications; detect and report non-conformance; ensure that all nonconformance products or activities identified are reported; propose the corrective and preventive action where possible and appropriate and record the completion the Non Conformance.

4.4. Site Engineer and Foreman

Site Engineer & Foreman responsible in all activities on site are carried out in accordance with the schedule and the construction drawing and take care all worker to be work with their responsibilities and make a decision when some non-conformance occurring their report to senior engineer

5. SAFETY

Refer to the site safety policy for general safety controls. One of the main aspects of this procedure is Safety and Health Control. This is to control occurrence of injuries as well as damage to equipment and properties during the entire construction period. In order to ensure a safe working environment during the entire construction period, the following safety measures will be implemented:

5.1. Machinery and Equipment:

Prior to using any machineries/equipment at site, it shall be inspected and certified by qualified person.
Periodic Preventive Maintenance shall be made on all equipment and machineries.
All operators and drivers are to be equipped with valid driver's/operator's license or permit from concerned government agency.
Only authorized drivers or operators will be allowed to operate machineries or equipment.
Only authorized signalman shall be assigned together with the operator or driver.
All lifting equipment as well as its accessories such as sling wire, nylon sling, shackles, chain blocks crane hook and latch shall be inspected periodically.

5.2. Personal Protective Equipment:

Personal Protective Equipment (PPE) shall be issued to all workers such as safety shoes, hardhat, working gloves, earplug, safety goggles (if required) and safety belt and or safety harness for workers who will be assigned in elevated places 2.0meter and above.
Wearing of the basic PPE shall be enforced fully.

5.3. Safety Arrangement during the Foundation Work:

Emergency Action Plan — refer to Appendix-B

Note:

All new recruits shall undergo proper orientation and safety induction before they are deployed at site for work.

6. Work Procedure

6.1. Preparation of Works:

Foundation works will not commence until confirmation that all pre-construction planning and safety checks are completed.
The supervisor shall be familiar with the latest construction drawings and method statements.
Plant and equipment requirements will be assessed on a case-by-case basis for each foundation location and agreed with the Construction Manager prior to starting the works.

6.2. Survey and Setting out

Before work starts survey department will establish baselines and benchmarks from which co-ordinates and elevations will be taken to set out the foundation works.

6.3. Excavation

Excavations will generally be executed in open cut to the size, slope and elevation shown on the construction drawings and/or design calculations.
Survey will set out and check edge slope and bottom founding level of excavation.
Excavation will be carried out with excavator and the excavated material loaded directly into dump truck and transported to temporary stockpile area.
A small bucket or manual digging will be used when excavating between piles.
The final bottom founding level under each foundation will be inspected by QC and tamped or compacted as per design requirements before pouring blinding concrete.
For a description of all related work activities refer to MS0501 -General method statement for open-cut excavations.

6.4. Dewatering

From the site soil report the relative groundwater level is approx. -2.5m below existing ground level
During excavation and after reaching the required excavation level a dewatering system will be installed as required and any water discharged to the vicinity drainage.
For a description of all related work activities refer to MS0506-General method statement for dewatering excavations.

6.5. Piles (where applicable)

Following final excavation the piles will be cut down to design pile cut off level.
Removed sections will be lifted out and taken to designated disposal area.
After cleaning, the pile head Treatment will be done to connect pile to foundation.
For a description of all related work activities refer to MS0405-Method statement for pile cut-off.

6.6. Blinding Concrete

Bottom of the excavation should be dry and tamped or compacted to a uniform level before pouring the 50mm thick lean concrete blinding layer.
For a description of all related work activities refer to MS0601-General method statement for concrete.

6.7. Foundation

After QC inspection of the prepared founding level and lean concrete base layer then construction of the foundation will follow.

6.7.1 Rebar

Rebars will be cut and bent on site in line with the agreed construction sequence.
Installation of rebar will begin as soon as blinding concrete has hardened enough for trafficking (normally 12 hours).
A mobile truck crane and/or manual workers will be used for rebar installation.
Rebar placement sequence will follow the latest rebar construction shop drawings.
Suitable concrete spacers will be used to achieve the desired covers and additional rebar spacers will be installed to maintain support of top steel and any cast-in items.
All pedestal column starter bars and cast-in anchor bolts will be accurately located and securely fixed in the correct position.
Location, spacing, verticality and cover shall be checked during the installation process and QC will make a final inspection prior to calling up concrete.
For a full description of all work activities refer to MS0602-General Method Statement for Rebar.

6.7.2 Formwork

The formwork system to be adopted for each foundation type and size will be as specified in approved calculations prepared by the Temporary Works Design Engineer. The different types of formwork for site installation purposes are summarized in Table Appendix?
Plywood sheathing with timber and steel props will be used for formwork and manual labour will be used for lifting and placing according to survey-lines of the foundation outline.
Approved form release agent is applied prior to lifting-in and erection of the clean forms.
Forms are connected tightly together and braced to the excavation profile or waling in the case of a sheet pile wall.
For a full description of all work activities refer to MS0603-General Method Statement for F01mwork.

6.7.3 Concrete

1 no concrete pump will be available (with back-up pump) for placing concrete at a rate of around 35-40m3/hr. In some cases, pouring concrete will be done by bucket and 25T mobile crane at a rate of 1 0-15hr.
A minimum of4nos of 50mm vibrators shall be used for compaction.
Unless agreed otherwise the foundations will be poured at one time in layers, starting from the centre and spreading out to each side. CHECK IF CORRECT!
Keep concrete alive without performing any cold joints.
Manual tools and float are used to finish the top surface.
For a full description of all work activities refer to MS0601-General Method Statement for Concrete.

6.8. Embedded Items

All embedded items and cast-in anchor bolts shall be placed to the specified installation tolerances shown on the construction drawings.
Special care will be taken to place and maintain embedded materials to the proper setting location to prevent movement during the progress of the work and to tamp concrete thoroughly around them.
For a full description of all work activities refer to MS0901- General Method Statement for embedded items.

6.9. Repair and Touch-up.

After striking of forms a QC inspection will be conducted to decide whether any repairs to the concrete surfaces are necessary.
For a full description of concrete repair procedures and materials to be used refer to MS0604- General Method Statement for Concrete repair and touch-up.

6.10. Backfilling

Backfilling operations will be executed in two (2) stages using suitable excavated sand material.
The first stage fill will be placed up to the top of foundation level and will commence as soon as formwork has beenremoved and QC inspection of foundation is approved.
NOTE: - If this method is adopted then curing f foundation will be done using ??????? curing compound.............................................................................................................................................................................................................................................................................................................................................................................................................................
Backfilling will be done in loose layers not more than 250mm in thickness.
Suitable vibrator plate/rollers and/orwater will be used to achieve the compaction requirements for each layer field density test will be performed to check the soil compaction to 95% maximum dry density.
Any embedded cableway conduits and earthing/grounding wires, drainage pipes and trenches etc. should be installed simultaneously with the backfilling laye18.
After completion of the concrete pedestal then the second stage fill will be carried out up to grade level below proposed finished ground level
For a full description of all work activities refer to MS0505- General Method Statement for backfilling of excavations.

6.11. Pedestal

Pedestal columns vary in height between??? ????? and
Heights exceeding ????????? will be cast in two (2) lifts.
Formwork will be made using plywood form panels in sizes to suit manual installation and dismantling.
All construction joints will be properly prepared at location indicated on the construction shop drawings.
For general construction details and work procedures refer to General Method Statements for Rebar, formwork and concrete.

7. TOLERANCES

As final design drawings and/or Main Contractors instructions.

8. REFERENCES

Specification: Client's Technical Specification for Civil Works, Section 6 — Material and Workmanships Sub-section 6.4 "Concrete Work".
Safety provisions: Refer to Site Safety Plan.
Related Method Statements:
MS0601; General Method Statement of Concrete o MS0602; General Method Statement of Reinforcement o MS0603; General Method Statement of Formwork o MS0604; General Method Statement of Concrete Repair and Touch up Drawings: Refer to latest "For Construction" drawing list.

9.APPENDICES

Appendix A: Activity Organization Chart
Appendix B: Emergency Action Plan
Appendix C: 1. Foundation Location Plan

Foundation Schedule
Foundation Construction Sequences

10. EXHIBITS

Title: Foundations
Appendix A: Activity Organization Chart.

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Rigging Plan For Heavy Lifting

AL SOQOOF10/18/2020HSE PROCEDURES/PLAN No comments

RIGGING PLANFOR LIFTING STEAM DRUM 72 TO AT BOILER BY WINCH

1. GENERAL

This procedure provides information for the erection of Steam Drum Boiler at Project.

2.PURPOSE

This Procedure is to make sure that all people involved in the erection, assembly and welding of Steam Drum activity understand and familiar to do the work with quality control system for getting quality result as per client specification and requirement, drawing, standard and code.

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3. GENERAL NOTE

3.1. Inspection

As per the works required inspection, carry out inspection under attendance of Superintendent / Engineer and as surreally record is result.

3.2. Safety

A safety officer presents all times Safety Briefing.
Job Safety Analysis (JSA) must be carried out for all crane lifts and all other tasks that have potential risk to personnel of equipment.
Install scaffolding where necessary to install bolt in each beam and member connection.
Pre lift study before any lifting activity.
Lift briefing and Safety briefing before any lift; assign responsibility to all personnel involved. (Signalman, Rigger to crane driver, etc.)
Ensure all equipment required for installation is on hand and in position before lift i.e. Chain blocks, Lever blocks, Podgy, Drifts, Hammer, and Spanners. Etc.
Tag lines must be used to control lift.
Ground conditions must be ready before activities.
Set up safety rope around lifting area of Steam Drum area and put notice board entered “KEEP OFF EXCEPT PERSONNEL AND CONCERNED”.
Lifting equipment should be in certification and tagged.
Crane and other machinery shall be inspected and certified.

3.3. Lifting

All conditions adapted to the lifting procedure. Prior to commencement of lifting works, assuredly carry out check of lifting equipment.

3.4. Assembly and erection

Erection steam drums accordance with the manuals and drawings.

4. RESPONSIBILITY

4.1. Chief Construction

Responsible for the overall planning, coordination and control of erection work.

4.2. Field Engineer

Responsible for field erection work implementation and maintaining acceptable quality standard.

4.3. Field Superintendent and Supervisor

Responsible for the actual performance of the erection crew and examine the actual progress of work to ensure that it fit the drawing, specifications and standards.

4.4. Quality Control Engineer

Responsible for monitor and inspect the erection activities to ensure it is being done in compliance with procedure, ITP (Inspection and Test Plant), drawing, Project specification and other reference standard document and procedures.

4.5. Supporter Activities

These activities will support by Material Control, Quality Control, Welding Section, and others section related with these activities.

5. BASIC REQUIREMENT

5.1. Schedule and Planning

Master schedule is usually provided by Main Contractor. The detailed schedule is prepared by Contractor according to his planning which is based on Main Contractor’s master schedule. The milestone and the critical path can be identified which require proper planning. The sequence of erection activities and the resources required is included in the planning.

5.2. Erection Drawing and Erection Manual

Erection drawing and manual usually provided by Vendor. The Field Engineer and Superintendent shall check all drawings intended for Steam Drum Erection. All the information required is completed and all drawings shall be of latest revision.

5.3. Packing List

Packing List shall be provided by Vendor. This included all the listing of materials, equipment and parts that are supplied.
The Packing List should indicate the quantity of the material and equipment supplied and its specification as described in the erection drawing. This will also indicate the size and the total weight of the component and the method of storage. Also the packing number and material coding is very essential.

5.4. Storage Area and Warehouse

Upon a thorough check on the drawing and the packing list, the quantity of materials and equipment is already known, including the method of storing, the size of the storage area and the warehouse can be identifying.

5.5. Resources

Identification of resources is integral part of planning and scheduling is the most essential part of the basic requirement in undertaking Structure Boiler in particular and in all jobs in general. Resources means, the materials, Labour and equipment needed to perform Structure Boiler Project.

6. PREPARATION WORK

6.1. Checking of Steam Drum Erection Drawings

This has to be done by the Chief Construction, Field Engineer, Superintendent and Supervisor to determine the correct resources needed to perform the job.

6.2. Checking of Client Supplied Material and Equipment

Checking and inspection of the materials and equipment including the spare parts is to be done by the material control. He will make sure that all materials, equipment and spare parts received from Main Contractor, conform to the quantity and the specifications started in the packing list or shipping.

6.3. Checking of Erection Materials, Equipment, Tools and Machinery

In the early stage of planning, these resources had been already identified. The schedule of mobilization as on planed schedule made by the Chief Construction and Engineer.

6.4. Checking of Labour

Labour requirement for every stage of erection job is prepared by the Chief Engineer and his erection team, which is in accordance to their planning.

7. ORGANIZATION CHART

8. STEAM DRUM ERECTION SEQUENCE

It is assumed in this procedure that before starting the erection of the Steam Drum, the supporting structure were already erected and checked by others and clearance to proceed with the Steam Drum System erection had been obtained. The following sequences are for reference only. During actual field assembly, refer to lifting procedure and erection drawing (Rigging plan).

8.1. Remarks:

The length of steam drum is 16436 mm and the span between grid G2 and G4 at ELev. 46500 mm is 18000 mm. Therefore, the drum no needs to be tilted. The electric winch will be mounted on support. The movement and restraint will be by chain blocks. The electric winch will be operated from an electric current. The actual loads on electric winch as the drum are 7 ton, in actual load at pulley are 35 ton.

8.2. Preparation Works:

Preparatory works such as strand guides and temporary scaffold access platform at top deck steel for jack operators and erectors and other levels access for watchman at various elevations must be prepared in advance.

9. LIFTING PROCEDURE OF 72 TON BOILER DRUM

Drum shall be delivered with center offset towards grid K1.
Restrain the end of drum at grid K1 with chain blocks to prevent drum from hitting the column at grid K1 during its initial lift off.
Lift the drum by approximately 100 mm and hold it for 15 minutes while all direct load bearing temporary and permanent girders and beams, winch system are checked for any undue deflections or connections (steel/hose) non conformities.
Once the system has been cleared for safe lifting, the wood/steel/concrete blocks that are supporting the drum at ground floor are removed.
Lift Winch 1 and Winch 2 by slowly.
At this position, the drum shall clear the steel on both sides. A continuous monitoring on the condition of the lifting system shall be done. The watchmen shall continuous follow the drum while on its way up to check for any obstruction along the way of the drum. If there is any obstruction the watchmen will inform the lifting controller to hold the lifting until the obstruction is cleared, then resume lifting.
Lift both ends together until the highest end is clear - above the Elev. 46500 mm.
Lift the drum until U-Bolt connection can be made.
After U-Bolt installation is complete, transfer the load from the lifting cables to the bolts.
The lifting device shall be dismantled together with the temporary support to clear the way for erection work to progress.

10. LIFTING TOOLS

Electric Winch capacities 10 ton : 2 unit.
Tackle Block capacities 50 ton : 4 unit
Rolling Block capacities 15 ton : 6 unit
Rolling Block capacities 5 ton : 1 unit
Shackle Omega capacities 50 ton : 2 unit
Chain Block capacities 10 ton : 2 unit
Temporary Hanger capacities 50 ton : 2 unit
Sling 22mm 500 meter : 2 unit
Wire Clip 7/8 inch : 6 pcs

11. RIGGING ANALYSIS

11.1. Winch

Base-mounted winches, or tuggers, are a compact, versatile tool for many hoisting and pulling operations. They are particularly useful in areas not accessible to mobile cranes or where there is not enough headroom for a crane to operate. Figure 1 shows a tugger and snatch block arrangement for hoisting. Make sure that the rope leaves the drum at a downward angle and that the loose end is securely anchored.

11.2. Load Distribution

Figure 1

Load of Steam Drum 72 ton
Accessories 8 ton
Total Load 80 ton

Load Distribution Every Point:

Load = ( 80 ton)/(2 Point)=40 ton

11.3. Anchorage Points

Hoists, winches, tirfors, and other rigging devices require secure anchorage points. Anchors may be overhead, in the floor, or at lateral points in walls or other structures. The arrangement may involve columns, beams, beam clamps, welded lugs, slings, or block and tackle. Whatever the method, riggers must be certain of the loads involved and the anchorage required.