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LINDE ENGINEERING Pearl GTL Project Shell Project No: HP-3000-QAT Contractor Project No : 5887 Project

LINDE ENGINEERING

LINDE ENGINEERING Pearl GTL Project Shell Project No: HP-3000-QAT Contractor Project No : 5887 Project Document
LINDE ENGINEERING Pearl GTL Project Shell Project No: HP-3000-QAT Contractor Project No : 5887 Project Document

Pearl GTL

Project

Shell Project No: HP-3000-QAT

Contractor Project No : 5887

Project Document Number: T- 4.234.082

Project Rev.: A

Page 2 of 13

Purchase Order Number:

2MH127

Tag/Item Number(s):

N/A

Unit(s):

ASU

PCWBS:

Z

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

D

A

03.02.2008

 

Ready For Construction

   

SB

UA/MC

 

ZG

RFC

C

O

30.10.2007

 

Issued For Company Comments

 

IO

 

MC

 

ZG

ICC

B

 

24.10.2007

 

Issued for Review

   

IO

 

MC

 

ZG

IFR

A

 

20.10.2007

 

Issued for Internal Review

   

MS

 

MC

 

ZG

IIR

GAMA

Project

Date

 

Description

 

Prepared

Checked

Approved

Status

Rev.

Rev

 

By

 

By

 

By

No.

No.

     

ORIGINATOR

   
   
   
LINDE ENGINEERING AG

LINDE ENGINEERING AG

   

Document Title:

 

METHOD STATEMENT FOR ANCHOR BOLT INSTALLATION

Contractor

   

Document No.

     
Gama Qatar Co. W. L. L.

Gama Qatar Co. W. L. L.

GAM

MTS

CIV

GTL

016

D

LOC470

Org.

Doc.

Disc.

 

Geogr.

Seq.

Rev.

Vendor Code

 

Code

Type

Code

Area

No

No

Project Document Number: T-4.234.082

Rev No: A

D o c . T i t l e : GAM-MTS-CIV-GTL-016 Rev. D Method Statement

Doc. Title

:

GAM-MTS-CIV-GTL-016 Rev. D Method Statement for Anchor Bolt Installation

QQQ AAA TTT AAA RRR

Date

:

03.02.2008

TABLE OF CONTENTS

1. PURPOSE

5

2. SCOPE

5

3. HSSE

5

4. REFERENCES

6

5. DEFINITIONS

6

6. RESPONSIBILITY

6

6.1. Site Manager

6

6.2. Civil Works Manager

6

6.3. Site Engineer

6

6.4. Work Supervisor

7

6.5. QA/QC Officer / Inspector

7

7. EQUIPMENT & MANPOWER

7

7.1. Equipment

7

7.2. Manpower

8

8

9. QUALITY ASSURANCE 10

10. ATTACHMENTS 10

8. METHOD OF EXECUTION

JSA

10

D o c . T i t l e : GAM-MTS-CIV-GTL-016 Rev. D Method Statement

Doc. Title

:

GAM-MTS-CIV-GTL-016 Rev. D Method Statement for Anchor Bolt Installation

QQQ AAA TTT AAA RRR

Date

:

03.02.2008

1. PURPOSE

The document describes the methods proposed to be used for anchor bolts installation that will be carried out as part of ASU Construction Works of Qatar Shell GTL Plant (Pearl) in Ras Laffan Industrial City of Qatar including similar works in TSF Area.

2. SCOPE

This method statement identifies the basic structure of the anchor bolts installation system and technique used for the successful completion of the works.

3. HSSE

All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and international standards/codes, and Company and Contractor requirements and instructions. All personnel will go through Gama, Linde and Company Safety Induction courses as well as other trainings as identified by their supervisor. A Job Safety Analysis (JSA) specific for this work including a Risk Assessment is prepared and attached herein. Such JSA addresses the hazards associated with each task within the scope of this Method Statement and introduces the controls that will be implemented to reduce the associated risks to acceptable levels. The JSA will be used by the Site Supervisor as the basis of his TSTI / TSTO and Toolbox Talks. All personnel will have PPE required for their specific tasks in addition to the minimum PPE (coveralls, safety goggles, safety shoes, high-visibility vests, gloves) at site at all times as required. In the event of a release, fire or explosion, employees will secure their area and evacuate to the nearest muster point. Once all employees are evacuated the supervisor will conduct a headcount to verify all employees are out of harms way. The supervision will report this to Contractor. Emergency Contact numbers for Company, Contractor and Gama will be posted onsite. All vehicles and equipment used for the subject work will be inspected and certified as required. Drivers and operators will be competent and will have attended all required trainings set forth in project procedures and specifications. All rebar ends will be protected by capping.

D o c . T i t l e : GAM-MTS-CIV-GTL-016 Rev. D Method Statement

Doc. Title

:

GAM-MTS-CIV-GTL-016 Rev. D Method Statement for Anchor Bolt Installation

QQQ AAA TTT AAA RRR

Date

:

03.02.2008

4. REFERENCES

 

:

DEP 34.19.20.31-Gen

:

DEP 34.14.20.31-Gen

:

T-13.376.358

:

T-13.376.359

:

T-4.234.541

:

5. DEFINITIONS

Qatar Construction Standard Reinforced Concrete Foundations and Structures Steel Structures Amendments and/or Supplements to Reinforced Concrete Foundations and Structures Amendments and/or Supplements to Steel Structures QC Docs for Concrete Works Other related documents of RLIC, Company, Contractor and Gama

Company

:

QSGTL or its PMC

Contractor

:

Linde Engineering AG

Subcontractor

:

Gama Qatar Co. W. L. L.

Contract

:

QSGTL Pearl Plant – C2 ASU Construction Works

QCP

:

Quality Control Procedure

ITP

:

Inspection and Test Plan

QA/QC

:

Quality Assurance / Quality Control

JSA

:

Job Safety Analysis

6. RESPONSIBILITY

6.1. SITE MANAGER

The site manager will provide inputs to the project execution plan to ensure that strategies & philosophy are properly addressed.

6.2. CIVIL WORKS MANAGER

The Civil Works Manager is responsible for the overall management of the project construction team to ensure that safe and effective operations are conducted and properly documented.

6.3. SITE ENGINEER

He will be overall responsible for safe execution of the whole job including:

Confirming the installation location from schedule of approved construction drawings.

Organizing of equipments and tools needed for the job.

Assigning skilled personnel for the job.

Sequence of activities to be carried out for the work as per this method of statement.

D o c . T i t l e : GAM-MTS-CIV-GTL-016 Rev. D Method Statement

Doc. Title

:

GAM-MTS-CIV-GTL-016 Rev. D Method Statement for Anchor Bolt Installation

QQQ AAA TTT AAA RRR

Date

:

03.02.2008

Conduct inspection and surveillance.

Notify to Contractor engineer for inspection as applicable.

Ensure all Contractor and Company regulations are followed.

Ensure all personnel involved are in safe working condition.

6.4. WORK SUPERVISOR

He will be responsible for safe execution of the following activities:

Conduct TSTI with the concerned work force prior to start the work.

Ensure that relevant work permits for the job are obtained prior to start the work.

Conduct daily toolbox talks for the entire work force prior to start day work.

Assigning a competent work crew for specific activities, details of activities and task information will be given to the work crew.

Organizing tools and equipment needed to the work site.

Inspection and supervision of work.

Ensure all Contractor and Company safety regulations are followed as applicable.

6.5. QA/QC OFFICER / INSPECTOR

He will be responsible for:

Assurance of approved methods and materials are being used and conformance of the specifications.

Stage inspections and surveillance in accordance with ITP and assurance of quality of work as per specification and erection procedures.

Incoming material inspection and review of test certificates.

7. EQUIPMENT & MANPOWER

All equipment will be inspected and approved by the Contractor, when required, and all personnel will be inducted and trained before and during mobilization.

7.1.

EQUIPMENT

Survey equipments and instruments

Boom-truck (if needed)

Hand tools

D o c . T i t l e : GAM-MTS-CIV-GTL-016 Rev. D Method Statement

Doc. Title

:

GAM-MTS-CIV-GTL-016 Rev. D Method Statement for Anchor Bolt Installation

QQQ AAA TTT AAA RRR

Date

:

03.02.2008

7.2.

MANPOWER

Site Engineer

Foreman (Work Supervisor)

HSSE Engineer

Surveyor & Helpers

Boom-truck operator

Formwork workers with helpers

Rebar workers with helpers

Banks men / Flagmen

If the above-listed equipment or manpower proves not sufficient for the timely completion of the facilities and project; additional will be provided to complete the works on time and in line with rules, regulations and specifications of Contractor, Company and RLIC.

8. METHOD OF EXECUTION

Prior to the commencement of the Anchor Bolt installation works, the site levels & coordinates will be surveyed, verified and setout as per the related Drawings.

All anchor bolts will be placed in forms before the concrete is poured. Anchor Bolts will be set using templates placed at the approximate elevation of the base plate, carefully plumbed & checked for location and elevation. They will be held in position rigidly to prevent displacement during casting. Threads on anchor bolts will be protected by greasing and wrapping of threads.

Steel, plywood and/or timber templates may be used.

Templates will not be supported on forms unless forms will be reinforced to prevent displacement or deformation.

D o c . T i t l e : GAM-MTS-CIV-GTL-016 Rev. D Method Statement

Doc. Title

:

GAM-MTS-CIV-GTL-016 Rev. D Method Statement for Anchor Bolt Installation

QQQ AAA TTT AAA RRR

Date

:

03.02.2008

TYPE K M16 TO M30

TYPE K M36 TO M 100 TYPE G

TYPE KR

TYPE K M16 TO M30 TYPE K M36 TO M 100 TYPE G TYPE KR •

Anchor bolts will be protected from physical damage and corrosion until installation of the upper structures.

Projected part of anchor bolts and nuts will be covered by vinyl sheet during concrete pouring.

After concrete pouring, bolt threads and nuts will be greased and securely covered by vinyl sheet and wood plate (or cloth) bound by wire.

Threads of Bolts will be taped and protected during the placement of concrete.

Bolts location & elevation will be rechecked after concrete pouring.

The bolts must be placed in the formwork precisely in position, in elevation and in exactly vertical position, according to the formwork drawings. The bolts must be secured against movement during casting of concrete.

Final deviation of the bolts from the position specified in the formwork drawings, horizontally and vertically, must not exceed ± 3 mm.

D o c . T i t l e : GAM-MTS-CIV-GTL-016 Rev. D Method Statement

Doc. Title

:

GAM-MTS-CIV-GTL-016 Rev. D Method Statement for Anchor Bolt Installation

QQQ AAA TTT AAA RRR

Date

:

03.02.2008

In the case of a large number of bolts (12 or more) for one vessel (generally in the case of

columns only) the bolts shall be installed in staggered elevations, to facilitate the placing of the vessel base ring over the bolts. For this purpose 4 bolts, which are offset from each other by

90° on the bolt circle will be installed 20 mm higher than shown in the formwork drawing.

Where the foundation plate is substantially wider than the plinth carrying the vessel (e.g. in the case of tall columns), extension of the anchor bolts into the foundation plate shall be avoided. For support of large diameter anchor bolts see LS 201-21

For support of large diameter anchor bolts see LS 201-21 9. QUALITY ASSURANCE A Quality Assurance

9. QUALITY ASSURANCE

A Quality Assurance System will be operated conforming to related standards. Controls and

checks will be established and documented through T-4.234.541 (Item 3.0)

10. ATTACHMENTS

JSA

 
   
 

QQQ AAA TTT AAA RRR

JOB SAFETY ANALYSIS FORM

JSA For: T-4.234.082 Rev. O

 
JSA For: T-4.234.082 Rev. O   NEW   REVISED Page No: 1 of 3

NEW

 

REVISED

Page No: 1 of 3

Job being analysed: Anchor Bolt Installation

 

Department/Section doing JSA: HSSE & Construction

 

JSA Members:

 

Job Performers:

Normal Approvals:

   

Name

Signature

Date

General job requirements / Common Personal Protective Equipment.

JSA by:

       

Job Supervisor:

       

1. The following Personal Protective Equipment shall be worn:

Additional Approvals (Determined by Job Supervisor in correlation with Linde HSSE Manager).

 

Approved coveralls, safety goggles, safety helmet, safety shoes and gloves.

   

Name

Signature

Date

Discipline Superindent (Linde)

         

HSSE Representative (Linde)

       

OTHERS (List Below):

       

2.Permit To Work.

Approval required for hazardous work detailed in the Linde Work Permit Procedure. Changing conditions and emergency procedures Stop work. Switch off equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing employees are reported to Linde HSSE Dept. When all clear is given, check with Linde HSSE before returning to work.

LINDE EMERGENCY TELEPHONE NO.

HSSE MANAGER:

 

Pearl HOT LINE :

    JOB SAFETY ANALYSIS / RISK ASSESSMENT FOR T-4.234.082   SCOPE :
   

JOB SAFETY ANALYSIS / RISK ASSESSMENT FOR T-4.234.082

 

SCOPE :

QQQ AAA TTT AAA RRR

ANCHOR BOLT INSTALLATION

     

Initial Risk

   

Residual Risk

ITEM

ACTIVITY

 

HAZARD / POTENTIAL

P

C

R

 

CURRENT

 

ADDITIONAL

P

C

R

 

CONSEQUENCES

 

CONTROLS

 

CONTROLS

 

1 Survey the site level, coordinates and set - out.

1.1

Hit by traffic or equipment while performing survey works.

B

3

LOW

1.1.1

Employees shall wear a flourescent work vest.

1.1.1.1

All vehicle movement to be guided by competent Banksmen with fluorescent vests.

B

1

LOW

1.1.2

Barricade and secure working area with signboard.

   

1.2

Improper use of hand tools, hand and eye injuries while installing markers.

     

1.2.1

Employee shall wear the proper PPE when using hammers or other devices for installing survey markers

1.2.1.1

Never use defective hand tools.

     

1.2.1.2

All tools shall be inspected & colour coded.

C

2

LOW

i.e. approved eye protection, and gloves.

B

2

LOW

 

1.2.2

Provide necessary protection on markers such as rebar caps, or any protective cover.

 

2 Mobilize tools and materials to worksite.

2.1

Back, arm. & muscle injuries from lifting - strains, sprains while mobilizing survey equipment.

     

2.1.1

Break the job down into manageable portions.

2.1.1.1

The safe work methods and hazards associated with tasks shall be covered in TSTI / TSTO

     

B

2

LOW

2.1.2

Ensure all employees use proper lifting techniques i.e. lift with their legs, and not their back.

B

1

LOW

2.2

Slip, trip and fall hazards.

     

2.2.1

Area shall be properly maintained all equipment and materials must be

2.2.1.1

Removed unnecessary materials in the work place.

     

C

2

LOW

properly stored and picked up.

B

1

LOW

2.2.2

Housekeeping shall be on going and picked up at the end of the day.

 

3 Setting up of templates using crane.

 

3.1

Falling or dropped loads.

     

3.1.1

Third party crane inspections.

3.1.1.1

Supervisor/foreman shall ensure that the TSTI / TSTO is properly executed at the work front and hazards discussed.

     

3.1.2

Daily crane checks.

B

5

MED

3.1.3

Competent riggers.

B

2

LOW

   

3.1.4

Quarterly and Daily inspection of rigging gear and equipment.

     

3.1.1.2

Ensure the area is properly barricaded and secured.

     

3.1.5

Third party crane operator.

3.2

People struck by suspended or swinging load.

     

3.2.1

Barricade and secured area and install safety sign boards.

3.2.1.1

Supervisor/foreman shall ensure that the TSTI / TSTO is properly executed at the work front and hazards discussed.

     

B

4

MED

3.2.2

Use tag lines to control load.

B

2

LOW

 

3.2.3

"DO NOT" lift load over people.

3.2.4

Do not allow people to walk under the load.

 
   

JOB SAFETY ANALYSIS / RISK ASSESSMENT FOR T-4.234.082

 

SCOPE :

QQQ AAA TTT AAA RRR

ANCHOR BOLT INSTALLATION

     

Initial Risk

   

Residual Risk

ITEM

ACTIVITY

HAZARD / POTENTIAL

P

C

R

 

CURRENT

 

ADDITIONAL

P

C

R

 

CONSEQUENCES

 

CONTROLS

 

CONTROLS

 

4 Placed anchor bolts in anchor plate and tighten.

4.1

Hand & finger injury due to improper used of tools in tightening of nuts.

     

4.1.1

Hand tools should be inspected,

         

B

2

LOW

approved & color coded.

B

1

LOW

4.1.2

All employees should inspect their tools before use.

 

5 Pouring of concrete.

5.1

Concrete splash to eye.

B

2

LOW

5.1.1

Use approved safety glass.

   

B

1

LOW

5.2

Muscle strain or sprain while pushing, pulling, lifting, and carrying hose concrete.

C

2

LOW

5.2.1

Ensure all employees use proper lifting techniques i.e. lift with their legs not their back.

5.2.1.1

Discuss in TSTI / TSTO

B

1

LOW

5.2.2

Ensure employee managing the concrete hose has good footing to properly balance his movement.