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METHOD STATEMENT FOR TIE WORKS

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TABLE OF CONTENTS

1. GENERAL 2
2. PURPOSE 2
3. SCOPE 2
4. TERMS & DEFINITIONS 2
5. REFERENCES 2
6. RESPONSIBILITIES 3
7. ORGANIZATION CHART 6
8. EQUIPMENT, TOOLS & MANPOWER 6
9. PERSONNEL QUALIFICATION 710.
METHODOLOGY- PREPARATORY WORK, WORK EXECUTION METHOD 7
11. HEALTH SAFETY ENVIRONMENT 1112.
ATTACHMENTS 15

1. GENERAL
This document covers the sequence activities for Tie in works at The Evonik utility supply project.
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2. PURPOSE
The purpose of this document is to follow proper methodology and to carry out the activities in
sequence for Tie in works at The Evonik utility supply project.

3. SCOPE
The scope of the work method statement is to outline the procedure and work sequence for Tie in
works at The Evonik utility supply project. This Works Method details the followings,
Responsibilities.
Organisation chart.
Manpower & Equipment used.
General requirements.
Lifting plan.
Lifting sequence.
Tie in Activities.
Associated activities.
Risk Assessment.

4. TERMS & DEFINITIONS


WPS Welding procedure Specification.
PQR Procedure qualification Record.
WSH - Work Place Safety And Health
ITP Inspection and Test Plan.
RA Risk Assesment.

5. REFERENCE
Work Place Safety And Health Act
Work Place Safety And Health(General Provisions) Regulations
Work Place Safety And Health(Construction) Regulations 2007
WSH(Operations Of Cranes) Regulations 2011
SS536: Code of practice for the safe use of mobile cranes
SS528: specification for personal fall arrest system
SS537 code of practice for safe use of machinery
Code of practice for working safely at heights.
Project Quality Plan
Welding Control Procedure for Piping
WPS and PQR Welding Book For Piping
Piping material specification.
General specification for piping
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General requirements for field fabrication of Piping


ASME B31.3 Process Piping
ASME SEC II Part C Specifications for Welding Electrodes and Filler Metals
ASME SEC IX Welding and Brazing Qualifications
SUTO-ALL-P08-4-009 (Pipe Cleaning Procedure)_Rev3
SUTO-ALL-P08-4-004 (Piping Material Specification)_Rev4
SUTO-ALL-P08-4-015 (Basic Requirements for installation of Piping )_Rev5

6. RESPONSIBILITY
6.1 Project Manager
Undergone Project Manager's Safety Course and possess valid certificate.
Familiarize himself with the Company's environmental, health and safety management
system and ensure its effective application.
Take prompt corrective actions to remove any unsafe or unhealthy work conditions and to
maintain effectively such corrections made.
Ensure good housekeeping is practiced on site.
Ensure that environmental, health and safety is planned into all operations.
Review all working methods and process, both new and existing to see that all
environmental, health and safety are met.
Act as Chairman to the site safety, health and environment committee and conduct monthly
site committee inspection and meeting.
Participate in all incident investigation and dangerous occurrences incidents.
6.2 Project Engineers
Familiar himself with the Company's environmental, health and safety management system.
Review any new or changes in processes, equipment and materials to ensure that safety,
health and environment are not disregarded.
Establish and maintain a programme for the identification and assessment of hazards.
Assist in the investigation of every serious or fatal accident and dangerous occurrence and
recommend preventive measures.
Ensure that method statements, hazard analysis and safe work procedures for hazardous
operations must be submitted by the sub-contractors prior to commencement of work on site.

6.3 WSH Coordinator


Undergone Building Construction Safety Supervisor Course and WSH Co-coordinator
Course possess valid Certificate.
Ensure that all rules and regulations as stipulated in the WSHA (Construction) Regulations
are met.
Inspect and rectifying any unsafe place of work and unsafe practices.

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Checking sub-contractors work to ensure compliance with the WSHA (Construction)


Regulations.
Liaison with sub-contractors with respect to environmental, health and safety works
undertaken by them.
Assist the Safety Manager, Workplace Safety and Health Officer and Environmental Control
Officer in all safety, health & environment matters.
Carry out site safety, health and environment programmes and procedures.
Assist in organizing safety, health and environment awareness activities such as toolbox
meetings, safety, health and environment orientation, safety, health and environment
promotional activities, etc.
Ensure that issuance of personal protective equipment are properly recorded and
documented.
Coordinates and assures compliance with the Risk Assessment Program

6.4 Planning Engineer


Shall be responsible for monitoring progress throughout the construction process and
comparing this with the projected schedule of work with introducing appropriate logistics
solutions and resources.

Shall be responsible for day to day micro planning in coordination with project engineer and
supervisor and report activities to Project Manger.

6.5 QA/QC Team

Shall be responsible for inspection on production of pipes ,fittings and spools to ensure the
procedures are being followed in order to ensure that quality standards being achieved as per
Project procedures, requirements and specifications.

Shall be responsible for maintenance of NDT records & Project documentation.

6.6 Lifting Supervisors


Undergone Lifting Supervisor Safety Course and possess valid certificate
Possess relevant experience in lifting operations for a period of not less than one year before
the appointment as a lifting supervisor.
Co-ordinate all lifting activities.
Supervise all lifting operation by a mobile crane or tower crane in accordance with the
lifting plan.
Ensure that only registered crane operators, appointed riggers and appointed signalmen
participate in any lifting operation involving the use of a mobile crane or a tower crane.

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Ensure that the ground conditions are safe for any lifting operation to be performed by any
mobile crane.
Brief all crane operators, riggers and signalmen on the lifting plan
If any unsatisfactory or unsafe conditions are reported to him by any crane operator or
rigger, take such measures to rectify the unsatisfactory or unsafe condition or otherwise
ensure that any lifting operation is carried out safely.

6.7 Crane Operators


Undergone Crane Operator's Training Course and possess valid certificate.
Before the start of every work shift, to carry out operational tests on all limiting and
indicating devices under no load conditions before any lifting operation is carried out and
shall enter the results of such tests in a log book or log-sheet.
To ascertain whether the ground conditions, in particular the ground surface on which a
mobile crane is to be operated, are safe for travel or any lifting operation; and if he is of the
opinion that it is not safe for travel or any lifting operation, he shall report this to the lifting
supervisor.
To ensure that any outrigger when it is required is fully extended and secured.
Not to carry out any lifting operation unless he has been briefed by the lifting supervisor on
the lifting plan.
Not to hoist any object if he is unable to ascertain the weight of the load.
Not to hoist any load unless he has received a clear signal from a signalman.
Not to engage in any act or manoeuvre which is not in accordance with safe and sound
practice.
Not to hoist any load if there is any obstruction in the path of manoeuvre and if there is any
such obstruction, he shall report this immediately to the lifting supervisor.
Not to manoeuvre or hold any suspended load over any public road or public area unless that
road or area has been cordoned off
Not to operate a mobile crane or a tower crane within 3 metres of any live overhead power
line.
Not to use the crane for any operation for which it is not intended, including pulling or
dragging a load
To ensure that any stationary truck mounted or wheel mounted crane is adequately and
securely blocked while it is on a slope.
To report any failure or malfunction of the crane to the lifting supervisor and to make an
appropriate entry of the failure or malfunction in the log book or log-sheet of the crane.

6.8 Riggers
Appoint a rigger in a workplace unless the person has successfully completed rigger training
course acceptable to the Commissioner.
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Check the slings to be used for slinging the loads to ensure that the slings are of good
construction, sound and suitable material, and adequate strength and free from patent defect.
Ensure that an adequate number of legs of the sling are used and that the slinging angle is
correct so as to prevent the sling from being overloaded during the hoisting.
Determine the weight of the load which is to be lifted and inform the crane operator of the
weight of the load;
Ensure that only proper lifting gears are used in conjunction with the sling.
Ensure that the load to be lifted is secure, stable and balanced.
Ensure that any loose load (which includes any stone, brick or tile) is placed in a receptacle
to prevent the load or part thereof from falling during the lifting operation.
Place adequate padding at the edges of the load which come in contact with the sling so as to
prevent the sling from being damaged; and
Report any defect in the lifting gear to the lifting supervisor.

6.9 Signalmen
Undergone Signalman's Training Course and possess valid certificate.
Ensure or verify with the rigger that the load is properly rigged up before he gives a clear
signal to the crane operator to lift the load.
Give correct and clear signals to guide the crane operator in the maneuver of the load safely
to its destination.

6.10 Banksmen
He will be in-house trained, with a whistle and hi-visibility vest.
Assist in assessing the ground conditions prior to the entry of equipment/ machinery/
vehicle.
Use standard signals to guide the movements of machinery/equipment/vehicle at/to the
location of works to be carried out.
Communicate to the drivers/operators during the movements of the
machinery/equipment/Vehicle.
Station full time on site assisting in guiding all vehicular movements on site.
Report any incidents/accidents to his immediate supervisor, sembcorp site/safety personnel
The movements of machinery/equipment/vehicle will be stopped during the absence of the
banksman to prevent any incidents on site.
The operator/driver must be able to see the banksman during the communication process.
The banksman must be stationed in such a way not to be in the line of fire (front, behind or
in-between) of the equipment movement

6.11 Foremen/ Supervisor

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Responsible for the safety, health & welfare of all workers either assigned or not assigned to
him but may be working temporary in his area.
Ensure that workers know safety, health and environment rules and regulations, follow safe
job procedures and be aware of all major hazards associated with their work and work areas.
Maintain satisfactory standards of housekeeping in his assigned area.
Investigate all incidents to worker(s) and/or equipment in his area and assist Workplace
Safety and Health Officer to put up accurate incident report on all such investigation.
Ensure that all workers working in his area use the appropriate personal protective
equipment.

6.12 Fitter
To do Fit-up work under the supervision of Foreman/Supervisor.
To do edge preparation for pipes and fittings as per drawing requirements.
Align the pipes and fittings using appropriate tools like clamps, chain block, etc.
Maintaining welding requirements such as root gap,and root land as per WPS.

6.13 Welder
Checking the welding requirements according to WPS, and follow accordingly.
To do proper grinding work without slag and under cuts.
To do welding operation accordding to WPS.

6.14 Fire Watchman


Assist in the setting up of hot work area, including barricade and warning signs
Remove all flammable materials with in vicinity
Ensure an adequate fire extinquisher is to hand
Arranging fire blanket in the specific work area in a manner as not allowing the spark to
come out of the fire blanket.
Monitor hot work activity and stop the work if any unsafe condition is observed
Monitor for potential fire hazard due to hot work
Warn others of the hot work activity and ensure personnel not directly involved in the
activity.
To be stationed through the hot work to closely monitor for probable fires.

6.15 Workers
Accepting individual responsibility for their own safe behavior as well as sharing
responsibility with their fellow workers and line supervision to look out for their own as
well as their co-workers.
Work in a safe manner at all times.
Complying with HSE requirements which apply to an individuals work activities.
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Keeping the work area in an orderly condition.


Wear PPE provided to them and inspect it daily.
Comply with work instructions and permits.
Attend daily tool box/pre-task meetings
Inspect all tools before use and on a daily basis.

7. ORGANIZATION CHART

8. EQUIPMENT, TOOLS AND RESOURCES


8.1 Equipments
8.1.1 Welding generator.
8.1.2 Argon, Acetylene & Ocygen cylinders
8.1.3 Pipes & Fittings.
8.1.4 Pipe supports.
8.1.5 Oven
8.1.6 Personal Protective Equipments
8.2 Tools
8.2.1 Measuring and Leveling Tools
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8.2.2 Clamping Tools


8.2.3 Hand held Tools- Spanner, screw driver, plumb etc.
8.2.4 Welding Torch.
8.2.5 Portable power Tools like Grinding machine, Drilling Machine etc.
8.2.6 Power & Welding cables
8.2.7 Fire blanket.
8.2.8 Tripod stand
8.2.9 Cable stand
8.2.10 Fire Extinguisher
8.3 Man Power
8.3.1 Project Engineer 1 person
8.3.2 Safety Co ordinator 1 person
8.3.3 Foreman / supervisor 1 person
8.3.4 Fitter 1 person
8.3.5 Welder 1 person
8.3.6 Fire watchman 1 person
8.3.7 General worker 3 persons

9. PERSONNEL QUALIFICATION
All personnel delegated to the work would have undergone the relevant mandatory and
project specific in-house training

All personnel would be competent for the tasks that they will be carrying out,

Supervisory personnel will act as lead person by following and guiding the team.

Please refer the attachment for the competency personnel certificates.

10. METHODOLOGY
10.1 Preparatory Work
Ensure that the document received bear the stamp Issued for Construction and are of
latest revision.

The documents submitted/referred with this method statement shall be considered as


an integral part of this method statement and shall be read in conjunction with the
same.

Lifting Supervisor & crane operator will check & plan the travel routes prior to
mobilization. Ensure travel routes & access to the jobsite is in good condition and free
from obstruction.

Check and confirm crane set-up positioning.

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The engineering drawings and documents received shall be clearly understood to find
out the service, material specification, size, thickness, QA/QC requirements, pipe
routing quantity etc. line wise and area wise.

Make sure that all the Quality control and Pre-Construction formalities, approvals, and
preparations are done sufficiently in advance to start the construction activity as per
the schedule.

A checklist of all requirements shall be made internally to avoid any omission of them.

All equipment to be used in the work should be initially checked and approved by
Evonik / Sembcorp authorized personnel.

Positioned the trailer near the designated area and proper and adequate clearance
should be maintained between the fence and the trailer

Trailer must be secured with hand breake.

Working area shall be barricaded with proper devices & warning signs to display.

Unauthorized person are not allowed in the area barricaded off

Workers shall wear appropriate PPE for the task.

Safety Coordinator & supervisor shall be present at all time during work activity.

10.2 Work Execution Method


10.2.1 Lifting Work:
All lifting tools, equipments and ropes used for lifting shall be inspected and certified
by WSH regulations. Activities shall be done according to the proper method
statement for lifting.

Submit method statement and RA for review and approval by Evonik / Sembcorp
before commencing the mentioned work.

Apply the lifting permit before work commence. Lifting supervisor will conduct tool
box and brief the safe lifting operation before work start.

Lifting plan shall be filled up and attached with load chart and LM certificate shall be
submitted during application for permit.

Prior to Lifting Works, it must have an approved Lifting permit and Lifting Plan.
Which indicate the type of cranes & lifting gears accessories indicated. The lifting
plan must be attached with the lifting permit and display in the lifting area.

Before starting the lifting work, the assigned people must wear proper PPE and
adequate safety procedure must be implemented.

All employee and worker involved in the work should first undergo training or safety
induction with Sembcorp

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WEC shall employ an experienced, competent and responsible Lifting supervisor to


plan and execute lifting operations.

Barricade the marked location scheduled for lifting operation with safety signages.

To Provide safe work during lifting of pipes, there are consideration which take
according to weight of the pipe.

The site supervisor should prepare the site area to be clean and clear from obstruction.

Positioned the LorryCrane / Mobile Crane near the designated area and steel plate
should be place over the landed of the crane out-rigger.

Positioned the trailer near the designated area and proper and adequate clearance
should be maintained between the fence and the trailer

Trailer must be secured with hand breake.

Repeat the process until all materials were unloaded.

Safety equipment must always present and ready for immediate use.

Care must be taken such that the boom cannot hit the pipe rack.

For more details for lifting please refer the doc: SUTS-SA2-MSRA-4-001.

10.2.2 Piping Work:


Submit method statement and RA for review and approval by Evonik / Sembcorp
before commencing the mentioned work.

Apply the Hot work permit before work commence. supervisor will conduct tool box
and brief the safe hot work operation before work start.

Prior to hot work initiation, it must have an approved hot work permit and location
plan. The hot work permit must display in the hot work area.

Before starting the hot work, the assigned people must wear proper PPE and adequate
safety procedure must be implemented.

All employee and worker involved in the work should first undergo training or safety
induction with Sembcorp

All tools and equipments used for erection shall be inspected and certified by WSH
regulations. Activities shall be done according to the proper method statement for
Piping installation and erection works.

Pre-fabricated spools shall be shifted to site carefully; care shall be taken while
handling and stacking of spools to prevent any possible damage.

The Pre-Fabricated spools shall be identified by spool and line numbers before
erection.
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Before erection of spools ensure for inside cleaning of the spools and their items.

The pre-fabricated supports shall be installed as per drawings, the pipe supports details
shall be followed in the piping layout drawings and Isometric drawing for location and
supports detail drawing.

All pipe openings shall be sealed before, during and after erection to prevent the
ingress of moisture and foreign matter. Threaded ends shall be plugged and sealed by
waterproof grease tape or purpose made plastic caps or plugs. End cap or cover shall
be placed on the open valve ends.

Erection of spools shall be carried out area by area as per piping layout drawings and
Isometric drawings.

Approved and safe scaffolding and temporary platforms shall be arranged to carry out
erection, fit up and welding of field joints at elevated positions.

Erect the spools in position using crane or other lifting devices as per the drawings.

Safety equipment must always present and ready for immediate use.

Shifting of pipe spool on pipe racks should be done on the roller support if required.

Piping installation on pipe rack shall be from lower level to higher level.

Joints shall be aligned and complete the fit-up / welding as per applicable WPS,
Isometric drawing and Project specifications

NDT and other inspection shall be completed for the field joints and recorded
properly.

The final correction and modifications made to fabricate spool in order to allow for
stress free installation, which should include; adjustment to pipe support, adjustment
of flanges where free spaces are available in bolt holes, cutting and re- welding or
introduction of additional field joints or fit-up pieces.

10.2.2 Pipe Supports


Fabrication and installation of all pipe supports, hangers, guides and other support
attachments shall be done in accordance with the details in the clients drawings.

Welding preparations for the pipe to pipe supports and structural steel welding for pipe
supports shall be in accordance with corresponding WPS

All pipe support shall be individually indentified by number and this number shall be
marked on the piping layout plans.

A 6 mm weep hole shall be drilled for dummy supports and shall be located near the
base plate for all vertical dummy supports, and near the run pipe at 6 oclock position
for all horizontal dummy supports.

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10.2.3 Flange Connections


All flanged connections shall be made using fully threaded stud bolts and nuts. A
minimum of one complete thread shall protrude from the nut after completion of
tightening.

All temporary gaskets shall be identified by color coding on their handles exposed.

All bolt heads shall be assembled from the same side. A logical sequence of Bolt
tightening shall be followed.

Special attention shall be given to ensure that in line items such as orifice flanges,
spectacle blinds, valves, strainers etc. are installed and oriented correctly as indicated
on isometrics and drawings.
Flange bolt holes shall be oriented as follows, unless otherwise indicated on the
construction drawings:

Flange face vertical- Bolt holes to straddle vertical centerlines

Flange face horizontal- Bolt holes to straddle horizontal centerlines

10.3 Associated Activities:


10.3.1 Welding
Before starting welding, the assigned people must wear proper PPE and adequate
safety procedure must be implemented.

The work area should be pre-tested to confirm there is no hazardous gas (eg. H 2S,
CO2, LEL ), before to carry out any welding work.

To provide adequete spark prevention measure at specific work area.(eg. Fire booth)

A fire watchman must be appointed on the work place to monitor the potential fire
hazard due to welding work.

Fire extinguisher must be placed in the work area.

All welding electrodes shall be kept in required condition in both storage and welding.

The ends to be welded shall be properly cleaned to remove paint, oil, grease, rust,
oxides, sand, earth and other foreign matter. The ends shall be completely dry before
the welding.

On completion of each run, craters, welding irregularities, slag etc., shall be removed
by the grinding and chiseling. Separate grinding wheels and wire brushes should be
used for Carbon steels & stainless Steel.

The welding work piece shall be shielded against high winds and rain.

The welding face shall be prepared in such a way that, the face must be cut and grind
smoothly and the imperfections (Slots, spatters, surface oxide due to cutting and
rusting) shall be removed from the welding area

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The pipe line joints shall be aligned as accurately as possible and the pipe must be
supported properly to avoid bending and displacement during welding.

The fit up joint shall be welded after checked by the QC inspector for acceptance and
registered.

All branch connections shall be joined to headers with full penetration welding. The
bore side shall be ground smooth, free from cracks.

Welding shall be done as per approved WPS for the particular piping. Welding
consumable shall be checked before starting of welding.

Each weld layer shall be cleaned before starting to weld next layer. The cleaned area
shall be free from slag. Any visual defects like cracks, pores, spatters weld shall be
removed by grinding before the next layer is applied. The ends of weld layer shall be
removed by grinding at take-up points of each weld.
Appearance of finished weld shall be as even as possible and free from spatter, under
cut, cracks, excess reinforcement etc. with reference to ASME B31.3 and relevant
WPS.

All parts that may be affected by the welding operations, such as accessories,
insulation joints and such, shall be adequately protected.

For flange to pipe connections if welding shrinkage can lead misalignment, two
similar flanges shall be joined by inserting a temporary gasket and then welded.

Where internal misalignment exceeds 1.6mm, internal trimming after approval from
the Company shall be done in accordance with ASME B31.3.

10.3.2 Pre-Heating
Preheat for the various grades of materials shall be in accordance with the specified
Welding Procedures and Specifications

Wet joints shall be dried by burner heating for a distance of 100 mm from the weld
joint and shall be warm to the hand before welding unless a greater pre-heat
temperature is required.

Temperature-indicating crayons, thermocouples, or calibrated contact pyrometers shall


be used to measure preheat and interpass temperatures.

The preheat temperature shall be established over a minimum distance of 75 mm on


each side of the weld.

11. HEALTH, SAFETY AND ENVIRONMENT

WEC HSE Manager shall ensure that the work is performed accordance to the approved
Construction Safety Manual and precautions specified in the work permit. He shall
ensure that barricades, warning tapes, warning signs, firefighting equipments and first
aid kits are readily available at the working area.
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Tool box talk shall be conducted on a daily basis to inform the workers of the recent
safety issues and incidents and to get feedback of any unreported unsafe acts. Feedback
will then be processed and resolved.
11.1 Safety Procedures
Area shall be barricaded adequately with warning signs.

All Equipments and tools shall be checked for good conditions before commencing the
work.
Unauthorized persons shall be excluded from the area.

Adequate caution boards and warning signs shall be provided.

On completion of job, the area shall be cleared of any materials and keep clean and tidy.

Hazard analysis for hazardous operation shall be carried out prior to commencing the
works.
12. ATTACHMENT

1. ITP.
2. Certificates.
3. RA

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