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EMPLOYER:

QATAR RAILWAYS COMPANY


P.O. BOX 29988
Doha State of Qatar

CONTRACTOR:

P.O. Box 31412


Doha State of Qatar

LEAD DESIGNER: SUBCONTRACTOR:

P.O. Box 24656


P.O. Box 22403
Doha State of Qatar
Doha State of Qatar

2 2017-16-05 SOLB26 IFA DZU 3rd Issue

1 2017-16-03 SOLB26 IFA DZU 2nd Issue

0 2017-12-03 SOLB26 IFA DZU First Issue

Rev. Date Issue Review Approval Description


(YYYY-MM-DD) Subcontractor Contractor Contractor

PROJECT:

RED LINE SOUTH UNDERGROUND


Contract No.: RTC/039/2012
TITLE:
METHOD STATEMENT FOR FABRICATION OF
Qatar Rail, Red Line South Underground -
Entrance Shelters and Pop-Ups

M 0 0 3 S L B S T S M E S 0 0 0 0 1 2
Project Code Organization Code Discipline Code Document Type Sequence No. Rev.

DOCUMENT INFORMATION (TO BE FILLED BY ISSUER)

M003-QGD-QMS-FRM-00038 Rev. 5 Date of Form: 2015-12-03


METHOD STATEMENT FOR
FABRICATION OF
RED LINE SOUTH Qatar Rail, Red Line South Underground -
UNDERGROUND Entrance Shelters and Pop-Ups
Date: 16.05.2017 Codification: M003-SLB-STS-MES-00001 Rev: 2 Page 2 of 79

WBS SECTION OF
RSSTNNN
WORKS
WBS MAJOR WORKS ARCHITECTURAL FINISHES
PROJECT STAGE CONSTRUCTION
DESIGN STAGE IFC

SUMMARY OF DOCUMENT CHANGES

Page Chapter Modifications


Appendix
37 Intervention Points revised.
B

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METHOD STATEMENT FOR
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UNDERGROUND Entrance Shelters and Pop-Ups
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METHOD STATEMENT FOR
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UNDERGROUND Entrance Shelters and Pop-Ups
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SUBCONTRACTOR REVIEW AND APPROVAL PROCESS

Name Position Date Signature

Subcontract Company Name


or
Comments:

REVIEW PROCESS

Name Position Date Signature

Comments:
HSE

Name Position Date Signature

Comments:
QA/QC

Name Position Date Signature

Comments:

Engineering

Designer Review YES Name of


necessary? NO Designer:
YES
DVE Review necessary?
NO
Temporary Works Manager Review YES
necessary? NO
Other Review YES Name:

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METHOD STATEMENT FOR
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UNDERGROUND Entrance Shelters and Pop-Ups
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necessary? NO
REVIEW PROCESS

Name Position Date Signature

Company Name
Comments:
Designer

Name Position Date Signature

Company Name
Design
Comments:
Verification
Engineer

Name Position Date Signature

Comments:
Temporary
Works
Manager

Name Position Date Signature

Company Name
Other Comments:
Review

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METHOD STATEMENT FOR
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UNDERGROUND Entrance Shelters and Pop-Ups
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Contents

1.0 INTRODUCTION .............................................................................................. 7


2.0 REFERENCES, DEFINITIONS AND ABBREVIATIONS .................................. 7
3.0 PERMITS.......................................................................................................... 8
4.0 QA CLASSIFICATION OF MATERIALS ........................................................ 10
5.0 CONTROL, STORAGE, PROTECTION OF SPECIFIC MATERIALS ............. 13
6.0 PLANT AND EQUIPMENT ............................................................................. 15
7.0 METHODOLOGY, CONSTRUCTION ............................................................. 16
8. QUALITY MANAGEMENT ............................................................................. 28
9. HS MANAGEMENT AND ENVIRONMENTAL MANAGEMENT ..................... 28

Appendices

Appendix A Organization and Responsibilities


Appendix B Inspection and Test Plan and Checklist (ITP)
Appendix C Health, Safety, Environment Risk Assessment
Appendix D Work Programme
Appendix E Dimensional Tolerances (Annex D) as per EN 1090

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METHOD STATEMENT FOR
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UNDERGROUND Entrance Shelters and Pop-Ups
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1.0 INTRODUCTION

1.1 Purpose
This method statement describes the techniques and methods to be
implemented and the resources to be utilized for the Fabrication of Structural
Steel works for Qatar Rail, Red Line South Underground - Entrance Shelters and Pop-
Ups

Works described herein will be carried out by Subcontractor (SOLB26) under the direct
supervision by QDVC. The interrelation between
QDVCs and Subcontractors organization chart is shown in Appendix A together with
the list of Roles & Responsibilities of both. By subcontract, S/C is bound to strictly
follow and implement this MS.

To ensure effective implementation of this MS, the relevant ITP shall be read in
conjunction with the MS and shall accompany this document (refer to Appendix
B).

The purpose of this method statement is to define the rules and enable the site
personnel to be aware of all the procedures and hazards involved and to plan for a
safe method of work.

1.2 Scope

This method statement describes the methods and procedures to be adopted for
the Structural Steel Works for Qatar Rail, Red Line South Underground -
Entrance Shelters and Pop-Ups.

The MS scope of works includes the following:

i. Fabrication of Structural Steel Members


ii. Corrosion Protection of Steel

2.0 REFERENCES, DEFINITIONS AND ABBREVIATIONS

2.1 References

The following documents define the requirements to be employed to demonstrate


compliance of the works defined in this method statement:

Project Quality Management Plan


Inspection and Testing Procedure

2.2 Standards and Specifications

Qatar Construction Specifications 2010

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BS-EN-ISO Standards
EN 1090-2, Execution of Steel Structures (EXC3: Quality level B as per BS EN
ISO 5817)
EN 1993-1-8 Part 4 Welded connections
EN 1993-19 welds subject to fatigue principles

2.3 Definition and Terms

QDVC-GS E&C-AL Darwish Engineering JV Main Contractor


QATAR RAIL: Qatar Rail Company Employer
SOLB26: Steel Construction Subcontractor

2.4 Abbreviations

QCS 2010 - Qatar Construction Specifications 2010


QHSE - Quality, Health, Safety and Environment
QA/QC - Quality Assurance / Quality Control
ITP - Inspection and Test Plan
PPE - Personal Protective Equipment
SONO - Statement of No Objection
QAM - Quality Assurance Classification of Materials
MS - Method Statement
N/A - Not Applicable
MLPA - Main Logistics & Production Area
S/C - Subcontractor
WP - Work Procedure
TBC - To Be Confirmed
MSDS - Material Safety Data Sheet
IFC - Issued for Construction
WPS - Welding procedure specification
NDT: Non-Destructive Testing
UT: Ultrasonic Test
SSPC: Society for protective Coating
CNC: Computerized Numerical Control
PMT: Photo-multiplier Tube
SMAW: Shield Metal Arc Welding
FCAW: Flux-cored Arc Welding
MIG: Metal Inert Gas
SAW: Submerged Arc Welding

3.0 PERMITS

All the necessary licenses, permits and approvals required in the execution of the activities
will be obtained prior to commencement of the work.

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Stakeholders:

Approval Permit to Work


Stakeholder
required required
Kahramaa Electricity NO NO
Kahramaa Water NO NO
Ministry of Municipality And Urban NO
NO
Planning
Ministry of Environment NO NO
Ashghal Road Affairs NO NO
Ashghal Drainage Affairs NO NO

Ashghal Road Operation and NO NO


Mantainence Department
Traffic Department NO NO

Ooredoo NO NO

Qatar Petroleum NO NO

Qatar Gas NO NO

Doha International Airport NO NO

Qatar Museum Authority NO NO

Note: For land allocated to Qatar Rail, only Qatar Rail Permit is required.

Internal Permit:
Lifting
Working at height
Hot works
Work at night

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4.0 QA CLASSIFICATION OF MATERIALS

The main material suppliers used in this works or package is as follows:

Material(s) QA Classification
Fabricated Structural Steel members Steel grade
QAM1
S275JR (BS Standard)
Welding Consumables QAM1
Bolts QAM1
Shear studs/Anchor bolts QAM1
Primer Paint/Coating QAM1

QAM1 Materials that must be submitted to the QDVC-GS E&C Darwish Engineering JV
for approval and to Engineers Assistant for SONO.

QAM2 Materials that must be submitted to the QDVC-GS E&C Darwish Engineering JV
QC for approval.

4.1 Material Supply

The quality of material should be according to design specifications and IFC drawings.
The grade of structural steel shall conform to the project specifications as noted on the
IFC drawings with minimum yield strength as per specified therein.

The steel shall be free from mill scale, surface defects, flaky rust, slag inclusions,
laminations, pitting and be of full weight or thickness within tolerances specified in
standard.

Approved (Material Submittal with SONO from Engineers Assistant) steel material will
be used. As a normal standard mill certificate will be available for steel ordered.

Material for this project shall be marked so that identification is facilitated. All
identification and marking system shall be established. All steel material procured shall
be properly documented to ensure conformity to specification and it shall be the
responsible of the control foreman or staff to ensure conformity of steel to the
specifications.

4.2 Material identification and traceability

After receipt of raw material warehouse responsible person shall verify the material
and forward the raw material inspection report to quality acceptance. Project engineer
will inspect the raw material and verify the heat number for punching as per
identification and traceability procedure. Refer project specification and quality plan.

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The fabrication engineers / foreman shall be responsible to arrange to mark the item
number and punch the material code number on each member.

(a) Material Qualities (QCS 2010 for reference)

i) Material shall be steel in rolled sections, structural hollow sections, plates


and bars and shall comply with the appropriate standard shown in Table
2.1.
ii) The steel designations used in this publication are those given in BS 5950.

b) Material Testing

i) All steel shall have been specifically tested in accordance with the
appropriate material quality standard shown in Table 2.1 (for reference).
ii) Material testing shall be carried out as per QCS 2010. ASTM A36 or
equivalent material shall be tested.

c) Test Certificates

i) The Contractor shall obtain the manufacturer's test certificates and submit
them to the Engineers/Engineers Assistant for review. All steel to be used
in the Works shall have a test certificate.

ii) Dimensions and Tolerances

Dimensions and Tolerances shall comply with the appropriate standard


shown in Table 2.1 (for reference).

Table 2.1 - Material and Dimension Standards

Dimension
Form Material Quality Dimensions
Tolerances

U.B and U.C BS 4 : Part 1


Joists BS 4 : Part 1
Channels BS EN 10025 BS 4 : Part 1
Angles BS 4848 : Part 4 EN 1090 - 2
Clause 11.2.2.1
Plates and Flats Not Applicable
Structural
Hollow Sections BS EN 10210 BS 4848 : Part 2
Hot Finished

Hollow Sections EN 1090 - 2


BS 6363 BS 6363
Cold Finished Clause 11.2.2.3

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Galvanized
EN 1090 - 2
Open Sections BS EN 10147 Not Applicable
Clause 11.2.2.5
and Strip

Welding Consumables EN 10025 Not Applicable EN 1993

Notes:

1. Material quality requirements for Fine Grain Steels are given in EN 10113 Material
quality requirements for Weather resistant grades are given in EN 10155.

2. BS EN 10210-1 contains material quality requirements for Non-alloy and Fine Grain
Steels.

3. Tolerances for plates cut from wide strip produced on continuous mills are given in
BS EN 10051.

4. All structural steelwork, including structural fasteners and welding consumables etc.
shall comply with the EN 1993 and EN 10025.

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5.0 CONTROL, STORAGE, PROTECTION OF SPECIFIC MATERIALS

Materials requiring storage prior to being incorporated in the works shall be


stored and protected as per the materials MSDS.

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METHOD STATEMENT FOR
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UNDERGROUND Entrance Shelters and Pop-Ups
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All steel supplied shall be stored in a safe condition with proper care take
during storage to ensure that no damage occurs, which renders the materials
unserviceable. All steel material shall be stored at the shop/yard above the
ground on the platforms, skids or wooden pallets or concrete blocks.

5.1 Stacking

Fabricated components which are stored prior to being transported or erected


shall be stacked clear of the ground and arranged if possible so that water
cannot accumulate. They shall be kept clean and supported in such a manner
as to avoid permanent distortion.

5.2 Visible Markings

Individual components shall be stacked and marked in such a way as to ensure


that they can be identified.

Upon arrival of materials at the storage yard, the assigned material controller
will match delivery notes and shall verify the consignment. The material
controller, then, report to the site supervisor the received material list and
quality condition.

Unloading can be done manually or with cranes. A spreader should be used for
lifting long components. Lifting nylon or cloth belts with suitable SWL shall be
used for unloading the materials to minimize the damage. Be sure to hook belts
to component with the right no. of points and position so that the load of
component itself do not damaged or broken.

Proper planning of material delivery would minimize storage requirement and


additional handling from the site storage, particularly heavy items.

Before erection the fabricated materials should be verified at site with respect to
mark numbers, key plan and shipping list.

Safe transportation of fabricated items to the site, their proper storage and
subsequent handling are the pivotal processes for the success of fabrication of
structural steel work.

All materials receipt at site shall be visually inspected by site supervisor for any
damage. Remedial works to the damage shall be taken immediately, if
possible, to avoid any delay to erection.

To avoid materials being moved so much on jobsite that might cause


unexpected damages of paint, shapes, when material delivered to job site, they
must be unloaded and arranged closed to the designed erection point. Up to
The materials shall be stacked in locations according to the building/areas,

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should be near to the lifting position adjacent to the area to be erected. This is
to facilitate the sorting and delivery during the erection.

6.0 PLANT AND EQUIPMENT

All equipment to be used in this work will be inspected and approved by JV Plant Inspector
prior to commencing the work. If required, a third party inspection shall be performed by a
licensed inspection body. All equipment to be used shall be 5 years old or less as per the
Project Requirements.

A regular maintenance schedule will be followed and conducted by the subcontractors


competent mechanics and technicians to ensure that the equipment is well maintained and
serviceable.

Main Equipment:

Equipment / Plant Nos.

1
Mobile crane

Boom Lift 2

Built-up section machine 1

CNC plate cutting machine 1

Compressor 2

Welding Machine As required

Generator As required

Overhead crane 3
Plate Bending Machine
1
Shot Blasting Machine
2
Telehandler
1
Forklift
1
Trailer
2

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Under hung monorail crane


1
Permanent magnetic lifter
1
Grinder
As required

Instrument / Auxiliaries Nos.


Survey instrument As required
Hand tools As required

The above-mentioned work equipment and machinery quantities will be subject to change to
suit the site requirement and meet the work programme. Complete standby plant &
equipment will be made available at all time for immediate replacement in case of equipment
failure.

Inspection certificates for all heavy equipment will be checked and obtained where required
before allocation of machinery. These certificates will be maintained by the Plant
Department as QA/QC and HSE records. All drivers/operators must hold the required valid
driving/operation licenses.

7.0 METHODOLOGY, CONSTRUCTION

7.1 General

All personnel that will be required to work on site will attend safety induction and
method statement briefing prior to the start of works. Inducted workers will be issued
with QDVC-GS E&C Darwish Engineering JV ID cards. Lifting and/or installation by
mobile crane shall be executed with an approved QDVC-GS E&C Darwish Engineering
JV HSE and in accordance with Work Procedure ).

Prior to commencement of activities under the Scope of Works, SOLB26 shall convene
a kick off meeting with QDVC-GS E&C Darwish Engineering JV Construction Team,
Subcontractors, QA/QC, and HSE team. A separate task launch meeting shall be held
as indicated in the Inspection and Test Plan to address the job hazards related to the
Works.

SOLB26 will coordinate with other Contractors and/or Subcontractors working at the
Site to discuss possible clashes with the existing or future utilities at site. There will be
no works to be executed by other Contractor or Subcontractors at the same time within
the zone where SOLB26 is erecting structural steel.

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METHOD STATEMENT FOR
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Relative steel works shall be in accordance to QCS 2010 Section 16.

7.2 Sequence of works

SOLB26 will execute the fabrication of structural steel works for Qatar Rail, Red Line
South Underground - Entrance Shelters and Pop-Ups in the manner identified in the
flowchart:
Kick off meeting between all
parties referenced in Sec 7.1

Task Launch meeting between


all parties referenced in Sec 7.1

Fabrication Process Inspection

Dimensional Inspection Fabrication and


Inspection
(Allowable Deviation) Protection
(Primer paint)
Protection
Inspection
(Blasting and Primer Paint)

7.2.1 Fabrication Process

The fabrication of steel works shall be carried out as per approved IFC drawings and
specifications.

7.2.1.1 Cutting plans

The cutting plan shall be prepared for the material before commencement of fabrication
work. Material mark number shall be provided for easy identification.

7.2.1.2 Marking

Marking shall be carried out as per cutting plan under the guide lines of
fabrication foremen and subsequently verified by the fabrication engineer
prior to cutting. Prior to marking the material shall be checked for its
identification and defects. Necessary items shall be carefully and accurately
marked in accordance with approved IFC drawings.

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7.2.1.3 Cutting

Marking cutting shall be carried out either by shear, plasma, laser cutting,
CNC profile cutting and drilling machine. The edge of all plates shall be
perfectly straight and uniform throughout. Cut edges shall be visually
examined for laminations and inclusions. All corners shall be shaped so as to
be notching free, sheared for field shall be done in the shop.

7.2.1.4 Straightening

All steel material shall be straight and free from bends or twists. If the sections
are distorted or twisted during transit, storage etc. they shall be straightened
and/or flattened by straightening machine at ambient temperature, though
minor bends may be corrected by limited heating under supervision.

Procedure No. S26-QC-PRO-034 Remedial Procedure

7.2.1.5 Bending

The bending of plates and sections to specially required shapes shall be done on appreciate
machine. No distortion shall be allowed. Distorted elements should not be used or repaired.

7.2.1.6 Holes

Punching and or drilling shall be done accurately as per the drawing and burrs
removed effectively. The holes shall be drilled / reamed within the allowable limits
specification in project specification. Holes for bolts shall not be formed by a
gas cutting process.

7.2.1.7 Notches

The ends of all joints, beam and girders shall be cut truly square unless
required otherwise and joist flanges shall be neatly cut away or notched
where necessary, the notches being kept as small as possible.

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7.2.1.8 Assembly

Structures shall be assembled in jigs or on suitable surface plates with proper


layouts. The parts to be joined groove welds shall be brought into correct
alignment. The members to be welded shall be held in the correct position by
bolts, clamp and wedges where practicable. Any wedges used to space root
gaps shall be removed from the root gaps immediately after tack welding and
before making the root run. After completion of joint fit-up, QC inspector will
check the fit-up and he will release the joint for welding.
The fabrication components shall be assembled in such a manner that they
are neither twisted nor otherwise damaged. In order to minimize distortion in
a member the components shall be positioned by using clamps, clips, jigs
and other suitable manner and fasteners shall be placed in a balanced
pattern.

If necessary items like roof trusses shall be trial assembled as per approved
assembly drawing keeping in view the actual site condition prior to dispatch
to site for erection, so that they can be conveniently pre - assembled before
erection. Necessary match marks shall be made on these components before
disassembly in the shop and dispatching.

7.2.1.9 Welding

Welding procedure approval and welders qualification and welding


operations performance qualification test shall be made in accordance with
AWS D1.1.

7.2.1.10 Edge Preparation Inspection

The edge or surface of parts to be joined by welding shall be uniform, smooth


and cleaned from all foreign materials such as moisture, slag, oil, grease,
paint, scale or rust. Edge preparation shall be verified for proper groove angle
and root face dimensions. Welding groove dimension shall be inspected as
per IFC drawings under tack-welded condition prior to welding. The allowable
misalignment of adjoining plates to be butt- welded shall be in accordance with relevant
standards.

7.2.1.11 Fit-up Assembly

The member or plates to be welded are fit-up aligned and retained in position
to welding operations. The location of integral parts / members to be
assembled shall be checked dimensionally prior to full welding. Tack welds
shall be used for secure alignment. Generally, the tack welds shall be subject

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to the same quality requirement as the final welds unless otherwise specified.
Tack welds containing any cracks shall be removed thoroughly and replaced
with sound track welds. Size and location of tack welds based on
specification.

7.2.1.12 Backing Strip Inspection

Back-stripped surface shall be visually checked for roof gap prior to start welding

7.2.1.13 Welding Process

The following practices shall be used for welding:

Run-out and run-off plates shall be welded at the ends of weld lines of crucial butt
welds
Prior to welding the surface to be welded and filler material to be used shall be
checked
Prior to welding root opening, groove angle and crucial dimension shall be checked
and groove face shall be free from oil, water and dirt
Prior to welding the welding current shall be measured the most appropriate welding
condition (current & Voltage) shall be maintained with ammeter and voltmeter
throughout welding work
All welding is to be carried out in an approved environment and if necessary,
additional protection may be required. All joints are to be dried before welding in
damp climate condition
During welding work, the most appropriate arc length, angle and welding speed shall
be maintained so that welding defects shall be avoided and arc energy requirement
are satisfied
Fillet weld terminating at the end of members shall be returned continuously around
the corner for the distance of not less than twice the size of the weld
Surface of butt joint required to be flush shall be finished so as not to reduce the
thickness of the inner base metal or weld metal than 1mm or 5% of the thickness
whichever is the smaller not leave reinforcement that exceed 1mm
All reinforcement shall blend smoothly into the plate surfaces with transition areas
free from undercut
Chipping and gouging shall be used, provided grinding follows them
In the case of multi-layer welding, slags and spatters on each completed bead shall
be removed prior to the start of welding for the following layer
All craters shall be filled to the full cross section of the welds.

7.2.1.14 Type of Welding Process

All welding activity shall be carried out as per the approved welding procedure specification.

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The following welding process used in fabrication works:

MIG & MAG Process

SMAW Process

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FCAW Process

SAW Process

7.2.1.15 Electrodes

The electrodes used for welding shall be of suitable type and size depending
upon specifications of parent materials, the method of welding, the position
of welding and quality of welds desired. However, only low hydrogen

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electrodes (E7018) shall be used for plates and sections. All low hydrogen
electrodes shall be baked and stored before use as per manufactures
recommendation. The electrodes shall be baked and stored before use as
per manufactures recommendation. The electrodes shall be re-backed at
250C to 300C for one hours and later on cooled in the same oven 100C.
From baking oven the electrode shall be transferred to a holding oven
maintained at 60C - 70C. The electrodes shall be drawn from this oven for
use. Where coated electrodes are used they shall meet the requirement of
relevant standards, bare electrode and granular flux conform to relevant
standards. Where charpy V Notch values are required on the base metal,
an electrode meeting the requirement of BS-EN-ISO or AWS and having a
minimum average charpy v-notch impact strength of 25 ft, Ibs at -20c.

7.2.1.16 Preheat and Inter-pass Temperature

Preheating of above 65 degree C shall be applied for over 38mm thick of


S355JR, JO, J2 and K2 steel plate by means oxy-acetylene flame or noncarbonizing like
LPG while joined by partial or full penetration welds in tension the specified preheat
temperature and minimum inter-pass temperature shall be maintained during
welding progress. Thermo-chalk or other approved methods shall be used for
measuring the plate temperature.

Preheat shall be done uniformly on the surface at a distance of 4 times the thickness away
from the joint groove for t<50mm or at a distance of 75mm from joint groove preparation
from t>50mm on either side of the plate.

7.2.1.17 Sequence of welding (Control of Distortion and Shrinkage)

The sequence of welding shall be selected to ensure that the


components assembled welding is free from distortion and large residual
stresses are not developed.

In assembling and joining parts of a structure or of built up members


and in welding reinforcing parts to members, the procedure and sequence
shall be such as will minimize distortion and shrinkage.

In so far as practicable, all welds shall be deposited in symmetrical


sequence so that shrinkage on both sides of the structure will be equalized.

Joints expected to have signification shrinkage shall be welded before


joints expected to have lesser shrinkage and with as little restraint as
possible.

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METHOD STATEMENT FOR
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All shop splices in each component part of cover plate beam or built up
members shall be made before such component part is welded to other
components part of the member.

All welding shall be carried out continuously to completion or to a point


that will ensure freedom from cracking before the joint is allowed to cool
below the minimum specified preheat and inter-pass temperature.

Butt weld in flange plates and / or web plates shall be complete before the flange and webs
are welded together.

The ends of butt welds shall have full throat thickness. This shall be
obtained on all main butt welds by use of run off run on pieces adequately
secured on either side of main plates additional metal remaining after the
removal of extension pieces shall be removed by grinding or by gas cutting.

7.2.1.18 Visual Examination of welds

Each reinforcement height for butt welds and leg dimensions for fillet shall be checked in
additional to bead contour appearance. Also, possible presence of such service defects,
undercut, crack, surface porosity etc. shall be checked visually. The reinforcement on each
side of butt-welded joints shall be checked in accordance with relevant standards.

Temporary lugs brace and clips shall be welded in connection with Welding Procedure
Specifications (WPS) and these shall be removed without damaging the base metal and are
ground flash and smooth.

7.2.1.19 Procedure for Built Up Columns

Preparation of Material Marking of steel shall be done in accordance with the stop drawing
and cutting plan. Material cutting shall be carried out by gas. Either by pug cutting or CNC
machine to cut plates to the required sizes. The dimension and shape of the edges to be
joined by welding shall be checked as per approved drawing / specification. Surface and
edge preparation shall be free from loose scale, slag, grease, paint and other foreign matter.
Edge preparation shall be verified for proper groove and root face dimensions. Joint surface
shall be free from fins and tears.

Fit- up Assembly Built up Columns steel structural shall be assembled in jigs or on suitable
surface plates with proper layouts as per the drawing. Column bottom plate
will be kept at bottom and sides two vertical plates will be fit up with the bottom
plate by means of Butt weld joint. Stiffener plates will be provided at least
every 1 meter to avoid the distortion and to maintain the built up box column
sizes & shape. The top plate shall be fit-up with this two plates and complete
the fit-up of Built up box column by tack weld. After completion of full built up

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box column joint fit-up, S/C SOLB26 QC Inspector will check the fit- up and
release for welding.

Welding shall be carried out as per the approved welding procedure


specification (WPS) and welders. Run-on and run off plates shall be welded
at the ends of Built up Column Box section. Before welding start, joint shall
be smooth & free from dust or any other loose particles. Minimum inter-pass temperature
shall be maintained during welding progress. During weld most appropriate arc length, angle
and welding speed shall be maintained so that welding defects shall be avoided.

In the case of multi-layer welding, slags and spatters on each completed bead
shall be removed prior to the start of welding for the following layer. After
completion of welding all temporary lugs, Run-on and run-off plates shall be
removed without damaging the base metal and the area ground flash and
smooth. All welding area shall be clean and inspect as per specification. After the
completion of inspection and test for Built-up box column release it for further activities.

7.2.1.20 Non- Destructive Testing (NDT)

Non- destructive testing shall be performed as follows:

NDT FREQUENCY TABLE

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All third party inspection Agency shall be engaged as independent and


approved testing and inspection agency to carry out the UT and MPT on weld
metal (if there is project specification)

General Requirement of Visual Inspection Weld visual inspection shall be carried by


fabrication engineers or certified welding inspector as per approved standards for
external defects like, surface porosity, under cut, excess penetration, and overlap,
lack of penetration or incomplete fusion and fillet sizes.
General requirements of Liquid penetrant testing (PT) Liquid penetrant testing
procedures shall be in accordance with ASTM 165 or approved standards. This test
shall be carried during the welding process while back gouging. The evaluation of

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METHOD STATEMENT FOR
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indications and the acceptance criteria shall be in accordance with sec 8 Div. 1
ASME code or relevant EN-ISO standards.
General requirement of Magnetic Particle Testing (MT): Magnetic particle testing
procedure shall be in accordance with approved Standard. The Evaluation of
indication and the acceptance criteria shall be in accordance with approved
standards. Independent testing authority MPI reports shall be obtained for fillet
welds.
General requirement of ultrasonic test/examination (UT): The ultrasonic testing of
plates for lamination shall be in accordance with SA 435 and UT of Butt joint shall be
in accordance with approved standards. Independent testing authority UT reports
shall be obtained for all butt joints.

7.2.2 Dimensional Inspection

The fabricated steel structural shall be inspected in accordance with respective approved
fabrication drawing and specification. Overall length, orientation, diagonal measurement and
all other dimension shall be verified and recorded. If dimensions are not with required
tolerance the member shall be corrected prior to further process.

All dimensions shall be recorded in approved format. 100% visual inspection shall be carried
out for external defects. QDVC-GS E&C Darwish Engineering JV QA/QC shall conduct the
final inspection and review all inspection reports and prepared as inspection and test plan
(ITP).

7.2.3 Protection (Primer Paint)

7.2.3.1 Blasting (Surface Preparation)

Abrasives for blast cleaning shall be clean, dry and free of any constituent.
Silica sand shall not be used. Surface preparation shall be in accordance with
ISO-8501-01 and technical data sheet of specified paint. Abrasive shall be
100% for shot and 100% for manual blasting. The surface grade quality and
finish shall be SA 2 (ISO 8501-1: 1988) or as recommended by
manufacturer. Surface profile shall be 40 to 70 microns, since too low height, prevent proper
adhesion and too high profile may lead to profile peaks protruding the coating resulting in
early pinpoint rusting. Paint shall be applied to dry, clean prepared surfaces under
controlled favourable weather conditions and in accordance with manufacture
data sheet.

7.2.3.2 Painting Application

Painting shall be applied as per the project & QCS 2010 Section 16
specification. Dry film thickness shall be checked prior to shipment to project
site and painting inspection reports shall be maintained. Preparation
generally shall comply with requirements SSPC and printed instruction of

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manufacturer. Check that all coating material to be used are recommended


by the manufacturers for the particular surface and condition of expose.
Painting shall be carried out with skilled workers. All coating materials shall
be applied evenly in coat free over-spray, dry-spray, wrinkling, sagging,
curtaining, holidays, thin spot, pinholes and other film defects.

7.2.3.3 Packing and Delivery

The painting structural after fabrication shall be protected from further


damage during transportation. The materials will be loaded on the trailers
using timber supports and separators and secured properly to prevent any
damage to the material while transportation to site. Fabrication items will be
delivered loose. Minor fabrication items, which are not likely to be subject to
permanent deformation during handling operation (i.e. bracing etc.) may be
bundled or hoped. Small items (i.e. bolts, loose, cleats etc.) will be packed in
crates / drums or loaded on pallets.

8. QUALITY MANAGEMENT

All works will be undertaken in compliance with the quality requirements of the Contract, and
Project Quality Management Plan.

All works requiring inspection and testing to demonstrate conformity with requirements will
be undertaken in accordance with the Inspection and Testing Procedure.

Where nonconformities are found / identified, they will be addressed in accordance with
Procedure for Control of Non-Conformances.

The quality control activities associated with the works will be conveyed to all personnel
involved in the execution of the works by the Project QA/QC and Construction Manager prior
to the commencement of the work.
The equipment and instruments used for measurements on site will be calibrated and
certified. The relevant documents will accompany the corresponding equipment and
instruments.

Necessary internal and external trainings shall be provided to the staff carrying out the job to
ensure that the quality standards required on the project are met. Skilled and competent
personnel shall be deployed to undertake the job.

9. HS MANAGEMENT AND ENVIRONMENTAL MANAGEMENT

9.1 Specific Health & Safety Requirements & Precaution Measures

d) General

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METHOD STATEMENT FOR
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The works shall be carried out in compliance with the applicable HS legal &
Environmental Legal and contractual requirements as well as Health and Safety
Plan.

Any emergency situations that may occur on site shall be dealt following the
procedures, responses and controls as described in the Emergency
Preparedness and Response Plan.

The significant HS hazards& Environmental hazards and risks related to the


works covered by this document have been identified, and documented in Risk
Assessment.

The environmental hazards and risks shall be identified and documented in


accordance with the HS and Environmental Risk Assessment Plan.

The identified hazards and associated risks and mitigation controls shall be
communicated to the workforce through registered Pre-task briefings at the
beginning of each shift.

Works shall be carried out according to the requirements of the various


applicable statutory regulations related lifting and handling heavy equipment and
shall safeguard operators and others who may from time to time be in the vicinity
of works from all avoidable hazards.

e) Personal Protective Equipment

The minimum PPE as per the project HS Plan that all personnel involved in the
works will wear as follows:

i) Safety Helmet (helmets color as specified in contract documents).

ii) Safety Boots.

iii) Safety Rope.

iv) High Visibility Vest (orange color).

v) Protective eye wear (glasses)

vi) Gloves

vii) Any other PPE deemed appropriate and/or necessary.

Personnel not directly involved in physical work who are visiting the site must
also wear all the required personal protective equipment at any time they are

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METHOD STATEMENT FOR
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outside of their vehicle, with the exception of gloves, which are discretionary.
Personnel who are visiting the site but not leaving the PPE free designated
areas which, if present on the site, will be clearly defined by signs and barriers
(typically around the offices and car park), are not required to wear PPE (but it is
recommended, especially protective eye wear).

f) Manpower

Safety and Health induction shall be conducted by the JV Health & Safety
Department prior to commencement of works to each person involved in works.
All operators involved in the works execution and the workers undertaken critical
tasks shall be competent and certified to undertake the works. The drivers shall
hold a valid Qatari license. All workers will receive a daily briefing around the
works they are to undertake that day.

All personnel shall wear the required Personal Protective Equipment (PPE) in
accordance with the Health and Safety Plan.

The Site Engineer is responsible for the job and will be present at site during
working hours and a Safety Officer as well to monitor all activities.

Any incident, injury and near miss will be reported immediately to the Safety
Department and Site Manager.

The welfare facilities (see Health and Safety Plan) for the site works including
drinking water cooler, shaded area, workers toilet blocks, dedicated smoking
area, emergency standby vehicle will be established prior to commence the
works.

(d) Plant and Equipment

All plant and equipment shall be inspected by the JV Plant & Equipment
department prior to start the work.

The subcontractor will also practice a daily visual inspection to all plant and
equipment. A pre-shift visual inspection must be contacted and recorded as per
the equipment checklist. For plant and equipment inspection, refer to Plant and
Equipment Inspection & Maintenance Procedure.

The following will be ensured as a minimum:

(i) All equipment shall have valid certificate and inspections.

(ii) Plant/ machine operators will have all round 360o visibility at all times.

(iii) Regular maintenance of plant will be carried out as per manufacturer


recommendation.

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METHOD STATEMENT FOR
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(iv) Plant movement and operation will be coordinated and managed to ensure
safe and efficient operation.

(v) All persons on site will be briefed on the hazards of working adjacent to
traffic or in the vicinity of moving plant/ equipment & instructed to maintain
eye contact at all times with machine / vehicle operators.

(vi) No sleeping or resting will be allowed underneath stationary plant/


equipment or vehicles.

(e) Access / Egress on Work Site

Only authorized personnel will be permitted to enter the work site. Upon arrival at
site the following checks will be made and any non-compliance will result in that
person being prevented from entering the work site:

(i) Evidence of receiving site specific safety induction (register of attendance/


helmet sticker)

(ii) Appropriate Personal Protective Equipment (PPE)

(iii) All staff shall have their ID card with them at all times, as evidence of site
induction and competence.

At the end of each working day all access to the work site will be secured. A
night time patrol will ensure that the work area is secure and that safety
precautions are in place. The following will be ensured as a minimum:

1) Access / egress routes shall be clearly defined by designated walkways/


traffic routes/ loading-unloading areas, signage/barriers & lighting.

2) Access / egress routes will not be blocked as a result of the work.

3) Vehicle traffic routes will be maintained as two-way street.

(f) Emergency Preparedness

(i) All accidents/incidents and near misses shall be reported immediately to


site management of QDVC and Qatar Rail/Engineers Assistant

(ii) In the event of a serious accident the area will be segregated off and a full
investigation will be carried out with initial report submitted to QDVC within
24 hours.

(iii) JV personnel will meet the emergency services at the site entrance and
escort them to the scene of the accident.

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METHOD STATEMENT FOR
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(iv) Emergency contact names and mobile numbers are displayed in the site
office and rest areas.

(v) Fire extinguishers will be placed at designated points around the site office
and welfare areas.

(vi) Mobile Plant and Equipment will have fire extinguishers fixed in place.

(vii) Smoking will only be allowed in designated areas.

(viii) Trained first aiders will be available on site and first aid kits available in the
site offices.

(ix) Engineer, Supervisor and Foremen shall be supplied with complete set of
First Aid Kit to be kept inside their vehicle in order to give immediate
treatment in case of accident happen.

(g) Working at Night

In case night work will be carried out, the following should be ensured:

(i) Ensuring the availability of tower lights.

(ii) Checking the inventory of safety equipment to make sure they are
sufficiently available, appropriate and in good working condition. Retro-
reflective signage, barriers, cones, signage, reflective tapes and lighting
equipment will be provided for night time construction works.

(iii) Large machinery movement will be directly supervised.

(iv) Housekeeping. Proper storing of tools after use.

(h) Medical / First Aid Facilities

Prior to the commencement of work, confirmation will be made that all


appropriate and required first aid facilities and trained first aiders are available on
the site and if necessary, shall be made available for prompt attention to the
injured person.

For minor injuries, JV's vehicle assigned to the job site will be used for
transporting injured persons to the first-aid station. If the person needs
transportation to hospital, an ambulance will be required.

(i) Site Security

Watchman will be kept full time on site for security purpose for the new gates
proposed under this document.

(j) Emergency Contact Numbers

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METHOD STATEMENT FOR
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The emergency contact numbers list shall be kept up to date at all times and
shall be displayed on site at such locations so as to be readable by all personnel.

All emergency contact numbers are included on the notification card and QDVC
badge given to all inducted working personnel.

(k) Special Environmental Protection Measures and Mitigation Measures

The Contractor will employ the best practical means to avoid nuisance and
disturbance to residents and the public. The Contractor should strictly adhere to
Qatar Rail Employers Framework Construction Environmental Management Plan
(CEMP-QR) and Contractors Construction Environmental Management Plan
(CEMP-C).

The significant Environmental hazards and risk related to the works covered by
this document along with the control measures for each hazard have been
identified, and documented in the Environmental Risk Assessment .

Accumulation of waste and disposal will be prevented by provisions of skips, as


per the Construction Environmental Management Plan and Construction Waste
Management Plan.

The dust suppression will be implemented in case there is excessive dust


generation during movement of vehicles on site, in accordance with the Dust
Management Plan.

For transporting/handling/delivery of materials and use of generator/tower lights,


environmental measures shall be implemented and in place (Secondary
containment or spill trays) in references to Material and Equipment Management
Plan.

In case of chemical spill on the ground, contaminated soil or material will be


removed immediately and store in the designated hazardous waste area. Refer
to Hazardous Material Management and Emergency Response Plan. Report any
spill incident to Environmental Manager for proper clean and disposal of
contaminated soil, materials and containers.

Noise management plan shall be as per Construction Noise and Vibration Plan.

Template: M004-FAY-DCM-TMP-00001-Rev.2 / August 2014


METHOD STATEMENT FOR
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Appendix A
Organization & Responsibilities

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RED LINE SOUTH UNDERGROUND
Pop-Ups
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M003-SLB-STS-ITP-00001 Rev. 0 Date of Form: 2015-12-03


METHOD STATEMENT FOR
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RED LINE SOUTH UNDERGROUND
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ROLE & RESPONSIBILITIES


Subcontractor (SOLB26)
SN Role Nos Responsibilities
Project Manager is responsible for overlooking the
progress of the whole project, time schedule and he is
dealing with the contractual part and he is in direct
contact with the QDVC in terms of any problems related
1 Project Manager 1
to operations/ logistics on site which affecting the
progress and time schedule, attend progress meetings,
coordinating with site team to attend the needed
progress on time and without delays.
The HSE Manager is in direct contact with the QDVC
HSE Manager in terms of any HSE issue and ensures
2 HSE Manager 1 all controls are followed and implemented with
appropriate actions are in place to mitigate the
identified risks.
Land Surveyor
3 1 Mark and checks all reference and coordinate points
Engineer
4 QA/QC Engineer 1 Responsible for site inspection and quality control
Reviewed recorded daily inspection report at
worksite
Deploy qualified painting personnel to carry out the
works and supervised by qualified QA/QC Inspector
Maintain all quality records
Conduct inspection and monitor the required tests.
6
Fabrication
1 Determine and report any NCR and recommend
Engineer corrective actions.
Ensure that all personnel should be fully aware with
the all quality requirements and application for all
quality documents as relevant to their discipline.
Ensure appropriate supervision control of all work
activities so that all quality related operations are
effectively covered
He is dealing with all safety issues and coordinating
7 Safety Officer 1 directly with HSE team on site and responsible to report
to JV HSE officer regarding safety issue at site.
8 Safety Supervisor 1 Monitors HSE rules and regulation at site.

9 QA/QC Inspector 1 Responsible for testing and to follow up for the results.
Responsible for any untoward accident/incident and
10 First Aider 1
emergency situations occurs at site
11 General Foreman 1 Directly supervising the work of all the labour force
Responsible for supervising the work of all labour force
12 Foreman 1-2
for a specific task/area.
M003-SLB-STS-ITP-00001 Rev. 0 Date of Form: 2015-12-03
METHOD STATEMENT FOR
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RED LINE SOUTH UNDERGROUND
Entrance Shelters and Pop-Ups
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Equipment Competent person for the safe and rational use of


13 As required
Operator equipment
14 Erectors As required Carry all work instructions coming from Foreman
Responsible to control movement of work vehicles and
15 Banksmen As required
plant

M003-SLB-STS-ITP-00001 Rev. 0 Date of Form: 2015-12-03


METHOD STATEMENT FOR
FABRICATION OF
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RED LINE SOUTH UNDERGROUND
Entrance Shelters and Pop-Ups
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Appendix B
Inspection and Test Plan (ITP)

M003-SLB-STS-ITP-00001 Rev. 0 Date of Form: 2015-12-03


INSPECTION & TEST PLAN FOR STRUCTURAL STEEL
RED LINE SOUTH UNDERGROUND
FABRICATION
Contractor SUBCONTRACTOR Doc No M003-SLB-STS-ITP-00001 Rev 2 Issue Date 2017-05-16 Page 1 of 4 Qatar Rail
(3) Checks (4) Intervention Points

Engineers
(1)

Assistant
3rd Party
SOLB26
Responsible (5) Verification

IMAR
Activity (2) Works Description Checking Activity to be Control Required
No Acceptance Criteria Job Documents
Performed Documents Frequency
Function

1.0 PRELIMINARIES/APPROVALS

Method Statement for


Project Prior to start
1.1 Method Statement Approving MS Method Statement Approved MS H R Structural Steel
Engineer of work
Fabrication Works
Welding Procedure
Welding Procedure Specification / Procedure Project Prior to start Specification and
1.2 Approving WPS / PQR Approved WPS / PQR QA Engineer H R
Qualification Records Specifications of work Procedure
Qualification Records
Project Prior to start Welder Qualification
1.3 Welders Qualification Approving WQTR Approved WQTR QA Engineer H R
Specifications of work Test Records
Non-Destructive
Project Prior to start
1.4 Non-Destructive Testing (NDT) Procedure Approving NDT Procedure Approved NDT Procedure QA Engineer H R Testing (NDT)
Specifications of work
Procedure
Approved NDT Operator
Approving NDT Operator Pre- Project Prior to start NDT Operator
1.5 NDT Operator Pre-Qualification Documents Pre-Qualification QA Engineer H R
Qualification Documents Specifications of work Records
Documents
List of Inspection Test Register of Inspection
& Measuring Test & Measuring
Prior to start
1.6 List of Calibrated Equipment Verification of Equipment calibration Equipment with Valid calibration certificates QA Engineer H H Equipment with
of work
Recent Calibration attached Calibration
Certificate Certificates

2.0 INCOMING MATERIAL

Receipt Inspection
Mechanical and Chemical
Prior to start Report with attached
Raw materials (Angles, Beams, Channels, Project requirements in
2.1 Approving MAR QC Inspector H W Mill Test Certificates,
Plates, Bars, Hollow sections) Specifications accordance to European of work
Approved Materials
Standard EN 10025
Approval Form (MAF)
Receipt Inspection
Project Approved Paint Coating Prior to start Report with attached
2.2 Coating Materials Approving MAR QC Inspector H W Mill Test Certificates,
Specifications System of work
Approved Materials
Approval Form (MAF)

Intervention Points (Engineers Assistant to be notified by Contractor of readiness of Hold Point and Witness Intervention Points)
This point is used to designate an operation which the organization is not
Document to be submitted for Approval as
H - Hold Point allowed to perform or begin without the presence of inspecting entities or formal W - Witness Weekly one or more visit. R - Review contractually required
authorization
M003-QGD-QMS-FRM-00103 Rev. 4 Date of Form: 2015-12-03
INSPECTION & TEST PLAN FOR STRUCTURAL STEEL
RED LINE SOUTH UNDERGROUND
FABRICATION
Contractor SUBCONTRACTOR Doc No M003-SLB-STS-ITP-00001 Rev 2 Issue Date 2017-05-16 Page 2 of 4 Qatar Rail
(3) Checks (4) Intervention Points

Engineers
(1)

Assistant
3rd Party
SOLB26
Responsible (5) Verification

IMAR
Activity (2) Works Description Checking Activity to be Control Required
No Acceptance Criteria Job Documents
Performed Documents Frequency
Function

Receipt Inspection
Project Prior to start Report with attached
2.3 Bolts, Nuts, Washers and Connectors Approving MAR Approved MAR QC Inspector H W Mill Test Certificates,
Specifications of work
Approved Materials
Approval Form (MAF)
Receipt Inspection
Prior to start Report with attached
Welding Consumables
Project Approved MAR QC Inspector
2.4 Approving MAR H W Mill Test Certificates,
Specifications of work
Approved Materials
Approval Form (MAF)

3.0 FABRICATION WORKS

- As per approved
- Prior to
Fabrication Drawing /
Fabrication /
Cutting plan Fit-up
- All cut piece steel Method Statement for
Cutting and Marking / Numbering of Materials QC Inspector - Prior to
3.1 - Approved Drawing H W Structural Steel
materials shall be Drilling /
Fabrication Works
marked clearly either Bending
by hard stamped or (where
applicable)
paint markers
Project Material Traceability
3.2 Material Traceability Checking of mill certificates Approved Drawing QC Inspector All deliveries H R
Specifications Report
Method Statement for
- As per approved Structural Steel
- Prior to
Fit-up Inspection Fabrication Drawing / QC Inspector Fabrication Works
3.3 Fit-up Inspection Approved Drawing release for H W
Dimension and Visual
Cutting plan welding
Welding Inspection
Report

4.0 WELDING WORKS

Welding Procedure
Project QC Inspector
4.1 Welding parameters - Approved WPS RANDOM W W Specification & Welder
Specifications Qualification Test

Intervention Points (Engineers Assistant to be notified by Contractor of readiness of Hold Point and Witness Intervention Points)
This point is used to designate an operation which the organization is not
Document to be submitted for Approval as
H - Hold Point allowed to perform or begin without the presence of inspecting entities or formal W - Witness Weekly one or more visit. R - Review contractually required
authorization
M003-QGD-QMS-FRM-00103 Rev. 4 Date of Form: 2015-12-03
INSPECTION & TEST PLAN FOR STRUCTURAL STEEL
RED LINE SOUTH UNDERGROUND
FABRICATION
Contractor SUBCONTRACTOR Doc No M003-SLB-STS-ITP-00001 Rev 2 Issue Date 2017-05-16 Page 3 of 4 Qatar Rail
(3) Checks (4) Intervention Points

Engineers
(1)

Assistant
3rd Party
SOLB26
Responsible (5) Verification

IMAR
Activity (2) Works Description Checking Activity to be Control Required
No Acceptance Criteria Job Documents
Performed Documents Frequency
Function

AWS D1.1 Table 6.1 - Dimension and Visual


Project
4.2 Weld visual Visual Inspection Visual Inspection QC Inspector 100% H W Welding Inspection
Specifications Acceptance Criteria Report
100%
Dimension and Visual
Project component
4.3 Dimensional Check Dimension Inspection NSSS QC Inspector H W Welding Inspection
Specifications parts and cut
Report
section

5.0 NON-DESTRUCTIVE TESTING

Full
AWS D1.1 AS per AWS D1.1 Penetration Ultrasonic Test
5.1 Ultrasonic Testing UT Inspection ND Operator H W
Section 6.13 Section 6: Part C Butt Welds = Reports
100%
1.) Full
Penetration
Butt Welds =
AWS D1.1 AS per AWS D1.1 Magnetic Particle
5.2 Magnetic Particle Testing MP Inspection ND Operator 100% H W
Section 6: Part C Section 6: Part C Inspection Reports
2.) Fillet
Welds = min.
20%

6.0 PAINTING

Prior to
Surface Preparation
Surface Preparation and Protective Project As per approved MAR and application of
6.1 Surface preparation QC Inspector H W and Protective
Coating Inspection Specifications MS coating
Coating Report
system
Surface Preparation
and Protective
Surface Preparation and Protective Project Approved Paint Coating Random, as
6.2 Check of Wet Film Thickness QC Inspector H W Coating Report,
Coating Inspection Specifications System required
Approved Materials
Approval Form (MAF)
Surface Preparation
Surface Preparation and Protective Project Approved Paint Coating 100% for
6.3 Check of Dry Film Thickness QC Inspector H W and Protective
Coating Inspection Specifications System every steel
Coating Report,

Intervention Points (Engineers Assistant to be notified by Contractor of readiness of Hold Point and Witness Intervention Points)
This point is used to designate an operation which the organization is not
Document to be submitted for Approval as
H - Hold Point allowed to perform or begin without the presence of inspecting entities or formal W - Witness Weekly one or more visit. R - Review contractually required
authorization
M003-QGD-QMS-FRM-00103 Rev. 4 Date of Form: 2015-12-03
INSPECTION & TEST PLAN FOR STRUCTURAL STEEL
RED LINE SOUTH UNDERGROUND
FABRICATION
Contractor SUBCONTRACTOR Doc No M003-SLB-STS-ITP-00001 Rev 2 Issue Date 2017-05-16 Page 2 of 4 Qatar Rail
(3) Checks (4) Intervention Points

Engineers
(1)

Assistant
3rd Party
SOLB26
Responsible (5) Verification

IMAR
Activity (2) Works Description Checking Activity to be Control Required
No Acceptance Criteria Job Documents
Performed Documents Frequency
Function

structure Approved Materials


member Approval Form (MAF)

7.0 FINAL DOCUMENTS

Materials Receiving
100% for Inspection report
Attached required
100% - every delivery at every steel (MRIR) / Structural
7.1 Inspection Reports - relevant delivery DCC H R
site structure Fabrication
documents
member Acceptance
Certification

Intervention Points (Engineers Assistant to be notified by Contractor of readiness of Hold Point and Witness Intervention Points)
This point is used to designate an operation which the organization is not
Document to be submitted for Approval as
H - Hold Point allowed to perform or begin without the presence of inspecting entities or formal W - Witness Weekly one or more visit. R - Review contractually required
authorization
M003-QGD-QMS-FRM-00103 Rev. 4 Date of Form: 2015-12-03
Report No
Project No
SURFACE PREPARATION & PROTECTIVE COATING REPORT Date of Insp.

www.solb26.com Page 1 of
PAINT SYSTEM (TYPE):
APPLICATION METHOD:

VISUAL APPEARANCE OF COATING:

AMBIENT CONDITION SURFACE PREPARATION BATCH NO.


SURFACE SURFACE
DATE TIME DRY BULB C WET BULB C DEW POINT C RH % STANDARD OF BLAST SURFACE PROFILE REMARKS PART A PART B
TEMP C CLEANING STD

BLASTING
PRIMER COAT
INTER. COAT
TOP COAT
COATING DETAILS
Primer (micron) Internmediate Coat (micron) Top Coat (micron)
Item Number
WFT Reading MIN MAX AVE WFT Reading MIN MAX AVE WFT Reading MIN MAX AVE

PAINT INSPECTOR QA/QC MANAGER TPIA CLIENT

Name

Signature

Date

S26-QF-059_Rev.02_15.10.2015
Project No.

DIMENSIONAL AND VISUAL WELDING INSPECTION REPORT Report No.

Shift

CLIENT Date

REQUIRED ACTUAL
DRAWING NO REVISION ITEM MARK NO QTY FIT UP WELDER NO VISUAL NDT REMARKS
DIMENSION DIMENSION

SOLB26 CLIENT THIRD PARTY

NAME

SIGNATURE

DATE

S26-QF-058_Rev.05_19.07.2016
Report No
MAGNETIC PARTICLE Date of
INSPECTION REPORT Examination
www.solb26.com
Page

Customer Project No Drawing No

Assembly or
Object Material
Part No

Specification Test Procedure Test Scope

No
Surface As it is Sand blasted Heat
Before
Condition Ground Machined Treatment
After
Direct Current Row
Magnetization Flexible Cable
Yoke Equipment
Technique Bobin / Coil
Induced Current
Fluorescent Wet
Test Medium Brand
Color Contrast Dry
Current Type Ampere-Turns Pole Distance
Current Intensity Coil Diameter UV-Light Intensity
Contrast Paint Carrier Medium Visible Light Intensity

Yes
Field Strength Test Medium Check Demagnetization
No

Weld No Welder No NDT Category Result (*) Remarks

(*) Result (1) ( Acceptable / No Indications)


(2) (Acceptable / No Unacceptable Indications)
(3) (Rejected / Unacceptable Indications)

MPI Technician QA/QC Manager TPIA CLIENT

Name

Signature

Date

S26-QF-034-Rev.03_16.11.2015
Report No
MAGNETIC PARTICLE Date of
INSPECTION REPORT Examination
www.solb26.com
Page

Weld No Welder No NDT Category Result (*) Remarks

(*) Result (1) ( Acceptable / No Indications)


(2) (Acceptable / No Unacceptable Indications)
(3) (Rejected / Unacceptable Indications)

MPI Technician QA/QC Manager TPIA CLIENT

Name

Signature

Date

S26-QF-034-Rev.03_16.11.2015
Rapor No:
Report No
Muayene Tarihi:
ULTRASONIC TEST REPORT Date of Examination
www.solb26.com Sayfa No:
Page
Mteri: Sipari No: Para Tanm:
Customer Project No Object
Para No: Resim No: Malzeme:
Part Code Drawing No Material
Yok/No
Isl lem : ncesi/Before Cihaz: Temas Svs:
Heat Treatment Equipment Coupling Medium
Sonras/After
Standart: Muayene Talimat: Muayene Kapsam:
Test Specification Test Instruction Test Scope
Mesafe Kalibrasyonu Duyarllk Kalibrasyonu / Sensitivity Adjustment
Distance Calibration
Kalibrasyon. DGS:Rh Kalibrasyon Kalibrasyon
S DGS:Rl DDSR Yanstcs
Prob Prob PD
Bloku
DGS:Sca. DSDH
Bloku SJ VJ VT V VR
No. Probe SPD Calibration RB:Rh Calibration Calibration VV
(mm) Block RB:Rl (mm) Block Reflector (mm) (dB) (dB) (dB) (dB)

Kaynak Yntemi Kaynak


Kaynak Dikii No ap/Kalnlk Prob No Tarama Yn Sonu Kaydedilen Belirtiler
Welding No.
Weld Seam No Diam./Thk. Probe No Scanning Direction Result Recordable Indications
Process Welder No

UT Technician QA/QC Manager TPIA Client

Name

Signature

Date

S26-QF-032_Rev.02_16.11.2015
Rapor No:
Report No
Muayene Tarihi:
ULTRASONIC TEST REPORT Date of Examination
www.solb26.com Sayfa No:
Page
Tarama
Prob Yn
Kaynak No x y z x Vu Hu Aklama
Weld No mm mm mm mm dB dB Remarks
No Scan.dir.

z y

UT Technician QA/QC Manager TPIA Client

Name

Signature

Date

S26-QF-032_Rev.02_16.11.2015
Rapor No:
Report No
ULTRASONIC TEST Muayene Tarihi:
Date of Examination
REPORT
www.solb26.com Sayfa No:
Page
Kaynak Dikii Kaynak Yntemi Kaynak
ap/Kalnlk Prob No Tarama Yn Sonu Kaydedilen Belirtiler
No Welding No.
Diam./Thk. Probe No Scanning Direction Result Recordable Indications
Weld Seam No Process Welder No

UT Technician QA/QC Manager TPIA Client

Name

Signature

Date

S26-QF-032_Rev.02_16.11.2015
Report No
Project No
RECEIPT INSPECTION REPORT Date of Inspection
RML Rep. No.
www.solb26.com
Page
Required Cast No
Nr. Material Description Qty Unit P.O. No D.N. No Damage Acc/Rej Remarks
Grade /Batch No
1
2
3
4
5
6
7
8
9
10
11
12
13
Q.C Inspector QA/QC Manager TPIA Client
Name

Signature

Date

S26-QF-030_Rev.06_19.06.2016
METHOD STATEMENT FOR
FABRICATION OF
Qatar Rail, Red Line South Underground -
RED LINE SOUTH UNDERGROUND
Entrance Shelters and Pop-Ups
Date: 16.03.2017 Codification: M003-SLB-STS-MES-00001 Rev: 1 Page 39 of 81

Appendix C
Health, Safety, Environment Risk Assessment

M003-SLB-STS-ITP-00001 Rev. 0 Date of Form: 2015-12-03


Report No 4

HAZARD IDENTIFICATION AND RISK ASSESSMENT REPORT Rev 4

Page
www.solb26.com
Area/Department Fabrication

Date/Updated Date 06.04.2016

Next Review Date

Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)

Risk assessment and OCP


incompetent operator Minor/Major injuries 4 3 2 24 only Certified operator,
adressing to the operators.
N

All the lifitng


certified operator, gear,overhead should
select the Right lifting gears have valid third party
Failure of lifting gears Minor/Major injuries 4 3 2 24 as per the materials. certificate and colour N
Provide softener to avoid coded.
cutting . Addressing the risk
assessment and ocp .
certified operator
suspended Load not being
Tool box talk
moved above the access
Hit by suspeded load Minor/Major injuries 4 2 2 16
ways.
Provide whistle to the N
operator .
Dont move the load above
and near to the personel
Addressing the risk
All the lifting gear,overhead
assessment and ocp
should have valid third party
permanent disability .Regular maintetance
Fall of load
property damage 4 3 2 24 certificate and colour coded.
record for the overhead
N
Provide softener to avoid
crane
cutting the sling.
Lifting in slow in motion

1 Overhead crane Refreshing training


The hook of the chain sling permanent disability ,checking the hook
jams with working bench property damage 4 3 2 24 only Certified operator,
whether the latch close or
N
not

All the critical load carried


only by certified rigger.
Selection of the lifitng
only
permanent disability equipment as per the
Inadequate slinging method
property damage 4 3 2 24 Certified
material needed.
N
operator,
Continues supervision
required for the critical
lifting /transfering the load.

Certified operator,Operator The safe working load


Overlaoding the over head permanent disability should aware the weight of marked on th crane.
crane property damage 4 3 2 24
the load.if not known ask Risk assessement and
N
your supervisor or engineer. OCP addressing .

Only Certifed operators will


Only Third party Certified
operate EOT crane.
Rigger will supervise the
Lack of communiction for permanent disability Third party certifed Lifting
Tandem lifting property damage 4 3 2 24
gears,Crane and operators.
tanden lifting. N
Proper lifting plan in place
Continues supervission for
for the tandem lift.
the task.

S26-HS-62_Rev.02_15.10.2016
Report No 4

HAZARD IDENTIFICATION AND RISK ASSESSMENT REPORT Rev 4

Page
www.solb26.com
Area/Department Fabrication

Date/Updated Date 06.04.2016

Next Review Date

Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
Automatic shot blasting Machine PPE (Dust Mask,Eye Area should be barricaded
Glasses,Ear Muffs or Ear to prevent unauthorized
Hit by flying shot from the
Eye, Ear inury 2 5 2 20 Plugs) entry,Follow the daily N
machine inspection checklsit

Using good condition lifting Competent operators


gears with third party involve in lifting,Daily
Fall of material during loading certified and colour visaul inspection for the
and unloading from the Personel injury 4 2 2 16 coded,Only trained lifting equipments and N
conveyor roller operator use the EOT folow the daily inspection
Crane operator . checklist.
Area covered by the steel follow the daily inspection
Fall in surrounding pit Fatal accident grids. checklist
Y

outgoing and incoming All the


material is controlled by maintenance/emergenccy
motorized rollars and by fault analysis hould be
Caught in the machine Fatal accident machine operator only. done by Authorized team
Y
only.

Rollers operated by provide Stand by


authorized personnel personnel will be monitor
only,Provide signages. the roller while transfer the
Caught between the material
and rollers
Major Injury 4 2 2 16 materials to avoid
crossing of the other
workers. Daily inspection
checklist to be followed.
Address the Risk Safe working capacity for
property damage /personal assessment ,safe the conveyor marked on
overloading the conveyor injury to the nearby 4 2 2 16 operational control for the roller.Dialy checklist filled
personells. task. Conduct Tool box talk by the operator.

Addtiional tray/stand as per Ensure the stability of the


the materiails load ,size,shape and
weight.Design safe and
2 unstability of the materails in property damage /Minor or
the conveyors Major injuries 3 4 1 12 approved trays or stand as
pert the fabricated
materails for to have
proper stability.
Provide Safe Guard for all follow the daily inspection
rotation parts for the roller as Minor /Major injury the rotating parts .Donot checklist
well the blasting machine Permanent disabilties remove any safe gurard maintenace and repair Y
unless you are not done by authorized staff.
authorized.
ELCB fitted on sub main maintenace and repair
distribution panel,power done by authorized staff.
Electric Shock Fatality/severe burn shut down before repair and Follow the Lock out /Tag
Y
maintenance, out procdure.

S26-HS-62_Rev.02_15.10.2016
Report No 4

2 HAZARD IDENTIFICATION AND RISK ASSESSMENT REPORT Rev 4

Page
www.solb26.com
Area/Department Fabrication

Date/Updated Date 06.04.2016

Next Review Date

Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
Follow the safe working Implement a safe system Implement a safe
procedure for confined procedure for working in working procedure in
Entry in the confined space,Tool bax talk and the confined the confined space
space(Shot blasting Pit)
Inhalation of toxic Gas/Fatality Y
awareness program space.Implement confined
space permit system.
PPE (filter mask ,Ear
plug,Eye Glasses Adressing of Risk
etc),Periodic changing of assessement and safe
Respiratory/Pulmonary
Inhalaton of Dust /High noise
disorder/Ill health 2 5 2 20 the filter , Dust mask,ear work procedure ,Daily N
plug required for all the Inspection checklist to be
nearby workers.,Training followed
and and Tool box talk ,
Trained operators ,Tool box Control for the operational
Machine operated by talk and specific training key or lock out tagout
unauthorized Personals.
Major incident 2 3 5 30 conducted. while machine is un Y
Attendants.
Only competent personel Lock out tagout procedure
allowed for the follows.Confined space
Failure of maintenance maintenance ,Training and permit to be followed in th
activity/Poor Maintenance
Property damage ,Fatalities toolo bax talk pit. Y
Periodic inspection to be
done . And colour coded.
Machine is controlled by Addressing of Risk
infra red safety system. assessment ,OCP
Contact with running saw
Personel injury /amputation 5 2 1 10 Machine will stop addressing Daily N
blade immidiately if someone Inspection checklist to be
enter in working area followed
Infra red safety device, Addressing of Risk
machine is operated by assessment ,OCP
Caught between material
during clamping
Personel injury 4 2 1 8 authorized operators addressing Daily N
only,OCP available Inspection checklist to be
followed
Adjustments are being done
prior to start the Use al ways the crossing
Foot caught between
convectors
Personnel injury 4 2 2 16 machine,infra red safety ramps.Donot walk on the N
device in place. top of conveyors.
3 Band Saw (Peddinghaus) Material is handled at end Appoint a stand by
Caught between conveyor points only,operated by personels to watch the
rollers
Fatal accident 4 2 2 16 authorized operator crossing of the N
workers,Provide Signages
only authorized operator Always use walk ways
Caught between the transfer
operate transfer modules. provide .
module while material is being
transfer from blasting machine
Major injury 4 2 2 16 Donot walk on the top of N
conveyor.
to band saw machine.

S26-HS-62_Rev.02_15.10.2016
Report No 4

HAZARD IDENTIFICATION AND RISK ASSESSMENT REPORT Rev 4

Page
www.solb26.com
3 Band Saw (Peddinghaus)
Area/Department Fabrication

Date/Updated Date 06.04.2016

Next Review Date

Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
Always use the lifting Appoint a competent
equipments with colour certified riggger for
Material fall during offloading coded .Ensure the third unloading the materails
the material from rollers to the Personel injury 4 2 2 16 party certificate valid for the from the conveyor.. N
ground. lifting equipments used by
the personnels.
Good quality and Appoint a competent
appropriate capacity chain certified riggger for
slings are being used,load is unloading the materails
slung correctly before from the conveyor..Follow
Fall of pipe during loading and
offloading
serious injury 3 2 2 12 lifting.All the lifting the daily inspetion N
equipments should be checklist .Vissual
colour coded . inspection to be done
before lifting .Address the
risk assessment and ocp.
Always stack the pipe in the Donot stack any pipes in
racks. designated area.Follow the
Ensure the pipes are daily inspection checklist .
Improper stacking of pipes serious injury 4 3 2 24
stacked properly and
N

stopper inplace.

Trained operators ,Tool box The safe working load for


talk and specific training each trolley marked in
conducted.Safe working TONS for easy
capacity marked on the understanding.Daily
trolley.Set the trolley on inspection checklist to be
Pipes falling from the trolley
minor /Major injury basis of pipe size . followed .Daily visual
due to insufficient
Property damage 3 4 2 24
inspection to be done for
balance/overloading
the hydraulic leakage.
Address the Risk
assessment and
operational control
procedure.
Machine is operated by Follow the daily inspection
operator from the control checklist ..Addressing the
panel only.adustments are Risk assessment and OCP
Hit by moving pipe serious injury 3 3 2 18
being done before starting to the involved groups.
N
the cutting.

Machine is operated by Follow the daily inspection


operator from the control checklist .Clean and
panel only,Operator is change the respeiratory
Hit by rotating chuck serious injury 3 3 2 18 present till the job finished. .Addressing the Risk N
Donot wear any loose assessment and OCP to
clothes,jewellery rings . the involved groups.
4 CNC Pipe Cutting Machine

S26-HS-62_Rev.02_15.10.2016
Report No 4

HAZARD IDENTIFICATION AND RISK ASSESSMENT REPORT Rev 4

Page
www.solb26.com
Area/Department Fabrication

Date/Updated Date 06.04.2016

Next Review Date

Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
4 CNC Pipe Cutting Machine
Certified operator,CNC Combustable materials are
controlled torch,protective removed before
screen glass,fire commencing the work.
extinguishers.All the cyliders Follow the daily inspection
Fire severe burns,fatality should be secure with checklist ..Addressing the Y
chains .Provide flash back Risk assessment and OCP
arrestor for the to the involved groups.
cylinders.Keep distance
from the direct spark.
Operator is operating from
the CNC control only Always keep the scrap box
Hit by falling scrap pieces Personel injury 2 3 3 18
maintaining safe distance roller near to cutting zone.
N
from cutting head
ELCB fitted on sub main maintenace and repair
distribution panel,power done by authorized staff.
Electric Shock Fatality/severe burn 2 3 3 18 shut down before repair and Ensure the inspection N
maintenance, color coding /Maintenance
inspection sticker inplace
Trained operators ,Tool box Control for the operational
Machine operated by talk and specific training key or lock out tagout
unauthorized Personals.
Major incident 2 3 5 30 conducted. while machine is un Y
Attendants.
Ensure the working Follow the daily inspection
condition of mechanical checklist .Clean and
exhaust system. change the respeiratory
Appropriate PPE 's to be .Addressing the Risk
worned at all assessment and OCP to
Inhalation of fumes Respiratory problem 2 3 3 18
times.(Respirator.Safety the involved groups.
N
Glass,etc. Air filter cleaning for the
machine done by the
competent personnels and
wear appropriate PPE's.
Always wear the ear plugs. Follow the daily inspection
Trained and competent checklist .Addressing the
high noise hearing loss 2 3 3 18 operator.Signage in place Risk assessment and OCP N
to the involved groups.

Caught between the transfer Material is handled at end Appoint a stand by


module while material is being points only,operated by personnels to watch the
transfer from blasting machine Personal Injury 4 2 2 16 authorized operator crossing of the N
to peddighhaus drilling workers,Provide Signages
machine
Sensor are in place for Before starting the
crossing of unauthorized machine verify that nobody
permanent diability entry. endangered by starting of
Trap between machine
fatalities the machine. Y
Installation of Permanent
fence in the surrounding

S26-HS-62_Rev.02_15.10.2016
Report No 4

HAZARD IDENTIFICATION AND RISK ASSESSMENT REPORT Rev 4

Page
www.solb26.com
Area/Department Fabrication

Date/Updated Date 06.04.2016

Next Review Date

Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
Address the Risk Safe working capacity for
property damage /personal assessment ,safe the conveyor marked on
overloading the conveyor/and
injury to the nearby 4 2 2 16 operational control for the roller.Dialy checklist filled N
drilling bench task. Conduct Tool box talk by the operator.
personells.

Competent Install permenent fense


permanent diability Operator.Warning signage around the roller which
Trap between rollers
fatalities for unauthorized entry near to operator cabin
Y

Competent Operator. Follow daily inspection


Donot overload the machine checklist.
Property damage/Serious before starting the
Overloading the machine
injuries 3 4 2 22 work.Confirm to the N
instrcution table in the
capacity of the drill bit.
Adequate the coolant Follow the daily inspection
checklist .Addressing the
overheating Property damage 3 2 2 12 Risk assessment and OCP N
to the involved groups.
Check the coolant level.
Always wear the ear plugs. Follow the daily inspection
Trained and competent checklist .Addressing the
5 Peddinghuas Drilling Machine operator.Siganege in place Risk assessment and OCP
high noise hearing loss 2 3 3 18 to the involved groups. N

Donot clean the iron waste Addressing the risk


or touch the drill bits during assessment and ocp
the drilling. .follow the daily inspection
Donot wear any loose checklist.
permanent diability cloths,Jewellery,Watch rings
Entanglement in rotation parts
fatalities etc.
Y
Only Trained and competent
operator are allowed to
operate the machine.

Only Competent certified All the lifitng


rigger will load the materail gear,overhead should
from the conveyor. have valid third party
Major incident donot use any damaged certificate and colour
unsafe loading method Property damage lifting gears. coded. Y
fatalities Addressing the risk
assessment and ocp
.follow the daily inspection
checklist.

S26-HS-62_Rev.02_15.10.2016
Report No 4

HAZARD IDENTIFICATION AND RISK ASSESSMENT REPORT Rev 4

Page
www.solb26.com
Area/Department Fabrication

Date/Updated Date 06.04.2016

Next Review Date

Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
Competent Addressing the risk
operators.always wear assessment and ocp
appropriate PPE.(Safety .follow the daily inspection
Flying particles Eye injury/minoe incident 3 3 2 18
Glass,Helmet,Earplug,etc) checklist. Nobody allow to
N
stand near to the machine

Only competent personals Lock out tagout procedure


allowed for the follows.Confined space
Failure of maintenance maintenance ,Training and permit to be followed in th
activity/Poor Maintenance
Property damage ,Fatalities tool box talk pit. Y
Periodic inspection to be
done . And colour coded.
Plates are lifting with plate
lifting Address the Risk
Fall of material during loading magnet(Techniomagnate), assessment and OCP
and unloading
Personal Injury 4 1 4 Authorized operators. .Follow the daily inspection
N
Refer Risk assessment checklist
colum)
Ensure the steel support
plate are inplace. Address the Risk
assessment and OCP
Failure of working bench Personal Injury 3 2 2 12 Replace the damged plate
.Follow the daily inspection
N
on time.
Competnent operator. checklist

CNC controlled Removal of combustable


torch,Flashback- and ignitative materials
arrestors,good quality Address the Risk
Fire explosion Fatality/severe burn hoses.Fire extinguisher assessment and OCP
Y
.Follow the daily inspection
checklist.
PPE,Certified operator Address the Risk
Ensure the steel support assessment and OCP
Fall into the cutting plate are inplace. .Follow the daily inspection
stand/bench
Serious Injury 3 3 27 Replace the damaged plate
checklist
N
on time. Provide additional planks
Competnent operator. for the walkways
PPE(Leather Gloves)
Address the Risk
Contact with hot assessment and OCP
surface/Handling hot material
Severe burns 3 3 2 18
.Follow the daily inspection
N
checklist
Ear plug provided for the Regular noise monitoring
personnals .Number of warning sign to
be increased
6 CNC PLATE Cutting Machine High noise generated during loss of hearing /concentration
activity problem 4 2 3 24 Address the Risk N
assessment and OCP
.Follow the daily inspection
checklist

S26-HS-62_Rev.02_15.10.2016
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HAZARD IDENTIFICATION AND RISK ASSESSMENT REPORT Rev 4

Page
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Area/Department Fabrication

Date/Updated Date 06.04.2016

Next Review Date


6 CNC PLATE Cutting Machine
Consideration Rating Controls Significance
Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
ELCB fitted on sub main maintenance and repair
distribution panel,power done by authorized staff.
shut down before repair and Follow the Lock out /Tag
Electric Shock Fatality/severe burn 5 2 3 20 maintenance,maintenace out procdure. N
and repair done by
authorized staff.

Ensure the working Follow the daily inspection


condition of mechanical checklist .Clean and
exhaust system. change the respeiratory
Appropriate PPE 's to be .Addressing the Risk
worned at all assessment and OCP to
Inhalation of fumes Respiratory problem 2 3 3 18 times.(Respirator.Safety the involved groups. N
Glass,etc. Air filter cleaning for the
machine done by the
competent personnels and
wear appropriate PPE's.
Only competent personals Lock out tagout procedure
allowed for the follows
Failure of maintenance maintenance ,Training and
activity/Poor Maintenance
Property damage ,Fatalities tool box talk Y
Periodic inspection to be
done . And colour coded.
Trained operators ,Tool box Control for the operational
talk and specific training key or lock out tagout
Machine operated by
unauthorized Personals.
Major incident 2 3 5 30 conducted. while machine is un Y
Attendants.

Machine is operated by
authorized operator
Follow the daily inspection
only,area is closed for other
Expousre to metal chips checklist .Addressing the
around the machine
Personal Injury 3 3 2 18 workers Donot
Risk assessment and OCP
N
clean/remove the melt
to the involved groups.
chips while the machine is
running.
PPE (Eye Protection) Follow the daily inspection
checklist .Addressing the
cutting oil splash in the eye Eye injury 2 3 2 12
Risk assessment and OCP
N
to the involved groups.
Machine is operated by Install automatic shut off
authorized operator only, device or isolation as
Contact with Spindle Arm
Major Injury 4 3 2 36 PPE (operator is not control to prevent Y
(Drilling Rod) allowed to wear loose cloths entanglement or any
watch jewellry). unwanted event..
wheel handle is always be in
closed position,Operator Follow the daily inspection
maintain a distance from checklist .Addressing the
Hit by Hand wheel Major Injury 3 3 3 27 moving hand wheel.
Risk assessment and OCP
Y

S26-HS-62_Rev.02_15.10.2016
to the involved groups.
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Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
Competent Operator. Follow daily inspection
Donot overload the machine checklist.
7 Radial drilling before starting the
Overloading the machine /drill Property damage/Serious
bits injuries 3 4 2 22 work.Confirm to the N
instrcution table in the
capacity of the drill bit.

Adequate the coolant Follow the daily inspection


checklist .Addressing the
overheating Property damage 3 2 2 12 Risk assessment and OCP N
to the involved groups.
Check the coolant level.
Provde adequate
permanent lighting . Follow the daily inspection
checklist .Addressing the
inadequate illumination Minor /major Injury 3 2 2 12
Risk assessment and OCP
N
to the involved groups.

ELCB fitted on sub main maintenace and repair


distribution panel,power done by authorized
Electric Shock Fatality/severe burn shut down before repair and staff.Visual inspection prior Y
maintenance, to each operation.
Only competent personals Lock out tagout procedure
allowed for the follows.Confined space
Failure of maintenance maintenance ,Training and permit to be followed in th
activity/Poor Maintenance
Property damage ,Fatalities tool box talk pit. Y
Periodic inspection to be
done . And colour coded.

Authorized operators. Only Address the Risk


Fall of material during loading certified Rigger are allowed assessment and OCP
and unloading
Personal Injury 4 1 2 8 to load ing and unloading .Follow the daily inspection N
task. checklist
Donot overload the bench All the working bench
.IF you dont know the designed as pe the
weight of the load ask your approved load calculation
Overloading the work property damage
3 4 2 24 engineer.Materal approved drawing. If N
bench/additional plat forms Major injuries Drawing inplace additional temperary
support rquired NDT and
MPI test report.
Certified operator for CMM Follow the daily inspection
welding line. checklist .Addressing the
Visual inspection before Risk assessment and OCP
Permannent disability moving the machine.
Stuck between the wheel/rails
Fatalities to the involved groups. Y
Reduce the speed for the Install the sound alarm
moving. device while moving or
sensor.

S26-HS-62_Rev.02_15.10.2016
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Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
PPE(Leather Gloves)
Address the Risk
Contact with hot assessment and OCP
suface/Handling hot material
Severe burns 3 3 2 18
.Follow the daily inspection
N
checklist

8 CMM beam wedling line Not wearing Loose


materails,Gloves and
Permanent diability jwellery .Address the Risk Keep safe body distnace
caught with Moving roller
fatalities assessment and OCP from the moving parts.
Y
.Follow the daily inspection
checklist

Permanent diability
Stuck between the materails
fatalities

ELCB fitted on sub main maintenance and repair


distribution panel,power done by authorized
Electric Shock Fatality/severe burn shut down before repair and staff.Visual inspection prior Y
maintenance, to each operation.

Trained operators ,Tool box Control for the operational


Machine operated by talk and specific training key or lock out tagout
unauthorized Personals.
Major incident 2 3 5 30 conducted. while machine is un Y
Attendants.

Only competent personals Lock out tagout procedure


allowed for the follows.
Failure of maintenance
activity/Poor Maintenance
Property damage ,Fatalities maintenance ,Training and Y
tool box talk
Periodic inspection to be
Authorized operators. Only
Address the Risk
certified Rigger are allowed
Fall of material during loading assessment and OCP
and unloading
Personal Injury 4 1 2 8 to load ing and unloading
.Follow the daily inspection
N
task.
checklist
Competent operator.Area
Follow the daily inspection
closed to avoid other
checklist .Addressing the
workers.
Risk assessment and OCP
Operator maintain safe body
caught between rollers major injuries 5 3 2 30
distance form the
to the involved groups. Y
Install the sound alarm
machine.The machine will
device while moving or
run only when the control is
sensor.
held in run position.
Provide adequate
9 Plate bending mchine Install the permannent
barricadding and signages
Falling in to the pits minor /Major injuries 4 3 2 24 steel grid on the top of the N
pits

S26-HS-62_Rev.02_15.10.2016
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9 Plate bending mchine Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
Always wear the appropriate
PPE's (hand Address the Risk
gloves,helmet,shoes,covera assessment and OCP
Sharp edges cut /abrassion 3 3 2 18 ll etc.Trained and competent
.Follow the daily inspection
N
operator.Siganages in place checklist

Only competent personals Lock out tagout procedure


allowed for the follows.
Failure of maintenance
activity/Poor Maintenance
Property damage ,Fatalities maintenance ,Training and Y
tool box talk
Periodic inspection to be
competetnt operator .
Address the Risk
Donot wear any loose
assessment and OCP
Contact with drilling rod cut injury 3 3 2 18 cloths,jewellery,rins,chains
.Follow the daily inspection
N
etc.
checklist
ELCB fitted on sub main maintenace and repair
distribution panel,power done by authorized
Electric Shock Fatality/severe burn shut down before repair and staff.Visual inspection prior Y
maintenance, to each operation.

Competent operator
Address the Risk
Safe body distance from the
assessment and OCP
Scattering metel chips personnel injury 3 3 2 18 equipments
.Follow the daily inspection
N
checklist
Adequate the coolant Follow the daily inspection
10 Drilling machine checklist .Addressing the
overheating Property damage 3 2 2 12 Risk assessment and OCP N
to the involved groups.
Check the coolant level.
Competent Operator. Follow daily inspection
Donot overload the machine checklist.
Property damage/Serious before starting the
Overloading the machine
injuries 3 4 2 22
work.Confirm to the
N
instrcution table in the
capacity of the drill bit.
Competent operator
Address the Risk
Always keep the machine in
assessment and OCP
stable position.
.Follow the daily inspection
Unstability of the machine Peoperty damage/Injuries 3 3 2 18 Donot keep the the machine
checklist Clean the
N
in the edges.
surface from moisture of
oil grease or dust.
Rollers operated by Always monitor the roller
authorized personnel while transfer the materials
only,Provide adequate to avoid crossing of the
Caught between the conveyor
rollers
Major Injury 4 2 2 16 barricading and signages. other workers. Daily N
inspection checklist to be
followed. Provide Fence
if required.
S26-HS-62_Rev.02_15.10.2016
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Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
Only competent trained Address the Risk
operator to use the machine assessment and OCP
.Follow the daily inspection
incompetent operator Major Injury/property damage 3 4 2 24 checklist. N
Refreshment training to
conducted

Certified operator,All the Combustable materials are


hoses of oxy ,plasma or removed before
other gases fuel cutting commencing the work.
system has a flash back Follow the daily inspection
arrestor systemi fitted. checklist ..Addressing the
Fire severe burns,fatality controlled torch,protective Risk assessment and OCP Y
screen glass,fire to the involved groups.
extingushers.All the cyliders
should be secure with
chains .Keep distance from
the direct spark.
Only competent operator. donot use the machine as
Adressing the manual . manual drilling or burning
Always keep the Manual device.
inplace. Installed Sensor to
No sensor is working while prevent damage or injury
wrong method of using Property damage/Serious
machine injuries 2 4 2 16 machine in manual jog when running. N
mode.

Competent operator Addressing the risk


Donot wear any loose assessment and ocp
clothes,jwellery,rings etc. .follow the daily inspection
Donot pick u the workpiece checklist. Nobody allow to
or cut materials during stand near to the machine.
Entaglement in the Permanent disability
rotating/moving parts Fatlities cutting or drilling. Separate the operator Y
cabin and cutting area.

PEDDINGHAUS HSFDB 2500


11
B

Competent Addressing the risk


operators.always wear assessment and ocp
appropriate PPE.(Safety .follow the daily inspection
Glass,Helmet,Earplug,etc) checklist. Nobody allow to
stand near to the machine.
Flying particles Eye injury/minor incident 3 3 2 18
Provide permanent fence
N

Glass type to protect the


flying steel particles.

S26-HS-62_Rev.02_15.10.2016
Report No 4

PEDDINGHAUS HSFDB 2500


HAZARD IDENTIFICATION AND RISK ASSESSMENT REPORT Rev 4
11
B
Page
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Area/Department Fabrication

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Next Review Date

Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
Ear plug provided for the Regular noise monitoring
personnals .Number of warning sign to
be increased
High noise generated during loss of hearing /concentration
activity problem 4 2 3 24 Address the Risk N
assessment and OCP
.Follow the daily inspection
checklist
ELCB fitted on sub main maintenance and repair
distribution panel,power done by authorized staff.
Electric Shock Fatality/severe burn 2 3 3 18 shut down before repair and Ensure the inspection N
maintenance, color coding /Maintenance
inspection sticker inplace
Ensure the working Follow the daily inspection
condition of mechanical checklist .Clean and
exhaust system. change the respeiratory
Appropriate PPE 's to be .Addressing the Risk
worned at all assessment and OCP to
Inhalation of fumes Respiratory problem 2 3 3 18 times.(Respirator.Safety the involved groups. N
Glass,etc. Air filter cleaning for the
machine done by the
competent personnels and
wear appropriate PPE's.
Only competent personals Lock out tagout procedure
allowed for the follows
maintenance ,Training and
Failure of maintenance
activity/Poor Maintenance
Property damage ,Fatalities toolo bax talk Y
Periodice inspection to be
done . And colour coded.

Trained operators ,Tool box Control for the operational


Machine operated by talk and specific training key or lock out tagout
unauthorized Personals.
Major incident 2 3 5 30 conducted. while machine is un Y
Attendants.

Certified operator,Operator The safe working load


Overlaoding the over head permanent disability should aware the weight of marked on th crane.
crane property damage 4 3 2 24
the load.if not known ask Risk assessement and
N
your supervisor or engineer. OCP addressing .

4 2 2 8 Operational control Clean the plates before


procedure,Trainings lifting ,Donot lift te plate
Load fall at the time when with moisture surface or
magnetization in progress
Personal injury oil,grease or dust content. N
Periodic inspection of the
equipment
Plate lifting magnet
12 Certified operator,Minimum Always use tag line
(Technomagnet)
two personal handle the e=while loading or shifting.
property damage load Addressing the Risk
uncontrol of the load
Mjaor injuries
2 3 5 30 Y
assessment and OCP to
the involved groups.
S26-HS-62_Rev.02_15.10.2016
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Plate lifting magnet
12 Review Date
Next (Technomagnet)

Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)

Periodic inspection to be Follow the daily inspection


done by competetnt checklist .Addressing the
electricain and colour Risk assessment and OCP
property damage
Faulty equipments
Mjaor injuries
2 3 5 30 coded.Period lifting to the involved groups. Y
equipements inspection to
be done periodically and
colour code
pipes/profile are lifting with Address the Risk
Fall of material during loading valid and colour coded assessment and OCP
and unloading
Personal Injury 4 1 4 lifting gears
.Follow the daily inspection
N
Authorized operators. checklist
At the time of operation Daily inspection checklist
,operator keep safe body to be followed.
Caught between the materals major injury 5 3 2 30 distance from the machine. Address the Risk Y
Donot wear any loose assessment and OCP to
clothes,Jewellery,Rings etc. the group.

High quality hoses Periodic inspection of the


provided.Always wear safety equipment.
glasses Address the Risk
Hydraulic splashes to the eyes Eye irritation 4 2 2 16
assessment and OCP
N
.Follow the daily inspection
Hydraulic press for Pipe/profile checklist
13 ELCB fitted on sub main maintenace and repair
Bending machine
distribution panel,power done by authorized
Electric Shock Fatality/severe burn shut down before repair and staff.Visual inspection prior Y
maintenance, to each operation.
Only competent personals Lock out tagout procedure
allowed for the follows
maintenance ,Training and
Failure of maintenance
activity/Poor Maintenance
Property damage ,Fatalities tool box talk Y
Periodic inspection to be
done . And colour coded.

Trained operators ,Tool box Control for the operational


talk and specific training key or lock out tagout
Machine operated by
unauthorized Personals.
Major incident 2 3 5 30 conducted. while machine is un Y
Attendants.

S26-HS-62_Rev.02_15.10.2016
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Date/Updated Date 06.04.2016

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Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
Trained operators ,Tool boxAddress the Risk
talk and specific training assessment and OCP
conducted. .Follow the daily inspection
Donot wear any loose hand checklist
gloves,Jewellery,Rings.etc Keep distance from the
machine
Loss of body parts Donot place your hand or
Pinch point
Permananent disability 2 3 5 30
finger on the
Y
cutting/bending place or
Keep away you hand and
finger under metal plates
as you are bending or
cutting the plate.
Sign boards
Competent operator Addressing the risk
Donot wear any loose assessment and ocp
clothes,jewellery,rings etc. .follow the daily inspection
Entaglement in the Permanent disability Donot pick u the workpiece checklist. Nobody allow to
rotating/moving parts Fatlities Y
or cut materials during stand near to the machine.
bending or cutting .

Competent operator Competent operator


Donot wear any loose Donot wear any loose
clothes,jewellery,rings etc. clothes,jewellery,rings etc.
Donot pick u the workpiece Donot pick the workpiece
hand caught between the Loss of body parts or cut materials during or cut materials during
bending plates Permananent disability cutting or bending cutting or bending. Y
Operator confirm the hand
are free from the plate
before pressing the button.

DURMA plate cutting and Competent operator . Donot operate the


14 Manual inplace machine if pressure is
bending machine
more than the
Overload/pressure the Property damage recommended pressure
machine Major incident , 2 3 5 30 Y
(folow the pressure
tag).Never exeed the
capacity of the machine.
Competent operator . Addressing the risk
Sensor inplace assessment and ocp
.follow the daily inspection
checklist. Nobody allow to
stand near to the machine.
Unauthorized entry of the Provide permanent fence
personels
Major injury/Fatality Y
to protect Unauthorized
entry. Visual inspection
around the machine before
starting the machine.

S26-HS-62_Rev.02_15.10.2016
DURMA plate cutting and
14
bending machine

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Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
ELCB fitted on sub main maintenace and repair
distribution panel,power done by authorized
Electric Shock Fatality/severe burn shut down before repair and staff.Visual inspection prior
Y
maintenance, to each operation.
Only competent personals Lock out tagout procedure
allowed for the follows
Failure of maintenance maintenance ,Training and
activity/Poor Maintenance
Property damage ,Fatalities tool box talk
Y
Periodic inspection to be
done . And colour coded.
Trained operators ,Tool box Control for the operational
Machine operated by talk and specific training key or lock out tagout
unauthorized Personals.
Major incident 2 3 5 30 conducted. while machine is un Y
Attendants.

Regular house water fire hose reel,fire


keeping(cleaning and sprinklers,fire alarms
removel of combustible Follow the daily inspection
material),fire extingushers checklist .Addressing the
Risk assessment and OCP
Fire Hazard sever burns,fatality to the involved groups Y
Fire watcher provided to
inspect 30 minute post hot
work activities finishing to
ensure fires dont occur.

2 3 12 Competent, trained
,Qualified and third party
Authorized persons to
Exposure to welding slags Superficial burns conduct welding work N/A N
activities.PPE(welding
apron,leather gloves,safety
shoes)
2 3 2 18 Using appropriate filter(no
Expousre to welding flash(ultra 12 or high) ,Long Sleeved
Eye/Skin irritation N/A N
violet and infra red) overalls,protection screens
to protect other workers.
2 3 3 18 Adequate ventilation,Wear
appropriate
PPE(Respirator,welding Yearly Master health
Welding fumes Respiratory Problems N
mask,leather welding checkup
gloves,apron etc,Regular
breaks during in place.
Competent, trained
,Qualified and third party Follow the daily inspection
Property damage ,major checklist .Addressing the
Incompetent operator 3 3 2 18 Authorized persons to N
incident conduct welding work Risk assessment and OCP
activities. to the involved groups.

S26-HS-62_Rev.02_15.10.2016

15 welding
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Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)

Certified welders,quaterly
Proper earthing to be
inspection and colour
coding by electrical done.Periodic inspection
Electric Shock Fatal accident
and color code the welding
Y
department,Elcb fitted on
15 welding main sub-panel boards machine

Secure the cyilinders with


chain
Periodic inspection to be
done.
Hot works equipments
Follow the daily inspection
,Oxyacetylene,Welders,etc
checklist .Addressing the
to be inspection prior to use.
Property damage ,major Risk assessment and OCP
Falling of cyilnders
incident 3 3 2 18 Gas cylinders must be fitted
to the involved groups.
N
with flashback arrestors
Ensure the there are no
Gas hoses must be crimped
leaks from valves and
Ensure valves and guages
tubes or torches.
are properly fixed.

cable mangement inplace donot cross the cable in


walkways clearly marked the wallways.
Roll the cable when the
Tripping and slipping hazard minor/major injury 2 3 2 12 work fininsh or attendant. N
Provide additional channel
to take alll the cable form
pannels.
Only competent personals Periodic maintenace to be
allowed for the done and colour coded
Failure of maintenance maintenance ,Training and
activity/Poor Maintenance
Property damage ,Fatalities tool box talk
Y
Periodic inspection to be
done . And colour coded.
Trained operators ,Tool box Unplug the machine while
Machine operated by
Major incident 2 3 5 30 talk and specific training machine is un Attendants. Y
unauthorized Personals. conducted.
Certified welders Follow the daily inspection
Wear appropriate PPE's checklist .Addressing the
burns/scalds. minor /major degree burn 3 4 2 24 (Leather welding hand Risk assessment and OCP N
gloves,welding apron,shoes to the involved groups.
mask etc.
Competent, trained persons Follow the daily inspection
to conduct welding work
Property damage ,major checklist .Addressing the
Incompetent operator
incident 3 3 2 18 activities.
Risk assessment and OCP
N
to the involved groups.
safety guard fitted on every Periodic maintenace to be
grinder,dead man done and coloue coded
Contact with the running disc Serious Injury, 4 2 2 16 switch,quaterly inspections N
coding,trainings,PPE
S26-HS-62_Rev.02_15.10.2016
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Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
Using good quality Periodic maintenace to be
discs,using right disc for the done and colour coded
Disc break during work Serious Injury, 4 2 2 16 job (cutting disc for cutting N
and grinding disc for
grinding),safety guard
PPE (Helmet with face
Follow the daily inspection
shield,protective
checklist .Addressing the
Expousre to metal chips Eye/Facial injury 3 3 2 18 clothing),protective screen
Risk assessment and OCP
N
to prevent expousre to other
to the involved groups.
workers.
PPE (Ear Plugs)
High Noise Ear Damage/loss of hearing 3 5 2 15 N/A N

Regular house water fire hose reel,fire


keeping(cleaning and sprinklers,fire alarms
removel of Combustible Fire watcher provided to
Fire Fatal accident material),fire extingushers inspect 30 minute post hot Y
work activities finishing to
16 Grinding ensure fires dont occur.

Donot cut/grind the material anti-kickback safety clutch


under pressure.Release the
pressure and cut/grind the
Kickback minor/major injury 2 3 2 12 materials, N

cable mangement inplace donot cross the cable in


walkways clearly marked the walkways.
Roll the cable when the
Tripping and slipping hazard minor/major injury 2 3 2 12 work finish or attendant. N
Provide additional channel
to take all the cable form
panels.
Only competent personals Periodic maintenace to be
allowed for the done and colour coded
Failure of maintenance maintenance ,Training and
activity/Poor Maintenance
Property damage ,Fatalities tool box talk Y
Periodic inspection to be
done . And colour coded.

Trained operators ,Tool box Unplug the machine while


Machine operated by talk and specific training machine is un Attendants.
unauthorized Personals.
Major incident 2 3 5 30
conducted.
Y

Hot works ( Gas


Hot Material(metal spatter,hot 2 3 12 PPE(welding apron,leather
Cutting,heating) work pieces)
Superficial burns gloves,safety N/A N
shoes,Gauntlets)
2 3 2 6 Water coolers,ORS
Dehydration,Heat distribution in hot
Heat Stress
Cramps,Heat strokes weathers,First Aid room with N/A Y
Nurse
S26-HS-62_Rev.02_15.10.2016
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Hot works ( Gas
Date/Updated Date 06.04.2016
Cutting,heating)
Next Review Date

Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)

1 Good quality Fire alarm,fire hose


hoses,valves,regular reel,sprinklers
Leakage of gas Flashfire/Explosion inspections,Fire Periodic inpsection for the Y
exingushers leak detection
cylinders are carried and Follow the daily inspection
Fall of Cylinder during work or secured in a trolly with a checklist .Addressing the
transfer
Explosion chain/permanent locked in Risk assessment and OCP
Y
the beam. to the involved groups.
Flashback arresstor fitted on Installation of flashback
Back fire due to blocked every cylinder arrestors at nozzle points
nozzle
Explosion as well as walve points Y

Hot works are not Fire alarm,fire hose


performed in the presence reel,sprinklers,first aid
of combustible room with nurse.
material,PPE(Leather Fire watcher provided to
Fire Fatal accident
Gloves,Eye inspect 30 minute post hot
Y
17 Protection,protctive work activities fininshing to
Clothing),fire extinguisher ensure fires dont occur.

used igniter for igniting the Follow the daily inspection


wrong lighter for igniting the Fire/explossion gas cutting set.(donot use checklist .Addressing the
torch burn gas filled lighter for ignite). Risk assessment and OCP Y
to the involved groups
2 3 2 12 well ventilated
area,repirators are being
used when hot works
Fumes Respiratory Problems performed on coated N/A N
material (galvanised
steel,stainless steel,carbon
steel)
hose mangement inplace donot cross the hose in the
walkways clearly marked wallways.
Tripping and slipping hazard minor/major injury 2 3 2 12 Rolll the hosewhen the N
work fininsh or attendant.

Trained operators Follow the daily inspection


deignated storage for all the checklist .Addressing the
cylinders.avoid freestanding Risk assessment and OCP
storage of empty cylinders in Fire/explossion
undesignated area burn Empty cylinder .kept back to the involved groups Y
in the storage

Competent, trained persons


Follow the daily inspection
to conduct welding work
Property damage ,major checklist .Addressing the
Incompetent operator
incident 3 3 2 18 activities.
Risk assessment and OCP
N
to the involved groups.

S26-HS-62_Rev.02_15.10.2016
Report No 4

HAZARD IDENTIFICATION AND RISK ASSESSMENT REPORT Rev 4

Page
www.solb26.com
Area/Department Fabrication

Date/Updated Date 06.04.2016

Next Review Date

Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
Using good condition lifting Competent operators
gears with third party ,riggers involve in
Fall of material during loading certified and colour lifting,Daily visual
and unloading in the blasting Personal injury 4 2 16 coded,Only trained inspection for the lifting N
tent operator use for the EOT equipments and folow the
Crane operator . daily inspection checklist.

PPE (Blasting apron with air Regular check up of


fed helmet),Dead man blasting machine and
18 Manual Blasting silicosis(Ocupational lung handle fitted on hoses by maintenance
Expousere to grit blast during
blasting
disease),Major injury,Eye 4 2 2 16 hose,certified department,Yearly master N
injury blaster,separate area for health check up.
manual sand blasting,

Only competent personals Lock out tagout procedure


allowed for the follows
Failure of maintenance maintenance ,Training and
activity/Poor Maintenance
Property damage ,Fatalities tool box talk Y
Periodic inspection to be
done . And colour coded.
Trained operators ,Tool box power off when not in used
Machine operated by
Major incident 2 3 5 30 talk and specific training Y
unauthorized Personals. conducted.

Using good condition lifting Competent operators


gears with third party ,riggers involve in
certified and colour lifting,Daily visual
Fall of material during loading
and unloading in the painting
Personal injury 4 2 16 coded,Only trained inspection for the lifting N
operator use for the EOT equipments and folow the
Crane operator . daily inspection checklist.

Qualified painters,PPE PFT test


Ocupational (Respirators),MSDS and
Inhalation and Ingestion
Asthma,Respiratory Problems 4 3 2 24 COSHH addresingTrainings N

P.P.E (Eye Protection,hand Follow the daily inspection


protection full body checklist .Addressing the
Paint Splash in the coveralls),OCP
Serious Eye Injury,contact Risk assessment and OCP
eyes,contact with the
dermatitis 3 2 2 12
to the involved groups.
N
skin(Injection Injury)
MSDS and COSHH
addresingTrainings
Address the Risk Safe working capacity for
property damage /personal assessment ,safe the working.
Failure of working bench injury to the nearby 4 2 2 16 operational control for the N
personells. task. Conduct Tool box talk
19 Painting

S26-HS-62_Rev.02_15.10.2016
Report No 4

HAZARD IDENTIFICATION AND RISK ASSESSMENT REPORT Rev 4

Page
www.solb26.com
Area/Department Fabrication

Date/Updated Date 06.04.2016

Next Review Date

Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
19 Painting Mixing of the paint in the Follow the daily inspection
designated area only. checklist .Addressing the
Storage of the paint in the Risk assessment and OCP
paint spillages environmental side effects 3 4 2 24
closed area, to the involved groups.
N
Paint handle by only MSDS and COSHH
qualified trained painters addressingTrainings
dispose the empty paint Follow the daily inspection
cans only in the seprarate checklist .Addressing the
skip provided. Risk assessment and OCP
incorrect disposal environmental side effects 3 4 2 24 Disposal in the Approved to the involved groups. N
area (MIC) MSDS and COSHH
addressingTrainings

S26-HS-62_Rev.02_15.10.2016
Report No 4

19 Painting HAZARD IDENTIFICATION AND RISK ASSESSMENT REPORT Rev 4

Page
www.solb26.com
Area/Department Fabrication

Date/Updated Date 06.04.2016

Next Review Date

Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
separate painting area,only
Expousre to wokers (Other shortness of painters are allowed at the
than Painters),Painting breath,respiratorty tract 2 3 2 12 time of painting N/A N
inspectors etc. irritaion

Naked flames,cigarette water fire hose reel,fire


lighters,Hot works (Grinding sprinklers,fire alarms
and Cutting) are not allowed
Fire Hazard Fatal accident in painting area,Fire
Y
extinguishers in place

Ensure OCP and/or RAMS Provision of Toolbags or


are discussed with the work belts while working.
group prior to works Tools must be used in
commencing accordance with
Trained, Competent and manufacturers instructions
Physical Authorised Supervision Ensure tool inspection
Minor or major injury 3 3 2 18 present at all times to color code N
ensure employees/workers Works supervisor to ensur
are adhering to safe working all work crews involved
procedures with use of tools have
been trained in their safe
use.

Ensure OCP and/or RAMS Always use Right tools for


20 Use of Hand tools are discussed with the work right job
group prior to works
commencing
Trained, Competent and
improper tools Minor or major injury 3 3 2 18 Authorised Supervision N
present at all times to
ensure employees/workers
are adhering to safe working
procedures
Wear appropriate PPE
loss of sensation (Gloves/Goggles/Hearing
Noise/Vibration
hearing loss 3 3 2 18 protection/Head Protection N
and safety Footwear)

Ensure safe procedure Avoid manual handling


and/or RAMS are discussed wherever possible. Use
with the work group prior to mechanical means e.g.
works commencing. cranes, chain blocks, FLT,
Musculoskeletal injury spinal injury 3 4 2 24
Training and tool box talk Genie hoist, pallet trucks,
N
conducted.Always lift with wheel barrows, sack trucks
you leg not your back. etc.

S26-HS-62_Rev.02_15.10.2016
Report No 4

HAZARD IDENTIFICATION AND RISK ASSESSMENT REPORT Rev 4

Page
www.solb26.com
Area/Department Fabrication

Date/Updated Date 06.04.2016

Next Review Date

Consideration Rating Controls Significance


Non-
SI No Activity/Location/Process Routine Hazards Risks Remarks
routine
N A E L S P PC RPN Existing Preventive (Y/N)
Ensure load is suitable to be Avoid manual handling
lifted. Is the packaging/bag wherever possible. Use
damaged mechanical means e.g.
-Wear suitable gloves at all cranes, chain blocks, FLT,
cut times. Gloves suitable for Genie hoist, pallet trucks,
shifting of sharp edges
minor/major injury 3 4 2 24
carrying bolt bags may not wheel barrows, sack trucks
N
be suitable for handling cold etc.
rolled steel! Dynemaor
Kevlar gloves are available
for sharp objects.
4.Ensure weights are known Avoid manual handling
or assessed accordingly. wherever possible. Use
21 Manual Handling -No individual to lift more mechanical means e.g.
than they are comfortable cranes, chain blocks, FLT,
with e.g. 25kg. Genie hoist, pallet trucks,
-Load to be carried as close wheel barrows, sack trucks
to the body as possible, etc.
preferably at waist height
Heavy Loads. spinal injury 3 4 2 24
and all the workers to be
N
trained on safe lifting
procedure to avoid injury.
-Personnel to be trained in
correct Manual handling
techniques.

Personnel to be trained in Avoid manual handling


correct Manual handling wherever possible. Use
techniques. mechanical means e.g.
Property damage cranes, chain blocks, FLT,
Dropping of loads/materials.
minor/major injury 3 4 2 24 N
Genie hoist, pallet trucks,
wheel barrows, sack trucks
etc.

S26-HS-62_Rev.02_15.10.2016
METHOD STATEMENT FOR
FABRICATION OF
Qatar Rail, Red Line South Underground -
RED LINE SOUTH UNDERGROUND
Entrance Shelters and Pop-Ups
Date: 16.03.2017 Codification: M003-SLB-STS-MES-00001 Rev: 1 Page 40 of 81

Appendix D
Work Programme

M003-SLB-STS-ITP-00001 Rev. 0 Date of Form: 2015-12-03


C170 - RLSU Entrance Shelters - Rev2 - 8Feb2017 26-Feb-17 16:43

Activity ID Activity Name Original Start Finish Total Float N D J F M A M J J A S O N D J F M


Duration 3 0 1 2 2 0 1 1 2 0 0 1 2 2 0 1 1 2 0 1 1 2 0 0 1 2 3 0 1 2 2 0 1 1 2 0 0 1 2 3 0 1 2 2 0 1 1 2 0 0 1 2 2 0 1 1 2 0 1 1 2 3 0 1 2 2 0 1 1 2 01

Fabrication 161 18-May-17 26-Nov-17 19


26-Nov-17, Fabrication
Shelters 161 18-May-17 26-Nov-17 19
Fabrication P
Package 1 161 18-May-17 26-Nov-17 0 26-Nov-17, Shelters
AMB - Al Doha
D Al Jadeda 52 18-May-17 20-Jul-17 55 26-Nov-17, Fabrication Pa
FAB1020 AMB - Entrance 02 (Capital Security) - Type 1A 26 18-May-17 17-Jun-17 41 20-Jul-17, AMB - Al Doha Al Jadeda
FAB1000 AMB - Entrance 01 (On Station) - Type 4A 29 27-May-17 02-Jul-17 32
FAB1030 AMB - Entrance 03 (Al Osais) - Type 1A 26 18-Jun-17 20-Jul-17 55
AME - Oqba
Oqb Ibn Nafie 28 03-Aug-17 05-Sep-17 45
FAB1010 AME - Entrance 01 - Type 4A 28 03-Aug-17 05-Sep-17 45 05-Sep-17, AME - Oqba Ibn Nafie
AMC - Umm
Um Ghuwailina 81 18-May-17 23-Aug-17 0
FAB1060 AMC - Entrance 02 - Type 2A 27 18-May-17 18-Jun-17 0 23-Aug-17, AMC - Umm Ghuwailina
FAB1050 AMC - Entrance 03 - Type 2A 27 19-Jun-17 23-Jul-17 0
FAB1070 AMC - Entrance 04 - Type 2A 27 24-Jul-17 23-Aug-17 0
AMD - Al M
Matar 71 03-Jul-17 24-Sep-17 0
FAB1110 AMD - Entrance 04 (Station) - Type 4A 27 03-Jul-17 02-Aug-17 40 24-Sep-17, AMD - Al Matar
FAB1100 AMD - Entrance 01 (Airport Park) - Type 2A 26 24-Aug-17 24-Sep-17 0
KUB - Al M
Mansoura 53 25-Sep-17 26-Nov-17 0
FAB1140 KUB - Entrance 01 - Type 2A 26 25-Sep-17 25-Oct-17 0 26-Nov-17, KUB - Al Mans
FAB1130 KUB - Entrance 02 - Type 2A 26 26-Oct-17 26-Nov-17 0
Fabrication P
Package 2 108 29-May-17 05-Oct-17 63
AME - Oqba
Oqb Ibn Nafie 25 06-Sep-17 05-Oct-17 63 05-Oct-17, Fabrication Package 2
FAB1040 AME - Entrance 02 - Type AME 02 25 06-Sep-17 05-Oct-17 63 05-Oct-17, AME - Oqba Ibn Nafie
AMC - Umm
Um Ghuwailina 52 29-May-17 31-Jul-17 39
FAB1090 AMC - Entrance 05 - AMC 05 26 29-May-17 01-Jul-17 39 31-Jul-17, AMC - Umm Ghuwailina
FAB1080 AMC - Entrance 01- Type AMC01 26 02-Jul-17 31-Jul-17 39
AMD - Al M
Matar 27 01-Aug-17 31-Aug-17 39
FAB1120 AMD - Entrance 02 (Pizza Hut) - Type AMD02 27 01-Aug-17 31-Aug-17 39 31-Aug-17, AMD - Al Matar

Actual Work Critical Remaining Work Page 8 of 12 TASK filter: All Activities

Remaining Work Milestone Oracle Corporation


C170 - RLSU Entrance Shelters - Rev2 - 8Feb2017 26-Feb-17 16:43

Activity ID Activity Name Original Start Finish Total Float N D J F M A M J J A S O N D J F M


Duration 3 0 1 2 2 0 1 1 2 0 0 1 2 2 0 1 1 2 0 1 1 2 0 0 1 2 3 0 1 2 2 0 1 1 2 0 0 1 2 3 0 1 2 2 0 1 1 2 0 0 1 2 2 0 1 1 2 0 1 1 2 3 0 1 2 2 0 1 1 2 01

Painting 147 11-Jun-17 03-Dec-17 15


03-Dec-17, Painting
Painting Package
Packa 1 147 11-Jun-17 03-Dec-17 0
AMB - Al Doha
Doh Al Jadeda 34 11-Jun-17 23-Jul-17 55 03-Dec-17, Painting Pac
PNT1150 AMB - Entrance 02 (Capital Security) - Type 1A 8 11-Jun-17 19-Jun-17 41 23-Jul-17, AMB - Al Doha Al Jadeda
PNT1160 AMB - Entrance 01 (On Station) - Type 4A 9 21-Jun-17 04-Jul-17 32
PNT1170 AMB - Entrance 03 (Al Osais) - Type 1A 8 15-Jul-17 23-Jul-17 55
AME - Oqba Ibn Nafie 9 28-Aug-17 07-Sep-17 45
PNT1230 AME - Entrance 01 - Type 4A 9 28-Aug-17 07-Sep-17 45 07-Sep-17, AME - Oqba Ibn Nafie
AMC - Umm Ghuwailina 62 12-Jun-17 26-Aug-17 44
PNT1220 AMC - Entrance 02 - Type 2A 8 12-Jun-17 20-Jun-17 55 26-Aug-17, AMC - Umm Ghuwailina
PNT1210 AMC - Entrance 03 - Type 2A 8 17-Jul-17 25-Jul-17 71
PNT1200 AMC - Entrance 04 - Type 2A 8 17-Aug-17 26-Aug-17 5
AMD - Al Matar
Mat 52 27-Jul-17 26-Sep-17 38
PNT1190 AMD - Entrance 04 (Station) - Type 4A 8 27-Jul-17 05-Aug-17 40 26-Sep-17, AMD - Al Matar
PNT1180 AMD - Entrance 01 (Airport Park) - Type 2A 8 17-Sep-17 26-Sep-17 38
KUB - Al Mansoura
Man 39 18-Oct-17 03-Dec-17 0
PNT1250 KUB - Entrance 01 - Type 2A 8 18-Oct-17 28-Oct-17 27 03-Dec-17, KUB - Al Ma
PNT1240 KUB - Entrance 02 - Type 2A 8 23-Nov-17 03-Dec-17 0
Painting Package
Packa 2 90 21-Jun-17 08-Oct-17 63
AME - Oqba Ibn Nafie 8 28-Sep-17 08-Oct-17 63 08-Oct-17, Painting Package 2
PNT1290 AME - Entrance 02 - Type AME 02 8 28-Sep-17 08-Oct-17 63 08-Oct-17, AME - Oqba Ibn Nafie
AMC - Umm Ghuwailina 34 21-Jun-17 02-Aug-17 65
PNT1270 AMC - Entrance 05 - AMC 05 8 21-Jun-17 03-Jul-17 47 02-Aug-17, AMC - Umm Ghuwailina
PNT1260 AMC - Entrance 01- Type AMC01 8 25-Jul-17 02-Aug-17 65
AMD - Al Matar
Mat 8 26-Aug-17 04-Sep-17 39
PNT1280 AMD - Entrance 02 (Pizza Hut) - Type AMD02 8 26-Aug-17 04-Sep-17 39 04-Sep-17, AMD - Al Matar

Actual Work Critical Remaining Work Page 9 of 12 TASK filter: All Activities

Remaining Work Milestone Oracle Corporation


METHOD STATEMENT FOR
FABRICATION OF
Qatar Rail, Red Line South Underground -
RED LINE SOUTH UNDERGROUND
Entrance Shelters and Pop-Ups
Date: 16.03.2017 Codification: M003-SLB-STS-MES-00001 Rev: 1 Page 41 of 81

Appendix E
Dimensional Tolerances (Annex D) as per EN 1090

M003-SLB-STS-ITP-00001 Rev. 0 Date of Form: 2015-12-03

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