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Doc. SWF14
Rev. B
Date: 12/11/12
Page 1 of 25
METHOD STATEMENT
Assembly & Disassembly of Terex Demag CC8800-1 Crawler Crane
ALEME-HL-1076 BNPP(Braka Nuclear Power Plant) Project Hyundai Engineering & Construction Co., Ltd ALEME-MS-CC8800-1
B A Revision
AMH JT Prepared
SW SW Checked
JT PS Approved
Approved Client
CONTENTS
1. INTRODUCTION............................................................................................................................. 4
1.1. SCOPE OF DOCUMENT ............................................................................................................. 4 1.2. PARTIES ..................................................................................................................................... 4 2. MANAGEMENT OF OPERATIONS ............................................................................................... 5 2.1. THE ALE ENGINEER & PROJECT MANAGER ........................................................................... 5 2.2. THE ALE OPERATIONS SUPERVISOR ..................................................................................... 5 2.3. MANAGEMENT OF CHANGE ..................................................................................................... 5 2.3.1. Category 1 (Minor) Deviation ............................................................................................. 5 2.3.2. Category 2 (Major) Deviation ............................................................................................. 5 2.4. SITE SAFETY .............................................................................................................................. 6 2.5. TOOLBOX TALK RECORD ......................................................................................................... 7 3. PREREQUISITES AND INITIAL CONDITIONS ............................................................................. 8 GENERAL.................................................................................................................................... 8 RESPONSIBILITIES .................................................................................................................... 8 CONTROL OF OPERATION ....................................................................................................... 8 ORGANOGRAM .......................................................................................................................... 9 3.1. 3.2. 3.3. 3.4.
OPERATIONAL PROCEDURES ........................................................................................................... 10 3.5. PRE-OPERATION PREPARATORY WORKS ............................................................................... 3.6. OPERATIONAL PROCEDURE.................................................................................................. 10 3.7. DEMOBILISATION OF ALE EQUIPMENT ................................................................................. 23 4. 5. 6. PROJECT DRAWINGS AND REFERENCE DOCUMENTS ........................................................ 23 CERTIFICATION .......................................................................................................................... 24 RISK ASSESSMENTS AND ASSOCIATED DOCUMENTS ........................................................ 25
1.
INTRODUCTION
LEGISLATION
Health & Safety at Work Act 1974 Lifting Operations and Lifting equipment Regulation 1998 Provision and Use of Work Equipment Regulations (PUWER) 1998 The Management of Health & Safety at Work Regulations 1999 BS 7121 Safe Use of Cranes
OTHER
ALE General Terms & Conditions ALE HSQE Procedures
1.2. PARTIES
The relevant parties involved with the rigging operation are listed below: - Client - ALE Main contractor and Cranes Subcontractor transport and lifting
2.
MANAGEMENT OF OPERATIONS
Outlined below are the responsibilities of ALE personnel. This section also details the procedures to follow if a deviation from the original operations procedure occurs.
Where necessary, engineering deviations / changes will be approved by the client or nominated third party. On approval, any changes in the method statement and / or intended scope of work affecting the safe system of work will be communicated to the work force by means of a recorded toolbox talk. All deviations and / or changes will be recorded and authorised within the record box provided within this method statement. A record of authorised changes during scope of work is available within the template of any Method Statement devised for the erection and/or operation of any (ALE) equipment. An example is provided below:
Cat
Date
Change to MS
Action
ALE Engineer
ALE Supervisor
Example of a record of authorised changes during the execution of work within an ALE method statement
Content of TBT:
Supervisors Signature:
3.
3.1. GENERAL
1. 2. 3. Method Statement is subject to approval prior to the commencement of work. Method Statement to be read in conjunction with the attached JHA (Job Hazard Analysis). After any break in the operational procedure, a walk round and visual inspection will be made of the equipment in its current set up to check that nothing has changed since leaving the work place. Minimum Personnel Protective Equipment (PPE) to be worn on site is as follows: Overalls, Hard Hat, Safety Footwear, Eye Protection, Gloves, Full Safety Harnesses (where necessary).
4.
3.2. RESPONSIBILITIES
1. 2. 3. Clear area for working afforded at all times by client. Ground preparatory work to be carried out prior to arrival of crane and to be able to withstand the loadings imposed during this operation whilst not exceeding a settlement of ** mm. Client to supply mechanical handling equipment (i.e. craneage and forklift truck [if required]) for the sole use of ALE on-site activities.
7.
8.
After any break in the operational procedure, a walk round and visual inspection will be made of the equipment in its current set-up to check that nothing has changed since leaving the work place. 9. The ALE operators are capable of fixing most problems that can occur during the operations. 10. Other maintenance engineers are available on call to assist in rectifying any equipment malfunction in the shortest possible time.
3.4. ORGANOGRAM
Clients Representative
Subcontract Transport
4.
OPERATIONAL PROCEDURES
On the days that any activity takes place there will be a toolbox talk prior to the start of activities that will review the following items: a) Procedures, requirements and details specified in the work plans and drawings. b) Review of safety items such as weather concerns, plant activity, escape routes, contingency plans, locations of fire-fighting and personal safety equipment etc. Note: Weather forecasts will be obtained prior to the movement. If the forecasts, in conjunction with the actual wind speed readings taken on the site / crane wind speed indicators, do not give a sufficient window of suitable weather, then the movement/lifting programme will be re-assessed. c) Designate key personnel, such as slinger-signaller, tagline handlers etc. d) Complete and sign off all appropriate checklists and safety permits. e) Check the placement of all banners and barricades that define the safety boundaries of the work areas. Discuss and give due consideration to any additional appropriate steps that any participant feels is necessary to perform a safe and timely operation. Limits Wind speed 24hr weather forecast (wind) Visibility Potential lightning Starting time Surface Go < 9.8m/s Dropping > 30m < 30% < 10.00hr Good traction available No go > 9.8m/s Increasing < 30m > 30% >10.00hr Poor traction
The cranes to be utilised for the assembly of the crane are specified as follows: 250Te Telescopic Crane 150Te Telescopic Crane
Confirm rigging area is clear and has required space to assemble the crane safely. Confirm that any necessary permissions / permits to work are in place to commence rigging. Position the Intermediate Section on Steel Supports for the commencement of rigging.
% Capacity 66.4
Crane 150t
% Capacity 28.1
4. Insert the short catwalk grating (4) with the auxiliary crane between the catwalks (1 and 2) at the front and secure with locking bolt.
% Capacity 79.6
Crane 150t
% Capacity 84.4
Crane 150t
% Capacity 76.5
The Superlift mast is fitted and tilted forwards. The lifting beam for attaching the main boom is fitted on the fixed bridle. Hoist ropes H1, H2 and H3 are fed over the guide sheaves and between the sheaves up to the mast foot section and lashed in place on the mast basic boom.
% Capacity 83.7
Assemble main boom in the above sequence & attach to the superstructure using the backmast & auxiliary crane. Guide reeving rope from the reeving winch under the main boom forwards to the head over the sheaves in the head and over the main boom up to the mast foot section. Connect the hoist ropes individually with the reeving rope and use the reeving winch to draw forward to the crane head and lash in place. The corresponding hoist must then be paid out. Reeve the reeving rope between the sheaves in the hook block and the sheaves in the head in accordance with the correct reeving drawing. Reeve hoist rope H1 and H2 as far as required number of hoist falls Attach hoist rope H1 and H2 to the fixing point. Lift the rope shackle from the transport mount on the head remove pin, guide the rope shackle halves around the front strands of the hoist rope H1and H2 and pin again.
Connecting the Telescopic Tube Connect the telescopic tube using auxiliary crane to superstructure & connect to superlift tray.
Crane 150t Load (t) 18.0 Tackle (t) 1.7 Total Load (t) 19.7 Radius (m) 10.0 Capacity (t) 41.7 % Capacity 47.2
Boom up the main boom crane is now ready to work. For a more detailed description refer to the operators manual.
4.2. DEMOBILISATION OF ALE EQUIPMENT DISSASSEMBLEY IS THE REVERSE OF THE ABOVE OPERATION. PROJECT DRAWINGS AND REFERENCE DOCUMENTS
DRAWING NUMBER HL1076-001
DESCRIPTION Provisional Rigging Location of Terex CC8800-1 By 250t & 150t Cranes
Reference documents:
5.
CERTIFICATION
All lifting equipment within this procedure is to have current test and/or inspection certification at the time of the operation. Copies of the test and inspection certificates will be available from the Project Site Supervisor. As Attached
6.
As Attached JHA
Activity:
Description of Work:
Arrival, Offloading and Construction of Terex Demag CC8800-1 1600Te Crawler Crane.
Not Required
BNPP HSE Plan and safety procedures are to be followed at all times. Minimum PPE to be worn at all times. This JHA to be available at all points of work operatives must be informed of this JHA and understand the risks involved in the works. Tool box meeting / pre-job brief to be given at the start of each work shift and before starting a new task or activity. Paramedical or ambulance facilities to be available.
LS Likelihood / Frequency CS Severity of consequence HSJV Hyundai Samsung Joint Venture Consequence: E Environmental H Health S Safety
Analysis criteria: Probability Rare (1) Possible (2) Likely (3) Often (4) Frequent (5) 15 25 8 12 46 13 Descriptor Environment Frequent Often Likely Possible Rare Descriptor Environment Catastrophic Major Moderate Minor Insignificant Long term severe / permanent impact on ecosystem Significant widespread impact on ecosystem Significant localized impact on ecosystem Minor changes to ecosystem Insignificant occasional change to ecosystem Continuous or will happen frequently. 5 12 times per year. 1 5 times per year. Once every 5 years. Less than once every five years Consequence Health and Safety Multiple fatalities Fatality Serious injuries off site medical treatment Injuries on site medical treatment Minor injuries first aid 5 4 3 2 1 Severity Insignificant (1) 1 2 3 4 5 Extreme Risk (E) High Risk (H) Moderate Risk (M) Low Risk ((L) Minor (2) 2 4 6 8 10 Moderate (3) 3 6 9 12 15 Major (4) 4 8 12 16 20 Activity must not proceed in current form. Activity must be modified to include further control measures and be subject to detailed HSE dept assessment. Activity can proceed subject to appropriate direct and continuous supervision and/or task modification. No action required. Activity can proceed subject to compliance with the specified control measures. Likely Frequency Health and Safety Occurs several times a year at location. Occurs several times a year in similar industries in UAE Has occurred at least once in UAE Has occurred in industry (Worldwide). Never encountered in industry. 5 4 3 2 1 Severity Probability Catastrophic (5) 5 10 15 20 25
Activities
1 LIFTING Mobiles cranes Fork Lift
Hazards
Equipment falling from crane rigging and piece being lifted. Ground subsidence under lifting equipment. Inoperative ASLI or intermittent reading. Failure of lifting tackle.
Consequence (E/H/S)
Injury - on site medical treatment. Serious injury - off site medical treatment Fatality. Multiple Fatality. Damage to equipment.
LS 3
CS 2
RATING
Residual risk
PTW needed
15
Yes
High winds/extreme weather. Structural failure of crane or hoist rope. Failure of lifting points or structural integrity of load being lifted. Engine failure on crane. Uncoordinated lifting equipment. Boom fouling on equipment or structure. Suspended load over equipment with personnel working in close proximity.
Collision with other plant / traffic. Damage to property. Crane unstable, overturning or collapse. Overloading of crane, damage to structural strength or members. Load falling from height, damage to load and impact zone. Possibility of suspended load on crane hook and delayed programme. Damage to surround structures.
LIFTING (continued)
All equipment to be lifted must be capable of withstanding loadings imposed into any lifting point or attachment thereof. Operator daily and weekly inspections shall be completed and recorded to ensure continuous monitoring of safety systems and manufacturers requirements for maintenance and inspection audited on site. Preventative maintenance on crane engine to reduce possibility of failure. Mechanics available on site to repair any problems immediately. Radios used to give instructions, also system of hand signals known to all riggers and persons who may direct crane operations. Persons involved will speak the same language. If communication is lost all operations will stop immediately. Personnel will not be permitted to work or observe in an area underneath the lifted item. All crane lifts are planned such that any foul points are identified and steps taken prevent them. Should a potential boom foul be identified during the lift, the lift will be stopped. For lifts where equipment or load is in proximity to site structures, extra care to be taken to check for clearances prior to and during the lift operations. During lifting operations the ALE lift supervisor shall direct all crane movements. Personnel will not be permitted to work or observe in an area underneath the lifted item. During a lift the item will be controlled by tag lines and the lift supervisor will be in contact with the crane operator to control the lift at all times, and to stop the lift if necessary. Any potential clashes with other structures will have been identified during the planning of the lift, and steps taken to ensure no contact was made. No personnel shall be under a suspended load and where machinery connections are required limited personnel will conduct these duties.
RIGGING / MANUAL HANDLING Attachment of lifting tackle. Pinned connection of equipment parts.
Injury - on site medical treatment. Serious injury - off site medical treatment. Damage to equipment. Strain Injuries.
12
Correct use of PPE as necessary. Toolbox talks to discuss potential hazards to be undertaken as work progresses.. All operatives to be conversant and comply with correct manual handling techniques. Lifting equipment to be utilised as required. Instruction in manual handling techniques shall be delivered at induction stage and the use of mechanical handling equipment where possible shall take priority. Personal limits shall not be exceeded where MH operations are conducted and two personnel shall be employed where required to reduce the risk of personal injury All hand tools to be kept in good condition. Correct tool to be used for the job and each tool used correctly. Prior to eating or drinking personnel should clean their hands. All personnel will wear full PPE as required by to include protective gloves when working with steel wire rope. All operations will be conducted in accordance with the manufacturers instructions. Limited personnel only will conduct these operations and will be made fully aware of the potential for metal splintering and the requirement to wear PPE as necessary. Personnel will stand clear during hydraulic pinning connections until such time as it is safe to inspect the connection. Personnel will be made aware of the potential for pins to drop or release quickly during extraction. Where possible pins should be secured prior to extraction.
No
Tightening Bolts. Hand/finger injuries. Hammer use. Damage to property. Pin Insertion. Carcinogenic effect, skin irritation. Pin extraction. Hazardous materials during hydraulic connecting / disconnecting.
WORKING WITH MACHINERY / PLANT Mobile Cranes Flat bed Trailers Low bed Trailers
Operatives having parts of their body struck or trapped by mobile equipment e.g. Trailers, Cranes etc. Noise during mechanical operations. Working around moving vehicles. Maintenance to Plant & Equipment. Oil Spills. Operators or personnel falling from moving vehicles or trailers. Hazardous substances on crane. Moving machinery parts.
Injury - on site medical treatment. Serious injury - off site medical treatment. Lost time. Impaired hearing after sustained exposure . Damage to equipment. Bodily harm, crushing injuries, collision with other traffic/plant . Injuries and diseases caused by contact with fuels and lubricants and chemicals. Environmental hazard due to spillage . Fatality.
15
Correct use of PPE as necessary. During handling of the load or equipment, no personnel will stand under it or position themselves between the load and fixed objects. Non-essential personnel to keep away from noisy operations. Personnel to wear hearing protection as necessary. All operators to be trained and certificated in safe use of plant. Clear signaling/banking of plant/vehicles during operations. Operators to be aware of plant & equipment in immediate work area and keep a safe working distance between plant and fixed objects (e.g. buildings, electricity sources). Operatives to keep clear of access roads. Keep safe distance from moving vehicles. Give clear signal prior to moving. Maintenance to follow procedures set out in Operators handbooks, i.e., shutdown, brakes engaged, areas taped off etc. Oil spill kits and absorbent granules to be available on site. Drip trays to be used where applicable. Pre-commissioning checks on all plant to be used on site. No personnel are permitted to ride on moving vehicles or trailers unless a proper seating position is provided All users to be made aware of the hazards of each substance. Substances to be stored in proper containers, only necessary amounts kept on site. Personnel to be trained in dealing with leaks or spillage of substance. Use of guards on all machinery with moving parts.
Yes
WORKING AT HEIGHT Attaching / detaching rigging tackle at height. Boom construction. Accessing Cab.
Acess to and from work place, for crane operators and riggers. Falls from height.
Serious injury - off site medical treatment. Injury - on site medical treatment.
12
Use of safety harnesses and access platforms. Safe access and or egress shall be provided for all activities where personnel are required to work at height . Access ladders to cabs of plant and vehicles to be in good order . Provision of ladders and access scaffolding if necessary . Mandatory use of harnesses, access by way of scaffold or tied off ladder or MEWPS . Avoid work at height unless absolutely necessary. Constant supervision. No 2 tier working sterile areas below work at height. Training on working at height hazard prior to start work
Yes
16
Training on heat stroke hazard prior to start work Establishing of monitoring and control system on hot working condition Positioning of cold drinking water tank near working spot Provision of personal portable drinking water container Establishing of alternative resting system during hot season Establishing of night work program for possible work item during hot season. Provision of rehydration fluids working spot. on
No
Inadequate lighting.
12
Suitable lighting must be provided. Normally in the form of multiple mobile spot light systems. No area of operation to be in shadow. Extra care and attention to be taken during operations.
Yes
Pre-operation briefing in the form of a Toolbox Talk will be carried out normally at the start of every day and prior to any major or special lifting operations by the ALE supervisor to all persons involved in the operation, to ensure all persons understand the activities, roles and responsibilities. The toolbox talk will be recorded. Provision of two-way radios for direct communication from lift supervisor to operators. Hand signals to be agreed prior to operation.
No
Emergency procedure. Unfamiliarity of site conditions and specific risks to personnel. Changes to site conditions.
Serious injury - off site medical treatment. Injury - on site medical treatment.
15
Prior to any transport or lifting operations, a pre-operation check will be made to establish that the current site conditions have not changed and whether there are any changes to the conditions specified within ALE method statement. If there are any changes the ALE site engineer will discuss with the customer point of contact and an assessment made to determine how to proceed, following the ALE management of change procedure.. Prior to working on site, all personnel will attend site project HSE induction (where applicable). New workers will be accompanied by colleagues familiar with site and working conditions. Good housekeeping to prevent materials lying in walkways, clearance of spills of material. Personal safety awareness to be of the highest standard as required by an IIF injury and incident free philosophy. Personnel shall be responsible and encouraged for reporting any known hazard on site that may affect the safety of others.
No
Signature / Date
Signature / Date
Signature / Date
Ticked Yes or No
YES NO
Name: Position:
Content of the toolbox talk: (Include details of any documents you have made reference to):
No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Attendees Name
Signature
Date
Doc. SWF04
Rev. 2.0
Date: 01/10
Page 1 of 1