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METHOD STATEMENT

Assembly & Disassembly of Terex Demag CC8800-1 Crawler Crane

Doc. SWF14

Rev. B

This document is uncontrolled if printed

Date: 12/11/12

Page 1 of 25

METHOD STATEMENT
Assembly & Disassembly of Terex Demag CC8800-1 Crawler Crane

Project Number Project Client Document number

ALEME-HL-1076 BNPP(Braka Nuclear Power Plant) Project Hyundai Engineering & Construction Co., Ltd ALEME-MS-CC8800-1

B A Revision

12/11/12 22/10/12 Date

Details Updated Assembly / Disassembly Description ALE

AMH JT Prepared

SW SW Checked

JT PS Approved

Approved Client

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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

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1.

INTRODUCTION

1.1. SCOPE OF DOCUMENT


This Method Statement is concerned with the assembly of the Terex Demag CC8800-1 - 1600Te capacity lattice boom crane in the maxi lift configuration. The Method Statement and drawings will be made available to ALE employees and any other persons directly involved with the operations. All supervisors and personnel will be required to sign a document agreeing that they understand the work being carried out and that they are familiar with their own responsibilities.(Section 2.5.) It is the aim of this Method Statement to define and describe the equipment, safe system of work and procedures that will be employed by ALE to conduct the operations in compliance with the following legislative and guidance documentation:

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

APPROVED CODES OF PRACTICE


Manufactures Operating Procedures

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

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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.

2.1. THE ALE ENGINEER & PROJECT MANAGER


The ALE Engineer will prepare the method statement along with all drawings and calculations, which will be checked by the ALE authorised Manager. It is the responsibility of the ALE Project Manager to ensure that the on-site Operations Supervisor is adequately briefed on the content of this method statement.

2.2. THE ALE OPERATIONS SUPERVISOR


Prior to the commencement of the works the supervisor must ensure that all site personnel are adequately briefed on the contents of this method statement. This briefing shall take the form of a short toolbox talk. The supervisor must liaise with the ALE manager should site circumstances require material change to the methods to be employed during the operation and follow the ALE management of change procedure provided within this document. It is the responsibility of the supervisor to have completed all safety checklists and briefings as identified within this scope of works.

2.3. MANAGEMENT OF CHANGE


This procedure has been prepared to categorise and authorise any intended deviation from the intended scope of works outlined within this safe system of work. The ALE Operations Supervisor on site is responsible for the work being conducted in accordance with the current approved method statement. Any deviation from that approved method is categorised as follows:

2.3.1. Category 1 (Minor) Deviation


The ALE Operations Supervisor on site considers a deviation from the intended scope of work to be a small adjustment to meet local site conditions. They must bring this matter to the attention of the clients on-site representative. Where the client agrees that the adjustment is minor and would not introduce any risk to personnel or the integrity and safe operation of the equipment, authorisation to proceed may be approved by both parties concerned by signing of the changes to the method statement in the record of changes box provided within the method statement. Any changes must be communicated back to the ALE Engineer / Project Manager and communicated to the work force by means of a toolbox talk, which must also be recorded. The work may then proceed. Any change from the intended scope of work must comply with the manufacturers recommendations for the use of the equipment and any associated procedural documentation, i.e. ALE and client procedures and / or requirements. Where there is any doubt as to the implications changes may have on the safety and / or integrity of the system/equipment or any conflict from the clients representative on site, for whatever reason, this change will become a category 2 Major and the appropriate category 2 action will apply.

2.3.2. Category 2 (Major) Deviation


Category 2 deviations are those that the ALE Operations Supervisor or the clients nominated representative considers to be significant or deviations from category 1 that become category 2 as identified in 2.3.1 above. Any proposed deviations / changes to the intended scope of work under this category shall be communicated to the ALE Engineer / Project Manager who will revise the method statement and liaise with the client representative to agree any changes for approval prior to commencement of work.

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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

Clients Responsible Person

Example of a record of authorised changes during the execution of work within an ALE method statement

2.4. SITE SAFETY


When there is a situation or area on site that any person believes is no longer safe, and the unsafe situation is caused by factors beyond the control of ALE personnel, the supervisor has the authority to stop all ALE activities at all times. The unsafe situation / activities / area will be reported to the client for the client to take measures to make it safe again for the activities to continue. No ALE activities will be performed until the situation or area is again made safe for working by the client or the clients agent. Should the measures taken by the client prove inadequate, the works can and will be stopped until adequate steps have been taken. ALE cannot be held responsible for any delays resulting from works being stopped due to unsafe situations.

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2.5. TOOLBOX TALK RECORD


The following toolbox talk record is provided for the purpose of recording the initial toolbox talk on commencement of the works under the scope of this method statement. A toolbox talk record sheet is also provided within the appendix of this document and should be used to record any future toolbox talks conducted on site. A minimum of one daily toolbox talk should be conducted at the earliest opportunity prior to commencement of works. The record is to be completed by all ALE and subcontracted labour personnel employed within the scope work and working to this Method Statement and associated Risk Assessment. Prior to commencing the operation all site personnel are to sign below to confirm that a clear briefing explaining the job has been given and is understood: I am satisfied that I understand the work to be carried out. All known hazards have been identified to me and I have been made fully aware of the control measures in place to reduce any risk to both myself and others. EMPLOYEE NAME: SIGNATURE: DATE:

Content of TBT:

Supervisors Signature:

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3.

PREREQUISITES AND INITIAL CONDITIONS

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.

3.3. CONTROL OF OPERATION


Outlined below are the responsibilities of ALE personnel associated with ALEs on-site operations. 1. 2. 3. 4. 5. 6. All the equipment within this document is to have current certification at the time of this operation. All operations associated with the rigging of the crane are under the direct control of the ALE site supervisor. All ALE Personnel will have documentary evidence of competence to do the work and operate any machinery that they will be using. Prior to commencement of work, work areas and exclusion zones will be set up and demarcated using hazard bunting tape. Method statement to be ready in conjunction with the attached risk assessment documentation and COSHH Assessments. The tandem lift part of the assembled boom will be carried out in accordance with BS7121. The physical dimensions, weight and COG have been taken into account as well as the loadings on each crane. The lifting gear to be used has sufficient capacity to perform the lift. The motions of both cranes will be monitored by the supervisor who has previous experience of the lift being performed, he will have contact with both crane operators via radio. Both the AK912 & Telescopic have sufficient capacity to perform the lift but as an extra safety measure they have been de-rated by 25% When working at heights over 2 metres the rigging crew will wear the appropriate safety harnesses and use permanent platforms fitted to the crane. Where circumstances arise that there are no platforms, aluminium ladders will be used to gain access to the required area, safety harnesses will be worn when using ladders.

7.

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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

Host Site Representative

ALE Project Manager

Subcontract Transport

ALE Project Engineer

Subcontract Assist Cranes

ALE Operations Supervisor

ALE Operators & Riggers

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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

4.1. OPERATIONAL PROCEDURE


The crane will be rigged in the following configuration: Crawler base: Crawler Centres: Carbody Counterweight: Central Counterweight: Main Boom Length: Maxi lift Back Mast: Maxi lift Back Mast Radius: Hook Block: Maxi lift Counterweight: 15.20m long x 12.50m Wide 10.20m 295 tonnes 60 tonnes 138m 50m 24.0m or 30.0m 400Te / 800Te / 1600Te 0Te / 640Te

The cranes to be utilised for the assembly of the crane are specified as follows: 250Te Telescopic Crane 150Te Telescopic Crane

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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.

Assembling of the Chassis


The Middle Section and the two Cross Bars for the track frame are assembled using an auxiliary crane. Middle Section: Crane Load (t) 250t 50.3 Cross Bars: Crane Load (t) 150t 26.0 HB & Tackle (t) 2.0 Total Load (t) 52.3 Radius (m) 10.0 Capacity (t) 74.0 % Capacity 70.7

HB & Tackle (t) 1.7

Total Load (t) 27.7

Radius (m) 10.0

Capacity (t) 41.7

% Capacity 66.4

Assembling the Central Ballast on the Cross Bars


1. Attach the receptacle for central ballast (4) with the auxiliary crane to the rear cross bar 2). 2. Attach the receptacle for central ballast (5) with the auxiliary crane to the front cross bar 3). 3. Fit the central ballast in accordance with the load table using the auxiliary crane.

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Crane 150t

Load (t) 10.0

HB & Tackle (t) 1.7

Total Load (t) 11.7

Radius (m) 10.0

Capacity (t) 41.7

% Capacity 28.1

Fitting the Crawlers on the Chassis


1. Swing the track frame (2) into the pin locking positions on the cross bars (1). 2. Connect the hydraulic connecting lines (5 and 6), until now still unconnected, to the quick disconnect couplings on the cross bar and connect to connection points 5 and 6 of the Drive container. Crane Load (t) HB & Tackle (t) Total Load (t) Radius (m) Capacity (t) % Capacity 250t 45.0 2.0 47.0 10.0 74.0 63.5 150t 45.0 1.7 46.7 7.2 56.5 82.7

Assembling the Chassis Catwalk and Ladders


Set down the catwalk (1) with the auxiliary crane on the cross bar in the forward direction on the left and secure with locking bolts at the pinning points (6). 2. Set down the catwalk (2) with the auxiliary crane on the cross bar in the forward direction on the right and secure with locking bolts at the pinning points. 3. Insert the short catwalk grating (3) with the auxiliary crane between the catwalks (1 and 2) at the rear and secure with a locking bolt.

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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.

Assembling the Superstructure


1. Attach the hook suspension gear of the auxiliary crane to the four attachment points of the front frame (4), release the transport locks and lift the front frame from the transport vehicle. 2. Position the front frame over the chassis so that the dowel pin is flush on the pinning ring with the groove X on the slew ring of the chassis. 3. Lower the front frame until the pinning ring of the front frame Is lying in the double ring of the slew ring. Crane Load (t) HB & Tackle (t) Total Load (t) Radius (m) Capacity (t) % Capacity 250t 43.0 2.0 45.0 13.0 61.0 73.8

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Pinning the Superstructure Rear Frame with the Front Frame.


1. Attach the hook suspension gear of the auxiliary crane HK to the four attachment points of the rear frame. 2. Connect hydraulic connecting lines to the drive container and connect to the hydraulic quick releases on the front frame. 3. Release the transport locks and lift the rear frame (10) from the transport vehicle. 4. Swing the rear frame (10) into the lower pin locking position. Crane Load (t) HB & Tackle (t) Total Load (t) Radius (m) Capacity (t) % Capacity 250t 40.0 2.0 42.0 10.0 74.0 56.8

Assembling the Hoists


Attach the H1, H2 & H3 hoist to the auxiliary crane and swing over the assembly point. Carefully lower the hoist into the pin locking position. Crane Load (t) HB & Tackle (t) Total Load (t) Radius (m) Capacity (t) 150t 21.7 1.7 23.4 14.0 29.4

% Capacity 79.6

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Assembling the Carrying Arms on the Superstructure Front Frame


1. Raise the front supporting beam (1) with the auxiliary crane and attach to the upper pin guide (5) of the superstructure front frame (4). 2. Insert the locking bolts (7) in the lower holding device of the superstructure front frame (4) and secure with the fore lock. 3. Lift Drive container into position onto the carrying arms. Crane Load (t) HB & Tackle (t) Total Load (t) Radius (m) Capacity (t) % Capacity 150t 3.6 1.7 5.3 14.0 29.4 18.0

Crane 150t

Load (t) 30.0

HB & Tackle (t) 1.7

Total Load (t) 32.0

Radius (m) 11.0

Capacity (t) 37.9

% Capacity 84.4

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Assembling of the counterweight base plate.


1. Connect the hydraulic connecting lines 7 and 8 to the drive container and connect to the hydraulic quick releases on the rear frame. 2. Place the radio remote control (130) ready for operation in accordance with section 14. 3. Attach the hook suspension gear of the auxiliary crane with the rope bracing device to the four attachment points of the counterweight base plate. 4. Position the basic frame beneath the superstructure rear frame so that the bores in the holding brackets of the rear frame are flush with the corresponding bores in the base plate. 5. Press the pin locking cylinders for the base plates are fully extended. Crane 150t Load (t) 25.0 HB & Tackle (t) 1.7 Total Load (t) 26.7 Radius (m) 12.0 Capacity (t) 34.5 % Capacity 77.4

Fitting the Counterweight Mid Stack


1. Attach the counterweight section 15 t with the auxiliary crane to the lateral attachment devices and set down safely at the front on the brace of the superstructure rear frame, at the rear on the bearing plates of the derricking gear. 2. Stack the remaining four 10 t counterweight sections safely on the 15 t section. 3. Lay the two safety chains S over the plate stack, secure to the rear frame using clevises and tension. Crane 150t Load (t) 10.0 HB & Tackle (t) 1.7 Total Load (t) 11.7 Radius (m) 12.0 Capacity (t) 34.5 % Capacity 33.9

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Attach the counterweight sections


1. Attach the counterweight sections (1) with the auxiliary crane to the lateral attachment devices and set down safely on the base plate. 2. Set down all counterweight sections evenly on the right and left of the base plate. 3. On both plate stacks, pull the safety chain (2) from below using a suitable guide line up through the opening in the plate stack and secure in the tensioning console (3). 4. Tension the chain (2) by tightening the tommy screws at the same time on the tensioning console. Crane 150t Load (t) 10.0 HB & Tackle (t) 1.7 Total Load (t) 11.7 Radius (m) 13.0 Capacity (t) 32.0 % Capacity 36.6

Assembly of the Superlift Mast


1. Attach the mast basic boom (1) using the fixing points provided to the auxiliary crane, using suitable hook suspension gear. 2. Set down the mast basic boom (1) in front of the basic crane. 3. Attach intermediate section (2) with a suitable lifting tackle to the attachment points on the auxiliary crane. 4. Swing the intermediate section (2) with the auxiliary crane in front of the mast basic boom (1) and insert in the pin stops. 5. Place the hydraulic power pack in operation and pin the pin stops one after the other. 6. Pin intermediate section (3) with intermediate section (2) and intermediate section (2) with mast point (3) in the same way. 7. Secure all pin stops (S). 8. Open the holding devices of the bracing rods on the mast components and connect the bracing rods together. 9. Set down the bracing rods on the mast basic boom after pinning in the folded--up holding devices (X). 10. Connect the electric leads in the individual mast parts in accordance with the markings.

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Crane 150t

Load (t) 33.1

HB & Tackle (t) 1.7

Total Load (t) 34.8

Radius (m) 9.0

Capacity (t) 45.5

% 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.

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Assembling the Main Boom with Superlift


Main boom (type LSL), 138 m boom length 1 2 3 4 5 6 7 Foot section HA 10.00 m type 3227 Intermediate section 12.00 m type 3227-45-11 Intermediate section 12.00 m type 3227-40-11 Intermediate section 6.00 m type 3227-36-11 Intermediate section 12.00 m type 3227-36-11 Intermediate section 12.00 m type 3227-30-11 Intermediate section 12.00 m type 3227-30-12 Crane 150t Load (t) 39.3 Tackle (t) 1.7 12 13 15 21 23 24 Head 1250t 2.00 m Roller Set 675t Roller Set 615t Left Hand Intermediate section 12.00 m type 3227-20-11 Intermediate section 6.00 m type 3227-20-12 Intermediate section 12.00 m type 3227-17,5-11

Total Load (t) 41.0

Radius (m) 8.5

Capacity (t) 49.0

% Capacity 83.7

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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

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Fitting the Counterweight


The counterweight sections must be stacked evenly on both sides. There must never be a difference of more than one counterweight section between the two sides. The counterweight sections must be secured together to prevent them slipping. The individual stacks should be secured with sufficiently dimensioned lashing straps to the attachment eyes provided. The stacks must be secured so that there is no risk of the counterweight sections falling, even if the crane movement is stopped abruptly. Crane 150t Load (t) 10.0 Tackle (t) 1.7 Total Load (t) 11.7 Radius (m) 14.0 Capacity (t) 29.5 % Capacity 39.7

Boom up the main boom crane is now ready to work. For a more detailed description refer to the operators manual.

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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:

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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

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6.

JHA (JOB HAZARD ANALYSIS) AND ASSOCIATED DOCUMENTS

As Attached JHA

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Activity:

ALE Rigging Terex Demag CC8800-1

Project / Site location: Department Involved:

BNPP Site Mechanical Department

Description of Work:

Arrival, Offloading and Construction of Terex Demag CC8800-1 1600Te Crawler Crane.

Job Supervisor: H&S Supervisor: Ref No: Rev No:

Localized Shutdown: Date:

Required 12. Oct. 2012

Not Required

Sub-contractor: ALE Middle East John Trafford Mobile:

Contractor supervisor: General safety condition requirements:

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.

Minimum PPE required:

Hard hat, safety glasses or goggles, hi-visibility jacket, safety shoes

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.

1st Risk Assessment LS 5 CS 3


RATING

2nd Risk Assessment Control Measures


Correct use of PPE as necessary. Crane rigging to be securely attached to loads by means of properly designed lifting points/equipment. Land lines to be secured to loads during lifting operations where necessary. Operatives to be aware of and avoid working below overhead lifting operations. All items to be lifted will be inspected prior to the lift to ensure that there is no loose equipment or items that may fall off during the lift. No personnel will be permitted to stand under or close to a suspended item. Barrier flags or tape will be used to form an exclusion zone around the cranes and equipment being lifted. Crane operator to be adequately trained and certificated. Crane, lifting tackle and equipment to be well maintained, checked and certificated. Rigging Staff to be properly trained. Unauthorized persons to be kept clear of crane working area. Crane only to operate within clearly identified areas on site. 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). Ground conditions and composition investigated, and confirmed by client as suitable for loading applied. Check weight of items to be lifted, weigh items if necessary prior to lift. Wind speeds are checked and monitored prior to and during lifting operations via the cranes anemometer. Where high winds are expected or electrical storms are imminent crane booms will be lowered to grade where possible. All pre lift documentation will be completed prior to operations proceeding.

LS 3

CS 2

RATING

Action by (Due date)


Subcontract or site management team/ HSE

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.

Use of hand tools. Lifting items. Pulling items. Pushing items.

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.

Subcontract or site management team/ HSE

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.

Subcontract or site management team/ HSE

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

Subcontract or site management team/ HSE

Yes

GENERAL WORKING OUTDOORS

Intense Sun Extreme Heat Sand Storm

Skin burn Hand injury Eye irritation Dehydration Dermatitis

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

Subcontract or site management team/ HSE

No

NIGHT WORK (HOURS OF DARKNESS)

Inadequate lighting.

Injuries to personnel. Damage to equipment. Damage to property.

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.

Subcontract or site management team/ HSE

Yes

COMMUNICATION From operators to Supervisor to riggers.

Lack of communication or unclear instructions.

Injuries to personnel. Damage to equipment. Damage to property.

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.

Subcontract or site management team/ HSE

No

GENERAL WORKING ON A SITE.

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.

Subcontrac tor site manageme nt team/ HSE

No

Prepared by: Subcontractor

Signature / Date

Reviewed by: HSJV HSE Manager

Signature / Date

Approved by: HSJV Site Manager Approved By: HSJV

Signature / Date

Permit Required for the Activity

Ticked Yes or No

KEPCO Name: Position:

YES NO

Name: Position:

HSQE Briefing and Toolbox Talk Record Sheet


Date: Name of person delivering Talk: BNPP(Braka Nuclear Power Plant) Project Signature of person delivering Talk: Location:

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

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