Pearl GTL

Project
Shell Project No: HP-3000-QAT
Project Document Number: T.4.250.903

Purchase Order Number:

2MH127

Tag/Item Number(s):

N/A

Unit(s):

ASU

PCWBS:

LINDE ENGINEERING

Contractor Project No :
Project Rev.: O

Page 2 of 20

5887

QATAR SHELL GTL PROJECT (PEARL)

C2 AIR SEPARATION UNITS CONSTRUCTION

11.03.2008

Issued for Company Comments

RO

EE

ZG

ICC

21.02.2008

Issued for Review

RO

EE

ZG

IFR

17.02.2008

Issued for Internal Review

RO

EE

ZG

IIR

Date

Description

GAMA
Rev.
No.

Project
Rev
No.

Prepared Checked Approved

By
By
By
ORIGINATOR

Status

Document Title:

LINDEGINEERING AG

METHOD STATEMENT FOR PREFABRICATION OF

CS, TT & CN PIPE SPOOLS
Document No.

Contractor

Gama Qatar Co. W. L. L.

LOC470
GAM

MTS

MEC

GTL

008

Org.
Code

Doc.
Type

Disc.
Code

Geogr.
Area

Seq.
No

Rev.
No

Project Document Number: T.4.250.903

Vendor Code

Rev No: O

Doc. Title

Q A T A R

Date/Rev. No :

METHOD STATEMENT FOR PREFABRICATION OF CS,

TT & CN PIPE SPOOLS
11 March 2008 REV-C

TABLE OF CONTENTS
1.

INTRODUCTION _______________________________________________________5
1.1.

GENERAL_______________________________________________________________ 5

1.2.

SCOPE _________________________________________________________________ 5

1.3.

PURPOSE_______________________________________________________________ 5

2.

REFERENCE __________________________________________________________5

3.

DEFINITIONS __________________________________________________________6

4.

RESPONSIBILITIES ____________________________________________________7

5.

4.1.

PIPE PREFABRICATION SUPERVISOR ______________________________________ 7

4.2.

PLANNING ENGINEER ____________________________________________________ 7

4.3.

FABRICATION ENGINEER(S) AND FOREMEN _________________________________ 7

4.4.

PIPING ENGINEERS ______________________________________________________ 7

4.5.

WELDING SUPERVISOR AND FOREMEN_____________________________________ 7

4.6.

QC MANAGER, ENGINEER & TECHNICIANS __________________________________ 8

4.7.

SPOOLGEN SUPERVISOR _________________________________________________ 8

METHOD OF EXECUTION _______________________________________________8

5.1.

PIPE CUTTING ___________________________________________________________ 8

5.2.

WELD EDGE PREPARATION _______________________________________________ 8

5.3.

BRANCH CUT-OUTS ______________________________________________________ 9

5.4.

FIT-UP AND ALIGNMENT __________________________________________________ 9

5.5.

TACK WELDING _________________________________________________________ 9

5.6.

PREHEAT AND INTERPASS CONTROL _____________________________________ 10

5.7.

WELD INTERRUPTION ___________________________________________________ 10

5.8.

WELDING ______________________________________________________________ 10

5.9.

PWHT _________________________________________________________________ 10

5.10.

REWORK ______________________________________________________________ 10

5.11.

NDE___________________________________________________________________ 10

5.12.

MATERIAL HANDLING AND STORAGE _____________________________________ 11

6.

QUALITY ASSURANCE ________________________________________________12

7.

HSSE _______________________________________________________________12

8.

ATTACHMENTS ______________________________________________________12
8.1.

JOB SAFETY ANALYSIS _________________________________________________ 12

T.4.250.903 REV-C

Page 4 of 20

Doc. Title

Q A T A R

Date/Rev. No :

METHOD STATEMENT FOR PREFABRICATION OF CS,

TT & CN PIPE SPOOLS
11 March 2008 REV-C

1. INTRODUCTION
1.1.
GENERAL
This document describes the methods proposed to be used for the prefabrication of spools.
1.2.
SCOPE
This method statement defines responsibilities within GAMA-QATAR for the prefabrication of
spools
1.3.
PURPOSE
The purpose of this method statement is to ensure correct and safe implementation of
project specifications and the procedures for the prefabrication of spools.

2. REFERENCE
ASME B 31.3
ASME Sec. V
ASME Sec. IX
ASME Section II, Part C
T-13.377.441
T-13.377.438

Process Piping
Non Destructive Examination
Welding and Brazing Qualification
Specification for Welding Rods, Electrodes & Filler Metals
Quality Control Requirements for Welding
Specification for Traceability, Alloy Verification and Material
Substitution

T.4.250.931
DEP 30.10.60.18
DEP 31.38.01.11

Welding Consumable Control

Welding of Metal(Amendments/Supplements to API RP 582)
Piping-General Requirements
Shop & Field Fabrication of Piping Amendment
T.13.376.796E
Cleanliness Procedure Piping Systems
Project Quality Plan
Material Handling and Storage
Material Traceability & Marking
Equipment Preservation
General Welding Procedure
Welders Performance Qualification
Post Weld Heat Treatment Procedure
Weld Repair Procedure
ITP - Fabrication of Piping A/G & U/G
Flawless Start-up Initiative(FSI)
QCP - Procedure of Piping Fabrication A/G and U/G
Road Safety Procedure
Heat Stress Disorder Prevention Procedure
Work at Height Scaffolding
HSSE Plan Construction

DEP 31.38.01.31
T-4.250.930
T-4.234.542
T-4.250.927
T-4.250.928
T-4.250.932
T-4.250.938
T-4.250.939
T-4.250.913
T.4.250.940
T.4.250.920
T.13.377.360
T.4.250.935
T.4.129.857
T.4.129.872
T.4.129.868
T.4.095.303
T.4.250.903 REV-C

Page 5 of 20

Doc. Title

Q A T A R
T.4.095.807
T.4.219.660
T.4.129.855
T.4.184.595
T.4.129.859
T.4.129.854
T.4.129.864
T.4.129.850
T.4.129.860
T.4.129.865
T.4.129.856
T.4.129.861
T.4.129.866
T.4.129.871
T.4.129.656
T.4.129.852
T.4.129.861
T.4.129.867
T.4.129.853
T.4.129.863
ANSI / ASME B 16.25

Date/Rev. No :

METHOD STATEMENT FOR PREFABRICATION OF CS,

TT & CN PIPE SPOOLS
11 March 2008 REV-C

Nozzle Assemblies for Instrument Connection, Drain and

Vents
Permit To Work Handover Implementation Plan
Emergency Response
Land Road Transport HSE Case
Lifting Operations
Risk Assessment
Safe Use of Compressed Gases
Accident/Incident /Near Miss Reporting and Investigation
Manual Handling
Portable Power Tools
Hygiene and Housekeeping
Handling of Hazardous Materials
Use of Grinding Machines and Abrasive Wheels
Environmental Accounting
Construction Waste Management Plan
Entry into Confined Space
Working with Electricity
Hand Tools
Personal Protective Equipment
Welding and Flame Cutting
Butt welding ends Amendments and/or Supplements to DEP
31.38.01.31 GEN (April 2003) Shop and Field Fabrication
of Piping.

3. DEFINITIONS
Company
Contractor
Sub Contractor

: QSGTL or its PMC

: LINDE ENGINEERING AG
: GAMA QATAR

Contract
QCP
ITP
QA/QC
WPS
PQR
PWHT
CS
TT
CN
RT
MSDS
RAT

: QSGTL Pearl Plant C2 ASU Project

: Quality Control Procedure
: Inspection and Test Plan
: Quality Assurance / Quality Control
: Welding Procedure Specification
: Procedure Qualification Record
: Post Weld Heat Treatment
: Carbon Steel
: Low Temperature Carbon Steel
: Chrome Nickel Alloys, Stainless Steel
: Radiography Test
: Material Safety Data Sheet
: Risk Assessment Team

T.4.250.903 REV-C

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Doc. Title

Q A T A R
JSA
TBT
RA
PT
MT
T
NDE
NDT

Date/Rev. No :

METHOD STATEMENT FOR PREFABRICATION OF CS,

TT & CN PIPE SPOOLS
11 March 2008 REV-C

: Job Safety Analysis

: Tool Box Talk
: Risk Assessment
: Penetrant Testing
: Magnetic Particle Testing
: Thickness
: Non-Destructive Examination
: Non-Destructive Test

4. RESPONSIBILITIES
As per organisation chart, starting from Site Manager and ends at welding, piping foremen
level, including QC personnel, all the people within this link is responsible for execution of
this method statement.
Site Manager, Assistant Site Manager and Mechanical Works Coordinator are responsible
for the fulfilment of this procedure.
4.1. PIPE PREFABRICATION SUPERVISOR
Pipe Prefabrication Supervisor is responsible for implementation of piping works in
accordance with schedule, procedures, specifications, priorities and isometrics issued
for construction.
4.2. PLANNING ENGINEER
Planning engineer is responsible for planning the spool fabrication according to
priorities of piping activities of site, informing Spoolgen Supervisor to provide the spool
drawings and Isogen data accordingly. He is also responsible to release the request of
piping materials according to fabrication schedule.
4.3. FABRICATION ENGINEER(S) AND FOREMEN
They shall ensure safe and efficient working environment, monitor plant and equipment
requirements and ensure that the productivity and the quality are maintained by their
subordinates. They are responsible for ensuring proper material, welding consumables
and welding procedures are applied.
4.4. PIPING ENGINEERS
Are responsible for:
- Ensuring proper documentation and control of spool drawings used for fabrication.
- Request piping materials as per schedule.
- Liaise with contractor representative(s) to solve related technical issues.
- Coordinate with other sections and disciplines on site.
4.5. WELDING SUPERVISOR AND FOREMEN
Welding Supervisor and foremen are responsible to ensure the quality of welding, for
the safe working practices of welders, adherence to approved correct welding
procedure. They will ensure corresponding welding consumables and responsible to
following the consumable stock and ordering them. They are also responsible in
monitoring the welders productivity.
T.4.250.903 REV-C

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Doc. Title

Q A T A R

Date/Rev. No :

METHOD STATEMENT FOR PREFABRICATION OF CS,

TT & CN PIPE SPOOLS
11 March 2008 REV-C

4.6. QC MANAGER, ENGINEER & TECHNICIANS

QC manager is responsible for all Quality Control Activities related with pipe
prefabrication activities together with his engineers and technicians.
4.7. SPOOLGEN SUPERVISOR
Spoolgen Supervisor is responsible to produce spool drawings according to priority of
the fabrication, defined by planning engineer.

5. METHOD OF EXECUTION
5.1.

PIPE CUTTING
Spool drawings approved by GAMA-Qatar and LINDE ENGINEERING AG QC
departments will be released by planning engineer to fabrication engineer(s) according
to priorities of erection and fabrication. The Spool lengths will be determined according
to the pipes in stock and these lengths will be stated in the erection drawing, as a
result there will be minimum length adjustment during site erection.
Fabrication (piping) engineer will prepare cutting plan for pipes accordingly, request
the pipes, fittings from material supervisor and will give the same information to cutting
foreman.
Cutting foreman will arrange cutting and planning activities according to RFC drawings.
CS and TT pipes will be cut to the length either by cutting disc or by saw cutting or by
plasma cutting or by motorized flame cutting or by automatic pipe cutting & beveling
machines. After flame cutting a min. 2mm material will be removed from the cut
surface by grinding. Ref. DEP 31.38.01.31 for cutting and beveling preparation.
CN pipes will be cut to the length either by inox cutting disc or by plasma cutting or by
inox saw cutting or automatic pipe cutting & beveling machines with inox apparatus.
Flame cutting of CN is not allowed.
Marking for traceability: Identification mark that is composed of spool number, part/pos.
number, quality and heat number of the pipe will be written on the part with a
permanent marker by the operator who cuts it. Permanent free of chloride markers or
markers suitable to S.S. will be used to for heat nos. traceability in S.S. Pipes.

5.2. WELD EDGE PREPARATION

CS and TT pipes will be beveled either by portable pipe lathe or on by portable
grinding disc or by automatic pipe hot or cold cutting or beveling machines or by CNC
operated pipe beveling machine.
CN pipes will be beveled either by portable pipe lathe with inox apparatus or on by
portable inox grinding disc or fixed inox cutting or beveling machines with inox
apparatus or CNC operated pipe beveling machine with inox apparatus.

T.4.250.903 REV-C

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Doc. Title

Q A T A R

Date/Rev. No :

METHOD STATEMENT FOR PREFABRICATION OF CS,

TT & CN PIPE SPOOLS
11 March 2008 REV-C

5.3. BRANCH CUT-OUTS

It will be done for CS and TT pipes by either marking with templates and cutting by
flame cutting devices, or by chip removal processes or by CNC plasma pipe cutting
beveling machine depending upon the diameter and thicknesses.
It will be done for CN pipes by either marking with inox templates or inox chip removal
processes or if it is available by CNC plasma pipe cutting beveling machine will be
used depending upon the diameter & thicknesses. During these procedures inside of
pipes will be protected with suitable materials to avoid deterioration.
5.4. FIT-UP AND ALIGNMENT
Before fit up, all parts of spools will be checked for inside cleanliness. For But-welding
of all piping components (e.g. pipe ends, fittings and welding neck flanges), a uniform
root gap shall be provided as specified in the relevant welding procedures specification
and ANSI / ASME B 16.25.
Fit up of spools will be done on the benches or on working tables or on tripods whose
heights are adjustable. Careful attention will be given to the CN pipes and spools
which are not allowed to contact to CS and TT steel spools, during fit up and store CN
spools and pipes will get in contact with wooden timber or suitable materials. First, the
high low conditions and matching faces are going to be checked. If some mismatch
higher then below the mentioned tolerances is detected. This will be corrected and
ensured that the wall thickness after alignment is not reduced below the minimum
required wall thicknesses. End profile of the pipes & fittings will be butt welded and will
be maintained according to the requirement of ASME B 16.25.
5.5. TACK WELDING
Tack welding shall be carried out by qualified welders. Tack welds will be 25mm in
length and equally spaced around circumference in sufficient number to support pipe.
Tack welds, which are to be incorporated into the final weld, will be ground to a feather
edge. Defective tack welds will be ground out prior to welding and PT or MT will be
applied for surface inspection.
All Surfaces to be welded shall be thoroughly cleaned from oxide scale, oil or other
foreign matter and kept dry.
Weld number will be marked on each connection and spool reference Number shall be
stenciled in black color as follows in all cases:
Spools up to 18 Dia.
On the outside of the spool.
Spools above to 18 Dia.
On the inside of the spool.
For material traceability, material Check list will be filled out during the process.
The QC will be called for fit-up inspection and the drawing dimensions: beveled ends,
tack weld and marking visual checks will be performed. With the satisfactory result by
QC inspection, release for weld will be given by writing FT OK on each connection.

T.4.250.903 REV-C

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Doc. Title

Q A T A R

Date/Rev. No :

METHOD STATEMENT FOR PREFABRICATION OF CS,

TT & CN PIPE SPOOLS
11 March 2008 REV-C

5.6. PREHEAT AND INTERPASS CONTROL

Preheat will be applied by gas torches and maintained over a distance of 2t or 100 mm
whichever is larger either side of the joint, measured on the outside surface. Preheat
temperatures will be measured temperature indicating crayons.
5.7. WELD INTERRUPTION
At least 50% of the joint or the root and second pass, whichever is the greater will be
completed before welding joint is cooled to ambient temperature.
5.8. WELDING
Welding will be performed with approved WPS as mentioned on welding plan table by
qualified welders. Welder ID, filler material batch no, PWHT, NDT results will be filled
out during fabrication.
The main pipe will be welded. Then the branch connections will be done. Welder
numbers will be marked on each connection.
All root pass should be done by GTAW welding.
After welding in S.S. the root pass should be checked with magnet which is a witness
point by QCI.
After completion of welding inspections described in ITP will be applied. With the
satisfactory results of inspection the spool or part will be forwarded to PWHT, if
required.
5.9. PWHT
Heat treatment will be applied in compliance with the drawing requirements with the
proper means, either by mobile or by stationary equipment, according to approved
Preheat Treatment Procedure. The time-temperature diagram will be checked for
prescribed parameters.
Upon satisfactory results of heat treatment, NDT of the welds will be carried out.
5.10. REWORK
If it happens that unsatisfactory results were obtained by inspections, non
conformance will be reported by QC and the necessary method of rework will be
decided. Upon approval of the COMPANY, it will be applied.
After eliminating the non-conformance and repeating the remaining manufacturing and
inspection operations, PWHT and NDT operations will be applied.
5.11. NDE
NDE of process and power pipe work shall be in accordance with LINDE
ENGINEERING AG approved procedure.
Certified operators shall be employed for NDE

T.4.250.903 REV-C

Page 10 of 20

Doc. Title

Q A T A R

Date/Rev. No :

METHOD STATEMENT FOR PREFABRICATION OF CS,

TT & CN PIPE SPOOLS
11 March 2008 REV-C

Radiography shall be taken normally at night hours and in dedicated area specified for
the work.
On approval of RT joints by LINDE ENGINEERING AG, the same shall be offered for
radiography on specified format to NDE contractor.
All joints to be RT checked shall be tagged with Blue ribbon for identification.
The RT operator shall remove the Blue ribbon on completion of radiography.
The radiography film shall be submitted the next day for approval to LINDE
ENGINEERING AG.
Repair joints if any shall be tagged with Red ribbon.
Radiography repair shall be carried out under the supervision of welding inspector and
reoffered as above.
After NDT clearance, prefabricated spools shall be released for painting/storage.
Prefabricated and painted spools shall be released to field on request with traceability.
Before releasing for painting there should be a check by piping QC for any distortion.
The Piping spools should be tagged with line no. & spool no. for traceability.
5.12. MATERIAL HANDLING AND STORAGE
Raw pipes and fittings will be transported from the warehouse/yard to the shop yard
using mobile cranes, trailers and boom trucks.
Handling of the pipe materials/spools inside the shop shall be with E.O.T. crane, fork
lifts and manual trolleys.
Spools shall be shifted from the shop to the radiography area to painting/storage/field,
painting to storage with mobile crane, trailer and forklifts.
Spools shall be stacked on wooden sleepers with identification markings on top.
Spools shall be stacked unit wise and area wise.
Register shall be maintained for storage showing spools numbers stored in each
location and issue to site.
All open ends of spools shall be covered using end caps/plastic sheets or suitable
material.
All flange faces shall be protected with wooden/plastic covers.

T.4.250.903 REV-C

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Doc. Title

Q A T A R

Date/Rev. No :

METHOD STATEMENT FOR PREFABRICATION OF CS,

TT & CN PIPE SPOOLS
11 March 2008 REV-C

6. QUALITY ASSURANCE
A Quality Assurance System shall be operated conforming to related standards. Controls
and checks shall be established and documented through relevant QCP T-4.250.935, ITP
T-4.250.920 and relevant QCRs.

7. HSSE
All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan
Industrial City and International standards, codes, LINDE ENGINEERING AG and QSGTL
and/or its PMC requirements and instructions.
In addition all employees and GAMA subcontractor employees on site will have through
GAMA Qatar Site Safety Induction, LINDE ENGINEERING AG Safety induction and
QSGTL Safety Induction for site safety, health, environmental and security prior to work
activities. Other training courses will be attended as required by LINDE ENGINEERING AG
or QSGTL and/or its PMC as required.
At a minimum a generic Risk Assessment will have been prepared by the RAT ranking the
hazards associated with project works and control measures to be taken to mitigate the
hazards to an acceptable level.
Each work scope or task will have a completed and approved JSA identifying the potential
hazards and control measures that will be implemented to protect people and environment.
The JSA (RA) will be used by Supervisor as the basis of conducting his daily Pre-Task
meeting and his weekly TBT.
In addition to the above, employees conducting survey works will wear required PPE and
highly visible vest where traffic or other hazards may exist. For additional safety
requirements for a particular or specific task please refer to the JSA prepared for that task.

8. ATTACHMENTS
8.1.

JOB SAFETY ANALYSIS

T.4.250.903 REV-C

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Q A T A R

JOB SAFETY ANALYSIS FORM

Page No: 1 of 8

JSA For: T-4-250.903

Job being analysed: Prefabrication of Spools
Department/Section doing JSA: HSSE & Construction

JSA Members:
Job Performers:

Normal Approvals:

Name

Signature

Date

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

Signature

Date

General job requirements / Common

Personal Protective Equipment.
1.The following Personal Protective
Equipment shall be worn:
Approved coveralls, safety goggles,
safety helmet, safety shoes and gloves.

Discipline Superindent (Linde)

HSSE Representative (Linde)
2.Permit To Work.

OTHERS (List Below):

Approval required for hazardous work detailed in the Linde Work Permit Procedure.
Changing conditions and emergency procedures
Stop work. Switch off equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees.
Missing employees are reported to Linde HSSE Dept. When all clear is given, check with Linde HSSE before returning to work.
LINDE EMERGENCY TELEPHONE NO.

HSSE MANAGER:
Pearl HOT LINE :

583 40 72
474 88 88

JOB SAFETY ANALYSIS / RISK ASSESSMENT

FOR T-4.250.903

Q A T A R

ITEM
1

HAZARDS / POTENTIAL
CONSEQUENCES
Manual handling of 1.1 Personal injury, back
pipes materials.
injuries, muscle strains,
sprains.
ACTIVITY

Initial Risk
RISK
P C
RANK

1.2

Mechanical
movement to
laydown area

2.1

MED

1.1.3
1.1.4
1.1.5

1.2.1
1.2.2
3

LOW

Hand and finger

injuries.
C

Slip, Trip & Fall from

same level
B

1.3

Residual Risk

1.1.1
1.1.2
C

MED

Crushed injuries

MED

SCOPE : METHOD STATEMENT FOR CS, TT &

CN PIPE PREFABRICATION

1.2.3
1.2.4

MAIN
ADDITIONAL
CONTROLS
CONTROLS
Worker to wear appropriate
1.1.3.1 Provision for lifting aids when
gloves.
practical.
Break the load into manageable
portions.
Lift with your legs not your back.
Use the buddy system, Get help.
Provide pictorial sign boards with
correct lifting position.
Adequate stacking of materials.
1.2.1.1 Remove unnecessary materials
Regular housekeeping practices
in the work place.
and removal of trash and
unnecessary items.
Maintain access and walk paths.
Housekeeping shall be a priority,
walk and work areas shall be kept
free of materials and supplies.

1.3.1 Wear approved PPE, safety

goggles, safety helmet, safety
shoes, gloves, high-vis vests
1.3.2 Keep away hand and finger from
moving parts.

1.3.1.1 Supervisor/foreman shall

ensure that the TSTI is properly
executed at the work front and
hazards discussed.

2.1.1 Provide warning sign.

2.1.2 Personet to be trained in single/
banksman techniques in order to
ensure the material is loaded in a
safe manner
2.1.3 Provide trained&qualified
banksmen

2.1.1.1 Supervisor/foreman shall

ensure that the TSTI is properly
executed at the work front and
hazards discussed.

LOW

LOW

LOW

LOW

2.2

Falling materials.

2.2.1
2.2.2
D

HIGH
2.2.3

2.3

Lifting hazard

2.3.1

2.3.2

HIGH

2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
2.3.8

3 Cutting of pipes

3.1

3.2

Hand and finger

injuries.
Manual handling of
pipes.

3.1.1
C

MED
3.2.1

LOW

Ensure materials are fully secured 2.2.1.1 Supervisor/foreman shall

by competent and certified rigger.
ensure that the TSTI is properly
Use of tag lines to control the
executed at the work front and
load.
hazards discussed.
Wear approved PPE, safety
goggles, safety helmet, safety
shoes, gloves, high-vis vests
Ensure that crane operator is
2.3.1.1 Suitable equipment is to be
certified by Third party, valid
used to lift the steelwork.
certificates and driver's licenses.
2.3.1.2 Proper set up of crane; i.e. out
Ensure that all lifting gear/lifting
riggers fully extended.
tackle is properly inspected and
color coded.
Third party inspections.
Competent Riggers.
Daily crane inspections.
Automatic safe load indicator.
Tag lines are to be used to control
loads.
Barricade the working area with
sign boards indicating crane lifting
is in progress to prevent
unauthorized entry.
Wear approved PPE, safety
goggles, safety helmet, safety
shoes, gloves, high-vis vests
Approved quality hand gloves,
available in a full range of sizes to
ensure proper fit to maintain
dexterity.

LOW

LOW

LOW

LOW

3.3

Pipe cutting machine.

3.3.1
3.3.2

3.4

3.5

Damage to eyes.
Personnel injury.

HIGH

3.3.3

3.4.1
B

LOW

Defective equipment.

3.5.1

LOW

3.5.2
3.5.3

3.6

Cylinders explosion or
Fire

3.6.1
3.6.2

3.6.3
D

MED

3.6.4

3.7

Fire hazard.

3.7.1
C

LOW
3.7.2

Competent operators, trained on

3.3.1.1 Post the manufacturer safe
the machine they operate.
operating manual near the
Ensure that the guards are
machine and HSSE office.
properly installed and are being
3.3.1.2 Supervisor/foreman shall
used.
ensure that the TSTI is
Post near machine the
properly executed at the work
manufacturers safe operating
front and hazards discussed.
procedures in different languages. 3.3.1.3 Ensure equipment were
properly color coded and
inspected prior to use.

LOW

LOW

LOW

Oxygen cylinder valves/fittings to 3.6.1.1 Proper maintenance performed

be kept free from grease/oil..
by maintenance department
Flash-back arrestors to be fitted at
according to manufacturers
two ends of hoses and non-flow
recommendations.
check valve near cutting torch.
3.6.1.2 Ensure equipment were
Gas hoses and gauges to be
properly color coded and
maintained in safe conditions &
inspected prior to use.
inspected daily. Defective hoses
and gauges are to be replaced
immediately.
Cylinders to be used in the
vertical position and secured
against falling.

LOW

Suitable measures e.g. Provision 3.7.1.1 Removal of combustible

of fire blankets/fire watchers, will
material near the area.
be taken to prevent the risk of fire
during cutting operations.
Provide suitable fire extinguishers
at site.

LOW

Personnel carrying out gas cutting

operations will wear suitable eye
protection/PPE.
Daily inspection of equipment by
3.5.1.1 Proper maintenance performed
operator prior to use according to
by maintenance department
manufacturers recommendations.
according to manufacturers
Current Contractor inspection
recommendations.
certificate.
Monthly equipment inspection and
color code.

Alignment, fit-up,
and welding of
random lengths
pipes.

4.1

Grinding hazards

4.1.1

4.1.2
4.1.3
D

MED
4.1.4

4.2

Noise hazards.

4.3

Electric shock

4.2.1

LOW
4.4.1

LOW

Pinch point

4.4.2

4.5.1
B

4.6

Fire hazards

4.5

LOW

4.3.1
C

4.4

LOW

Slip, Trip & Fall from

same level

4.5.2
4.6.1

LOW
4.6.2

Grinders to be maintained in good

condition and inspected prior to its
use. Provided with color coding
for the month.
Guards to be fitted to grinders.
Changing of abrasive wheels to
be carried out by trained &
authorized personnel using proper
disc spanner.
Grinding operations will be
controlled in order to prevent the
risk of injury to other personnel
from sparks/metal splinters.
Ensure employee wear
appropriate hearing protection.
Welding machine to be effectively
grounded. Welding gear to be
properly insulated.
Suitable measures e.g. Provision
of fire blankets/fire watchers, will
be taken to prevent the risk of fire
during cutting operations.
Keep flames, sparks, molten
slags and hot metal from coming
in contact with combustible
materials.
Ensure competent employee will
carry out the task.
Ensure employee wear
appropriate hand gloves.
All tools must be kept in a suitable
holder to prevent it from being
tripping hazard.
Remove unnecessary materials in
the work place.

4.1.1.1 Provision of grinding shields to

contain sparks in proximity
4.1.1.2 Personnel carrying out grinding
work will wear suitable eye
protection.

4.2.1.1 Provide warning sign.

4.4.1.1 Discuss in TBT/ HIP.

4.4.1.2 Provision of suitable fire
extinguisher in the near area.
4.4.1.3 Removal of combustible
materials near the area.

LOW

LOW

LOW

LOW

LOW

LOW

4.5.1.1 Discuss in HIP/TBT.

4.6.1.1 Provide adequate stacking of

materials.

4.7

Fall of pipe during fine

alignment
B

NDT Work

5.1

Grooving and
Threading at
Fabrication Shop

6.1

LOW

LOW

MED

6.1.1 Ensure materials are fully secured 6.1.1.1 Supervisor/foreman shall

by competent & certified rigger.
ensure that the TSTI is
6.1.2 Use of tag lines to control the load.
properly executed at the work
6.1.3 Wear approved PPE, safety
front and hazards discussed.
goggles, safety helmet, safety
shoes, gloves, high-vis vests

LOW

LOW

6.2.1 Housekeeping shall be a priority,

walk and work areas shall be kept
free of materials and supplies.

LOW

LOW

6.3.1 Ensure all hand tools will be

6.3.1.1 Ensure tools are of correct
visually inspected prior to use,
type, size and they are in good
kept in good repair and used only
condition and color coded as
for intended purpose.
required.
6.3.2 Check electrical equipment prior to
use.Ensure it is properly
inspected, color coded for the
month and properly documented.
6.3.3 Ensure all electrical equipment
were properly grounded and built
with ELCB at their source.

LOW

Electric shock

LOW

Slip, Trip & Fall

B

6.3

5.1.1 Isolate/Barricade the area.

5.1.2 Ensure competent persons will
carry out the tasks.
5.1.3 Protective shields (time &
distance);Use/ shields (time &
distance).
5.1.4 Provide warning signs, proper
access during testing.
5.1.5 Schedule of NDE test requiring
radiation should informed in
advance to make aware the
employees.

Fall of materials.
D

6.2

MED

Health risk due to

radiation exposure.

4.7.1 Use chain puller or chain block in 4.7.1.1 Use of A-frame connected to
lifting pipe during fit-up works.
the chain block.
4.7.2 Cable sling shall be inspected
4.7.1.2 Pipe jack to be used as
before use.
secondary support for the pipe.
4.7.3 Provide adequate supports to hold
pipe.
5.1.1.1 Discuss in HIP/ TBT.
5.1.2.1 Ensure all work shall be
supervised at all times.
5.1.3.1 Obtain Permit to Work.

6.2.1.1 Removal of unnecessary

materials.

6.4

Cuts injury

6.5

Eye, hand & finger

injuries

6.6

7.1

7.2

LOW

LOW

Overloading

7 Welding works

LOW

Electric shock

LOW

LOW

Burn Injury

6.4.1 Ensure employee should wear

correct leather hand gloves.
6.5.1 Ensure employee wearing suitable
safety gloves, safety glasses and
safety shoes, safety helmet when
handling steel pipe.
6.6.1 Use safe rigging equipment for
lifting of materials. Ensure that it is
color coded for the month and
properly documented and
registered.
6.6.2 Loading will be closely supervised
with trained/certified banks men.
7.1.1 Ensure100% grounding system.
Grounding cable must be clamped
near the joint to be weld. Welding
cables, electrical cords must be
properly insulated.
7.1.2 Ensure equipment is of correct
type, size and they are in good
condition and color coded as
required.
7.1.3 Ensure good electrical connection.
7.1.4 Ground the work being welded.
7.1.5 Maintain the electrode holder,
work clamp, welding cable and
welding machine.
7.2.1 Wear appropriate protective
clothing, safety jackets, welding
apron, gloves, face shield.
7.2.2 Ensure work area properly
barricaded and displayed warning
signs to warn the workers.

LOW

LOW

LOW

LOW

LOW

6.6.1.1 The weight of such load will be

determined to ensure that
overloading is prevented.

7.1.1.1 Ensure all electrical equipment

were properly grounded and
built with ELCB at their source.
7.1.2.1 Dont touch electrically live parts
with skin or wet clothing.
7.1.3.1 Insulate yourself from work and
ground.
7.1.5.1 Dont allow any live electrical
parts to touch the ground.

7.3

Electrocution and burns.

7.4

MED

Arc rays
B

7.6

LOW

Fumes & gases

7.5

Slip, Trip & Fall from

same level due to
cluttered area.

7.3.1 Do not weld on containers having

combustible materials (paints /
thinner).
7.3.2 Do not weld on containers having
combustible materials (paints /
thinner).
7.3.3 Keep a fire watch

7.3.1.1 Maintained suitable fire

extinguisher in the welding area.

7.4.1 Provisions for mechanical

ventilation. If not possible, use
7.4.2 correct respirator.
Ensure the right positioning of
welders head & the used of
electrode.

7.4.2.1 Refer to MSDS.

7.5.1 Ensure employee wear a suitable

eye protection.

7.5.1.1 Only competent and trained

employee will carry out the
tasks.

LOW

LOW

7.6.1 Keep cables, materials, tools

neatly organised.

7.6.1.1 Housekeeping shall be a

priority, walk and work areas
shall be kept free of materials
and supplies.

LOW

LOW

LOW

LOW