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Page No: 2 OF 22
Method Statement for Generator Cooler Erection ACC
Saih Rawl Combined Cycle Power Station
Doc No : : LNG-75-102961-BA-6070-00063-0000-01
Document Preparation
Revision History
Revision
Date of Rev Revision Description
Number
01 20.02.2018 Issued for Review
Page No: 3 OF 22
Method Statement for Generator Cooler Erection ACC
Saih Rawl Combined Cycle Power Station
Doc No : : LNG-75-102961-BA-6070-00063-0000-01
Content
1. Introduction…………………………………………………………………................. 4
1.1 Purpose
1.2 Scope
3. References………………………………………………………………………………. 5
6 7
10 questions of safe lift
7 Resources 8
8. Appendixes.........................................................................................................................
9
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Method Statement for Generator Cooler Erection ACC
Saih Rawl Combined Cycle Power Station
Doc No : : LNG-75-102961-BA-6070-00063-0000-01
1 Introduction
1.1 Purpose
This Method Statement describes the system & procedures to be adopted for STG Cooler
erection at SRLCCPS Saih Rawl
1 .2 Scope
This procedure applies to STG Cooler erection at SRLCCPS Saih Rawl
Quality Control Plan : The term Quality Control Plan (Inspection Test Plan), is used to
identify activities that are to be controlled, the controlling
specification and the control mechanisms site and source
inspection control.
Procedure : Specified way to carry out an activity or a process
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Method Statement for Generator Cooler Erection ACC
Saih Rawl Combined Cycle Power Station
Doc No : : LNG-75-102961-BA-6070-00063-0000-01
3. References
List of reference given below are informative, however latest PDO Code of Practices,
Standards, Specifications and Procedures shall be followed throughout the contract.
All the work must be performed according to the following as listed and the most relevant
codes and standards with good practices.
Detailed Drawing
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Method Statement for Generator Cooler Erection ACC
Saih Rawl Combined Cycle Power Station
Doc No : : LNG-75-102961-BA-6070-00063-0000-01
Page No: 7 OF 22
Method Statement for Generator Cooler Erection ACC
Saih Rawl Combined Cycle Power Station
Doc No : : LNG-75-102961-BA-6070-00063-0000-01
4.7 Banksman
Banksman shall co-ordinate the lifting movements and maintains radio- and/or visual
communication with crane operator and persons close to the load and to participate in
JHA/risk assessment/ toolbox talk for the lift.
Should not get involved as Rigger when also performing the role of a Banksman.
4.8 Rigger
Rigger shall inspect the rigging, select rigging to suit the load, install the equipment and to
participate in JHA/risk assessment/toolbox talk for the lift. He is the person to
connect/disconnect the load.
4.9 HSE Advisor
HSE Advisor shall be responsible for coordination with HSE authorities of client. HSE Advisor
shall also monitor all the works to ensure that they are carried out correct and in safe manner
and advise supervisors for corrective measures, if required. He shall ensure that toolbox talks
are held which shall cover details of specific tasks to the personnel and specific job risks
involved are explained to the work force involved.
5. Lifting Procedure/Activity Sequence
1. Check the ground condition Position and set the crane to the required area as per the lifting
plan. All lifting activities to be done within the maximum radius and boom length shown in
the lifting plan
2. Lifting Equipment Controller Inspect all lifting tools and tackles as per lifting plan and check
the color code, SWL, and third party certificate.
3. Conduct toolbox meeting by lifting supervisor and briefly explain the task hazards, and risk
assessment to the entire team.
4. Check all third party certificate of crane operator, banksman and riggers.
5. Clear the obstacles from the lifting area. Area barricading and sign board to be provided
before the lifting activity.
6. After positioning of crane, operator takeout the boom out and position the hook block at
center of lifting hook on the material which is to be unloaded, and check the SWL of crane
in the SLI
7. Operator to lower the hook block to the lifting hook of the material and the rigger shall attach
the lifting tackles to the hooks after inspection.
8. Rigger shall fix the Lifting tackles to the load at the position shown in the lifting plan
9. Trial lift and check the center of gravity and check whether the load is balanced for the
crane.
10. Lift the load just 100mm from the ground position and ensure load is distributed equally on
four lifting points; Banks man shall give signal to Crane operator.
11. Lift slowly the Cooler assembly from the ground position and swing towards the Generator
cover top as per lifting sketch.
12. Positioning the cooler on the top of the generator and bolt tightening to be done.
13. After tightening the bolts, Banks man shall give signal to Crane operator to lower the hook
block. Remove the lifting tools from the load aft tightened.
14. Remove the crane from position. Lifting tackles shall be rolled, and sent back to store.
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Method Statement for Generator Cooler Erection ACC
Saih Rawl Combined Cycle Power Station
Doc No : : LNG-75-102961-BA-6070-00063-0000-01
All lifting activities to be done within the maximum radius and boom length shown in the
lifting plan.
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Method Statement for Generator Cooler Erection ACC
Saih Rawl Combined Cycle Power Station
Doc No : : LNG-75-102961-BA-6070-00063-0000-01
15. Resources
Equipment & tools
1. Crane 250 ton capacity-1 no
Registration no - 6339 YR
Model No& Serial No- CK 2500E-2 . JD04-02590
2. Web sling swl-10 ton,10 mtr – 4 nos
Identification Number - 19860 , 19858 , 19861 ,19855
3. Bow shackle 25 ton capacity-04 nos
Identification Number – BS 1243 ,BS 129 ,BS 1250 ,BS 1256
Page No: 10 OF 22
Method Statement for Generator Cooler Erection ACC
Saih Rawl Combined Cycle Power Station
Doc No : : LNG-75-102961-BA-6070-00063-0000-01
Appendix-1
EMERGENCY CONTACT NUMBERS
24-HOUR PDO EMERGENCY NUMBER 2438 5555 / 24675555
ROP + CIVIL DEFENCE 9999
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Method Statement for Generator Cooler Erection
Saih Rawl Combined Cycle Power Station
Doc No : : LNG-75-102961-BA-6070-00063-0000-01
# Tasks Comment
Page No: 13 OF 22
Steps per Task
3.1 Clear all personnel not required for the n/a The less people in the danger zone the better
lift outside of the physical barrier
3.2 Position Main Hook of Crane centrally over n/a Ensure the COG of crane is correctly aligned with the
load hook
3.3 Riggers take control of tag lines n/a Stay well clear of load, avoid pinch pints
3.4 Conduct Trial Lift n/a Small lift to prove crane/rigging/ground ok for lift
3.5 Lift 100 mm from the ground position. Check n/a crane should within the maximum Radius and boom
load is equally balanced on the four lifting length to lift and ensure the balancing of the load
hook. Then crane move towards the generator use tag line to control the load
cover
3.6 After proper positioning of cooler assembly n/a Orientation to be checked, allow minimum people in the
bolting to be done with the generator cover. danger zone, foundation bolt/bolts to be tightened
ensure proper tightening of bolt before release
the crane
Task 4 – De-Rigging
Steps Drawings Comment
4.3 Remove Crane Away from location n/a Ensure area is clear prior to moving boom
4.4 Store Lifting Accessories and return back to n/a Ensure all items are secure on the vehicle and to be
store properly stored in store
Page No: 14 OF 22
Task Risk Assessment Worksheet
Task 1 In-Load Equipment to Lift Area Step 1.1 Clear Lifting Area
Risk Matrix
Potential Incidents Consequences Current Controls Recommended Controls Responsibility
L M H
Slips, Trips and Falls Competent and experienced personnel on-site Ensure all personnel are wearing Supervisor
1.1.1 Personnel Injury x
leaving the lift Area appropriate PPE
Personnel Trapped, Tool Box Talk Banksman not to allow crane operator to Banksman
1.1.2 Pinched, struck by load Personnel Injury x move crane until area clear
Competent and experienced personnel on-site Supervisor
Deploy physical barriers
Task 1 In-Load Equipment to Lift Area Step 1.2 Deploy the Crane
Risk Matrix
Potential Incidents Consequences Current Controls Recommended Controls Responsibility
L M H
Personnel injury Damage Pre-Use Inspection conducted and Banksman to check crane pre-use Banksman
recorded inspection conducted thoroughly
to equipment Loss of Time
1.2.1 Crane Fails x Cranes maintained and serviced correctly Ensure good maintenance is timely done, maintenance
Check periodic maintenance register supervisor
Potential loss of control of Wind speed checked by crane operator and Banksman checks weather and ground Banksman
lift within limits conditions prior to deployment of crane
Poor environmental
1.2.2 Personnel injury x
conditions
Damage to crane or
other equipment
Potential loss of control of Ground where loads to be off-loaded has been Crane Operator to use Spreader mats for all Crane Operator
lift compacted lifts
Ground under crane not
1.2.3 Personnel injury x Ground checked by Banksman prior to If any doubt exists, Supervisor to conduct
suitable Supervisor
deployment of cranes soil test on the ground prior to
Damage to crane or commencement of lift
other equipment
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Task 1 In-Load Equipment to Lift Area Step 1.3 Deploy Lifting Accessories
Risk Matrix
Potential Incidents Consequences Current Controls Recommended Controls Responsibility
L M H
Lifting Accessories not Personnel Injury Thorough Before Use inspections Certification checked prior to Lifting
certified or correctly conducted and recorded deployment equipment
1.3.1 Damage to equipment x controller/
color coded Lift Plan followed
Loss of Time lifting
supervisor
Personnel Injury Competent and experienced crew on-site Banksman supervises rigging Banksman
Manual Handling
1.3.2 Loss of Time x Tool Box Talk Supervisor ensures correct PPE is worn Supervisor
Injury
MHE used where required
Task 2 Rigging Each Load Step 2.1 Attach web slings to Main Hook
Risk Matrix
Potential Incidents Consequences Current Controls Recommended Controls Responsibility
L M H
Personnel Injury Competent and experienced crew on-site Banksman supervises rigging Banksman
Manual Handling Loss of Time Tool Box Talk Supervisor ensures correct PPE is worn Supervisor
2.1.1 x
Injury
MHE used where required
Personnel Trapped, Tool Box Talk Banksman not to allow crane operator to Banksman
Personnel Injury
2.1.2 Pinched, struck by load x move crane until area clear
Competent and experienced personnel on-site Supervisor
Loss of Time
Deploy physical barriers
Task 3 Conducting the Lifts Step 3.1 Clear area of unwanted personnel
Risk Matrix
Potential Incidents Consequences Current Controls Recommended Controls Responsibility
L M H
Page No: 16 OF 22
Slips, Trips and Falls Personnel Injury Competent and experienced personnel on-site Ensure all personnel are wearing Supervisor
3.1.1 x appropriate PPE
leaving the lift Area Loss of Time
Tool Box Talk Banksman not to allow crane operator to Banksman
Personnel Trapped, move crane until area clear
3.1.2 Pinched, struck by load Personnel Injury x Competent and experienced personnel on-site
Enforce adherence to physical
barriers Supervisor
Task 3 Conducting the Lifts Step 3.2 Position Main Hook of crane centrally over Load
Risk Matrix
Potential Incidents Consequences Current Controls Recommended Controls Responsibility
L M H
Tool Box Talk Banksman not to allow crane operator to Banksman
Personnel Trapped, move crane until area clear
3.2.1 Pinched, struck by load Personnel Injury x Competent and experienced personnel on-site Supervisor
Enforce adherence to physical
barriers
Potential failure of crane Lift Plan adhered to Banksman ensures crane operator stays Banksman
within crane limits
Injury to personnel Weights actual and not assessed
Crane takes excess
3.2.2 x Correctly rated crane deployed
Load Use tag line to control the load.
Competent and experienced personnel on-site
Task 3 Conducting the Lifts Step 3.3 Riggers Take Control of Tag Lines
Risk Matrix
Potential Incidents Consequences Current Controls Recommended Controls Responsibility
L M H
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Task 3 Conducting the Lifts Step 3.4 Conduct Trial Lift – 100mm Maximum Lift
Risk Matrix
Potential Incidents Consequences Current Controls Recommended Controls Responsibility
L M H
Potential failure of crane Lift Plan adhered to Banksman ensures crane operator Banksman
stays within crane limits
Injury to personnel Weights actual and not assessed
Banksman ensures load is free to be
Damage to load and Correctly rated crane deployed lifted Banksman
3.4.1 Crane Fails equipment x
Competent and experienced personnel on-
site
Potential failure of crane Lift Plan adhered to Banksman ensures crane operator Banksman
stays within crane limits
Injury to personnel Weights actual and not assessed
Banksman ensures load is free to be
Damage to load and Correctly rated crane deployed lifted Banksman
Crane fails under equipment
3.4.2 x Competent and experienced personnel on- Supervisor positioned to monitor
outrigger pads site
from the ground or sink Supervisor
Outrigger Spreader Mats Deployed
under all four outriggers
Crane Operator
Potential failure of crane Lift Plan adhered to Banksman ensures rigging is in order Banksman
and appropriate to the load
Injury to personnel Weights actual and not assessed
Banksman ensures load is free to be
Damage to load and Correctly rated lifting accessories lifted Banksman
equipment deployed
3.4.3 Rigging Fails x Supervisor positioned to monitor
Competent and experienced personnel on- outriggers – Stop the Job if they lift
site Supervisor
from the ground or sink
Thorough Pre-Use Inspections conducted and
recorded
Potential failure of crane Lift Plan adhered to Banksman ensures rigging is in order Banksman/ supervisor
and appropriate to the load
Injury to personnel
Weights actual and not assessed Banksman to ensure Load only lifted Banksman
Load In-Balance Damage to load and slightly
3.4.4 equipment x Correctly rated lifting accessories Banksman
deployed Banksman to ensure COG in vertical
line with the crane hook
Competent and experienced personnel on-
site
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Task 3 Conducting the Lifts Step 3.5 After ensuring the load balance and swing position move towards
the generator cover.
Risk Matrix
Potential Incidents Consequences Current Controls Recommended Controls Responsibility
L M H
Potential failure of crane Lift Plan adhered to Banksman ensures crane operator stays Banksman
within crane limits
Injury to personnel Weights actual and not assessed Banksman
Banksman ensures load is free to be lifted
Damage to load and Correctly rated crane deployed
3.5.1 Crane Fails equipment x
Competent and experienced personnel on-site Supervisor to ensure competency supervisor
Potential failure of crane Lift Plan adhered to Banksman ensures crane operator stays Banksman
within crane limits
Injury to personnel
Weights actual and not assessed Banksman ensures load is free to be lifted
Damage to load and Banksman
Crane fails under equipment Correctly rated crane deployed Supervisor positioned to monitor
3.5.2 x
outrigger pads Competent and experienced personnel on-site from the ground or sink Supervisor
Outrigger Spreader Mats Deployed under
all four outriggers
Crane Operator
Potential failure of crane Lift Plan adhered to Banksman ensures rigging is in order and Banksman
appropriate to the load
Injury to personnel Weights actual and not assessed
Banksman ensures load is free to be lifted
Damage to load and Correctly rated lifting accessories Banksman
equipment deployed Supervisor positioned to monitor
3.5.3 Rigging Fails x outriggers – Stop the Job if they lift from
Competent and experienced personnel on-site the ground or sink Supervisor
Thorough Pre-Use Inspections conducted and
recorded
Potential failure of crane Lift Plan adhered to Supervisor ensures rigging is in order and Supervisor
appropriate to the load
Injury to personnel
Weights actual and not assessed Banksman to ensure Load only lifted Banksman
Damage to load and slightly
3.5.4 Load In-Balance equipment x Correctly rated lifting accessories Banksman
deployed Banksman to ensure COG in vertical line
with the crane hook Banksman
Competent and experienced personnel on-site Supervisor to ensure competency
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Cooler assembly to be install on generator cover and Ensure
Task 3 Conducting the Lifts Step 3.6 proper tightening of bolt before releasing the crane.
Risk Matrix
Potential Incidents Consequences Current Controls Recommended Controls Responsibility
L M H
Potential failure of crane Lift Plan adhered to Banksman ensures crane operator stays Banksman
within crane limits
Injury to personnel Weights actual and not assessed
Banksman ensures load is free to be lifted
Damage to load and Correctly rated crane deployed Banksman
3.6.1 Crane Fails equipment x
Competent and experienced personnel on-site Supervisor to ensure competency at site
Potential failure of crane Lift Plan adhered to Banksman ensures crane operator stays Banksman
within crane limits
Injury to personnel Weights actual and not assessed
Banksman ensures load is free to be lifted
Damage to load and Correctly rated crane deployed Banksman
Crane fails under equipment Outrigger Spreader Mats Deployed under
3.6.2 x Competent and experienced personnel on-site all four outriggers Crane Operator
outrigger pads
monitor outriggers – Stop the Job if they
lift from the ground or sink
Supervisor
Maintenance of slings LEC to ensure that lifting tackles are Lifting equipment
Personnel under fatality properly maintained controller/ lifting
3.6.3
suspended load x supervisor
Asset damage Clear all the people away from the lifting Ensure no one under travel area of load lifting supervisor
radius.
Provide barriers and signage’s around Ensure barriers and sign ages are provided lifting supervisor
lifting area
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Task 4 De-Rigging Step 4.2 Remove sling from main hook
Risk Matrix
Potential Incidents Consequences Current Controls Recommended Controls Responsibility
L M H
Personnel Injury Competent and experienced crew on-site Banksman supervises rigging Banksman
Manual Handling
4.2.1 Loss of Time x Tool Box Talk Supervisor ensures correct PPE is worn Supervisor
Injury
Personnel Trapped, Tool Box Talk Banksman not to allow crane operator to Banksman
Personnel Injury
4.2.2 Pinched, struck by load x move crane until area clear
Loss of Time Competent and experienced personnel on-site. Supervisor
Use manlifter to remove the lifting gears Deploy physical barriers. Proper
communication between manlift operator,
banksman and crane operator
Risk Matrix
Potential Incidents Consequences Current Controls Recommended Controls Responsibility
L M H
Personnel Injury Competent and experienced crew on-site Banksman supervises stowing of crane Banksman
Manual Handling hook
4.3.1 Loss of Time x Tool Box Talk
Injury Supervisor ensures correct PPE is worn
Supervisor
Personnel Trapped, Tool Box Talk Banksman not to allow crane operator to Banksman
Personnel Injury
4.3.2 Pinched, struck by load x move crane until area clear
Competent and experienced personnel on-site Supervisor
Loss of Time
Deploy physical barriers
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Task 4 De-Rigging Step 4.4 Store Lifting Accessories and return back to store
Risk Matrix
Potential Incidents Consequences Current Controls Recommended Controls Responsibility
L M H
Personnel Injury Competent and experienced crew on-site Banksman supervises rigging Banksman
Manual Handling
4.4.1 Loss of Time x Tool Box Talk Supervisor ensures correct PPE is worn Supervisor
Injury
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