Method Statement for storage tank Construction and Piping systems

Document Number: K1/22/MOS/005 Rev 0.2

METHOD OF STATEMENT
STORAGE TANK CONSTRUCTION & PIPING SYSTEMS

Document Number: KI/22/MOS//005

CLIENT : EBS GPG ARIA FZE

CONTRACTOR : KENZO INTERNATIONAL FZC

PROJECT: PROPOSED STORAGED TANK + OPEN SHED

 Method Statement for storage tank Construction and Piping systems
Doc No: KI/22/MOS/005 Rev 0.2

PROJECT ARIA
1 Project No & Title Ref: KENZO/CO/22-RO.1/10-1178
PR

Method Statement for storage tank

2 Document Title Construction and Piping systems EBS
GPG ARIA FZE CONTRACT
Contractor Document PROJECT ARIA
3
Reference No. Ref: KENZO/CO/22-RO.1/10-1178

4 TP Document Reference No. NIL

Subcontractor Document
5 NIL
Reference No. (if any)

Subcontractor Document
6 NIL
Review code. (if any)
7 Document Revision No. 0.1
Contract or initial Wayleave
8 KENZO/CO/22-RO.1/10-1178
No.

Insurance
9 P/4105/2/21/3000320
Policy No. and Expiry date

Workmen compensation
10 QJDWCP2021049862
Policy No. and Expiry date

From
11 KENZO INTERNATIONAL FZC
Company/Contractor

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TABLE OF CONTENTS

SL NO TOPIC

1 Scope of work

2 Contractor details

3 Responsibilities
4 Detailed Work Methodology
5 Preliminary works
5A Storage Tank Construction Methodology
5B Identification of Tank Materials
5C Storage Tank Construction and fabrication
5D Storage Tank Erection
5E Installation of Tank Appurtenances
6 Commissioning and Final Handover works
7 Emergency Procedures
8 Equipment and Tools
9 Risk Assessment

10 Material Data

11 Waste Management & Environment Plan

12 Attachment
13 Others

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1) SCOPE OF WORK

The Method Statement for storage tank construction provides detailed

information on the procedure and rules for conducting all fabrication, erection, and
testing of the storage tanks and similar static equipment. All the tasks /
Activities should be completed with utmost care with good workmanship and in
accordance with the specifications to realize satisfactory completion of the
entire activities. This document will provide a reference for a proper methodology to
realize the activities during a proper sequence for fabrication, Erection, and Testing
of the storage tanks

Reference Codes and Specifications for storage tank construction

• API 650
• IS 803
• ASME Sec IX
• Approved Drawing / Specification
• ASME Sec V

The scope of work involves obtaining necessary work permit, all necessary
equipment, machinery, and tools as required for completing the project works
under “Provision of General construction services” contract that includes
Mechanical and Civil, works as per satisfaction of HFZA Authority as per granted
project requirements of safety and quality.

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2) CONTRACTOR DETAILS

Contractor Name: KENZO INTERNATIONAL FZC

Contact No: +971526192020

Name Description Contact No

Aswin Cherukattil General Manager +971526192020

Baiju John Project Director +971568313200

Ajit Alias Project Engineer +971528717401

Eng. Fadel Civil Head +971544200433

Eng Kannan Baskar Site In Charge +971529766007

Eng Ashwin QA/QC Engineer +971529765859

Eng Semiu Safety Engineer +971555958618

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3) RESPONSIBILITIES

4.1) Project Manager

 The project manager will be overall responsible for execution of works.

 Project Manager shall be focal point to TP.
 Responsible for implementing the overall company safety plan.
 To ensure efficient execution of works in accordance to project
specification.
 To manage weekly coordination meeting.
 To have effective monitoring and control of project schedule.
 To arrange necessary manpower required for planned work.
 To arrange necessary equipment for the execution of project.

4.2) HSE In-charge

 Responsible for the overall safety of personnel, materials and equipment

during the construction and pre- commissioning stages.
 Responsible for the operations at site. Implementing safety standards and
ensure that they are maintained throughout the construction.
 Coordinate and preside over regular site safety meetings, to attain and
maintain effective communication between contractor and company
personnel.
 Follow established policies and procedures for site personnel.
 Manage the participation in occupational safety and health administration
(OSHA) inspection, providing inspectors with appropriate documents and
identifying safety measures.
 Enforce the Health, Safety and Environment rules and regulation where
necessary,
 prepare and issue safety reports.
 If any deviations are noticed during inspections, he shall require the
responsible supervisor to take corrective action immediately. He shall after
due consideration, exercise carefully his "STOP-WORK" authority for
appropriate action or any unsafe acts or unsafe conditions of which
immediate danger or serious consequence encountered and encourage all
employees to use it as well.
 Assist and advise in the reporting and investigation of accident/ incident and
make recommendations to avoid recurrence as per company and client HSE
procedure.
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 Effectively displaying and maintaining publicity material on site posters,

safety signs and banners and distributing safety literature.
 Inspect and ensure Heat stress procedure implementation.
 Conducting the client safety audit with site manager and supervisory staff
and follow up.
 HSE Officer shall be on site full time and ensure with PA that all control
measures are in place.

4.3) QA/QC In-charge

 Responsible for the overall Quality control of all the construction activities at
site.
 Responsible for all inspection, inclusive of witnessing, recording and
reporting.
 Responsible for all inspections, that are executed efficiently and
expeditiously in order to fully comply with the project QA/QC requirements.
 Co-ordinate with TP QA/QC for all QA/QC matters.
 Responsible for preparation of inspections, documentation and test plans as
per project specification requirements.
 Responsible to ensure all materials are within the correct project
specification prior to installation on site.
 Welding materials control and handling including baking, holding, issue and
return and respective logbooks endorsement on daily basis.
 WPS and supporting PQR packages to be generated and matching with all
project welding tasks and selected to be used as per each application.
 Request for inspection issue and follow-up in liaise with Company QA/QC.
 NDE coordination and reports review including liaise with Company QA/QC
for approvals and clearance.

4.4) Site Superintendent

 Responsible for implementation and monitoring of all related works at site as

per approved drawings.
 Responsible for preparation of work method statements and safety rules.
 Responsible to assign manpower and ensure availability of materials,
consumables, equipment and tools,
 Co-ordinate with all discipline of HSE / QA/QC / Planning / procurement /
Construction
 / Operation / other stake holders in the field (Site construction focal point).
 Responsible for plan analysis, methodologies and to recommend the best
option of execution at site.
 Interpret construction drawings and study the contract document and
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applicable standards or specification prior to execution.

 Submit site daily reports, inspection request and monitoring.
 Responsible that all site works are done according to all applicable quality
standards.
 Responsible to coordinate all installation works at site.

4.5) Supervisor/Performing authority

 The Project Supervisor will inspect the site on a regular basis and must keep
day today supervisory records for the steps of works until completion of all
work.
 Performing authority shall be on site at all the times.
 Follow the TP procedure.
 Delivering daily pre-start talk / toolbox talks as per the daily given tasks and
document the attendance sheet.
 All permits to work system shall be followed / implemented by supervisor
such as planning / preparing / submitting / receiving completed permits and
cancellation of permits on time.
 At the end of the day-to-day work, supervisor must ensure that good
housekeeping is maintained.
 Reporting any accident, incident and near misses to site safety, Project
Manager and TP.
 Arrange shade rest and cool water for workers.
 Arrange Hiab, Crane, Welding machines.
 Arrange welders, fitter / fabricator, riggers, labor’s and required tools.
 Ensure To discuss MOS with all workers and implement them.
 Ensure that all the working personnel must have the personal Gas monitors.

4.6) Workers

 The workers shall wear the required PPE at all times.

 All the workers will be trained for the job they are performing and the type of tool
/procedure to be used to avoid the risk.
 All workers should follow the toolbox talk and their supervisor instructions and
not perform any work not related to the work and which is not safe.
 All workers must inform their colleagues/ Supervisor when they are leaving site
for any reason.
 Practicing Stop work Authority and report it.
 Reporting any accident, incident and near misses to supervisor and safety
officer.
 Workers non-compliance to safety and work quality requirements shall be

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recorded.

4.7) Responsibilities of Confined space rescue team members

 Follow the Rescue plan.

 The first, and the one at highest risk, is the entrant.
 Know how to use all required equipment.
 Know the procedures for communication with the attendant.
 Know how to alert the attendant of hazardous or prohibited conditions.
 Know how to exit the space if necessary (that is, self-rescue).
 Confined space attendant
 Warn away unauthorized personnel.
 Confined space entry supervisor.

4) DETAILED WORK METHODOLOGY

A) PRELIMINARY WORKS

a) Preliminary Workflow process

Up on receiving PO / WO from TP, contractor shall:

1. Submit Work Schedule

2. Obtain BP from Hamriyah Free zone Authority.
3. Obtain required Way leaves. Way leaves clearance is to be obtained from
all required authorities as required by PROJECT ARIA and all wayleave
approved comments given by stakeholder is to be strictly followed.
4. Obtain permit to work for all site related activities.
5. Study the construction drawing and raise technical queries if necessary.
Technical queries are to be raised to KENZO if there are changes to the
design as per actual site conditions or for any general query related to
site/work

b) Pre-Mobilization

1. Conduct pre-site inspection and take note of items like number of workers
required.
2. Mean of access for equipment's, locations of existing facilities of pipeline,
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power source location, overhead power lines, underground cables and

services.
3. Potential hazards and any other items that may affect performance of the
work.
4. Pre-permission from operations for lay down of materials, supplies &
equipment.
5. Identify the location of the assembly points /evacuation plan.
6. Workers resting location and position of porta-cabins.

c) Mobilization

This activity involves the following:

1. Pre-inspection of the required resources to ensure they are in good

operating condition prior to bringing them to the worksite.
2. Setting up temporary structures or facilities at the worksite.
3. Providing barricades and safety warning signs where required.

Storage Tanks in a Tank Farm

Storage Tank Construction Methodology

The storage tank construction methodology can be performed in the sequence listed
below:

1. Identification of Tank Materials

2. Tank Construction and Fabrication
3. Annular and Bottom Plate Fabrication
4. Shell Plate Fabrication
5. Roof Plate Fabrication
6. Appurtenances
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7. Spiral Stairway and hand railing

8. Storage Tank Erection
• Annular Plate laying
• Bottom Plate laying
• Erection of Cone Roof plates and Structures
• Shell Course Erection
• Appurtenances installation
Identification of Tank Materials
All items required for tank fabrication like Plates, fittings, and other components of
the tankage system must be clearly identified by marking heat numbers by hard-
punching on each part. Each weld joint shall be marked with a joint Number with
Welder Number.

Storage Tank Construction and fabrication

All fabrication works like tank material identification, marking, cutting, rolling and
welding must be performed as mentioned in the latest API 650. The workmanship
shall be good in every respect. It must be meeting all safety, Quality Control & Non-
Destructive Testing requirements, with the coordination of Engineer-In-Charge.

• Lay all the plates, Structural & pipes in such a fashion that facilitates proper
checking of dimensions & heat no.
• Mark the components as per the drawings.
Tank Annular and Bottom Plate Fabrication

• Mark the plates as per the drawing

• Perform the cutting operation after proper inspection.
• All the cutting operations shall be administered by Gas Cutting.
• Grind the cut edges smoothly to get rid of burrs and slag.
• Stack the plates at designated places within the fabrication yard in proper
Sequence.
• The backing strip shall be fitted and tacked with an annular plate as per the
drawing.

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• After completion of the fabrication underside of annular and bottom plates

shall be blast cleaned and painted as per the specification to the satisfaction
of the Engineer-in-charge.
• Check the Joint Position, Root gap for welding after welding Inspection by
weld visual & NDT as per API 650.

Tank Shell and Bottom Plate Fabrication

Tank Shell Plate Fabrication

• Lay all the plates within the open area such as how easy it is for marking
and cutting.
• Mark the plates as per drawing and to the satisfaction of the Engineer-in-
charge.
• The cutting operation includes beveling shall be administered by the gas
cutting method on all four sides.
• Grind the cut edges smoothly to get rid of slag and burr.
• The stings prepared plates shall be shifted by crane to the rolling area.
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• The plates shall be fed to the rolling machine. by means of a crane & proper
lifting tools and tackles.
• The plate shall be rolled as per drawing details and therefore the radius shall
be checked using a Template.

• Proper care shall be taken for the graceful curvature. 36’’ Long (5 to 6 mm
thick). The template shall be wont to check rolling curvature accurately.
• The Template shall be checked and cleared by the inspection authority.
• The rolled plates shall be inspected and shall be within 3 mm of tolerance
limit.
• The rolled plates shall be shifted to the shot blasting yard to hold out the
shot blast as per specification.
• Final profile and dimensions check shall be administered before sent for
erection.
Tank Roof Plate Fabrication

• Mark the roof plate as per the drawing.

• All the cutting operations as per requirement shall be administered after
getting the clearance from the inspection authority.
• All the cutting operations shall be administered by the gas cutting method on
all four sides. Grind the cut edges smoothly to get rid of burrs & slag.
• Structural items of the roof shall be fabricated as per drawing.
• These roof plates shall be shifted to the blasting yard to hold out the blasting
and painting
Tank Appurtenances

• Mark the specified items of the Appurtenances as per the drawing. All the
cutting operations as per requirement shall be administered after getting the
clearance from the inspection authority.
• All the cutting operations shall be administered by the gas cutting method.
• Grind the cut edges smoothly to get rid of burrs & slag.
• Flanges face being covered with an appropriate cover to guard against
damage during handling, fabrication, and transportation.
• The whole shell nozzle, roof appurtenance, i.e. flanges, flanges to pipe joint
and other requirements, etc. Shall be fabricated as per approved drawings.
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• All the fabrication and welding activities shall be administered after the
stage-wise inspection wherever required.
• The NDT requirements are as per code specification.
Spiral Stairway, Hand Railing of Storage Tanks

• All the structural items shall be straightened before marking and cutting.
• Mark the components as per drawing.
• All the cutting operations, as per requirement shall be administered after
getting the clearance from the inspection authority.
• All the cutting operations shall be administered by the gas cutting method.
• Grind the cut edges smoothly to get rid of burrs & slag.
• Fabrication like fitting, welding, drilling, etc. shall be administered as per
drawing and after the clearance from the inspection authority.
• After fabrication of these structural items shall be blasted and painted as per
requirement.
Storage Tank Erection
There are two methods for storage tank erection:

• the Jacking method &

• the conventional method.
The conventional method is tough & unsafe as compared to the jacking method
that’s why the jacking method for Tank erection is used everywhere.

In the jacking method, we calculate the overall weight of tank ages except for
the bottom & deck, and accordingly, jacks are used. The number of jacks to be
used is directly subjected to the weight of the tank to be lifted.

Laying of Storage tank Annular Plate

• Check the extent of foundation as per specification Latest API 650 clause
8.4.2. After getting clearance for annular plate laying, mark the 0 degrees,

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90 degrees, 180 degrees, 270-degree coordinates on the inspiration from

the point of reference.
• Lay the annular plate as per the approved drawing. Out radius of the annular
plate shall be on the positive side (5 to 10 mm.) so as to realize the
ultimately required radius after weld shrinkage.
• The orientation of the annular plate joint shall be as per the approved drawing.
• Fit from annular plate’s joints shall be administered using proper jigs and
fixtures as shown in the drawing.
• Care shall be taken while fit-up, such there shouldn’t any gap between the
annular plate and backing strip.
• Annular plate joints welding shall be administered by welding alternative joints
at four quadrants.
• Qualified welders shall be engaged for the welding work consistent with WPS.
If any defect is found the defect weld shall be removed by grinding and re-weld
and Conducting the LPT check test.
• Repeat the sequence until the defect is cleared.
• Complete the welding, clean the ultimate weld surface by wire brushing and
grinding.

• Remove the jigs and fixtures which were used for fit-up of the annular joint
and grind the tack.
Radiography shall be taken as per API-650 Sec-8.
Laying of Storage Tank Bottom Plate

• Lay the middle plate on the inspiration top as per the drawing.

• With co-ordination of Centre plate lay rock bottom plates consecutively as per
drawing.
• Laps shall be maintained while the fit-up of a short seam and long seam as per
drawing.
• Temporary tack weld to be performed on the Long-seam to avoid uneven
movements, while the fit-up and welding of short-seam.
• Short seam welding is going to be administered alternatively to avoid
distortion.

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• After the completion of short-seam welding, remove the temporary tacks on the
Long- seam by grinding to facilitate the long-seam fit up. Short seam welding is
going to be administered alternatively to avoid distortion.
• After the completion of short-seam welding, remove the temporary tacks on the
Long- seam by grinding to facilitate the long-seam fit up.
• Minimum laps shall be maintained while the fit-up of long-seam as per
approved drawing.

• Joggling shall be administered by hammering wherever necessary. (Three

plates Joining junction.)
• Before starting the welding, channels shall be tacked along the long seam to
avoid distortion. After completion of shot seam welding long seam welding is
going to be administered alternatively to avoid distortion. a
professional welder shall be engaged and welding shall be performed as per
approved WPS.
• After Completion of welding thoroughly clean the weld joint by wire brushing
and grinding.
• Sketch to annular plate joint shall be welded only after shell to bottom joint
welding.
• All rock bottom plate joints vacuum box tests shall be administered as per
the approved Process and code specifications.
• If any defect is found the defect weld shall be removed by grinding and re-
weld and conducting the vacuum box test. Repeat the sequence until the
defect is cleared.
Erection of Cone Roof Plates and Structures

• After completion of the highest two shell courses erection, fit-up, welding,
and curb ring fit up & welding shall be done.
• Erect the fabricated Centre Drum, Roof Truss, and cross girders as per
drawing.
• Complete the welding of Roof structure by approved welders and as per
approved WPS. Erect and Lay the Roof plates on the structure as per the
Drawing. While fit from the short seams and long seams Lap to be
maintained as per Drawing.
• Weld the short seams by welding the alternative joint or sequence
mentioned within the drawing to stop the distortion.

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• Provide proper support lengthwise of the long seam and weld the joints as
per drawing sequence.

Spiral Stairway of Storage Tanks

Erection of Storage Tank Shell

• After the completion of the welding of Annular plates and bottom plates,
mark the tank inner radius on the annular plates.
• Fix 25 Nos. of erection tools at the equal interval on the annular Plates &
transfer the within tank diameter on the stools.
• The last 2 shell courses shall be erected by the conventional method.
• Balance shell courses shall be erected by the conventional method.
• The rolled shell plates shall be shifted to the tank foundation area
stacked around the periphery by using a crane.
• Proper care shall be taken while handling the rolled plates.
• Care shall be taken that the shell plate is erected to the diameter marked on
the annular plate. Jigs and fixtures shall be used to align the shell plates.
• Complete the fit up except the ultimate joint which shall be fitted and welded
after completion of the welding of the opposite joints. (To avoid shrinkage).
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• Peaking shall be checked at the top, middle, and bottom of the vertical
joints employing a Sweep board of 36” long. Plumpness shall be checked for
the verticality of the shell course at every 60° and shall be within the
tolerance (tolerance 1/200 of the entire shell height).
• For perfect verticality, channels shall be provided at the regular
interval inside the shell course (3 to five meters) providing the channels shall
facilitate the alignment shell course.
• Tack welds of the fitted vertical joints shall be ground smooth. Offer for
inspection and obtain clearance from Engineer-in-charge for the vertical fit-
up Complete the primary side welding by using qualified welders.
• After completion of first side welding, the back-chip shall be administered for
sound metal from the other side of the weld by grinding.
• Back-chipped grooves shall be offered for inspection before starting the
welding.
• Complete the 2nd side welding using qualified welders.
• Joint Nos. & welder No. shall be marked on both sides of the weld joint.
Care shall be taken to avoid peaking and roundness distortion. Clean weld
joints from each side by wire brushing and grinding. After completion of
welding from each side remove all the temporary jigs and fixtures and flush
grind the tacks. (Do the weld refill wherever required) and therefore
the portion checked by M.P.T.
• Check the plumpness, circumference and therefore the radius, offer for
inspection to the satisfaction of the Engineer-in-Charge. While
erecting subsequent coarse 3mm thick spacers shall be kept between the
shell courses.
• Erection channels shall be fixed between the jacked shell and to be erected
shell course plates at regular intervals to align and hold the last shell in a
vertical position.
• Check to peak at vertical joints of shell employing a sweep board of 36″wide,
acceptable tolerance shall the as per API-650.
• Complete welding of last course vertical seam inside after getting clearance
from the Engineer-in-charge. Back chip & welding shall
be administered following as same as for other shell courses to the
satisfaction of Engineer – in – Charge.

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• Check Verticality of the last shell course, Verticality (plumpness) tolerance

shall be as per API – 650 (max. out of plumpness at the highest of the shell
relative to the rock bottom of the shell to not exceed 1/200 of total shell
height from top of the last shell to Bottom).
• While welding care shall be taken for banding and therefore the roundness.
Back-chip shall be administered by grinding for the sound metal and to the
satisfaction of Engineer-in-Charge. Complete the 2nd side welding and
clean the joint thoroughly from each side by grinding and wire brushing.
Check banding, plumpness, and record within the approved format to the
satisfaction of Engineer – In-Charge.
• Take the repair spot RT and re-offer for the inspection to the satisfaction of
Engineer-In- Charge. Spiral staircase Erection shall be administered as per
drawing including brackets & avoiding fouling with welds.
• Remove all the temporary cleats and tacks by grinding. If any defect is found
the defect shall be repaired by grinding the defect area for the sound metal
plus 150mm from both ends of the defect.
• Conduct the DP test on the repair spot. perform the entire
• Process until the repair is cleared to the satisfaction of Engineer – In –
Charge.
• After completion of the shell to the bottom outside welding visual
inspection is going to be administered to the satisfaction of the Engineer-In
Charge.
• On completion of the shell to bottom welding / NDT and having completed all
erection and welding work on the tank inside associated with the roof and
roof structure, all unwanted materials, and scrap shall be far away
from inside the tank.
• RT of the vertical and horizontal joints shall be completed.
• Sketch to Annular plate joint fit up shall be administered after completing the
shell to bottom welds.
• Vacuum box test shall be administered for rock bottom plate short seam,
long seam, and sketch to annular plate joint. If any repair occurs an
equivalent shall be repaired and re-tested as per the approved procedure
and API-650.
Fig. 6: Storage Tank Construction at Site

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Installation of Tank Appurtenances

• Flanges to pipe joint shall be prefabricated and required NDT shall be

completed before erection.
• Mark the nozzle location as per drawings. Cut the openings by gas cutting
after proper Inspection-by-inspection authority.
• Erect the nozzles as per the orientation & the elevation shown within
the drawing. Install RF. pads wherever required before nozzle erection.
• Suitable jigs & fixtures shall be provided to stop the distortion during the
welding.
• Orientation, elevation & projection shall be maintained as per drawing and
offer for the inspection clearance. Proper care shall be taken for welding by
providing jigs & Fixtures to stop distortion.
• Welding shall be as per WPS and to be welded by the qualified welder.
• The man-Hole neck shall be fabricated and therefore the longitudinal joint
shall be radiographed. All the RF Pad weld shall be pneumatically tested at
a pressure of 1.05 Kg/Cm². The pneumatic test shall be administered to the
satisfaction of the engineer in charge.
• All the shell nozzles finally weld from each side and RF. Pads welds shall be
inspected visually and by LPT, to the satisfaction of the engineer-in-charge.

Pipe route survey and marking.

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Long section survey is to be taken for new pipe route as per the approved
drawing and location co-ordinates by using standard survey instruments. If
there is any deviation / obstruction as per the approved drawings, this has to
be first informed to the concerned TP Engineer/Supervisor before proceeding
with pipe stringing activities.

a) Pipe spool, material transportation, storage and Pipe stringing

1. All materials supplied by TP shall be stored in a proper place and

covered properly to avoid dust and debris.
2. None of the materials are allowed to be kept directly on the ground.
3. The materials must be kept either on top of wooden channels or it must
be kept in proper supports to avoid direct contact with ground.
4. KENZO QA/QC has to check the materials received from TP store for
any damage, verify the size, shape, type, specification and quantity. If
any damage or any defects is observed, this must be informed to KENZO
and it has to be replaced prior to removal of the material from KENZO
store / yard.
5. PROJECT ARIA, supplied materials shall be stored in Project White
castle stores and shall be shifted to the respective site stores according
to the requirements.
6. Pre-permission is required from TP operations before laying down of
materials, supplies & equipment on-site.
7. Materials shall be transported in Hiab, trailer, six-wheel vehicles as per
requirement.
8. Pipes shall be unloaded parallel to the pipeline routes surveyed and
marked. Crane, Hiab, Forklift, JCB or manual handling shall be used for
this activity depending on the size of the pipes.
9. Pipes shall be placed on temporary supports for ease of fit-up and
welding requirements.
10. Special care shall be taken during crane lifting operations if there
are any overhead power transmission lines, live pipelines nearby the
workplace. Follow TP procedure

b) Work procedure for site welding and installation

 Daily toolbox talk should be conducted before start of any job / activity at
site and records shall be maintained at site.
 All pipes shall be internally free from foreign materials and contaminations.
 All the fit-ups shall be done as per approved weld geometry.
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 Method Statement for storage tank Construction and Piping systems
Doc No: KI/22/MOS/005 Rev 0.2

 Any variation from the scope / design shall be first approved from Project
ARIA prior to start of the works.
 Cover with fire blanket if any drain boxes or adjacent lines are present.
 Arrange proper earthing to welding machine.
 Multi-head gas burners shall be used for preheating if required. Electrically
Heated quivers will be provided at each welding station for the personal use
of the welders, when using low hydrogen electrodes
 Wind shields and enclosed welding stations are provided during welding as
required.
 Extraneous arc strikes on surface of pipes or fitting shall not be allowed
 Additional and secondary installation work (off-plot & on-plot) along with
other interconnection piping like process, vent, flare, drain, instrument gas /
air piping. Interconnection piping to be installed only after completion of
main pipeline installation and testing.
 The ground to be kept in a damp condition to quickly extinguish any sparks.
 Welding booth shall be covered with fire blankets and to be kept over the
welding joints.
 Minimum 20 nos. of fire extinguisher to be kept around the welding area.
 Bevels shall be prepared on both ends for fit-up by using oxy-acetylene
flame and 7” size electric grinder.
 Fit-up the new spool at location by using a crane and subject fit-up for
KENZO QA/QC inspection and its clearance for welding.
 Once the spool is positioned, crane shall be removed and spool be rested
on the temporary or permanent support prior to do any fit–up. Crane shall
not be used for fit- up.
 Once fit up is cleared, KENZO shall carry out the welding as per approved
welding procedure. 100% Visual inspection of completed weld joints shall
be carried out. Joints subject to RT shall be selected by PROJECT ARIA
QC. All NDE including hardness testing to be carried out as per drawing
requirements.
 After completion of the weld, slag shall be removed completely from the
weld crown, by power wire brushing. The completed weld shall be inspected
by KENZO welding inspector and the same shall visually certify the weld.
The completed welds shall have substantially uniform appearance around
the entire circumference of the joint.
 The weld joint number and welder identification code be marked close to the
weld and shall be recorded in the weld maps and DWR.
 Upon completion of weld joints same shall be offered for final inspection /
NDE tests as required by PROJECT ARIA .
 KENZO shall carry out Radiography test, hardness test and any NDE only
through PROJECT ARIA approved NDT sub-contractor.
 In case of a defect the weld shall be repaired in accordance with Project
Page 22
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 Method Statement for storage tank Construction and Piping systems
Doc No: KI/22/MOS/005 Rev 0.2

codes/project specifications. All repairs to the welds shall be done in

accordance with approved Welding Procedure Specification (WPS).
 The defects on parent material shall be removed only by grinding. Prior
approval shall be obtained for any repairs.
 Final 100% visual inspection shall be carried out upon completion of any
repairs followed by 100% NDT as per Company requirements.

c) Fit-up and welding

 Necessary work permits shall be obtained before commencing any fit-up

and welding activities at site.
 All the welders employed for the work must be TP approved and
 Approved welders are only allowed to execute the work.
 Welding equipment shall be properly grounded.
 All the prefabricated spools must be marked with Drawing No., Line No. and
Joint No's.
 If any hot work activities are going on, assure availability of fire watcher,
valid fire extinguishers at site all the time.
 Check certificate of calibration of welding equipment.
 Check welding equipment and all related ancillaries (cable, regulators,
oven, etc).
 For seal welded joints, all exposed threads must be seal welded and thread
tape must not be used.
 All welding & grinding activities shall only be done after covering work area
by fire blanket.
 Electrode and rod diameters shall conform to the requirements of approved
WPS.
 All the weld joints must be properly prepared before doing fit-up. Bevel
angle, root gap should be maintained as per approved WPS. Weld joint
area must be thoroughly cleaned.
 Surface of pipe at areas to be welded shall be free from dirt, grease, scale,
paint, grit or any other foreign material which may adversely affect the final
weld quality on minimum 1 inch band both outside and inside the pipe.
 Proper joint root gap shall be done to assure full weld penetration as per
approved WPS requirements.
 Tack welds shall be avoided wherever possible.
 Each weld shall be uniform in width and size throughout its full length.
 Each layer of welding shall be smooth and free of slag, cracks, pinholes,
and shall be completely fused to the adjacent weld beads and base metal.
 Weld spatter shall be completely removed when the weld is completed.
Grinding may be used for spatter removal provided that the wall thickness is
Page 23
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 Method Statement for storage tank Construction and Piping systems
Doc No: KI/22/MOS/005 Rev 0.2

not reduced below required minimum value.

 Clear identification shall be provided for all weld joints. Welder ID, joint
number and weld date always to be marked adjacent to the completed
welded joints
 Complete coverage for all welded joints in respective piping weld maps to
be available at all times.

d) Installation of pipe supports; anchor supports and structural steel

platforms if required.
 KENZO shall install pipe supports, anchor supports and structural
platform as per the approved TP drawings.
 Prior to install the pipe support, the co-ordinate of the GA / routing
plan (alignment sheet) to be verified / confirmed.
 Supports and platforms will be prefabricated and painted at shop.
 KENZO shall install the supports and platforms based on final field
dimensions. Base plates if required will be welded at site to meet
the site conditions. Similar sequence shall also be adopted for
installation of platforms.
 KENZO shall use truck mounted crane (Hiab) and Telescopic
cranes to place the supports and platform in position.
 Make sure existing foundation / support shall not be affected in
any way by project work activities. Butting of supports with existing
or new pipelines is not allowed
 Extra care shall be paid if there is a valve or flange connection in
the adjacent piping.

e) Demolition and removal of redundant piping, equipment’s,

foundations, etc.

 All required permits are to be applied before commencing

demolition, removal works.
 Redundant piping, equipment’s can be removed using crane, Hiab
or manual handling as required.
 Gas cutting, grinding may be employed in-order to cut spools into
manageable size for removal. All necessary precautions to be
followed during hot works. Gas test to be conducted by TP
Operations personnel
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 Method Statement for storage tank Construction and Piping systems
Doc No: KI/22/MOS/005 Rev 0.2

f) Non-Destructive Examination (NDE)

 NDE activities will be carried out only by NDE third party agency approved
by PROJECT ARIA .
g) Hydrotesting, pigging, cleaning and de-watering of tanks
 The pipe shall be hydrotested after mechanical completion.
Hydrotesting of lines to be done in accordance with KENZO
Approved Hydrostatic Test Procedure.
h) Insulation works
 All pipe joint insulation works to be carried out as per PROJECT
ARIA requirement, approved by TPI. Separate Procedure will
be submitted.

i) Mechanical completion

 Pre-MEI has to be conducted by KENZO after installation completion

before calling for actual MEI. Internal punch list is to be generated and
closed off.
 After successful completion of the installation work, KENZO shall be
arranged and the Completion Certificate shall be duly signed by Project
Whit castle Representatives. Punchlist will be generated and circulated
to all parties for closure of respective punches.

B) COMMISSIONING AND FINAL HANDOVER WORKS

a) Commissioning activities

KENZO shall supply only manpower for Commissioning assistance as required

by TP. After clearance PSSR shall be arranged by TP and punch lists shall be
generated.
b) Hand Over
After the successful completion of all activity, final Hand Over Pack shall be
prepared and submitted for approval.

c) De-Mobilization / Housekeeping
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 Method Statement for storage tank Construction and Piping systems
Doc No: KI/22/MOS/005 Rev 0.2

 All work areas will be cleaned and left in a tidy condition before
demobilization.
 All permits will be cancelled on time.
 After the completion of work, proper housekeeping, such as but not
limited to the following, shall be carried out.
 Demolition of any temporary structure. (if required).
 Returning re-usable materials to KENZO Yard.
 Proper segregation and disposal of all waste materials as per TP
Waste Management Procedures.

5)EMERGENCY PROCEDURES
 Any injury, no matter how minor, should be brought to the notice of Supervisor
and Safety Officer. Arrangement shall be done to take victim to the medical
Centre.

 When calling for an Ambulance, the following information shall be clearly

given:
a) Reporter’s Name, Badge Number and Company.
b) Reporter’s exact location.
c) Nature of injury.
d) What services are required i.e., ambulance and back-up assistance, etc.
 Emergency evacuation may be required for the following reasons
a) In case of gas leakage
b) In case of emergency alarm
c) In case of any serious injury
d) In case of high wind
e) In case of physical violence
f) In case of fire and explosion

Note: Extinguishing the fire shall only be done when it is safe to do

so without risk to personnel, plant and/or equipment.

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 Method Statement for storage tank Construction and Piping systems
Doc No: KI/22/MOS/005 Rev 0.2

6) EQUIPMENT AND TOOLS

7.1. Vehicles and Plant

 JCB Shovel
 Bobcat
 Water tanker
 Tele handler / Forklift
 Crane
 Low bed Trailer
 Truck
 Grinder
 Roller
 Excavator

7.2. Tools and Equipment

 Lifting gear (slings, shackles, chain blocks, etc.)

 Hand tools (spanners, hammers, etc.)
 Power tools (grinders, drills, etc.)
 Jackhammer
 Welding generator (with cables and electrode holder)
 Air compressor (with hoses)
 Cold cutter
 Anti-whip cable

7.3. Personal Protective Equipment (PPE)

 Safety helmet
 Safety spectacles (glasses), clear and dark
 Coveralls
 Safety shoes
 Earplugs (or earmuffs)
 Respiratory protection (dust mask, cartridge respirator, etc.)
 Gloves (cotton, heavy duty, leather, chemical, etc.)
 Full-body harness with twin lanyards and shock absorber
 Personal gas monitor

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 Method Statement for storage tank Construction and Piping systems
Doc No: KI/22/MOS/005 Rev 0.2

 Steel Toe gumboot

7.4. Site HSE requirements

 Fire extinguisher
 Safety warning tape
 Safety warning signs

7.4. Emergency Safety Equipment’s for Confined space

 Stretcher Basket
 Tripod
 First Aid Kit
 Safety Harness
 Gas Tester
 Fire Extinguisher
 Megaphone

Page 28
[Link]
 RISK ASSESSMENT

Pre- Start Checklist

Date 01-July-2020
Project Proposed storage tank + open shed
Rev 02

General Manager: Aswin Cherukattil

Project director: Baiju John
HSE Engineer: Olawale semiu

1 Description of Task / Activity: Welding, Concrete, Hydro Test, Masonry works, piping,
Excavation, PC & Foundation work, Compaction, Sub Grade
Filling, Steel & Tank Erection, Steel Fabrication
2 Manpower Required for Task: 95
3 Work Notification Status: N/A
4 Estimated / Planned Start Date: As per construction schedule
5 Duration of Activity: As per construction schedule
6 Night work and Equipment: As Needed, General lighting, Lights to be fitted on plant and
equipment and beacon lights ( rotating flashing)
7 Equipment and Materials: Mobile crane, Man-Lift(s), JCB/ boom loader, Forklift, Power
tools (Angle grinder, cutter machine, drill machine),
Welding Machine, Steel rolling machine.
8 Overhead Services /
Underground: Sequence of N/A
Works Activity:
9 Subcontractors to be Used: 4
10 Interface with Public: Possibly
11 Adjacent Activities & Interface No
with other Sub Contractors:
12 Logistics, Loading, Delivery: Material will be delivered to yard and transported to the
workplace as required.
13 Specific PPE Required: Hard hat, hand gloves, safety shoes, Ear Plug, goggles and
safety harness.
14 Environmental: Potential oil spill equipment
15 Elevated Positions: Ladders, Scaffoldings, MEWPs
16 Confined Space Entry: Yes

Page 1 of 25
 RISK ASSESSMENT

17 Hoarding / Fencing / Metallic fencing

Barricading/ Demarcation:
18 Access / Egress: Separate access to work area to be provided
19 Security Requirements: As per Aria security rules and regulations
20 Traffic: As per Aria traffic rules and regulations
21 Permit to Work Required As Per Aria HSE requirement
Details:
22 Work Near Water: N/A
23 Hazardous Substances: Bitumen , silicon sand
24 Excavations: Tanks farm, Admin building, Labours rest room
25 Lifting Equipment / Machinery: Mobile Crane, JCB/ Boom loader, Man Lift, Chain sling,
Chain Block,
26 Special Emergency As per Aria emergency Procedure
Arrangements:
27 Additional Comments:

Page 2 of 25
 Risk Assessment

Contract Ref: 1917 – Rev02

Proposed storage tank + Open shed
Risk Assessment Record
RA No. RA 002

Contract Proposed storage tank + Open shed+ Security+ Service Block+ Associated Facilities
Task Description Construction of storage tanks, Service Block , Labour Rest Room ,Open Shed, Office Building
Task Site Location Plot Nos. 2M-11A,13A,13B,Phase 1-Hamriyah Free Zone,Sharjah-UAE

RISK SCORE CALCULATOR

Use The Risk Score Calculator To Determine The Level Of Risk Of Each Hazard
What would the What is the LIKELIHOOD of an occurrence? Hierarchy of Controls
SEVERITY Severity Almost Very Very
Of an occurrence be? Likely Unlikely Can the hazard be Eliminated or removed from the work place?
Rating Certain Likely Unlikely
Catastrophic
High High High Med Med Can the product or process be substituted for a less hazardous
Multiple Fatalities / 5
Environmental release with detrimental 25 20 15 10 5 alternative?
effects requiring external emergency services
Major
High High High Med Low
Major Illness or Injury, disability/ 4 Can the hazard be engineered away with guards or barriers?
Environmental release with minimal off site 20 16 12 8 4
impact
Moderate
Serious but non-permanent injury or ill health High High Med Med Low Can Administrative Controls be adopted
Work days lost/ 3
On site release requiring environmental 15 12 9 6 3 i.e. procedures, job rotation etc
emergency plan to be activated
Minor
Medical attention needed. Med Med Med Low Low Can Personal Protective Equipment & Clothing be worn to
No work restrictions./ 2
Local on site environmental release treated 10 8 6 4 2 safeguard against hazards?
locally
Negligible Med Low Low Low Low RISK RATING (Likelihood x Severity)
Minor cuts & bruises or sickness/ 1
Nuisance release with no adverse impact 5 4 3 2 1 1-4 LOW RISK (No further action required)
5-10 MEDIUM RISK (Procedure to be available)
Likelihood Rating 5 4 3 2 1 11-25 HIGH RISK (Full time supervision present)

Page 3 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
• Ensure all required document
approval has been obtained.
• Ensure work area is clear and safe.
• Ensure access to work area for
vehicles and pedestrian is provided. Ensure Project
Injury to persons • Ensure all safety requirements are continuous Manager,
Untrained Project
and or work not complied with contract monitoring
Access to persons and Engineer,
01 being performed 4 2 8M requirements. Y 2 2 4L and close
work area or unsafe HSE Officer,
as per • Ensure all constraints on operations supervision is
equipment Supervisor, Site
requirement have been identified and available at
precautions are taken. all time Security
• Employee inductions and toolbox
talk for discussing risk assessment
and hazard identification and its
control measures
Delivery of • Boom loader/ Forklift should have
materials to Use of mobile valid registration and tested and
site. plant - Failure certified by approved 3rd party and
Offloading by of boom in good condition
forklift, JCB/ loader/forklift • Operator should be competent and Project
boom loader certified by approved 3rd party and Engineer,
Personnel injury/ HSE Officer,
02 and transport Failure of 3 4 12H in possession of valid driving license.
property damage Supervisor,
to work lifting • Ensure not exceeding safe working
location. accessories load (SWL). Operator.
Shifting , and fall of • Operators Cabin should be free from
Erection & load obstructions
Installation of • Inspect the Equipment prior to use
Fiber Glass and update the checklist

Page 4 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
Slides, Crushing/ • Lifting gears (sling, shackles etc.) to
Columns, caught under be color coded or tagged to identify
Radial Arms & load the they are inspected before use,
slide visual check to be done to ensure
components free of damage
• Sling should only be attached to a
lifting point (Fork mounted crane
hook attachment)
• Slings should not directly attach to
forks
• Fork Mounted Crane hook
attachment should be inspected and
have valid third-party certificate
• A trained banksman to be present
with the mobile plant during
unloading and transporting to work
location.
• Barricade offloading area to prevent
unauthorized entry.
• Mobile plant should be fitted with
reverse alarm.
• Employees awareness on moving
plant and equipment
• Proper supervision
Underground
• Ground conditions established by a
services - gas, Personnel injury/
Excavation of survey to identify the type of ground
03 electricity or fatality 3 5 15H Y 2 5 10M TBT
Trenches in which the excavation is to be
water Property damage
carried out; means of trench support

Page 5 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
Falling confirmed upon completion of trial Project
materials or holes Engineer,
plant • Remember that even work in shallow HSE Officer,
trenches can be dangerous. You may Supervisor,
Falls of need to provide support if the work
persons involves bending or kneeling in the
trench. No one should be in the
Ingress of trench unless it is safe to be there.
water • Where possible ensure that all water
sources are turned off before
Collapse of entering an excavation
sides • Do not go into unsupported
excavations that have not being
Weakening of battered to a suitable slope. Never
adjacent work ahead of the support.
structures • Do not store spoil or other materials
close to the sides of excavations. The
Noise spoil may fall into the excavation and
the extra loading will make the sides
more prone to collapse
• Contaminants removed following a
suitable risk assessment and method
statement
• Employees and Management must
ensure no-one enters an
unsupported unsafe trench
• Support materials on site before
excavation starts.

Page 6 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
• Plant and materials kept away from
the side of excavations to prevent
undue pressure or ingress of exhaust
fumes.
• if the depth is a particular risk of
anybody falling, suitable guard-rails
placed and suitable access
arrangements, such as ladders or
ramps, provided
• If there is a risk of water ingress,
suitable methods and/or equipment
provided to either prevent the entry
of water or to remove water, e.g.
water pumps
• If plant could fall into the excavation,
baulks or earth bunds should
• Where excavations are dug next to
structures, suitable preventative
measures established in case of
collapse, subsidence or damage
• Inspections of excavations carried out
prior to each shift, after any event
likely to affect strength or stability be
provided.
• Record of inspections recorded on
approved form AF3 daily
• Suitable personal protective
equipment [PPE]

Page 7 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
• The location of electric cables, drains,
gas and water mains etc. will be
determined and marked prior to the
commencement work. Local ESB
Networks staff to be consulted on
underground services. Local
authorities and, where necessary,
scanning are to be used to determine
service locations.
• It will be the liability of the contractor
to make good any damage done to
such services during excavation work,
to render them safe and secure
without undue delay.
• Excavations or openings will be
properly sloped or shored at all
times. A competent person must
approve trench designs prior to
entry. Warning lamps must be used
during hours of darkness or low
visibility.
• Excavations or openings in floors
must be properly fenced at all times.
• During excavation work the
surrounding areas must be
maintained in an orderly and tidy
condition.
• Where vehicles have to tip materials
into excavations, stop blocks can be

Page 8 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
used to prevent them from over-
running. Remember that the sides of
the excavation may need extra
support.
• Always work outside the reach of an
excavator bucket. Where this is not
possible, use safe systems of work to
prevent people being struck. Do not
stand directly under the bucket.
• Safe means of access will be provided
to excavations. Ladders will be in
good condition, extend 1 metre
above the excavation edge and be
secured.
• Heavy vehicles are to be kept away
from the edge of an excavation. At
no time should materials be stored
along the edge of an excavation.
• Flooded trenches should be "de-
watered" as quickly as possible.
Once emptied the trench is to be fully
inspected prior to entry.
• All personnel on sites, where work at
heights is being carried out, will wear
safety helmets.
• Appropriate safety equipment will be
used when necessary used.

Page 9 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
• Wind Speed should be monitored
always and work shall be stopped if
limit exceeds
• Crane operator and rigger must be
qualified and certified.
• All lifting gears must be inspected
before use to ensure safe to use.
• All lifting equipment and machinery
to be color coded or tagged to
indicate that it has been inspected.
• Crane load chart must be referenced,
and load weight verified in order to
determine suitability.
• Safe working load (SWL) is to be
maintained throughout the lifting
operation.
• Mobile crane must be set on firm
ground (free of underground services
and away from river at safe distance)
fully extended out riggers placed on
suitable outrigger pad, and clear area
for operation without overhead
hazards.
• Lifting area to be isolated by
barricading and watch man to be
posted where required to prevent
unauthorized entry.

Page 10 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
Entrapment
due to fall/ • Operator trained to the Approved
roll of pipe. CPCS standard as per the
Construction Regulations.
Operators • Vehicles should never be overloaded.
direct field of Loads should be evenly distributed,
vision secured and not protruding beyond
obscured by the sides or back of the vehicle.
load leading • Reverse beeper, flashing beacon,
to contact mirrors fitted
with other • Defective skids removed immediately
persons or from the line.
plant. • Heavy duty gloves to be worn by
Laying of Personnel Injury/ operatives handling skids.
4 5 20H Y 2 5 10M TBT
Pipes, Failure of fatality • All engines’ guards and covers to be
lifting in position and secured.
equipment. • Windows, lights, mirrors and camera
lens to be kept clean at all times
Inadequate • The cab floor to be kept clean and
supervision. free from any obstacles which may
affect the safe operation of the
Untrained Machine.
Operatives • Ground workers to wear Hi Visibility
Vests at all times and Hard-Hats.
Use of mobile • Warning signs will be erected to alert
phones by pedestrians of
operators. • Unloading/Loading Operations.

Page 11 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
Displacement • Traffic management must be in place
of load where loading/unloading is being
carried out on public roads.
Person being • Loads to be tipped only on suitably
struck by level ground to prevent overturning
suspended of skip.
pipe causing
serious injury
of harm.

Defective and
broken skids
causing
crushing of
limbs of
entrapment of
body parts.

Manual
Handling. • All MEWP must have valid test
Working on certificate issued by approved 3rd
Man Lift(s) – party.
Fall from • Only trained qualified person will be
height. allowed to operate the MEWP.
Stepping over • The ground condition of work
the guard rails location to be level and firm enough
of Man-Lift(s). to use MEWP.
Coming out of • Do not exceed safe working load
MEWP (SWL)/capacity of the platform.

Page 12 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
• Banks man should always present
Unstable with MEWP, while moving to other
ground location.
• Operatives on MEWP should wear
and use safety harness with double
lane yard and ensure 100% tie off.
• Wind speed should be monitored
always and stop work if wind speed
limit exceeds
• MEWP should be fitted with an
emergency device to protect
personnel’s, in case of any power
failure or malfunction
• Unwanted materials should not be
stored inside platform
• Operatives moving outside MEWP
platform to scaffold platform must
ensure 100 % tie off.
• Restrict area of operation by
barricading and signs.
Not Planned
• Scaffold should be erected by
to Use, but
competent and certified scaffolders.
just in case
• Competent and certified person to
Working at
Personnel injury/ inspect scaffold after erection or
height on 3 5 15H Y 2 5 10M TBT
fatality modification and once in 7 days to
scaffold
provided scaffold tag.
persons fall
• Operatives should ensure, before
from height
use, that scaffold is green tagged.
Falling object.

Page 13 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
Ergonomic • Ladder to be secured, inspected and
stress due to safe to use.
working in • Full body safety harness to be used
bad body and harness should be tied off on
positioning safe anchoring point.
• Tools and materials to be kept safely
on scaffold to prevent falling from
height.
• Training/ tool box talk to be
conducted to make employees aware
of the risk of back injuries etc.
• Hand gloves to be used when
activities are carried out that may
result in injuries.
• Supervision by competent person

• All portable power tools to be

220/110/22V
• All portable electrical equipment to Project
be color coded or tagged to identify Engineer,
that it has been inspected. HSE Officer,
Assembling Use of power
• Users to inspect the power tools and Supervisor,
04 slide tools - Electrocution 2 5 10H Y 1 5 5M TBT
extension cables before use to
components Electricity
ensure free of defects and safe to
use.
• PAT tested should be done for
electrical equipment’s except battery
operated equipment’s

Page 14 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
• Ensure ELCB or RCD to be used
between electrical supply and the
equipment
• Visually inspect tools before
using.
Hand injury from
Use of hand • Employees instructed not to use
using improper
tools 3 2 6M defective or damaged equipment Y 2 2 4L
or defective hand
• Use right tools for the job
tools
• Hand gloves cotton with latex
covering issued to staff
• Proper communication to be
ensured between workers
working
• Line of fire shall be identified and
communicated to all workers
Pinch Points Hand injuries 3 2 6M Y 1 3 3L TBT
during pre-work briefing
• Proper hand gloves shall be worn
to protect from pinch point
injuries

• Regular inspection of equipment to

ensure that it is in good state of
repair
Excessive Noise induced
2 3 6M • Hearing protection to be used by the Y 1 3 3L
noise hearing loss
operator and other operatives within
the noise zone.
• Warning signage to be posted

Page 15 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
• Hot work permit shall be obtained
prior to start hot work.
• All personnel’s working near the
welding area should be informed in Project
advance Engineer,
• Only trained and competent person Full time HSE Officer,
to do welding work’s supervision Supervisor,
• Use proper PPE’s while performing and safety Fire watch
Welding of welding work ( Welding Helmet with monitoring
05 Fire Personnel injury 2 3 6M y 1 3 3L
steel plates filter plates, Gloves, Aprons, Etc..) shall be
• All combustibles shall be removed required at
from the hot work area and the items site
which can’t be remove shall be
covered by fire blanket.
• Certified fire watchman with charged
fire extinguisher and fire blanket shall
be there to conduct fire watch.

• All welders must wear long sleeves or

arm cover to prevent skin from direct Full time
exposure from bright flash supervision Project
• All personnel’s working near the and safety Engineer,
welding area should be informed in monitoring HSE Officer,
Radiation Personnel Injury 2 3 6M Y 1 3 3L
advance shall be Supervisor,
• Only limited and authorized person required at Fire watch
are allowed while performing site
welding work

Page 16 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
• Use welding helmet with correct Full time
shade of filter supervision Project
• All personnel’s working near the and safety Engineer,
Arc rays can welding area should be informed in monitoring HSE Officer,
Personnel Injury 2 3 6M Ys 1 3 3L
burn eyes advance shall be Supervisor,
• Only limited and authorized person required at Fire watch
are allowed while performing site
welding work
• All hazardous chemical material
must have manufactures MSDS.
• COSHH assessment should be
available for all chemicals
• Inflammable and hazardous
substances will have designated
storage area with air conditioning
facility.
• Isolated storage area should be
Handling of Ill health, injury, provided for chemicals those are
hazardous and fire, explosion, reactive in nature.
flammable environmental • Chemical material must be
materials pollution properly labeled.
(blasting of • Proper signage must be posted
tanks with with hazard information.
silicon sand ) • Used and unused containers
must have separate label on it. Project
3 4 12H • Proper storing, handling and Y 1 4 4L Engineer,
disposal procedure as per MSDS HSE Officer,
to be followed. Supervisor

Page 17 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
• Emergency exits, stairway,
roadways and fire points must be
identified and kept free of
obstruction.
• Toolbox talk about storing,
handling and disposal of
inflammable and hazardous
waste should be conducted
• Proper ventilation and air
conditioning to be provided in
chemical storage area.
• Proper training should be given
to all operatives handling
inflammable and hazardous
chemicals
• Chemical waste to be disposed to
the disposal area provided
• No heat source or smoking in the
COSHH storage area
• Do not eat or drink when
handling hazardous chemical
substances.
• Do not mix hazardous waste with
general waste.
• Proper PPE as per MSDS and
proper supervision to be
ensured.
Project
Fire 3 3 9M • No smoking around chemicals Y 2 2 4L TBT
Engineer,

Page 18 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
• Store acetone in proper container HSE Officer,
with proper labeling and to be kept Supervisor
closed with lids always.
• Ensure proper storage.
• Suitable should be provided. Ladder
must be of sufficient height
extending [Link] above stepping off Project
point to provide adequate handhold Engineer,
and securely fixed at a correct angle HSE Officer,
Connect lifting (4:1 ratio, e.g. 1meter out for every 4 Supervisor,
gears on slide Work at meter height) while being used.
06 or other height – fall Personnel injury 3 4 12H • Ladder should be inspected before Y 1 4 4L
elevated from height use.
section • Ladder should only be used for its
intended use only
• Ladder to be secured or held by some
body.
• Trained operatives

• An exclusion zone is to be created

around all lifting operations for the
entire operation slew radius.
Lift the slide Loads could fall
Suspended • Ensure all access where park guest/ Pre lift
07 section to the or become 4 4 16H Y 2 4 8M
load public may use and enter to the work briefing Plan
position dislodged
area has been closed adequately and
warning signs in place and watchman
to be posted where required.

Page 19 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
• All personnel are to be instructed Project
that under no circumstance may they Engineer,
stand under the suspended. HSE Officer,
• All lifting and securing of lifting Supervisor,
equipment is to be done by a
certified competent rigger, slinger or
banksman.
• Tag lines are to be used to guide
loads to prevent persons standing
beneath the suspended load.
• Before start lift ensure that MEWP is
moved off and at safe distance.
• No lifting may take place in high wind Project
conditions. Lifting operations shall Engineer,
Full time
stop if wind conditions reach 32 HSE Officer,
monitoring
Load could be km/hr and an assessment shall be Supervisor,
Adverse and
blown out of made to decide if lifting operations Crane operator,
weather 2 5 10M Y 1 5 5L supervision
control by high may continue. Rigger
conditions by
winds • Licensed Crane Operator shall Inform
competent
PM, Foreman, Rigger and Signal man
person
should high wind readings occur
while load is suspended in the air
• All crane operators must be in
possession of a valid driver’s license, Project
Human error Load could fall or
third party training certificate Engineer,
by crane load could strike Pre lift
3 5 15H suitable for the type of equipment he Y 1 5 5L HSE Officer,
operator or other structures briefing plan
is operating. Supervisor,
slinger or people
• Slingers, riggers must be certified by Crane operator,
a third party company that they are Rigger

Page 20 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
competent and be in possession of a
certificate.
• Clear line of sight is visible hand
signals maybe used where this is not
possible two way radios must be Project
used for communication between Engineer,
Load could slew
crane operator and banksman or a HSE Officer,
Inadequate or be lowered
second banks man must be placed to Pre lift Supervisor,
communicatio into an undesired 4 4 16H Y 2 4 8M
direct eth load from where the 1st can briefing plan Crane operator,
n position causing
no longer se the load. Rigger
damage or injury
• Under no circumstances may an
unqualified person instruct or direct
the crane operator where to place
the load.
• Stores and or Workers should Project
check all equipment before using Engineer,
Hand injury from
Use of hand • Employees instructed not to use HSE Officer,
using improper 6
tools 3 2 defective or damaged equipment Y 2 2 4L Supervisor,
or defective hand M
• Use right tools for the job
tools
• Hand gloves cotton with latex
covering issued to staff

Working on
• All MEWP must have valid test
MEWPS – Fall
certificate issued by approved 3rd
Disconnect from height. Personnel Injury/
08 4 5 20H party. Y 2 5 10M TBT
lifting gears fatality
• Only trained qualified person will be
allowed to operate the MEWP.
Project
Engineer,

Page 21 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
Stepping over • The ground condition of work HSE Officer,
the guard rails location to be level and firm enough Supervisor,
of MEWP. to use MEWP.
Coming out of • Do not exceed safe working load
MEWP (SWL)/capacity of the MEWP
platform.
Unstable • Unwanted materials should not be
ground stored within
• Operatives moving outside MEWP
platform to scaffold platform must
ensure 100 % tie off.
• Self retractive fall protection device
to be used on areas where working
platform cannot be provided or
MEWP cannot be reached.
• Restrict area of operation by
barricading and signs.
• Scaffold should be erected by
competent and certified scaffolders.
• Competent and certified person to
Not
inspect scaffold after erection or
anticipated
Personnel injury/ modification and once in 7 days to
for this 3 5 15H Y 2 5 10M TBT
fatality provided scaffold tag.
project.
• Operatives should ensure, before
use, that scaffold is green tagged.
• Ladder to be secured, inspected and
safe to use.

Page 22 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
• Full body safety harness to be used
and harness should be tied off on
safe anchoring point.
• Tools and materials to be kept safely
on scaffold to prevent falling from
height.
• Trained operatives for the task
• Hand gloves to be used when
activities are carried out that may
result in injuries.
• Supervision by competent person

• All MEWP must have valid test

certificate issued by approved 3rd Project
Working on party. Engineer,
Man Lift(s) – • Only trained qualified person will be HSE Officer,
Fall from allowed to operate the MEWP. Supervisor,
height. • The ground condition of work
Fixing of Stepping over location to be level and firm enough
electrical and the guard rails Personnel Injury/ to use MEWP.
09 4 5 20H Y 2 5 10M TBT
plumbing of Man-Lift(s). fatality • Do not exceed safe working load
equipment Coming out of (SWL)/capacity of the platform.
MEWP • Banks man should present with
MEWP at all times while moving to
Unstable other location.
ground • Operatives on MEWP should wear
and use safety harness with double
lane yard and ensure 100% tie off.

Page 23 of 25
 Risk Assessment

Legal Additional Responsible

SI Hazard Consequence Risk Risk
Task Step P S Current Control Measures Req. P S Control Person
No. Details Details Rank Rank
Y/N Measures
• Unwanted materials should not be
stored inside platform
• Operatives moving outside MEWP
platform to scaffold platform must
ensure 100 % tie off.
Restrict area of operation by
barricading and signs.
• Where practicable manual handling
risk will be eliminated by utilizing
some form of mechanical means for
lifting or moving heavy objects
Serious short
• Where use of mechanical aids is not
term and long
Cable pulling - an option, consideration should be
term injuries to
manual 3 3 M given to seeking assistance Y 2 2 L
the back and
handling • Adopt team lifting techniques to lift
other parts of the
body or move heavy or awkward shaped
objects are involved
• Job or task rotation will be
considered where repetitive task
injuries are an identified risk
Equipment Hand injury from 3 3 9M • Gloves to be used Y 2 3 6M
with sharp sharp edges
edges
• Good housekeeping shall be ensured Supervisor to
Slip / Trip
at site by storing all tools and make sure Project
10 Housekeeping materials at designated place. proper Engineer,
Waste
Personnel Injury 2 3 6M Y 1 3 3L housekeepin HSE Officer,
accumulation
g has been

Page 24 of 25
 Method Statement for storage tank Construction and Piping systems
Doc No: KI/22/MOS/005 Rev 0.2

8) MATERIAL DATA

As per Client requirement

9.1) FIRST AID MEASURES

In case of contact, immediately flush eyes with plenty of water for at least 15
EYE CONTACT minutes. Get medical attention.

Flush contaminated skin with plenty of water. Remove contaminated clothing

SKIN CONTACT and shoes. Wash clothing before reuse. Clean shoes thoroughly before reuse.
Get medical attention.
If inhaled, remove to fresh air. If not breathing, give artificial respiration. If
INHALATION
breathing is difficult, give oxygen. Get medical attention immediately.
Aspiration hazard if swallowed. Can enter lungs and cause damage.
Do not induce vomiting.
INGESTION Never give anything by mouth to an unconscious person. Get medical attention
immediately

 Treatment should in general be symptomatic and directed to relieving

any effects.
 Product can be aspirated on swallowing or following regurgitation of
NOTES TO stomach contents, and can cause severe and potentially fatal chemical
PHYSICIAN pneumonitis, which will require urgent treatment. Because of the risk of
aspiration, induction of vomiting and gastric lavage should be avoided.
 Gastric lavage should be undertaken only after endotracheal intubation.
 Monitor for cardiac dysrhythmias.

9) WASTE MANAGEMENT & ENVIRONMENT PLAN

Waste generated on the site will be collected and disposed to the approved locations
on daily basis.

10) ATTACHMENT
All approved drawing, insurance copy, RT method of statement shall be attached
including other form of approval such as material inspection approval, MSDS for the
product hat being use during trial and final testing, inspection approval etc. shall
submit based on intimation.

11) OTHERS
Any missing activity at work site, the approved KENZO document shall be update

Page 34
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