PROJECT TITLE : REFURBISHMENT & UPGRADING WORKS FOR

VARIOUS PUMPING STATIONS (PHASE – 8)

PROJECT NUMBER : CP 729/2

CLIENT : ASHGHAL

CONSULTANT : PARSONS INTERNATIONAL LIMITED

DOCUMENT NO. : 729/2-GEN-DOC-0111

PETOSERV DOC’ NO : PT/CED-5058/MS/ M /023

REVISION : 00

METHOD STATEMENT FOR

INTALLATION OF EOT CRANES (PS-17)

PETROSERV LTD

P.O.BOX: 7098

DOHA-QATAR
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0 09-08-2012 For Approval MOHAMMAD REHAN SUNEED SUBAIRKUTTY AMR GAMAL

Reviewed By Project Approved By Construction
REV DATE DESCRIPTION Prepared By (PETROSERV)
Engineer(PETROSERV) Manager (PETROSERV)
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INDEX

CONTENT TITLES PAGE NO.

1.0 Purpose 4

2.0 Scope of Work 4

3.0 Reference & Attachments 4

4.0 Equipment 4-5

5.0 Responsibility 5-7

6.0 Safety precautions. 8-9

7.0 Preparations 9

8.0 Sequence of activity for installation. 10

09. Pre requirement and handling and storage 10-12

10. Work Description 12

11. Erection of 3 T EOT Crane 13-15

12. Erection of 3 T EOT Monorail crane 15-16

13. Final Check 16

14. Lists of items to be installed 17

15. HSE plan 17-18

16. Attachments: 18

a) Risk Assessments (Page No.19 to22)

b) Contract Drawings no. (17-W356) (Page No.23)

c) Installation inspection checklist cranes (Page No.24)

d) Approved ITP for cranes (Page No.25 to 27)

e) Assembly instruction for cranes.
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1. PURPOSE:
The Purpose of this Method Statement is to describe the installation of
single girder EOT (electrically operated overhead) crane and electrically
operated monorail crane in pumping stations PS-17 and the sequence of
activities involved

2. SCOPE OF WORK

This document applies to manage efficiently and control the supply and install
of single girder EOT (electrically operated overhead) crane and electrically
operated monorail crane and accessories s in the pumping station on going
to attain the zero tolerance accident.

3. REFERENCE & ATTACHMENTS

3.1.1 Project Specification (volume 2 of 4) –Section C Part 1, Clause 3.2.2 (k, l
& m).
3.1.2 QCS 2007 Specification , Section 9 –Part 7
3.1.3 Relevant Construction Drawings (17-W356)
3.1.4 Approved Material Submittal
3.1.5 Hazard Risk assessment
3.1.6 Checklist for installation of cranes
3.1.7 Approved ITP for cranes

4. EQUIPMENTS:

1. Jack hammer
2. Hand tools.
3. Crane capacity 20-50 ton.
4. Chain Block (5 ton)
5. Grinding and drilling machine.
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6. 400 A 3 phase welding machine.

7. Electrode heating oven.
8. 12 m aluminium scaffolding.
9. Electric chain blocks.
10. Laser range meter.
11. Megger.
12. Ammeter.
13. Safety belts and harnesses.
14. Wire rope /nylon slings.
15. Fire extinguisher.

5. RESPONSIBILITY

5.1 PROJECT MANAGER:

Project Manager shall be responsible for the overall project. The Project
Manager will be based on site and will be responsible for the
management of the project, both on and off site, through delegation
of duties in accordance with the organization chart and for the
effective implementation of the project management system. He shall
ensure that the proper tools and tackles are available for the timely
completion of this job in a quality manner.

5.2 CONSTRUCTION MANAGER:

Construction Manager shall be responsible for overall project .the
construction manager shall be planned as well as handle any issues
which arise during the site work.
The construction manager shall be obtained all necessary permits and
licences and ensure that proper work procedures are being carried out
at site.
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5.3 PROJECT ENGINEER:

Project Engineer is responsible for the overall site operation and works.
He shall ensure that the appropriate procedure is followed by all the
involved personnel taking into consideration all relevant shop drawings,
Reference drawings, statutory bench marks and reference points and
methodologies are correctly utilized. Responsible for the overall
fabrication installation, testing and commissioning activities. Responsible
for planning of site organization, resource mobilization, subcontracting,
site operation, construction methods and scheduling etc. ensure that
proper approved documents are in place prior to start of production
activities.
5.4 SITE ENGINEER:-

5.4.1 Co-ordination with all site personnel & control of Labour.

5.4.2 Direct monitoring and supervision of work.

5.4.3 Tool Box talk to Labour.

5.4.4 Confirming Health Safety Environment.

5.5 SAFETY OFFICER: -(these responsibilities are included but not limited
to):

5.5.1 Assists the Project Manager for implementation and monitoring of

the HSE system.

5.5.2 Carries out Hazard Risk Assessment for the site.

5.5.3 Ensures work site is in safe conditions.

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5.5.4 Ensures calibration & approval of all lifting equipments and

machineries.

5.5.6 Ensures first aid and emergency procedures for the site are
established and maintained.

5.5.7 Coordinates with the client for any safety related requirements at site.

5.5.8 Arranges safety induction program for the site personnel as required.
He ensures that daily toolbox meetings are conducted by Site
foremen/Supervisor.

(Refer H.S.E plan clause 8.6 Page no. 12 & 13 of 43)

5.6 QUALITY CONTROL:

Quality is a throughout process of installation, testing & commissioning

of the system. However following steps shall be followed.

1. QA/QC Engineer along with project engineer will monitor that all
components are installed as per contract specifications and
approved submittals.

2. Works inspection shall be submitted to Main contractor/consultant

for the following stages of work as per ITP: a) Material
receiving/inspection. b) Installation inspection of cranes. C) Testing
and commissioning of cranes.
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6.0 SAFETY PRECAUTIONS:

All work shall be carried out in accordance with approved PETROSERV’s

project safety plan. All personnel shall be provided with necessary
personnel protection equipment (PPE) and given required training to
ensure that all personnel involved in the work are aware of importance
of safety precautions equipment and consequences of abusing them.
Excavation permits will be prepared to ensure that all necessary
precautionary measures have been taken and other requirements are
fulfilled.

a) In deciding manning levels account must be taken of the

location of manholes and sewerage facilities in relation to
availability of means of summoning assistance in emergencies.
b) Unattended open manholes must be safely protected by suitable
barriers. Remember that some people are visually handicapped.

c) Whenever possible covers shall be lifted using lifting keys and

proper lifting and handling techniques or by the use of hydraulic
or other approved manhole lifting device.

d) Before entering the manhole ensure that the cover has been
removed to give natural ventilation for minimum of 5 minutes.

e) Before enter the drywell and wet well proper ventilation will be
used.

f) Test for toxic and flammable gases, and oxygen deficiency, using
approved detector. If toxic and flammable gases or oxygen
deficiency is detected do not enter the manhole.
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g) Before the any lifting activates the area is cordon of with safety
ribbons.

h) All machine, vehicles & equipments operator shall have valid

licences or certificate or approval.

i) While the welding, fire extinguisher and fire blankets will be

provided near welding areas to protect any fire hazards.

j) Proper and safe support temporary supports, scaffolding,

platform and access ladders will be provided. Erect and inspect
the temporary works by authorized specialist.

k) The approved electrical lockout/tag out safety procedure (doc

no. 729/2-gen-doc-0055) will be fallowed strictly followed & also
approved HSE PLAN.

l) Refer H.S.E plan clause and there sub classes 16, 17, 18, 19, 20, 21,
22, 23, 25, 26, 27, 33, 34, 36, 39, 40. Document No.729/2- GEN-
DOC-0019).

7. PREPARATIONS:

A. DOCUMENTS
A. Entry permits from Ashghal to enter pumping station.
B. Confined space permit.
C. Lock out/tag out (LOTO).
D. Permit of work.
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8. SEQUENCE OF ACTIVITY FOR INSTALLATION:

1. Mechanical Screen.
2. Penstock.
3. EOT Cranes.
4. Ductile Iron Pipes & Fitting.
5. Valves.
6. Dry Submersible Main Pumps.
7. Sump and Transfer Pump
8. Odour Control Unit.
9. High Pressure and Potable Pump
10. Air conditioning & Ventilation.
11. Instrumentation & control system.
12. Electrical items.
13. Civil work.

NOTE: 1) item no.1 to 10 will be covered under mechanical installations.

9. (A) PRE-REQUIRMENTS:

1. Ensure that approved materials are available to carry out the work.
2. Cranes are transported from stores according to good engineering
practice and physical verification.
3. Prior to commencement of work, areas and access will be inspected to
Confirm that safety precautions ensured.
4. All relative documents (approved shop drawing and approved method
statement) will be checked by site engineer prior to commencement of
work.
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5. Since this overhead crane is inside the enclosed building. All the
components of the EOT crane will be shifted inside the building piece by
piece by means of a mobile crane/fork lift or hand palette trolley and will
be erected by a manual chain block piece by piece.
6. Any temporary attachments should be made secure or removed prior to
lift.
7. All lifting eyes to be inspected.
8. Survey of road access to the site for mobilization of mobile cranes, trailers,
etc…
9. All lifting gear shall be certified and certificates shall be reviewed and
approved.
10. Arrangement and checking of lifting gear for the lift.
11. Inspection of the area and positioning of the crane (for shifting the crane
components inside the building)
12. Arrangements for manual lift of the crane inside the building.
13. Arrangements of suitable access / scaffolding for erection.
14. Tool box talk will be conducted with all the people involved in the
operation and discuss about the past lifts observations, assign individual
responsibilities before starting the job.

(B) HANDLING AND STORAGE:

1. Storage area for cranes has to be arranged with leveled wooden

platform .the area should be barricaded with tape.

2. Cranes are to be unloaded from the vehicle by crane only.

Ensure that the vehicle parked in a safe area and parking brake is

applied.
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3. The cranes pieces should be kept on the wooden platform, in

horizontal position only.

4. Always use fork lift to transport the cranes.

5. The cranes should be protected from direct sun light or moisture.

6. ITP will be checked for storage and handling, refer the attached ITP

10. WORK DESCRIPTION:

1. All the riggers, helpers and supervisors will be explained about the safety
aspects and requirements on the project.
2. All the people involved in the lifting operation will be briefed on the
requirement of the job.
3. The area near to the lift will be inspected for access / positioning of the
crane and make sure it is as per the requirement before getting the
equipments on site.
4. Mark the appropriate location of the crane on the site.
5. All the work / lift supervision will be managed by a lifting in charge on site,
who will be responsible for entire operation.
6. Lift will be communicated completely by means of hand signals with crane
operator. The complete lift will be signalled by lifting in-charge during the
complete operation.
7. Cordon of the area and remove all the non-essential persons from the area.
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11. ERECTION OF 3 T EOT (ELECTRICALLY OPERATED OVER HEAD)) CRANE

(1) INSTALLATION OF RUNWAY BEAM:

1. Install the runway beam over the corbel provided.

2. Used the packer plates and shims for levelling.
3. With laser range meter keep the centre to centre distance as mentioned in
approved shop drawing.
4. Fix the runway over the corbel using the fix bolts.

(2) Welding of Rails:

50 x 30mm (with primer) will be done by tack welding onto the travel beam /
girder by help of welding machine.

Tolerance for the rails / girder will be as follows:

a. Span - +/- 3mm to be maintained while aligning the beams. Measurement
for alignment to be recorded every six meters and furnished to us.
b. Tolerance on wheels of End Carriages will be +-- 7.5 mm.

During fixing of rails, 3mm tolerance will be kept for expansion of rail if any,
between the rails.

(3) Erection of Girder Beam:

1 Slowly lift the beam girder and push inside the building half way in and rest on
the frame with rollers at one end.
2. Hold the girder at one end with crane and push the girder slowly inside the
building. The girder will be manually guided inside to required position.
3. Similarly take all the components one by one inside the building.
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(4) Load Analysis:

Max. Weight of the crane component (girder): 0.90 t
2 nos. x 3 belt slings (4 m long) : 0.05 t
2 nos. x 6t bow shackles : 0.05 t
Total : 1.00 t
Capacity of chain block used is : 2.00 t

(5) Erection Description of 3 T EOT (ELECTRICALLY OPERATED OVER HEAD)

Crane:

1. End carriages are lifted up with the same Electric Hoist attached on the roof

for R/W Beams.

2. Both End carriages are tied on the rail using load binders.

3. Electric Hoist is attached to the hooking point provided on the Drop Beam

centre of the span.

4. Main Girder to be lifted by slinging on the centre.

5. Girders are lifted up bit diagonal to the span in order to reach above the

end carriages.

6. When Girder reach above the End carriage, the girder will be loosening

down to rest on the carriage, bolts are fastened up to 35kN and slings are

released.

7. Similarly second girder also lifted and bolted.

8. Load binders are removed from the end carriage after bolting the girders

and moved 1.5m from the lifting point to lift the Hoist Crab unit.
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9. Hoist unit to be lifted up.

10. Crane girders will be pushed back after Hoist Unit reaching above the rail

level.

11. Hoist Unit to be loosens down to rest on the cross travel rails and slings are

released.

12. All the electrical components of the crane will be lifted up manually and will

be assembled later.

13. Proper scaffolding will be used for the erection throughout the operation.

12. ERECTION OF 3 T EOT MONORAIL CRANE

(1) INSTALLATION OF MONORAIL BEAMS:

1. Marking to be done.
2. Drill the hole for the fixation
3. Raise the monorail beam to the roof.
4. Using the packer plates and shims for level and alignment the beam.
5. With laser range meter keep the horizontal alignment and level as
mentioned in approved shop drawing.
6. Fix the monorail beam in the soffit of slab.
(2) Load Analysis:
Max weight of the Hoist component: 0.250 t
2 nos. x 3 t belt slings (4 m long) : 0.050 t
2 nos. x 2 t bow shackles : 0.008 t
Total : 0.308 t
Capacity of chain block used is : 1.0 t x1 no
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(3) Erection Description of Monorail Hoist:

1. Shift the monorail hoist below the monorail beam.

2. Open the wheel gap 5 mm than the flange width of monorail.

3. Lower the load hook of manual chain block to the electric hoist level

4. Hook up the hoist.

5. The hoist is slowly lifted, once the hoist’s travel wheels are inside the

flange of monorail, the wheel gap are reduced to -100mm, resulting in

clean positioning of hoist on the flange of monorail beam.

6. Release the chain block hook from the hoist.

7. Electric Hoist is now ready for electrical connections.

(13) FINAL CHECK:

After completing all trims and accessories, a final inspection to be done:

1. All bracings in position and tightened.
2. All bolts in place and high strength bolts tightened to correct tension.
3. Check miss drilled holes and ensure the self tapping is fixed back tightly
in place.
4. Touch up any damaged point.
5. Clean up the site.

Once the installation is completed the entire assembly is to be tested with trail runs.
Testing and commissioning will be done by in co-ordination with consultant & client.
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During the installation of cranes the safety procedure will be involved to do works in
safe manner like safety barricades confined space entry procedure, identifying and
controlling the safety hazards and monitoring the works.

This time our well trained working team will be involved with the proper safety
equipments (PPE).

14. LIST OF ITEMS TO BE INSTALLED:

S.NO LOCATION TYPE OF CRANE TYPE OF HOIST INSTALLATION

1 PS-17 -Pump Single Girder Over Head Crane Chain Hoist Indoor
Room
2 PS-17- Motor Electrically Operated Monorail Rope Hoist Indoor
Room Carne
3 PS-17 –Screen Single Girder Over Head Crane Chain Hoist Indoor
Chamber

15. HSE PLAN:

Emergency plan (Section 40) covers all the potential emergencies as per Do.
No. : 729/2- GEN-DOC-0019

(1) .Emergency Evacuation Procedure:

Emergency evacuation procedure will be followed.
1) In case of any human injury.
2) In case of fire.
3) Project emergency contact telephone numbers and Petroserv personnel
telephone numbers will be displayed at all project location.
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(2).EMERGENCY TELEPHONE NUMBER:

Police Civil Defense and Emergency -999
Water and Electricity Emergency - 991
Accident and Emergency – Hamad Hospital - 44392111
Telephone Directory - 180
Construction manager: Mr. Amr Gamal - 66237128
Project Engineer- Mr.Suneed SubairKutty - 66834721
Safety Officer – Mr. Jithin S. - 55363249

16. ATTACHMENTS:

a) Risk Assessments (Page No.19 to22)

b) Contract Drawings no. (17-W356) (Page No.23)

c) Installation inspection checklist cranes (Page No.24)

d) Approved ITP for cranes (Page No.25 to 27)

e) Assembly instruction for cranes.