_Method Statement Tower Erection_2014.doc

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Method Statement

ERECTION OF TOWER

This Method Statement describes the specific safe working methods which will be used to carry out the described work. It gives details of work procedure with control measures to counter health and safety issues related to this work. The listed content of this Method Statement cannot be changed/ modified subjected to job scope/customer specifications without the prior permission of LBU /LPG Manager, Erection Head, Safety co ordinator and Project Manager. But task specific method statement once finalized & approved, that should not be modified during work execution.

Project Name

400/132 KV SUB-STATION PROJECT AT NTPC SOLAPUR

Site /Location

132 KV Transmission Line from NTPC Solapur to Ujani.

Planned schedule of Activity

02/05/2014 to 31/12/2014

Method Statement No.

ABB/TOWER STRUCTURE/ TL/02

Rev. No.

2( Proposed Dated 25.10.14 )

Risk Assessment Ref. No.

NABB/PS//OHS/JSEA/003

002 dated 22.10.2014

Rev. No.

Title :- Erection of Tower Structure-132KV-TL

Scope of work: - Supply,Civil,Erection, Testing and Commissioning of 132 KV Transmission Line from NTPC SOLAPUR to Ujjani .

Drawing References:-

Refer Attached List(Drg. No)

Technical Specification Document References:-

Technical Spec. VI[Part-1&2] & Part-V

Certification of Plant etc.

Hydra Regd. No.CG07NA3635 [M/s Unitech power Transmission Ltd]

Date Of Testing 01/04/2014 Valid Till date

Detail of Sub contractors Involved :-

M/S Unitech Power Transmission Ltd. Office Address- 136,Udyog Vihar, Phase-1, Gurgaon-122016, Haryana. Tel:0124-4571000/4571001

Mr. Rajesh Pillai-Project Manager

Mr.Anil Adappa/Mr. Kumar

Method Statement Prepared By : C P Singh (Site Manager)

Signature

Date

Method Statement Reviewed By:-

Mr. ANUJ MAHAJAN (Project Manager)

Mr. ARJUN SINGH ( Chief Project Manager)

Method Statement Approved By:-

1.0 Introduction (Describe purpose of the work, Give details of type and scope of work being carried out, work parties involved (include working hours). Client requirements/ specifications, Local legislation Enforcement authorities requirements i.e. The Police, Civil Defence, Environment Agency* (EIA) to be considered with reference to scope of work.

Purpose of the work: Construction of 132kV Transmission Line(From NTPC Solapur to Ujani)

Scope of Work:

-Segregation , Shifting of 132kV tower structure and hardware to the work place .

-Erection of 132 Tower Structure.

Working hours: 8 Hours a day

Client Specification: Ref customer specification- Tech. Spec. Section VI [Part 1 & 2] & Part IV

2.0 Location of Work (Give site address and precise location on site where work is to be carried out. Give details of any other locations in the proximity of the works which may affect the safety of the work or be affected by the work considering Surrounding Environment and what measures will be used to control these risks e.g. segregation, warning notices, fencing, Structural stability precautions)

Work to be carried out in 123KV Transmission Line(D/C & S/C) at Different Locations From NTPCC To Ujani.

3.0 Safety Document /Specific Approval Required (Details of any safety documents or specific approval (i.e. Client specific approval) required to undertake the work)

Site Specific Risk Assessment

PTW & Tool Box Talk in consultation with customer

PSS OHSAS Manual

OHS COP

ABB Site manual, Part-1 & 2

4.0 Access & Egress to the work area: Give details of any special access or egress arrangements (i.e. Ladders/MEWPS/Scaffold/Trestles/Step Ladder etc.) that will be used including any obstruction/restriction in safe access to work area. Consider the site access from the public road onto and around the site before vehicles arrive on site, taking into account the site traffic management plan, the designated work area for delivery vehicles and the storage area for materials

Compacted WBM / Kaccha Road available some locations.

5.0 Role & Responsibilities of Personnel/Parties Involved in activities:- Clearly define role and responsibilities of all personnel involved in activity i.e. Site management staff including subcontractors parties- Main contractor Project/Site Manager, Sub Contractor Site Manager, Project Engineer, OHS staff , Competent Supervisory Staff)

ABB Site management Staff:

Site manager: Mr. C P Singh

Site Safety Coordinator: Mr. Asit B Giri

M/S UNITECH POWER TRANSMISSION LTD. (Contractor) Site management Staff:

Project Manager: Mr. Rajesh Pillai

Site Manager: Mr. Anil Adappa

Civil Engineer: Mr.Kumar

Site Supervisor: Mr. Narendra singh / Mr.S K Mishra/Mr. Arun Roy

Safety Officer: Mr. Vargees

Site Manager :-

Erection Engineer :-

Safety Officer / Warden:-

Check for the isolation of area for erection

Check the Work permit from ABB (Client if required in case of shut down job).

Coordination with Client /Erection Agency/Safety Departments for continuous monitoring of activity.

Check the weather condition before start of work.

Ensure tool box talk is done before start of the work

Check fitness of worker visually.

Check the materials availability and tested tools & tackles with Proper lifting Machinery.

Present of Contractor Erection Engineer/Erection Supervisor/Certified Safety Supervisor for continuous monitoring of activity in work location.

Barricading of area during erection of work.

Check the proper illumination in yard for night work.- N/A Height work is not Permitted in night.

Cross check the location before start the activities involved height work.

Check the Work permit from ABB/Client.



Check the materials availability and tested tools & tackles with Proper lifting Machinery.

Present of Contractor Erection Engineer/Erection Supervisor/Certified Safety Supervisor for continuous monitoring of activity in work location.

Barricading of area during erection of work.

Access route to be decided and communicated to all concerned.

Check the proper illumination in yard for night work. N/A Height work is not Permitted in night.


Arrange Tool Box meeting with staff and workers before starting the activity.


Check for any underground / OH cables in the area and isolation if required.

Check the Work permit from ABB/Client.

Work Permit to be issued after checking the safety requirements of lifting Machinery, tools & tackles arrangements.

Close monitoring of activities involved height work and emergency preparedness.

Barricading requirements to be decided and communicated to concerned.

Check House Keeping.

Check the proper illumination for night work.

N/A Height work is not Permitted in night.

6.0 Working/Activity Description:- It is important that all operatives should have clear idea of those operational sequences and responsible supervisor must verify their competency prior to their engagement in operation.

6.1 Pre-Testing Checks

OHS Induction

Work specific Training

Ground condition in & around work place

6.2 Resources (Equipment , tools including manpower) Details i.e. Equipment and Tools, specific operational equipment, test kits, lifting resources, Details of materials to be used in operation, Details of the manpower allocated to the task, e.g. titles, qualifications, competences, direct manpower, contractors. Details of plant, tools and equipment to be used for the work, including the availability of relevant statutory documents, checks or inspections etc. Details of fencing, barriers, cones, chains, dangers notices, warning signs etc.

Machinery tools & tackles material as per list attached below.

Skilled Manpower for manual/Hydra/Crane/ Tractor trolley/truck shifting of material from storage yard to place of erection.

Approval to do work in Extended hours by BU Manager Height work not allowed in Extended Hours

Proper Illumination if working in extended hours with required permission

6.3 Details of Permits to Work required for activity: List out applicable Permits in sequence of work, for eg. PTW(Permit to work), SFT, LAP(Limited access permit)

Check for Work permit from Customer if the work to be performed under shutdown.

ABB work permit to be issued after checking the safety requirements.

Tool Box Talk prior to start of work.

6.4 Operational Sequence of work (i.e. Test Procedure) :- Full description of the work, setting out the methodology in a sequential manner, including any reference to any identified operational restraints. Also refer here sec. 5.0 responsibilities part for every step of work sequence).

Unloading /Shifting and Erection of Structure

Sr.No.

Activity

Details of Job sequence

Risk Involved

Control Checks

1

Unloading and shifting of lattice structure Tower/Beam

1. Unloading of material on an identified place of storage.

2. Identification of structure material.

3. Segregation of all material as per Bill of Material.

4. Shortage \ Damage report to be prepared.

1. Contact with rough edge.

2. Fall of material.

3. Failure of lifting equipment.

4. Slippage of material.

5. Toppling of crane/hydra bcoz of uneven access.

1. Ensure work permit is issued.

2. Ensure work specific tool box/training

3. PPE (Hand Gloves, Helmet, shoes) used.

4. Allow only authorize person to work.

5. Check the condition and load test report of all lifting tools /crane.

6. Use proper size of rope/slings/Belt as per weight of Material to be Lifted.

7. Ensure the transportation route must be firmed and levelled.

2.

Shifting and Erection of Main Leg Member.

1. Shift the structure, nuts, bolts and washers as per Bill of Material near to the place of Erection.

2. Clear the area near the foundation and check the anchor bolts of foundation.

3. Assemble the main leg member up to 2-3 section.

4. Fix and tighten the step bolts in criss cross manner in all the leg member for the movement of a person.

5. Provide the vertical life line in all the 4 leg member and keep 1 spare for change over.

6. Erect the main leg member by crane / Hydra and provide guide rope 2 side.

7. Remove the rope from crane/hydra hook by climbing thro step bolts.

8. Level the main leg member by water tube.

1. Tilting of Main leg member.

2. Fall of Material/Tools.

3. Fall of worker.

4. Failure of lifting material.

5. Toppling of Crane/Hydra.

6. Communication gap between Supervisor and crane operator.

1. All lifting tools / equipment must have valid test certificate.

2. Check the capacity of crane/hydra and weight of Material.

3. PPE (Hand Gloves, Full body harness ( energy Absorber)with 2 lanyard having opening minimum 80mm, Helmet, shoes) used.

4. Engineer/supervisor needs to be present till completion of work.

5. Allow only authorize /Trained person to work.

6. Ensure work specific tool box/Training..


8. Use proper size of rope/slings/Belt as per weight of Material to be Lifted.

9. All persons should away from the lowering material.

10. The load should be guide by the guide rope to prevent toppling.

3.

Erection of cross members up to section 2-3

1. Assemble 2/3 members as per the drawing.

2. Provide the packing washer where ever required.

3. Lift the above members and fix it on the main leg member.

4. Complete the fixing of cross members up to 2-3 section of main leg member.

1. Tilting of Main leg member.


3. Fall of worker.


5. Injury due to rough edge of members.

6. Toppling of Crane/Hydra.

7. Communication gap between Supervisor and crane operator.

1. All lifting tools / equipment must have valid test certificate.

2. Check the capacity of crane/hydra and weight of Material.

3. PPE (Hand Gloves, Full body harness( Energy absorber) with 2 lanyard having opening min 80mm, Helmet, shoes) used.




7. Use proper size of rope/slings/Belt as per weight of Material to be lifted.

4.

Erection of Derick and fixing of Balance leg/cross members.

To lift the next Section of Tower, the following steps to be followed :

1. The Derrick will have horizontal MS rod of 12mm dia x 200 Long welded 100 mm from top & bottom of Derrick. This rod will pass through the hole and welded at two ends. One pulley P1 is fitted to this rod using a rope for lifting the load.

2. Provide 2 -3 side guide rope on the derrick.

3. Fix one Pulley P2 on the top of the Main member A already erected (previous section).

4. Provide 2/3 life line on the Main member A through which derrick to be lifted.

5. Fix one pulley P3 at the bottom of the leg member at the foundation level for ease in hoisting the derrick.

6. Lift the derrick using Pulley P1 up to the level of main member A with the help of pulley P2 fixed on the top of main member.

7. Positioning ropes should be used to loosely tie the derrick and the Main leg member at two places so as to avoid tilting during hoisting of the derrick.

8. 2 trained workmen shall ascend on the Main member A using independent life line. They shall anchor themselves using double lanyard. They shall guide the derrick during upward movement.

9. Now,remove the rope from the top of the derrick and Connect the to the bottom of the derrick.

10. During this transition period, the derrick shall be fastened by positioning ropes to the main member.

11. Now hoist the derrick upwards using pulley P2 & P3 upto a level till the overlap of Main member A & derrick shall be 1-1.5 Mtr.

12. Now, the top of the derrick shall be above the main member A.

13. Tie/fasten the derrick with the main member A by rope at 2/3 places keeping a over lap of 1 to 1.5 Mtr between main member and derrick.

14. Remove the pulley P2 from Main member A.

.

Lifting of Main member (B) of next section

15. Provide the vertical life line with fall arrestor and step bolt in all the main member to be lifted.

16. Fix pulley P2 on the top of the main member to be lifted. (This is required for lifting the derrick to the next section.)

17. Lift the Main member (B) with the pulley provided on the top of derrick and fix it on Main member (A) with proper cleat plate/angle as per drawing

18. Remove the rope on the Main member (B) by climbing on the step bolts.

19. While descending, the step bolts on the Main member ( B) used to climb are removed. This is to facilitate the fixing of cross bracings.

20. Lift all the other main members as per the above sequence.

21. Provide the cross members and gusset plate.

22. This completes the erection of second section of the Tower.

23. Continue the same till the completion of tower up peak.

24. Remove the derrick and other lifting material etc.

25. Tighten all the bolts/nuts of the tower.

26. Once again align the tower and provide the check nut on the anchor bolt.

1. Tilting/Fall of Derrick.


3. Fall of worker.


5. Injury due to rough edge of members.

1. All lifting tools / equipment & winch / Hydra must have valid test certificate.

2. Provide the overlap of derrick and main member by 1 to 1.5 Mtr.

3. PPE (Hand Gloves, Full body harness with 2 lanyard having opening min 80mm, Helmet, shoes) used.




7. Use proper size of rope/slings/Belt as per weight of Material to be lifted.

8. Use tool bag to carry hand tools & small nuts and bolts.

9. Ensure fall arrestor along the leg with rope grab.

6.5 Isolation Requirements:- Before starting the work, identify the work area demarcation and accordingly isolate it from other part of operational interference. Responsible supervisor should cross verify adequate isolation arrangements for safe operation prior to receive Permit to work and if PTW not applicable then before start of operation during pre-check survey. Accordingly adequate caution tag/signs to be provided.

Check for any underground / overhead Cables prior to start of activity.

If so, Isolate same and get permit before start of work.

Barricading to be done near the place of erection.

Area to be levelled near the foundation.

6.6 Final Checks & restoration of work area after completion of work :- Those checks to be carried out by responsible supervisor in witness of his line hierarchy by use of specific checklist of certain operational checks and once those completed satisfactory, PTW(if applicable) to be closed and isolation arrangements to be restored by removing barricades/cautionary tags.

Remove all the site worker staff from site

Remove any balance material.

Remove all tools and Plants.

Closing of Work Permit after completion of activity.

7.0 Task Specific Hazards: - Refer to Task Specific Risk Assessment and attach in appendix

Attachment: - List of tools and plants.

In addition, please provide below control measures in risk assessment (as applicable).

Fall Protection

Measures:

(Where work at height cannot be avoided)

Use Full Body Harness with double lanyard to be used.

Provide vertical life line / fall arrestor.

Electrical Safety Measures

(1) For electrical connections ensure with ELCB, MCB & three core double insulated cable.

(2) Area Illumination is to be ensured for extended hours works.

Lifting Safety Measures

Use of specified Crane and Hydra according to Load Chart, Lifting belts and D-shackles capacity.

Others (please provide details)

Lunch break 1 Hr and Portable water container availability is need to be ensured.

Hazardous

Substances:

(Attach MSDS if required)

N/A

N/A

N/A

N/A

N/A

N/A

N/A

8.0 Emergency Provisions: - Relevant operational possibility of a programme in the case of emergency situation i.e. electrical supply restoration. In addition emergency response provisions i.e. first aiders, fire fighting, first aid arrangements, nearest onsite/offsite emergency response also to be considered during emergency planning.

1) Site Supervisor has to report any incident to Site Manager immediately.

2) Supervisor has to take off control over the danger and rescue over the incident

3) Site manager has to inform to the first aider

4) First aider to reach at spot with first aid box and stretcher and provide first aid treatment and raise siren in case of emergency

5) Site manager to call ambulance (if required)

6) Site manager alerts to Doctor and asked for treatment (if required)

7) Site manager to inform Project Manager, client and concern government authorities if required

Asit B Giri

Mobile No: 09766090757

ABB Site Office , ESSEL Office & NTPC First Aid Centre

CITY HOSPITAL

Phone No- 0217-2315155 / 2315156

9.0 Waste Disposal/Housekeeping and Environmental issues :- Details waste disposal processes and or housekeeping activities, Details of environmental impacts and control measures.

Our scope of work does not involve disposal of hazardous substances. Our works will generate negligible wastage. Those too will not be harmful and will be disposed of in the proper manner at designated place.

10.0 Personal Protective Equipment (PPE) :- PPE requirements for the task

YES/NO

Yes

Yes

Yes

No

No

No

No

11.0 Amendments and additional information:- Should any part of this method statement require amendment or alteration, this must be notified for agreement by all relevant parties prior to it being enforced.

13.0 Communication of method statement and signing off register: Communicate to all relevant parties (via a toolbox talk) and ensure it is signed by all personnel.

Emergency response plan and contact number displayed at all work locations and also communicated during Tool box meeting.

Persons involved with the work

I undersigned have read, discussed and fully understand the above method statement and risk assessment on activity and will adhere to all method of work and condition set down.

Name

Company

Designation

Date & Signature

H S SHARMA

C P Singh

ABB India Ltd

Site Manager

ASIT B GIRI

ABB India Ltd

Site safety supervisor

Rajesh Pillai

M/s Unitech Power Transmission Ltd.

Project Manager

Anil Adapa


Site Manager

Jojy Varghese


Safety Officer

Pawar

M/S Unitech Power Transmission Ltd

Store In-Charge

ANNEXURE for Point no- 6.2 (T & P Details)

TOOLS REQUIRED FOR TOWER/BEAM ERECTION

Sr No

Man power / Tools

Required

Remark

1

Erection Gang 15 person

1

2

Derrick

2

3

Wire Rope 12 mm 200 Mtrs

2

4

Poly propelyne rope

8

Bundle (200 Mtrs)

5

Torque Wrench

4

6

Double Pulley ( Set )

4

Open able

7

Single Pulley

4

8

Slings 1 Mtrs

4

For fixing Pulley

9

Slings 2 Mtrs

4

10

Rope pieces ( 2M to 5M)

LS

11

D shackle

4

For fixing Pulley

12

Crow bar

1

13

Spanner set

4

14

Plier

2

15

Hammer

2

16

Jute Bag

LS

17

Cotton hand gloves

20 Pair

18

Hydra/Crane/Winch Machine/Truck/Tractor

1 No

For Shifting and lifting the material

19

Vertical life line / fall arrester

5 No.

ANNEXURE OF LIST OF REFERENCE DRAWINGS

ABB Document No.

Description of Document

STRUCTURE DRAWINGS

3VIN100471T4564

765KV 7CA PORTAL DESIGN CALCULATION

ABB/ADN/STR-02

765KV 7CA PORTAL FABRICATION DRAWING

3VIN100471T4563

765KV 7CB PORTAL DESIGN CALCULATION

ABB/ADN/STR-01

765KV 7CB PORTAL FABRICATION DRAWING

3VIN100471T4565

765KV 7CC PORTAL DESIGN CALCULATION

ABB/ADN/STR-03

765KV 7CC PORTAL FABRICATION DRAWING

765KV 7GWCB BEAM DESIGN CALCULATION

765KV 7GWCB BEAM FABRICATION DRAWING

765KV 7GWCC BEAM DESIGN CALCULATION

765KV 7GWCC BEAM FABRICATION DRG

400KV GANTRY STRUCTURE

3VIN100471T4571

DESIGN CALCULATION FOR 400KV BEAM MKD. - G1

3VIN100471T1548

FABRICATION DETAILS FOR 400KV BEAM MKD. - G1

3VIN100471T4572

DESIGN CALCULATION FOR 400KV BEAM MKD. - G2

3VIN100471T1549

FABRICATION DETAILS FOR 400KV BEAM MKD. - G2

3VIN100471T4573

DESIGN CALCULATION FOR 400KV TOWER MKD. - TC

3VIN100471T1550

FABRICATION DETAILS FOR 400KV TOWER MKD. - TC

3VIN100471T4574

DESIGN CALCULATION FOR 400KV TOWER MKD. - TH

3VIN100471T1551

FABRICATION DETAILS FOR 400KV TOWER MKD. - TH

3VIN100471T4575

DESIGN CALCULATION FOR 400KV TOWER MKD. - TI

3VIN100471T1552

FABRICATION DETAILS FOR 400KV TOWER MKD. - TI

3VIN100471T4576

DESIGN CALCULATION FOR 400KV TOWER MKD. - TJ

3VIN100471T1553

FABRICATION DETAILS FOR 400KV TOWER MKD. - TJ

3VIN100471T4577

DESIGN CALCULATION FOR 400KV TOWER MKD. - TM

3VIN100471T1554

FABRICATION DETAILS FOR 400KV TOWER MKD. - TM

3VIN100471T4578

DESIGN CALCULATION FOR 400KV TOWER MKD. - TN

3VIN100471T1555

FABRICATION DETAILS FOR 400KV TOWER MKD. - TN

765KV EQUIPMENT STRUCTURE

3VIN100471T4566

DESIGN CALCULATION FOR 765KV EQUIPMENT STRUCTURE MKD. - LA

3VIN100471T1556

FABRICATION DETAILS FOR 765KV EQUIPMENT STRUCTURE MKD. - LA

3VIN100471T4567

DESIGN CALCULATION FOR 765KV EQUIPMENT STRUCTURE MKD. - BPI

3VIN100471T1557

FABRICATION DETAILS FOR 765KV EQUIPMENT STRUCTURE MKD. - BPI

3VIN100471T4570

DESIGN CALCULATION FOR 765KV EQUIPMENT STRUCTURE MKD. - ISOLATOR

3VIN100471T1560

FABRICATION DETAILS FOR 765KV EQUIPMENT STRUCTURE MKD. - ISOLATOR

3VIN100471T4568

DESIGN CALCULATION FOR 765KV EQUIPMENT STRUCTURE MKD. - CT

3VIN100471T1558

FABRICATION DETAILS FOR 765KV EQUIPMENT STRUCTURE MKD. - CT

3VIN100471T4569

DESIGN CALCULATION FOR 765KV EQUIPMENT STRUCTURE MKD. - CVT

3VIN100471T1559

FABRICATION DETAILS FOR 765KV EQUIPMENT STRUCTURE MKD. - CVT

400KV EQUIPMENT STRUCTURE

3VIN100471T1561

400KV EQUIPMENT STRUCTURE MKD - LA

3VIN100471T1562

400KV EQUIPMENT STRUCTURE MKD - BPI

3VIN100471T1564

400KV EQUIPMENT STRUCTURE MKD - CVT

3VIN100471T1563

400KV EQUIPMENT STRUCTURE MKD - ISOLATOR

3VIN100471T1565

400KV EQUIPMENT STRUCTURE MKD - CT

3VIN100471T1566

400KV EQUIPMENT STRUCTURE MKD - WT

3VIN100471T1568

400KV EQUIPMENT STRUCTURE MKD - LA - HIGH LEVEL

3VIN100471T1567

400KV EQUIPMENT STRUCTURE MKD - BPI - HIGH LEVEL

3VIN100471T1569

400KV EQUIPMENT STRUCTURE MKD - CT (High Level)

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_Method Statement Tower Erection_2014.doc