Pearl GTL Project

LINDE ENGINEERING

Contractor Project No : 5887 Shell Project No: HP-3000-QAT

Project Document Number: T- 4.234.082 Project Rev.: A Page 2 of 13

Purchase Order Number: 2MH127

N/A Tag/Item Number(s):

ASU Unit(s):

Z PCWBS:

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

D A 03.02.2008 Ready For Construction SB UA/MC ZG RFC

C O 30.10.2007 Issued For Company Comments IO MC ZG ICC

B 24.10.2007 Issued for Review IO MC ZG IFR

A 20.10.2007 Issued for Internal Review MS MC ZG IIR

Approved By

GAMA Project Rev Rev. Date Description

Prepared By

Checked By Status

No. No. ORIGINATOR

Document Title:

LINDE ENGINEERING AG

METHOD STATEMENT FOR ANCHOR BOLT INSTALLATION

Document No.

GAM MTS CIV GTL 016 D LOC470

Contractor

Gama Qatar Co. W. L. L. Org.

Code Doc. Type

Disc. Code

Geogr. Area

Seq. No

Rev. No Vendor Code

Project Document Number: T-4.234.082 Rev No: A

Doc. Title : GAM-MTS-CIV-GTL-016 Rev. D Method Statement for Anchor Bolt Installation

Date : 03.02.2008

T-4.234.082 Rev. A Page 4 of 13

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TABLE OF CONTENTS

1. PURPOSE _____________________________________________________________________5 2. SCOPE ________________________________________________________________________5 3. HSSE _________________________________________________________________________5 4. REFERENCES _________________________________________________________________6 5. DEFINITIONS _________________________________________________________________6 6. RESPONSIBILITY ______________________________________________________________6

6.1. Site Manager _____________________________________________________________________6 6.2. Civil Works Manager______________________________________________________________6 6.3. Site Engineer_____________________________________________________________________6 6.4. Work Supervisor _________________________________________________________________7 6.5. QA/QC Officer / Inspector _________________________________________________________7

7. EQUIPMENT & MANPOWER ____________________________________________________7 7.1. Equipment _______________________________________________________________________7 7.2. Manpower _______________________________________________________________________8

8. METHOD OF EXECUTION ______________________________________________________8 9. QUALITY ASSURANCE_________________________________________________________10 10. ATTACHMENTS_____________________________________________________________10

JSA ___________________________________________________________________________________10

Doc. Title : GAM-MTS-CIV-GTL-016 Rev. D Method Statement for Anchor Bolt Installation

Date : 03.02.2008

T-4.234.082 Rev. A Page 5 of 13

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1. PURPOSE

The document describes the methods proposed to be used for anchor bolts installation that will be carried out as part of ASU Construction Works of Qatar Shell GTL Plant (Pearl) in Ras Laffan Industrial City of Qatar including similar works in TSF Area.

2. SCOPE

This method statement identifies the basic structure of the anchor bolts installation system and technique used for the successful completion of the works.

3. HSSE All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and international standards/codes, and Company and Contractor requirements and instructions. All personnel will go through Gama, Linde and Company Safety Induction courses as well as other trainings as identified by their supervisor. A Job Safety Analysis (JSA) specific for this work including a Risk Assessment is prepared and attached herein. Such JSA addresses the hazards associated with each task within the scope of this Method Statement and introduces the controls that will be implemented to reduce the associated risks to acceptable levels. The JSA will be used by the Site Supervisor as the basis of his TSTI / TSTO and Toolbox Talks. All personnel will have PPE required for their specific tasks in addition to the minimum PPE (coveralls, safety goggles, safety shoes, high-visibility vests, gloves) at site at all times as required. In the event of a release, fire or explosion, employees will secure their area and evacuate to the nearest muster point. Once all employees are evacuated the supervisor will conduct a headcount to verify all employees are out of harms way. The supervision will report this to Contractor. Emergency Contact numbers for Company, Contractor and Gama will be posted onsite. All vehicles and equipment used for the subject work will be inspected and certified as required. Drivers and operators will be competent and will have attended all required trainings set forth in project procedures and specifications. All rebar ends will be protected by capping.

Doc. Title : GAM-MTS-CIV-GTL-016 Rev. D Method Statement for Anchor Bolt Installation

Date : 03.02.2008

T-4.234.082 Rev. A Page 6 of 13

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4. REFERENCES : Qatar Construction Standard DEP 34.19.20.31-Gen : Reinforced Concrete Foundations and Structures DEP 34.14.20.31-Gen : Steel Structures

T-13.376.358 : Amendments and/or Supplements to Reinforced Concrete Foundations and Structures T-13.376.359 : Amendments and/or Supplements to Steel Structures T-4.234.541 : QC Docs for Concrete Works

Other related documents of RLIC, Company, Contractor and Gama

5. DEFINITIONS Company : QSGTL or its PMC Contractor : Linde Engineering AG Subcontractor : Gama Qatar Co. W. L. L. Contract : QSGTL Pearl Plant C2 ASU Construction Works QCP : Quality Control Procedure ITP : Inspection and Test Plan QA/QC : Quality Assurance / Quality Control JSA : Job Safety Analysis

6. RESPONSIBILITY

6.1. SITE MANAGER

The site manager will provide inputs to the project execution plan to ensure that strategies & philosophy are properly addressed.

6.2. CIVIL WORKS MANAGER

The Civil Works Manager is responsible for the overall management of the project construction team to ensure that safe and effective operations are conducted and properly documented.

6.3. SITE ENGINEER

He will be overall responsible for safe execution of the whole job including:

Confirming the installation location from schedule of approved construction drawings. Organizing of equipments and tools needed for the job. Assigning skilled personnel for the job. Sequence of activities to be carried out for the work as per this method of statement.

Doc. Title : GAM-MTS-CIV-GTL-016 Rev. D Method Statement for Anchor Bolt Installation

Date : 03.02.2008

T-4.234.082 Rev. A Page 7 of 13

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Conduct inspection and surveillance. Notify to Contractor engineer for inspection as applicable. Ensure all Contractor and Company regulations are followed. Ensure all personnel involved are in safe working condition.

6.4. WORK SUPERVISOR

He will be responsible for safe execution of the following activities:

Conduct TSTI with the concerned work force prior to start the work. Ensure that relevant work permits for the job are obtained prior to start the work. Conduct daily toolbox talks for the entire work force prior to start day work. Assigning a competent work crew for specific activities, details of activities and task

information will be given to the work crew.

Organizing tools and equipment needed to the work site. Inspection and supervision of work. Ensure all Contractor and Company safety regulations are followed as applicable.

6.5. QA/QC OFFICER / INSPECTOR

He will be responsible for:

Assurance of approved methods and materials are being used and conformance of the specifications.

Stage inspections and surveillance in accordance with ITP and assurance of quality of work as per specification and erection procedures.

Incoming material inspection and review of test certificates. 7. EQUIPMENT & MANPOWER

All equipment will be inspected and approved by the Contractor, when required, and all personnel will be inducted and trained before and during mobilization.

7.1. EQUIPMENT

Survey equipments and instruments Boom-truck (if needed) Hand tools

Doc. Title : GAM-MTS-CIV-GTL-016 Rev. D Method Statement for Anchor Bolt Installation

Date : 03.02.2008

T-4.234.082 Rev. A Page 8 of 13

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7.2. MANPOWER

Site Engineer Foreman (Work Supervisor) HSSE Engineer Surveyor & Helpers Boom-truck operator Formwork workers with helpers Rebar workers with helpers Banks men / Flagmen

If the above-listed equipment or manpower proves not sufficient for the timely completion of the facilities and project; additional will be provided to complete the works on time and in line with rules, regulations and specifications of Contractor, Company and RLIC.

8. METHOD OF EXECUTION

Prior to the commencement of the Anchor Bolt installation works, the site levels & coordinates will be surveyed, verified and setout as per the related Drawings.

All anchor bolts will be placed in forms before the concrete is poured. Anchor Bolts will be set using templates placed at the approximate elevation of the base plate, carefully plumbed & checked for location and elevation. They will be held in position rigidly to prevent displacement during casting. Threads on anchor bolts will be protected by greasing and wrapping of threads.

Steel, plywood and/or timber templates may be used. Templates will not be supported on forms unless forms will be reinforced to prevent

displacement or deformation.

Doc. Title : GAM-MTS-CIV-GTL-016 Rev. D Method Statement for Anchor Bolt Installation

Date : 03.02.2008

T-4.234.082 Rev. A Page 9 of 13

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TYPE K M16 TO M30 TYPE K M36 TO M 100 TYPE KR TYPE G

Anchor bolts will be protected from physical damage and corrosion until installation of the upper structures.

Projected part of anchor bolts and nuts will be covered by vinyl sheet during concrete pouring.

After concrete pouring, bolt threads and nuts will be greased and securely covered by vinyl sheet and wood plate (or cloth) bound by wire.

Threads of Bolts will be taped and protected during the placement of concrete. Bolts location & elevation will be rechecked after concrete pouring.

The bolts must be placed in the formwork precisely in position, in elevation and in exactly vertical position, according to the formwork drawings. The bolts must be secured against movement during casting of concrete.

Final deviation of the bolts from the position specified in the formwork drawings, horizontally and vertically, must not exceed 3 mm.

Doc. Title : GAM-MTS-CIV-GTL-016 Rev. D Method Statement for Anchor Bolt Installation

Date : 03.02.2008

T-4.234.082 Rev. A Page 10 of 13

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In the case of a large number of bolts (12 or more) for one vessel (generally in the case of columns only) the bolts shall be installed in staggered elevations, to facilitate the placing of the vessel base ring over the bolts. For this purpose 4 bolts, which are offset from each other by 90 on the bolt circle will be installed 20 mm higher than shown in the formwork drawing.

Where the foundation plate is substantially wider than the plinth carrying the vessel (e.g. in the case of tall columns), extension of the anchor bolts into the foundation plate shall be avoided. For support of large diameter anchor bolts see LS 201-21

9. QUALITY ASSURANCE

A Quality Assurance System will be operated conforming to related standards. Controls and checks will be established and documented through T-4.234.541 (Item 3.0)

10. ATTACHMENTS

JSA

JOB SAFETY ANALYSIS FORM

JSA For: T-4.234.082 Rev. O Page No: 1 of 3Job being analysed: Anchor Bolt InstallationDepartment/Section doing JSA: HSSE & Construction JSA Members:

Job Performers:Normal Approvals: Name Signature Date General job requirements / Common Personal

Protective Equipment.JSA by:

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

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

Discipline Superindent (Linde)

HSSE Representative (Linde)

OTHERS (List Below): 2.Permit To Work.

Approval required for hazardous work detailed in the Linde Work Permit Procedure.Changing conditions and emergency proceduresStop work. Switch off equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing employees are reported to Linde HSSE Dept. When all clear is given, check with Linde HSSE before returning to work.

LINDE EMERGENCY TELEPHONE NO. HSSE MANAGER: Pearl HOT LINE :

NEW REVISED

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1.1 1.1.1 Employees shall wear a flourescent work vest.1.1.1.1

1.1.2 Barricade and secure working area with signboard.

1.2 1.2.1 Employee shall wear the proper PPE when using hammers or other devices for installing survey markers i.e. approved eye protection, and gloves.

1.2.1.11.2.1.2

Never use defective hand tools. All tools shall be inspected & colour coded.

1.2.2 Provide necessary protection on markers such as rebar caps, or any protective cover.

2.1 2.1.1 Break the job down into manageable portions.

2.1.1.1

2.1.2 Ensure all employees use proper lifting techniques i.e. lift with their legs, and not their back.

2.2 2.2.1 Area shall be properly maintained all equipment and materials must be properly stored and picked up.

2.2.1.1 Removed unnecessary materials in the work place.

2.2.2 Housekeeping shall be on going and picked up at the end of the day.

3.1 Falling or dropped loads.

B 5 MED

3.1.13.1.23.1.33.1.4

3.1.5

Third party crane inspections.Daily crane checks.Competent riggers.Quarterly and Daily inspection of rigging gear and equipment.Third party crane operator.

3.1.1.1

3.1.1.2

Supervisor/foreman shall ensure that the TSTI / TSTO is properly executed at the work front and hazards discussed.Ensure the area is properly barricaded and secured.

B 2 LOW

3.2 People struck by suspended or swinging load. B 4 MED

3.2.1

3.2.23.2.33.2.4

Barricade and secured area and install safety sign boards.Use tag lines to control load."DO NOT" lift load over people.Do not allow people to walk under the load.

3.2.1.1 Supervisor/foreman shall ensure that the TSTI / TSTO is properly executed at the work front and hazards discussed. B 2 LOW

Slip, trip and fall hazards.

C

LOW

1 LOW

B 2

B

CURRENT ADDITIONAL

2 LOW

RC

3 LOW

All vehicle movement to be guided by competent Banksmen with fluorescent vests.

ITEM ACTIVITY HAZARD / POTENTIAL PCONSEQUENCES

JOB SAFETY ANALYSIS / RISK ASSESSMENTFOR T-4.234.082

SCOPE : ANCHOR BOLT INSTALLATION

Initial Risk Residual Risk

C RCONTROLS CONTROLS

P

1 Survey the site level, coordinates and set -out.

Hit by traffic or equipment while performing survey works.

B

Improper use of hand tools, hand and eye injuries while installing markers. C LOW

2 Mobilize tools and materials to worksite.

Back, arm. & muscle injuries from lifting - strains, sprains while mobilizing survey equipment.

B 2 LOW

The safe work methods and hazards associated with tasks shall be covered in TSTI / TSTO B 1

2 LOW B 1 LOW

3 Setting up of templates using crane.

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CURRENT ADDITIONALRCITEM ACTIVITY HAZARD / POTENTIAL PCONSEQUENCES

JOB SAFETY ANALYSIS / RISK ASSESSMENTFOR T-4.234.082

SCOPE : ANCHOR BOLT INSTALLATION

Initial Risk Residual Risk

C RCONTROLS CONTROLS

P

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4.1 4.1.1 Hand tools should be inspected, approved & color coded.

4.1.2 All employees should inspect their tools before use.

5.1 Concrete splash to eye. B 2 LOW 5.1.1 Use approved safety glass. B 1 LOW5.2 5.2.1 Ensure all employees use proper

lifting techniques i.e. lift with their legsnot their back.

5.2.1.1

5.2.2 Ensure employee managing the concrete hose has good footing to properly balance his movement.

4 Placed anchor bolts in anchor plate and tighten.

Hand & finger injury due toimproper used of tools in tightening of nuts.

B 2 LOW B

2 LOW

Discuss in TSTI / TSTO

B

5 Pouring of concrete.Muscle strain or sprain while pushing, pulling, lifting, and carrying hose concrete.

C 1 LOW

1 LOW

MTS for ANCHOR BOLT INSTALLATION- 03.02.08.pdf016 Anchor Bolts Rev. O JSA.pdfCover

016 Anchor Bolts Rev..pdf