sms-17459-028 rev02 pipework installation...

Weldmec Construction Limited

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Safety Method Statement

BP IOG Terminal

WELDMEC \ SMS 17459-028 Rev 02

Installation and Welding of 10” & 6”Pipework at Low Level and at height on the Central Pipe Bridge

Rev Date Description Draft By

Checked By

Approved By

Client Approval

01 5/4/17 First BC

02 6/5/17 Second BC

Issues - Paper Copies – Electronic Copies -


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Safety Method Statement SMS 17459 – 028- Rev 02 BC Ref: Risk Assessments: - RA17459-028 Rev 02 BC Date permit required: 10th April 2017 Tasks. Installation and welding of the main pipework at low level

1. Prefabrication pipework in the hot work area. 2. Transporting to pipework to pipe supports. 3. Welding pipework in position.

Ref: - D6364-MP-3000/3001/3002 – Main Pipework - C3.pdf

Duration of works: 20 days Client: Air BP

Location: North and south areas of the rail track and along the

Central Bridge.

Person in Charge of Work:

No. Of People on Task: 4 to 6 (All men to have site inductions.) Pr

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Equipment to be used on site:

1. Hand tools, 2. Z6030 Diesel Artic Boom. 3. MEWP. 4. Telehandler. 5. Burning Gear – Hancocks

6. DC300AMP Arc Welder 7. 110v Maxistar 210 Tig welder 8. Grinders, 5” & 9” 9. Welding Tent 10. Slings/Strops

PTW Conditions: PTW Systems, Permit shall be signed on daily. Permits

handed back at the end of every day. Work areas should be left clean and tidy, all hazards identified and made safe.

Sequence and Method of Work to be done

Note – The Central pipebridge will be fully scaffolded to allow a safe working at height platform for the

welders and any other operatives.

1. Consider weather conditions in discussions with the PTW Authority. Agree if the works can be

undertaken.

2. Sign in and acquire Permits from Project Staff.

3. Carry out Toolbox Talk with all Operatives involved in the task, then all to sign TBT sheet.

4. Carry out plant checks (including slings/strops) and associated paperwork, record the data on the daily plant check sheets if not completed already.

5. Supervisors to assess/review workers have full PPE in procession and its fit for purpose.

6. Supervisor to review work area (including scaffolding) to ensure it is safe to commence work and to check all safety/demarcation barriers are erected.

7. All Roads to be closed when carrying out works, especially over the road sections. 8. Banksman to be in attendance at all times to assist in the safe movement of the MEWP & Telehandler

and to help ensure no collision with the central & western pipebridge either at ground level or at height. Proposed Sequence of Work: Pipework to be pre fabbed in the designated hot work area (see drawing) where reasonably practicable; pipework to then be strung out on their pipe supports and welded in position. Sections for the central bridge at high level will be made in 2no sections. (In the hot work area) these will be lifted on the bridge, (separate lift plan) then (potentially) 1no tie in weld performed at high level. Pipework will be prefabbed for the culvert-leaving tie in spools for the gantry. (Tie in point and details to be confirmed)

Butt welding and stringing out of pipework

1. A temporary mobile hot work area (including a welding habitat) will be established for welding the

pipework in situ. These hot work area’s are to be agreed at the start of the day and marked on a

drawing. All the necessary equipment to be set up, gas testing, Welding set, tents, bottles etc. for each

weld. This MUST be checked and signed off by the Supervisor prior to any welding commencing.


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(There will be sections of welding in position along the track to the centre bridge and up and over the

central bridge).

2. Using the fork lift carry and stack the sleepers to a desired height for the welders.

3. The banksman will then rig a section of pipework and call for the forklift.

4. The banksman will then instruct the operator to raise the length of pipe approx. 150mm, he will then

check the stability of the load.

5. If he is happy to proceed, he will then bank the forklift to the sleepers, the banksman shall steady the

pipe as it is transported to the sleepers.

6. The banksman will instruct the operator to lower the boom on the machine, once the pipework is on the

sleepers. He shall then insert wooden chocks where the pipe makes contact with the sleeper to stop it

from rolling.

7. A small pipe stand will be inserted under the end of the pipe where the butt is to be welded.

8. Using a grinder, the pipefitter will clean any paint and loose material from the face of the pipework, he

will then clean any rust and form the 35º angle chamfer to the end of the pipe, the pipefitter may

choose to flame cut the chamfer using the Hancock.

9. The pipe fitter will then install a clamp around the pipe in preparation for the next length.

10. The banksman will then, with the forklift go and rig another section of pipe and bring over to the existing

length of pipe.

11. Under instruction from the banksman the forklift driver will lower the length of pipe into the clamp, and

on to sleepers.

12. Move the welding plant to the location required making sure not to obstruct any other works.

13. Place the drip trays, fire extinguishers and earth the plant, connect the welding cable to the positive

and negative connections on the plant.

14. Clean any paint or rust from a small area of pipework to allow a good earth connection. Connect the

earth lead to the Pipework. Check that the earth connections are working.

15. Clean the area for the welding, using a to provide a good clean surface area.

16. Check the dimensions and locations are correct with Stopfords drawings.

17. The pipe fitter will then adjust the clamp to suit and space if necessary.

18. The Welder will then inspect the butt and confirm that he is happy to proceed.

19. The welder will strike the butt welding the root run first followed by the fills and cap as per the weld

procedure.

20. The welder will clean the welds in-between the passes using grinders.

21. Once the weld has been completed a firewatcher may need to be present for 30mins after the weld

has been finished (Location depending).

22. The gang shall then move to the next location to perform the next weld.

23. Repeat section 01 to 16 for all other in situ welds.

24. High-level sections on of pipework will be pre fabricated at low level this will be done in two

sections(proposed).

25. The sections will be escorted to the base of the bridge by telehandler guided by the banksman, and

placed in an appropriate place for the crane.


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26. A rigger will then rig the sections and attach to the chains.

27. The crane will then lift the both sections of the pipework this procedure will be guided by the banksman

and the pipefitter ensuring the pipework slews into the clamp. Operatives will be working at high level

from the erected scaffold.

28. Once the pipework is stable and secure in the clamp the banksman will instruct the operator to lower

the chains and de rig the pipework.

29. The welder will then inspect the butt to confirm he is happy with it.

30. Erect a temporary weld shelter around the weld, ensuring that fire blankets are on the floor to stop

sparks falling through scaffold boards.

31. Move the welding plant to the location required making sure not to obstruct any other works.

32. Place the drip trays, fire extinguishers and earth the plant, connect the welding cable to the positive

and negative connections on the plant.

33. Clean any paint or rust from a small area on the bridge to allow a good earth connection. Connect the

earth lead to the bridge. Check that the earth connections are working.

34. Transport all the equipment up the scaffold using the access ladders provided.

35. Clean the areas for the welding, using a to provide a good clean surface area.

36. A fire blanket to be placed on the scaffold board to stop sparks falling to ground level. .

37. Check the dimensions and locations are correct with Stopfords drawings.

38. The temporary weld shelter shall be deconstructed and carefully removed from the scaffolding.

Installation of Pipe clamp and welded shoes into position.

1. Locate the correct pipe shoes for the support.

2. Using a pipe stand place under the pipework and if required lift the pipework to enable the shoe to be

installed in between the pipe and the support.

3. Install the shoe on to the pipe and clamp using bolts.

4. For welded shoes rotate the pipe through 180º using the Telehandler, guided by the banksman.

5. Mark and clean any paint form the pipe where the shoe is to be located.

6. Tack the new shoe to the pipe and check orientation.

7. Allow the welder to fully weld the shoe in position.

8. Using the Telehandler guided by the banksman, rotate the pipe though 180º.

Prepared and Approved by: Brett Cousins WELDMEC Ltd

Client- Approved By:…………………………SIGNED…………………………DATE……………….

All personnel CARRYING OUT WORK to read and understand the above Safety Method

Statement


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Signed……………………………………………Print name……………………………Weldmec







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Risk Assessment

BP IOG Terminal

Rail Loading Enabling Works

Installation of 10” & 6” Pipework and Welding in Situ.

RA-17459-0028 for SMS-17459-028-Rev 02

Rev Date Description Draft

By Checked By

Approved By

Client Approval

01 5/4/17 Initial BC

02 6/4/15 Second BC

WELDMEC Risk Assessment Construction Limited

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Document Title: Risk Assessment

Document Owner:

B Scaplehorn

Document Type: Operational Risk Assessment

Revision Status Index Current Revision: 0

Summary of Changes Section Revision Number

0 1 2 3 4 5 Initial X Frist X Second X

WELDMEC Risk Assessment Matrix Construction Limited

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Potential Consequences: A B C D E

Harm to People

P

Environmental Impact

E

Asset Damage

A

Reputation Impact

R

Never heard of in the industry

Heard of in the industry

Occurs several times per year in industry

Happens several times per year in company

Happens several times per year at location

No injury or damage to health

Zero effect Zero damage No impact 0 Low Low Low Low Low Slight injury or health effects (including FAC and MTC), not affecting work performance, or causing disability

Slight effect; local environmental damage within fence and subsystems

Slight damage: no disruption to process (costs less than £10,000 to repair)

Slight impact: Public awareness but no public concern 1 Low Low Low Low Low

Minor injury or health affects affecting work performance (e.g. RWC or minor LTI < a few days, reversible health effects)

Minor effect: Contamination, single complaint, no permanent effect

Minor damage: Brief process disruption(costs less than £100,000 to repair)

Limited impact: Local public concern (e.g. may include media/political) 2 Low Low Low Medium Medium

Major injury or health effects (e.g. prolonged work absence, irreversible health damage)

Local effect: Limited loss of discharges of known toxicity, beyond fence

Localised damage: Partial shutdown (costs up to £1,000,000 to repair)

Considerable impact: Regional public or slight national media/political attention

3 Low Low Medium Medium High

1 to 3 fatalities or Permanent Total Disability from injury or occupational illness

Major effect: Severe environmental damage

Major damage: Partial operation loss, e.g. 2 weeks shutdown (costs up to £10,000.000

National Impact: National public concern. Mobilisation of action groups

4 Low Medium Medium High High

Multiple fatal injury or occupational illness

Massive effect: Persistent severe environmental damage

Extensive damage: Substantial or total loss of operation (cost in excess of £10,000,000

International impact: extensive negative attention in international media

5 Medium Medium High High High

HOW TO USE THE RAM: 1. For harm to People, select the severity of the consequence that could potentially harm people (0-5) 2. Estimate the likelihood of the potential outcome (A-E) using local knowledge. Likelihood is based upon previous

occurrences of that potential consequence due to this type of incident. 3. Repeat steps 1 & 2 for Asset Damage, Environmental Impact and Reputation Impact 4. The “worst case” risk classification is then used in subsequent activities (e.g. selecting investigation owner and

level of investigation). The “worst case” is the classification that gives the highest rating of LOW, MEDIUM or HIGH.

5. A “SIGNIFICANT” incident is one with an actual severity of 4 to 5

EXAMPLE: 1. An incident is estimated to have a potential severity of “3” under harm to People 2. How often have there been incidents of this type that has led to a severity of “3”?

Answer: This happens several per year within company –“D” 3. Risk Classifications for Harm to People is D3 (MEDIUM) 4. Other Classifications estimated as: - Asset Damage=B2 (LOW)

Environmental Impact=C3 (MEDIUM) Reputation Impact= A0 (LOW) 5. “Worst case” Risk Classification is: D3 - MEDIUM RISK

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Project BP Isle of Grain Terminal Enabling Works.

Author Brett Cousins

Activity Risk Assessment Installation and welding of new pipelines.

Revision No: 2

Hazard Risk Harm, Prob > Risk

Precautions Residual Risk

1. Fire or explosion, flammable atmosphere, gases.

1. Death or serious injury and suffocation.

2.

4/D=H 1. Follow terminal and project site induction rules, ensure RAMS are explained understood and signed off before starting work. TBT to be carried out with each worker and signed comfirmation.

2. Gas monitors, to be used prior to work starting and continuously during all works. .

3. Ensure all possible ignitions sources are kept

off site.

4. All Hot Work to be carried out in the designated Hot Work Area.

4/B=M

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Revision No: 2



1. Emergency Evacuation

1. Inadequate response to alarm or emergency situation.

2. Possible confusion could result in slips, trips and falls,

3. Panic state resulting in njuries. 4. Contractors unfamiliar with project and

facility muster points. 5. Falls from scaffolding during evacuation

/C 1. Staff will familiarise themselves with the

site alarms, emergency contact number for the control room, alarm points, emergency exits and assembly points, site wide evacuation plan.

2. Weldmec staff to carry client’s aide

memoir cards for site emergencies at all times (where provided at induction).

3. Weldmec supervisor to have intrinsically

safe radio to communicate with security, project team and terminal in case of emergency

4. Use buddy system with new starters for

first week so they are familiar with site, then covered by second tool box talk and followed by questions

/B=L

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Revision No: 2



1. Slips, Trips and

Falls 2. Tools and

equipment left on ground, trailing cables

3. Uneven surface,

spillages and rain, ice and snow.

1. Physical injuries to back,

2. Hands,

3. Arms,

4. Joints,

5. Including strains, pulled muscles, ligaments.

3/C=M

1. Wear approved workwear boots with

lace up fronts. Ensure have toe and mid sole protection. When working ensure you have a good firm stance prior to carrying out task.

2. Ensure all tools and equipment are tidied up after use.

3. Avoid any general debris stones, objects

in your path. Take part in good housekeeping methods. Avoid any spills such as oils greases, which may have not been cleaned up with spilt kit, or provide grit salt on iced areas

3/B=L

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Revision No: 2



1. Manual handling

2. Lifting weights which are too heavy

3. Lifting incorrectly

1. Physical injuries to back,

2. Hands,

3. Arms,

4. Joints,

5. Including strains, pulled muscles, ligaments.

3/C=M 1. Always use mechanical handling methods when

possible. Know your capabilities and only tackle jobs you can handle.

2. Can you handle it yourself, do you need help? Where possible establish the weight of the load before lifting. (TILE) .Tasks, Individual, Load and Environment.

3. Task; Look at the task and consider. Do we have to move it? If so can we use a mechanical aid?

4. Individual; Are you strong enough to lift it? Can you lift it without causing injury?

5. Load; Has it any sharp edges? Bend down and access the load by gripping it firmly and moving it a little. If in a box is it still secure?

6. Environment; Consider your route. Are doors swinging in towards you? Is there enough lighting? Are under foot conditions safe? Can you see your route once picked up the load?

7. Wear gloves in case of sharp edges. Adopt a good position, flex your knees. Get a good grip and keep load close into person.

3/B=L

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Revision No: 2



1. Using electrically powered hand tools and mechanical equipment

Injuries through incorrect use of mechanically and electrically operated tools and equipment.

1. Electrocution, 2. Burns, 3. Cuts, 4. Entrapment.

3/C=M 1. Full training to be given to operatives who are using powered tools.

2. Inspections of equipment and tools prior to

use, making sure they are in good condition. a. All tools to undergo periodic

maintenance. b. Correct tool for task. c. Ensure that all guards and handles

are fitted. 3. Correct Gloves to be used whilst carrying out

the works

3/B=L

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Revision No: 2



1. Plant and vehicle Plant collides with other plant, personnel or structures ,leading to:

i 1. Serious injuries, 2. 3. Fatalities 4. Damage to equipment and

structures

4/C=M 1. All site traffic adheres to 10 MPH site speed limit.

2. All vehicles use reverse parking. 3. Banksmen to be used in all reversing

manoeuvres 4. Banksmen to guide vehicles and plant under

structures

4/B=M

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Revision No: 2



1. Lifting Operations with telehandler/Fork lifts & Crane

1. Potential personel injuries; 2. – death 3. – broken bones 4. – crushing 5. Damage to existing services or

equipment.

6. Lifting equipment failure causing injury or damage to existing services

7. Ground Conditions making lifting operation unsafe

Underground services in location of lifts casusing machine to collapse whilst in lifting operations with potential injuries and damage to existing services or equipment

4/C=M 1. All plant and equipment to have in date test certificates and to be regularly maintained and inspected,

2. Plant operators to have current CITB or equivalent certificate. Copies of lifting certificates to be given to PTW authority

3. Slinging operations by experienced operatives and purpose made lifting belts etc to be used to minimise lifting equipment selection problems.

4. The site will be controlled by use and display of signs, markings and speed limits, which shall be adhered to at all times.

5. Movement of any plant in a restricted area MUST be controlled by Banksman(Weldmec) personnel.

6. All plant shall be equipped with reversing alarms & amber warning beacons. All plant shall be parked in an orderly manner.

7. All movement around the site shall be by designated routes.

8. High visibility clothing to be worn by all at all times. 9. All plant should be approached so that the

driver/Banksman/Slinger is aware of your presence. 10. All lifting gear shall be clearly marked with identity

number and safe working load. 11. All lifting gear shall be subject to visual examination

prior to and after use. 12. All lifting equipment shall be protected from sharp

edges. 13. No piece of equipment shall be overloaded. All hooks

shall be of the “C” type or to be fitted with a safety device. When attached all lifting gear to be checked for security prior to lifting/pulling.

14. Clear instructions and signs to be displayed in areas of restricted movement. All vehicle movement to be controlled by a Banksman. Ensure ground conditions are suiatable for the safe movement and location of the Telehandler

15. Check for any underground services or voids in the ground.

4/B=M

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Revision No: 2



1. Working in close proximity to live pipework

2. Working close to

electrical cables 3. Continuous tanker

venting stack on the bridge above the pipe.

1. Live aviation pipework on the bridge Risk of damaging pipework, loss of containment.

2. Possible tool impact causing fracture or leak, possible asphyxiation, explosion, burns, death

3. Inhalation of vapour causing

dizziness, falling, dropping tools, asphyxiation from vent pipe

4/C=M 1. TBT/ safety brief given to team prior to working close to live pipework and existing services. Two 9 kg Fire extinguishers will be present at work activity. Fire watcher to be stood by at all times

2. Check all cables with CAT and contact terminal works department to establish whether cables are alive or dead. If any cables are live then see if terminal department can isolate them during duration of task. If needed use lock out tag out system. If unable to isolate place a barrier between operative and cable. Ensure any live cables are clearly marked and workforce aware.

3. Ensure operative is competent in use of gas monitor. Monitor vapour levels prior and during task. Ensure emergency procedure is communicated to all operatives and bottom man in control of MEWP. Check battery levels on MEWP.

4/B=M

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Revision No: 2



1. Dropped

loads,

1. Serious injuries to operatives,

2. Potenital Death.

4/C=M 1. Banksman to be in charge of slinging, traversing and placing of pipes in systematic order. Only he gives signals.

2. Two operatives to assist in stringing

will manoeuvre pipes onto sleepers.

3. Small chocks will be used to prevent pipes rolling off.

4. This also aids in pipes being lifted

again into position for welding.

5. If possible wear thicker type gloves or Kong gloves to reduce likelihood of entrapment.

4/B=M

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Revision No: 2



1. Preparation and aligning of pipes for welding.

1. Hand and finger injuries, back injuries, strains, pulled muscles.

2. Using hammer to knock in wedges,

possible striking fingers, thumbs 3. Trapped fingers under pipes

4. Traped flanges in butt faces

3/C=M 1. Foreman to control aligning of two pipes using fork truck and 8 ton 360% for lifting.

2. All other non- essential operatives to

keep clear of working area.

3. Ensure clear signals are given when lowering two pipes on chocks.

4. Ensure operatives have hands and

fingers clear before giving signal to lower.

5. Keep fingers clear of clamp when

tightening on pipes.

6. Ensure hammer is in good condition, use fixed head if possible and strike metal wedge cleanly and firmly.

7. Ensure safety glasses are clean.

8. Never hold the pipe by the end, a

hug type approach is used.

3/B=L

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Revision No: 2



1. Cutting using oxy-acetylene equipment

2. Hancock attachment

1. Burns,

2. Clothing on fire,

3. Sparks,

4. Fire in other areas by sparks spreading,

5. Contact with other flammable

substances,

6. Explosion,

7. Loss of life,

8. Grass Catching fire

4/D=H 1. Ensure operatives are trained and competent in the use of the equipment.

2. Appropriate PPE must be worn. If fume removing helmets are not worn, periodically stop work and move to a safe area. Raise visor for a few minutes and breathe fresh clean air.

3. Application for a hot works permit must be raised through the permit authority and once authorised will be held by the permit authorised person on site at all times.

4. Ensure all equipment is inspected checked for leaks before use and recorded using daily plant and equipment sheets.

5. Ensure cylinders are secure in an upright position. Hoses must be secured with crimped fittings not jubilee clips. Flash back arresters are always fitted between cylinder and gauges and hoses. The torch will be lit by use of a flint gun.

6. Fire extinguishers will be placed near the works area.

7. Do not operate equipment with in an enclosed space.

8. Fire blanket to be used in close proximity to welding areas.

4/C=M

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Revision No: 2



1. Working at Height - from scaffolding

1. Falls causing life changing injury or fatality.

4/D=H 1. Scaffold structures shall be erected by a registered company using competent, trained persons and inspected daily by a competent person. They will be responsible for design, erection, alteration and dismantling of the scaffold. A more thorough inspection should be carried out every 7 days and details recorded. A scafftag card will be attached at the bottom of scaffold signed.

2. Scaffold should comply with NASC guidance notes TG20 and SG4: with a certificate.

3. Toe boards and guard rails shall not be removed. Any scaffold alterations will only be made by a competent person.

4. Heavy weighted objects shall not be placed on scaffold. All ladders must be at the correct angle 1 unit out for 4 units up and securely tied off.

5. Too much material on platform can cause access and egress problems.

6. Where possible secure any items or tools you need to take up to your person.

7. Objects should be suitably placed and not balanced on pipes/valves, tools and bolts not to be placed on access hatches.

8. Tool belts are advised

4/C=M

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Revision No: 2



1. Welding 1. Arc Eye

2. Fire

3. Electric Shock.

4. Burns

5. Fumigation.

3/C=M 1. Approperate Welding masks to be used, With a min EW shade on 8 for all welding.

2. Welding to take place under a welding tent (where reasonably practacible)

3. Glasses should be worn by non welding operatives.

4. Sinage placed to inform of welding works. 5. Fire extingushers to be present. 6. Constant gas monitoring whilst welding works

are carried out. 7. Fire blankers placed under where the weld is

taking place. 8. Ensure all cables are in good codition, ensure

you are stood on dry ground and have dry boots

9. Good quality dry welding gloves to be worn whilst welding.

10. Ensure welding takes place in a well ventilated area, ensure that ends of pipes are uncapped to realease fumes.

3/B=L

sms-17459-028 rev02 pipework installation...

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