IKRA Project –

Integrated Vinyl Plant Nizhny Novgorod

HVAC DUCT FABRICATION AT SITE Revision: 0 Status : IFC

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9631U-REN-MSP-2041-0001 07.09.2011

METHOD STATEMENT

HVAC DUCT FABRICATION AT SITE

9631U-REN-MSP-2041-0001

Contract No.9631U-G-CS02-2001-0002

Note: SP/CPY comments incorporated. Pages modified under this revision: 3,5,7,9

0 07.09.2011 IFC Alper AKSOY Kerem YILDIRIM Serkan CENGIZ

A 31.May.2011 IFR Alper AKSOY Kerem YILDIRIM Serkan CENGIZ

Date
Rev
DD-MMM-YY
STATUS WRITTEN BY CHECKED BY APPROVED BY
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Contents

1) PURPOSE ............................................................................................................................................... 3
2) REFERENCES .......................................................................................................................................... 3
3) SCOPE OF WORK ................................................................................................................................... 4
4) JOB CHECKLIST ...................................................................................................................................... 4
5) SEQUENCING OF ACTIVITIES .................................................................................................................. 4
6) MATERIAL AND EQUIPMENT.................................................................................................................. 6
7) PERSONNEL AND QUALIFICATION .......................................................................................................... 8
8 ) JOB SAFETY ANALYSIS ............................................................................................................................. 9
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1) PURPOSE

This document describes the methods proposed to be used for the HVAC (Heating Ventilation Air
Conditioning) rectangular duct fabrication and fittings fabrication at site activities within RusVinyl
IKRA Project.

2) REFERENCES

SNIP 41.01.2003: Heating, Ventilation and Air Conditioning

9631U-G JSD 3400 0051 0: Hvac Job Specification For Design Electrical Substations
(9631U-G-PP-0801- 9631U-G-PP-0802) All requirements as stipulated by Contract HSSE
documents
SNiP 03/12/2001 "Labor safety in construction. Part 1 General requirements”
SNiP 04/12/2002 "Labor safety in construction. Part 2 Construction Production”
SNiP 01.12.2004 "Construction organization"
(9631U-G-PP-0848-A) Safe Work Practices
GOST 12.1.004-91 `Fire Safety. General requirements`
All requirements as stipulated by Contract HSSE documents (9631U-G-PP-0801- 9631U-G-PP-
0802)
PPE Procedure (9631U-G-PP 0847)
PTW Procedure (9631U-G-PP 0840)
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3) SCOPE OF WORK

HVAC rectangular duct fabrication and fittings at site

4) JOB CHECKLIST

Thickness inspection of galvanized coated sheet metal for Hvac

Corrosion control of galvanized coated sheet metal
Dimensional inspection of manufacturing
Visual leakage inspection of connections

5) SEQUENCING OF ACTIVITIES

Step of work

5.1) Galvanized coated sheet metal cutting

5.2) Rolling of sheet metal

5.3) Galvanized coated sheet metal locking by hammering

5.4) Cutting of fittings and installation

5.5) Silicone application

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The sheet metal (coated galvanize) within the form of roll or plate will be cut by arm operated sheet
shear machine or scissor according to manufacturing dimensions.

The cut material’s one side will be sent through the lock machine. Every 25 cm intervals the cut
material will be bent by sheet folder machine. Later the material is formed into rectangular shape.

Rectangular shaped sheet metal’s flat side and bent side will be locked hammering by metal
hammer.

The joint profiles are cut according to dimension of the ducts by using rotary saw. The cut joint
profiles are connected to ducts using corner pieces by the tack welding machine or electrical screw
driver.
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The openings within the corner pieces are sealed by silicone application. After curing of the
silicone, the duct is ready for installation.

6) MATERIAL AND EQUIPMENT

Equipment planned for Hvac duct fabrication at site works is as follows:

• Galvanized coat sheet metal

• Micrometer
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• Arm operated sheet shear machine

• Lock machine

• Sheet folder machine

• Sheet metal scissor

• Silicon gun

• Silicon

• Hammer

• Tack welding machine

• Circular saw

• Duct joint profile

• Duct corner piece

• Screw driver

PPE REQUIREMENTS

o Hard hat (Gost 12.4.207-99)

o Safety shoes above ankle height
o Gloves (Anticut) (Gost P 12.4.010.1-75)
o Safety glasses (Gost p 12.4.230.1-2007)
o Coverall (Gost 27575 – 87)
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o Dust mask ( Gost P12.4.191-99 FFP3 )

o Safety harness with dual lanyard (Gost P12.4.224-99)
o Reflective vest
o Welders Mask
o Protective earplugs (SNR29)

7) PERSONNEL AND QUALIFICATION

• Site Engineer

• 1 Foreman

• ~ 2 HSE Officers

• ~ 2 HSE Workers

• 3-4 helpers
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8 ) JOB SAFETY ANALYSIS

Attachment 1 Job Safety Analysis form
JOB/TASK: HVAC DUCT FABRICATION AT SITE DATE of JSA submission to SERVICE PROVIDER
Work Area: IKRA SITE AREA Planned date and time of work: 27/05/2011
CONSTRUCTION CONTRACTOR: RENAISSANCE CONSTRUCTION Risk Assessment Team members G.TOPAL

Prevention,
Steps of Task (Sequencing as Residual
Hazards: Risks Protection,
per Method Statement): Risks
Mitigation Measures
Muscular Pain Responsible supervisor shall
conduct the STARRT
Hand injuries meeting before start to work
Working with hand tools
( Shear machine, sheet Hand Cuts which includes hazards, risks
folder mac) and mitigation measures.
After meeting workers shall
put their signatures.
To give time to rest for
workers prevention muscular
5.1) Galvanized coated sheet pain. Safety gloves (anti-cut
metal cutting ) required. All those
equipment includes passport
and Poisoned schemes
attached.

Pinching Their work must be

Manual Handling segregated ( Barricading )
Hand injury Use gloves if required use
Slips and trips anti cut gloves. No
handmade tools
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Prevention,
Steps of Task (Sequencing as Residual
Hazards: Risks Protection,
per Method Statement): Risks
Mitigation Measures
Electric Shock Do not use damaged
Working electrical tools hand tools.
Use Monthly color coding
system.Put label all
equipment showing the
inspection details
Visuial inspection needed.

To give time to rest for

Muscular Pain
Working with hand tools workers prevention
5.2) Rolling of sheet metal Hand injuries muscular pain.
Never use handmade
tools. All equipment
inspected.
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Steps of Task (Sequencing as per Prevention, Protection, Residual

Hazards: Risks
Method Statement): Mitigation Measures Risks

To give time to rest for

Muscular Pain
Working with hand tools workers prevention
(Hammer) Hand injuries muscular pain.
Never use handmade
tools. All equipment
inspected.

5.3) Galvanized coated sheet Never use handmade

metal locking by hammering equipment.
Hand Injuries
Mechanical Handling All equipment must be
Body Injuries inspected.
Always use trained person
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Steps of Task (Sequencing as per Prevention, Protection, Residual

Hazards: Risks
Method Statement): Mitigation Measures Risks

Pinching Use full Personal

Manual Handling Protective Equipment
Hand injury
Their work must be
Slips and trips
segregated ( Barricading )
Use gloves if required use
anti cut gloves.

Electric Shock Do not use damaged

5.4) Cutting of fittings and Working electrical tools hand tools.
installation Use Monthly color coding
system.Put label all
equipment showing the
inspection details
Visuial inspection needed.
Fire PTW required.
Welding (if required) Fire extinguisher.(Dry
Arc Eye
chemical powder)
Welding Mask.
Welding area shall be
fenced with a hard
barricade.Welding shelter
will use.
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Steps of Task (Sequencing as per Prevention, Protection, Residual

Hazards: Risks
Method Statement): Mitigation Measures Risks

To give time to rest for

Muscular Pain
Working with hand tools workers prevention
Hand injuries muscular pain.
Never use handmade
tools. All equipment
inspected.

Chemical Works Respiratory Problems Use specific protective

5.5) Silicone application
( Silicone Application)
Falling materials inside eyes.
Environmental effects
mask.Spirotek FFP3 GOST
12.4.191-99) that the
hazardous material
effects.
MSDS is necessary before
start to work.
Use spill tray.Protective
goggles must be worn at
all times.Coverall must be
used.
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SERVICE PROVIDER approval : YES / NO Date : dd/mm/yy

SERVICE PROVIDER
comments:_________________________________________________________________________________________________
______
___________________________________________________________________________________________________________
_______________________
SERVICE PROVIDER NAME + SIGNATURE(S)
________________________________ ________________________________
______________________
JSA review during STARRT meeting : ________ (Supervisor Signature/Date) ________ (Supervisor Signature/Date) ________
(Supervisor Signature/Date)
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SAFETY CHECKLIST

YES NO

1. PPE CONTROL X

2. EQUIPMENT CONTROL X

• Electrical Hand Tools X (Color Coded)

• Manual hand tools X ( Never use handmade tools)

3. IMPLEMENTATION OF WARNING SIGNS IN WORK AREA X

4. COMPLIANCE WITH HSE REQUIREMENTS X

5. WORK AREA BARRICADING X ( Welding Shelter)

6. WORK PERMIT AVAIBLE ON SITE X (Hot work permit)