Pearl GTL

Project
LINDE ENGINEERING

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

Project Document Number: T.4.250.903 Project Rev.: O Page 2 of 20

Purchase Order Number:

2MH127

Tag/Item Number(s): N/A

Unit(s): ASU

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

C O 11.03.2008 Issued for Company Comments RO EE ZG ICC

B 21.02.2008 Issued for Review RO EE ZG IFR

A 17.02.2008 Issued for Internal Review RO EE ZG IIR

GAMA Project Prepared Checked Approved

Date Description Status
Rev. Rev By By By
No. No. ORIGINATOR

Document Title:

METHOD STATEMENT FOR PREFABRICATION OF

LINDEGINEERING AG CS, TT & CN PIPE SPOOLS
Contractor Document No.
LOC470
GAM MTS MEC GTL 008 C
Org. Doc. Disc. Geogr. Seq. Rev.
Gama Qatar Co. W. L. L. Vendor Code
Code Type Code Area No No

Project Document Number: T.4.250.903 Rev No: O

 METHOD STATEMENT FOR PREFABRICATION OF CS,
Doc. Title : TT & CN PIPE SPOOLS

Q A T A R Date/Rev. No : 11 March 2008 REV-C

TABLE OF CONTENTS

1. INTRODUCTION _______________________________________________________5
1.1. GENERAL_______________________________________________________________ 5
1.2. SCOPE _________________________________________________________________ 5
1.3. PURPOSE_______________________________________________________________ 5
2. REFERENCE __________________________________________________________5
3. DEFINITIONS __________________________________________________________6
4. RESPONSIBILITIES ____________________________________________________7
4.1. PIPE PREFABRICATION SUPERVISOR ______________________________________ 7
4.2. PLANNING ENGINEER ____________________________________________________ 7
4.3. FABRICATION ENGINEER(S) AND FOREMEN _________________________________ 7
4.4. PIPING ENGINEERS ______________________________________________________ 7
4.5. WELDING SUPERVISOR AND FOREMEN_____________________________________ 7
4.6. QC MANAGER, ENGINEER & TECHNICIANS __________________________________ 8
4.7. SPOOLGEN SUPERVISOR _________________________________________________ 8
5. METHOD OF EXECUTION _______________________________________________8
5.1. PIPE CUTTING ___________________________________________________________ 8
5.2. WELD EDGE PREPARATION _______________________________________________ 8
5.3. BRANCH CUT-OUTS ______________________________________________________ 9
5.4. FIT-UP AND ALIGNMENT __________________________________________________ 9
5.5. TACK WELDING _________________________________________________________ 9
5.6. PREHEAT AND INTERPASS CONTROL _____________________________________ 10
5.7. WELD INTERRUPTION ___________________________________________________ 10
5.8. WELDING ______________________________________________________________ 10
5.9. PWHT _________________________________________________________________ 10
5.10. REWORK ______________________________________________________________ 10
5.11. NDE___________________________________________________________________ 10
5.12. MATERIAL HANDLING AND STORAGE _____________________________________ 11
6. QUALITY ASSURANCE ________________________________________________12
7. HSSE _______________________________________________________________12
8. ATTACHMENTS ______________________________________________________12
8.1. JOB SAFETY ANALYSIS _________________________________________________ 12

T.4.250.903 REV-C Page 4 of 20

 METHOD STATEMENT FOR PREFABRICATION OF CS,
Doc. Title : TT & CN PIPE SPOOLS

Q A T A R Date/Rev. No : 11 March 2008 REV-C

1. INTRODUCTION

1.1. GENERAL
This document describes the methods proposed to be used for the prefabrication of spools.

1.2. SCOPE
This method statement defines responsibilities within GAMA-QATAR for the prefabrication of
spools

1.3. PURPOSE
The purpose of this method statement is to ensure correct and safe implementation of
project specifications and the procedures for the prefabrication of spools.

2. REFERENCE
ASME B 31.3 Process Piping
ASME Sec. V Non Destructive Examination
ASME Sec. IX Welding and Brazing Qualification
ASME Section II, Part C Specification for Welding Rods, Electrodes & Filler Metals
T-13.377.441 Quality Control Requirements for Welding
T-13.377.438 Specification for Traceability, Alloy Verification and Material
Substitution
T.4.250.931 Welding Consumable Control
DEP 30.10.60.18 Welding of Metal(Amendments/Supplements to API RP 582)
DEP 31.38.01.11 Piping-General Requirements
Shop & Field Fabrication of Piping Amendment
DEP 31.38.01.31
T.13.376.796E
T-4.250.930 Cleanliness Procedure Piping Systems
T-4.234.542 Project Quality Plan
T-4.250.927 Material Handling and Storage
T-4.250.928 Material Traceability & Marking
T-4.250.932 Equipment Preservation
T-4.250.938 General Welding Procedure
T-4.250.939 Welders Performance Qualification
T-4.250.913 Post Weld Heat Treatment Procedure
T.4.250.940 Weld Repair Procedure
T.4.250.920 ITP - Fabrication of Piping A/G & U/G
T.13.377.360 Flawless Start-up Initiative(FSI)
T.4.250.935 QCP - Procedure of Piping Fabrication A/G and U/G
T.4.129.857 Road Safety Procedure
T.4.129.872 Heat Stress Disorder Prevention Procedure
T.4.129.868 Work at Height – Scaffolding
T.4.095.303 HSSE Plan Construction

T.4.250.903 REV-C Page 5 of 20

 METHOD STATEMENT FOR PREFABRICATION OF CS,
Doc. Title : TT & CN PIPE SPOOLS

Q A T A R Date/Rev. No : 11 March 2008 REV-C

Nozzle Assemblies for Instrument Connection, Drain and

T.4.095.807
Vents
T.4.219.660 Permit To Work Handover Implementation Plan
T.4.129.855 Emergency Response
T.4.184.595 Land Road Transport HSE Case
T.4.129.859 Lifting Operations
T.4.129.854 Risk Assessment
T.4.129.864 Safe Use of Compressed Gases
T.4.129.850 Accident/Incident /Near Miss Reporting and Investigation
T.4.129.860 Manual Handling
T.4.129.865 Portable Power Tools
T.4.129.856 Hygiene and Housekeeping
T.4.129.861 Handling of Hazardous Materials
T.4.129.866 Use of Grinding Machines and Abrasive Wheels
T.4.129.871 Environmental Accounting
T.4.129.656 Construction Waste Management Plan
T.4.129.852 Entry into Confined Space
T.4.129.861 Working with Electricity
T.4.129.867 Hand Tools
T.4.129.853 Personal Protective Equipment
T.4.129.863 Welding and Flame Cutting
Butt welding ends Amendments and/or Supplements to DEP
ANSI / ASME B 16.25 31.38.01.31 – GEN (April 2003) Shop and Field Fabrication
of Piping.

3. DEFINITIONS

Company : QSGTL or its PMC

Contractor : LINDE ENGINEERING AG
Sub Contractor : GAMA QATAR
Contract : QSGTL Pearl Plant – C2 ASU Project
QCP : Quality Control Procedure
ITP : Inspection and Test Plan
QA/QC : Quality Assurance / Quality Control
WPS : Welding Procedure Specification
PQR : Procedure Qualification Record
PWHT : Post Weld Heat Treatment
CS : Carbon Steel
TT : Low Temperature Carbon Steel
CN : Chrome Nickel Alloys, Stainless Steel
RT : Radiography Test
MSDS : Material Safety Data Sheet
RAT : Risk Assessment Team

T.4.250.903 REV-C Page 6 of 20

 METHOD STATEMENT FOR PREFABRICATION OF CS,
Doc. Title : TT & CN PIPE SPOOLS

Q A T A R Date/Rev. No : 11 March 2008 REV-C

JSA : Job Safety Analysis

TBT : Tool Box Talk
RA : Risk Assessment
PT : Penetrant Testing
MT : Magnetic Particle Testing
T : Thickness
NDE : Non-Destructive Examination
NDT : Non-Destructive Test

4. RESPONSIBILITIES
As per organisation chart, starting from Site Manager and ends at welding, piping foremen
level, including QC personnel, all the people within this link is responsible for execution of
this method statement.

Site Manager, Assistant Site Manager and Mechanical Works Coordinator are responsible
for the fulfilment of this procedure.

4.1. PIPE PREFABRICATION SUPERVISOR

Pipe Prefabrication Supervisor is responsible for implementation of piping works in
accordance with schedule, procedures, specifications, priorities and isometrics issued
for construction.

4.2. PLANNING ENGINEER

Planning engineer is responsible for planning the spool fabrication according to
priorities of piping activities of site, informing Spoolgen Supervisor to provide the spool
drawings and Isogen data accordingly. He is also responsible to release the request of
piping materials according to fabrication schedule.

4.3. FABRICATION ENGINEER(S) AND FOREMEN

They shall ensure safe and efficient working environment, monitor plant and equipment
requirements and ensure that the productivity and the quality are maintained by their
subordinates. They are responsible for ensuring proper material, welding consumables
and welding procedures are applied.

4.4. PIPING ENGINEERS

Are responsible for:
- Ensuring proper documentation and control of spool drawings used for fabrication.
- Request piping materials as per schedule.
- Liaise with contractor representative(s) to solve related technical issues.
- Coordinate with other sections and disciplines on site.

4.5. WELDING SUPERVISOR AND FOREMEN

Welding Supervisor and foremen are responsible to ensure the quality of welding, for
the safe working practices of welders, adherence to approved correct welding
procedure. They will ensure corresponding welding consumables and responsible to
following the consumable stock and ordering them. They are also responsible in
monitoring the welder’s productivity.

T.4.250.903 REV-C Page 7 of 20

 METHOD STATEMENT FOR PREFABRICATION OF CS,
Doc. Title : TT & CN PIPE SPOOLS

Q A T A R Date/Rev. No : 11 March 2008 REV-C

4.6. QC MANAGER, ENGINEER & TECHNICIANS

QC manager is responsible for all Quality Control Activities related with pipe
prefabrication activities together with his engineers and technicians.

4.7. SPOOLGEN SUPERVISOR

Spoolgen Supervisor is responsible to produce spool drawings according to priority of
the fabrication, defined by planning engineer.

5. METHOD OF EXECUTION

5.1. PIPE CUTTING

Spool drawings approved by GAMA-Qatar and LINDE ENGINEERING AG QC
departments will be released by planning engineer to fabrication engineer(s) according
to priorities of erection and fabrication. The Spool lengths will be determined according
to the pipes in stock and these lengths will be stated in the erection drawing, as a
result there will be minimum length adjustment during site erection.

Fabrication (piping) engineer will prepare cutting plan for pipes accordingly, request
the pipes, fittings from material supervisor and will give the same information to cutting
foreman.

Cutting foreman will arrange cutting and planning activities according to RFC drawings.

CS and TT pipes will be cut to the length either by cutting disc or by saw cutting or by
plasma cutting or by motorized flame cutting or by automatic pipe cutting & beveling
machines. After flame cutting a min. 2mm material will be removed from the cut
surface by grinding. Ref. DEP 31.38.01.31 for cutting and beveling preparation.

CN pipes will be cut to the length either by inox cutting disc or by plasma cutting or by
inox saw cutting or automatic pipe cutting & beveling machines with inox apparatus.
Flame cutting of CN is not allowed.

Marking for traceability: Identification mark that is composed of spool number, part/pos.
number, quality and heat number of the pipe will be written on the part with a
permanent marker by the operator who cuts it. Permanent free of chloride markers or
markers suitable to S.S. will be used to for heat nos. traceability in S.S. Pipes.

5.2. WELD EDGE PREPARATION

CS and TT pipes will be beveled either by portable pipe lathe or on by portable
grinding disc or by automatic pipe hot or cold cutting or beveling machines or by CNC
operated pipe beveling machine.

CN pipes will be beveled either by portable pipe lathe with inox apparatus or on by
portable inox grinding disc or fixed inox cutting or beveling machines with inox
apparatus or CNC operated pipe beveling machine with inox apparatus.

T.4.250.903 REV-C Page 8 of 20

 METHOD STATEMENT FOR PREFABRICATION OF CS,
Doc. Title : TT & CN PIPE SPOOLS

Q A T A R Date/Rev. No : 11 March 2008 REV-C

5.3. BRANCH CUT-OUTS

It will be done for CS and TT pipes by either marking with templates and cutting by
flame cutting devices, or by chip removal processes or by CNC plasma pipe cutting
beveling machine depending upon the diameter and thicknesses.

It will be done for CN pipes by either marking with inox templates or inox chip removal
processes or if it is available by CNC plasma pipe cutting beveling machine will be
used depending upon the diameter & thicknesses. During these procedures inside of
pipes will be protected with suitable materials to avoid deterioration.

5.4. FIT-UP AND ALIGNMENT

Before fit up, all parts of spools will be checked for inside cleanliness. For But-welding
of all piping components (e.g. pipe ends, fittings and welding neck flanges), a uniform
root gap shall be provided as specified in the relevant welding procedures specification
and ANSI / ASME B 16.25.

Fit up of spools will be done on the benches or on working tables or on tripods whose
heights are adjustable. Careful attention will be given to the CN pipes and spools
which are not allowed to contact to CS and TT steel spools, during fit up and store CN
spools and pipes will get in contact with wooden timber or suitable materials. First, the
high low conditions and matching faces are going to be checked. If some mismatch
higher then below the mentioned tolerances is detected. This will be corrected and
ensured that the wall thickness after alignment is not reduced below the minimum
required wall thicknesses. End profile of the pipes & fittings will be butt welded and will
be maintained according to the requirement of ASME B 16.25.

5.5. TACK WELDING

Tack welding shall be carried out by qualified welders. Tack welds will be 25mm in
length and equally spaced around circumference in sufficient number to support pipe.
Tack welds, which are to be incorporated into the final weld, will be ground to a feather
edge. Defective tack welds will be ground out prior to welding and PT or MT will be
applied for surface inspection.

All Surfaces to be welded shall be thoroughly cleaned from oxide scale, oil or other
foreign matter and kept dry.

Weld number will be marked on each connection and spool reference Number shall be
stenciled in black color as follows in all cases:
Spools up to 18” Dia. – On the outside of the spool.
Spools above to 18” Dia. – On the inside of the spool.

For material traceability, material Check list will be filled out during the process.

The QC will be called for fit-up inspection and the drawing dimensions: beveled ends,
tack weld and marking visual checks will be performed. With the satisfactory result by
QC inspection, release for weld will be given by writing “FT OK” on each connection.

T.4.250.903 REV-C Page 9 of 20

 METHOD STATEMENT FOR PREFABRICATION OF CS,
Doc. Title : TT & CN PIPE SPOOLS

Q A T A R Date/Rev. No : 11 March 2008 REV-C

5.6. PREHEAT AND INTERPASS CONTROL

Preheat will be applied by gas torches and maintained over a distance of 2t or 100 mm
whichever is larger either side of the joint, measured on the outside surface. Preheat
temperatures will be measured temperature indicating crayons.

5.7. WELD INTERRUPTION

At least 50% of the joint or the root and second pass, whichever is the greater will be
completed before welding joint is cooled to ambient temperature.

5.8. WELDING
Welding will be performed with approved WPS as mentioned on welding plan table by
qualified welders. Welder ID, filler material batch no, PWHT, NDT results will be filled
out during fabrication.

The main pipe will be welded. Then the branch connections will be done. Welder
numbers will be marked on each connection.

All root pass should be done by GTAW welding.

After welding in S.S. the root pass should be checked with magnet which is a witness
point by QCI.

After completion of welding inspections described in ITP will be applied. With the
satisfactory results of inspection the spool or part will be forwarded to PWHT, if
required.

5.9. PWHT
Heat treatment will be applied in compliance with the drawing requirements with the
proper means, either by mobile or by stationary equipment, according to approved
Preheat Treatment Procedure. The time-temperature diagram will be checked for
prescribed parameters.

Upon satisfactory results of heat treatment, NDT of the welds will be carried out.

5.10. REWORK
If it happens that unsatisfactory results were obtained by inspections, non
conformance will be reported by QC and the necessary method of rework will be
decided. Upon approval of the COMPANY, it will be applied.

After eliminating the non-conformance and repeating the remaining manufacturing and
inspection operations, PWHT and NDT operations will be applied.

5.11. NDE
NDE of process and power pipe work shall be in accordance with LINDE
ENGINEERING AG approved procedure.

Certified operators shall be employed for NDE

T.4.250.903 REV-C Page 10 of 20

 METHOD STATEMENT FOR PREFABRICATION OF CS,
Doc. Title : TT & CN PIPE SPOOLS

Q A T A R Date/Rev. No : 11 March 2008 REV-C

Radiography shall be taken normally at night hours and in dedicated area specified for
the work.

On approval of RT joints by LINDE ENGINEERING AG, the same shall be offered for
radiography on specified format to NDE contractor.

All joints to be RT checked shall be tagged with “Blue” ribbon for identification.

The RT operator shall remove the “Blue” ribbon on completion of radiography.

The radiography film shall be submitted the next day for approval to LINDE
ENGINEERING AG.

Repair joints if any shall be tagged with “Red” ribbon.

Radiography repair shall be carried out under the supervision of welding inspector and
reoffered as above.

After NDT clearance, prefabricated spools shall be released for painting/storage.

Prefabricated and painted spools shall be released to field on request with traceability.

Before releasing for painting there should be a check by piping QC for any distortion.

The Piping spools should be tagged with line no. & spool no. for traceability.

5.12. MATERIAL HANDLING AND STORAGE

Raw pipes and fittings will be transported from the warehouse/yard to the shop yard
using mobile cranes, trailers and boom trucks.

Handling of the pipe materials/spools inside the shop shall be with E.O.T. crane, fork
lifts and manual trolleys.

Spools shall be shifted from the shop to the radiography area to painting/storage/field,
painting to storage with mobile crane, trailer and forklifts.

Spools shall be stacked on wooden sleepers with identification markings on top.

Spools shall be stacked unit wise and area wise.

Register shall be maintained for storage showing spools numbers stored in each
location and issue to site.

All open ends of spools shall be covered using end caps/plastic sheets or suitable
material.

All flange faces shall be protected with wooden/plastic covers.

T.4.250.903 REV-C Page 11 of 20

 METHOD STATEMENT FOR PREFABRICATION OF CS,
Doc. Title : TT & CN PIPE SPOOLS

Q A T A R Date/Rev. No : 11 March 2008 REV-C

6. QUALITY ASSURANCE

A Quality Assurance System shall be operated conforming to related standards. Controls

and checks shall be established and documented through relevant QCP – T-4.250.935, ITP
– T-4.250.920 and relevant QCR’s.

7. HSSE

All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan
Industrial City and International standards, codes, LINDE ENGINEERING AG and QSGTL
and/or its PMC requirements and instructions.

In addition all employees and GAMA subcontractor employees on site will have through
GAMA Qatar Site Safety Induction, LINDE ENGINEERING AG Safety induction and
QSGTL Safety Induction for site safety, health, environmental and security prior to work
activities. Other training courses will be attended as required by LINDE ENGINEERING AG
or QSGTL and/or its PMC as required.

At a minimum a generic Risk Assessment will have been prepared by the RAT ranking the
hazards associated with project works and control measures to be taken to mitigate the
hazards to an acceptable level.

Each work scope or task will have a completed and approved JSA identifying the potential
hazards and control measures that will be implemented to protect people and environment.
The JSA (RA) will be used by Supervisor as the basis of conducting his daily Pre-Task
meeting and his weekly TBT.

In addition to the above, employees conducting survey works will wear required PPE and
highly visible vest where traffic or other hazards may exist. For additional safety
requirements for a particular or specific task please refer to the JSA prepared for that task.

8. ATTACHMENTS

8.1. JOB SAFETY ANALYSIS

T.4.250.903 REV-C Page 12 of 20

 Q A T A R JOB SAFETY ANALYSIS FORM
JSA For: T-4-250.903 Page No: 1 of 8
Job being analysed: Prefabrication of Spools
Department/Section doing JSA: HSSE & Construction JSA Members:
Job Performers:
Normal Approvals: Name Signature Date General job requirements / Common
JSA by: Personal Protective Equipment.

Job Supervisor: 1.The following Personal Protective

Equipment shall be worn:
Additional Approvals (Determined by Job Supervisor in correlation with Linde HSSE Manager).
Approved coveralls, safety goggles,
Name Signature Date safety helmet, safety shoes and gloves.
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 procedures
Stop 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: 583 40 72

Pearl HOT LINE : 474 88 88
 JOB SAFETY ANALYSIS / RISK ASSESSMENT SCOPE : METHOD STATEMENT FOR CS, TT &
Q A T A R FOR T-4.250.903 CN PIPE PREFABRICATION

Initial Risk Residual Risk

HAZARDS / POTENTIAL RISK MAIN ADDITIONAL
ITEM ACTIVITY P C P C R
CONSEQUENCES RANK CONTROLS CONTROLS
1 Manual handling of 1.1 Personal injury, back 1.1.1 Worker to wear appropriate 1.1.3.1 Provision for lifting aids when
pipes materials. injuries, muscle strains, 1.1.2 gloves. practical.
sprains. Break the load into manageable
1.1.3 portions.
C 4 MED 1.1.4 Lift with your legs not your back. B 2 LOW
1.1.5 Use the buddy system, “Get help”.
Provide pictorial sign boards with
correct lifting position.
1.2 Slip, Trip & Fall from 1.2.1 Adequate stacking of materials. 1.2.1.1 Remove unnecessary materials
same level 1.2.2 Regular housekeeping practices in the work place.
and removal of trash and
unnecessary items.
B 3 LOW 1.2.3 Maintain access and walk paths. B 1 LOW
1.2.4 Housekeeping shall be a priority,
walk and work areas shall be kept
free of materials and supplies.

1.3 Hand and finger 1.3.1 Wear approved PPE, safety 1.3.1.1 Supervisor/foreman shall
injuries. goggles, safety helmet, safety ensure that the TSTI is properly
shoes, gloves, high-vis vests executed at the work front and
C 4 MED B 2 LOW
1.3.2 Keep away hand and finger from hazards discussed.
moving parts.

2 Mechanical 2.1 Crushed injuries 2.1.1 Provide warning sign. 2.1.1.1 Supervisor/foreman shall
movement to 2.1.2 Personet to be trained in single/ ensure that the TSTI is properly
laydown area banksman techniques in order to executed at the work front and
B 4 MED ensure the material is loaded in a hazards discussed. B 1 LOW
safe manner
2.1.3 Provide trained&qualified
banksmen
 2.2 Falling materials. 2.2.1 Ensure materials are fully secured 2.2.1.1 Supervisor/foreman shall
by competent and certified rigger. ensure that the TSTI is properly
2.2.2 Use of tag lines to control the executed at the work front and
D 4 HIGH load. hazards discussed. B 3 LOW
2.2.3 Wear approved PPE, safety
goggles, safety helmet, safety
shoes, gloves, high-vis vests
2.3 Lifting hazard 2.3.1 Ensure that crane operator is 2.3.1.1 Suitable equipment is to be
certified by Third party, valid used to lift the steelwork.
certificates and driver's licenses. 2.3.1.2 Proper set up of crane; i.e. out
2.3.2 Ensure that all lifting gear/lifting riggers fully extended.
tackle is properly inspected and
color coded.
2.3.3 Third party inspections.
2.3.4 Competent Riggers.
C 5 HIGH B 3 LOW
2.3.5 Daily crane inspections.
2.3.6 Automatic safe load indicator.
2.3.7 Tag lines are to be used to control
loads.
2.3.8 Barricade the working area with
sign boards indicating crane lifting
is in progress to prevent
unauthorized entry.
3 Cutting of pipes 3.1 Hand and finger 3.1.1 Wear approved PPE, safety
injuries. C 4 MED goggles, safety helmet, safety B 1 LOW
shoes, gloves, high-vis vests
3.2 Manual handling of 3.2.1 Approved quality hand gloves,
pipes. available in a full range of sizes to
B 3 LOW ensure proper fit to maintain B 1 LOW
dexterity.
3.3 Pipe cutting machine. 3.3.1 Competent operators, trained on 3.3.1.1 Post the manufacturer safe
the machine they operate. operating manual near the
3.3.2 Ensure that the guards are machine and HSSE office.
properly installed and are being 3.3.1.2 Supervisor/foreman shall
used. ensure that the TSTI is
D 5 HIGH 3.3.3 Post near machine the properly executed at the work B 3 LOW
manufacturers safe operating front and hazards discussed.
procedures in different languages. 3.3.1.3 Ensure equipment were
properly color coded and
inspected prior to use.

3.4 Damage to eyes. 3.4.1 Personnel carrying out gas cutting

Personnel injury. B 2 LOW operations will wear suitable eye B 1 LOW
protection/PPE.
3.5 Defective equipment. 3.5.1 Daily inspection of equipment by 3.5.1.1 Proper maintenance performed
operator prior to use according to by maintenance department
manufacturers recommendations. according to manufacturers
B 3 LOW 3.5.2 Current Contractor inspection recommendations. B 1 LOW
certificate.
3.5.3 Monthly equipment inspection and
color code.
3.6 Cylinders explosion or 3.6.1 Oxygen cylinder valves/fittings to 3.6.1.1 Proper maintenance performed
Fire be kept free from grease/oil.. by maintenance department
3.6.2 Flash-back arrestors to be fitted at according to manufacturers
two ends of hoses and non-flow recommendations.
check valve near cutting torch. 3.6.1.2 Ensure equipment were
3.6.3 Gas hoses and gauges to be properly color coded and
D 3 MED maintained in safe conditions & inspected prior to use. B 2 LOW
inspected daily. Defective hoses
and gauges are to be replaced
immediately.
3.6.4 Cylinders to be used in the
vertical position and secured
against falling.
3.7 Fire hazard. 3.7.1 Suitable measures e.g. Provision 3.7.1.1 Removal of combustible
of fire blankets/fire watchers, will material near the area.
be taken to prevent the risk of fire
C 2 LOW B 1 LOW
during cutting operations.
3.7.2 Provide suitable fire extinguishers
at site.
4 Alignment, fit-up, 4.1 Grinding hazards 4.1.1 Grinders to be maintained in good 4.1.1.1 Provision of grinding shields to
and welding of condition and inspected prior to its contain sparks in proximity
random lengths use. Provided with color coding 4.1.1.2 Personnel carrying out grinding
pipes. for the month. work will wear suitable eye
4.1.2 Guards to be fitted to grinders. protection.
4.1.3 Changing of abrasive wheels to
D 3 MED be carried out by trained & B 2 LOW
authorized personnel using proper
disc spanner.
4.1.4 Grinding operations will be
controlled in order to prevent the
risk of injury to other personnel
from sparks/metal splinters.
4.2 Noise hazards. 4.2.1 Ensure employee wear 4.2.1.1 Provide warning sign.
B 2 LOW appropriate hearing protection. B 1 LOW
4.3 Electric shock 4.3.1 Welding machine to be effectively
C 2 LOW grounded. Welding gear to be B 1 LOW
properly insulated.
4.4 Fire hazards 4.4.1 Suitable measures e.g. Provision 4.4.1.1 Discuss in TBT/ HIP.
of fire blankets/fire watchers, will 4.4.1.2 Provision of suitable fire
be taken to prevent the risk of fire extinguisher in the near area.
during cutting operations. 4.4.1.3 Removal of combustible
C 2 LOW B 1 LOW
4.4.2 Keep flames, sparks, molten materials near the area.
slags and hot metal from coming
in contact with combustible
materials.
4.5 Pinch point 4.5.1 Ensure competent employee will 4.5.1.1 Discuss in HIP/TBT.
carry out the task.
B 2 LOW 4.5.2 Ensure employee wear B 1 LOW
appropriate hand gloves.
4.6 Slip, Trip & Fall from 4.6.1 All tools must be kept in a suitable 4.6.1.1 Provide adequate stacking of
same level holder to prevent it from being materials.
B 2 LOW tripping hazard. B 1 LOW
4.6.2 Remove unnecessary materials in
the work place.
 4.7 Fall of pipe during fine 4.7.1 Use chain puller or chain block in 4.7.1.1 Use of A-frame connected to
alignment lifting pipe during fit-up works. the chain block.
4.7.2 Cable sling shall be inspected 4.7.1.2 Pipe jack to be used as
B 4 MED before use. secondary support for the pipe. B 1 LOW
4.7.3 Provide adequate supports to hold
pipe.

5 NDT Work 5.1 Health risk due to 5.1.1 Isolate/Barricade the area. 5.1.1.1 Discuss in HIP/ TBT.
radiation exposure. 5.1.2 Ensure competent persons will 5.1.2.1 Ensure all work shall be
carry out the tasks. supervised at all times.
5.1.3 Protective shields (time & 5.1.3.1 Obtain Permit to Work.
distance);Use/ shields (time &
distance).
B 3 LOW 5.1.4 Provide warning signs, proper B 1 LOW
access during testing.
5.1.5 Schedule of NDE test requiring
radiation should informed in
advance to make aware the
employees.
6 Grooving and 6.1 Fall of materials. 6.1.1 Ensure materials are fully secured 6.1.1.1 Supervisor/foreman shall
Threading at by competent & certified rigger. ensure that the TSTI is
Fabrication Shop 6.1.2 Use of tag lines to control the load. properly executed at the work
D 3 MED 6.1.3 Wear approved PPE, safety front and hazards discussed. B 2 LOW
goggles, safety helmet, safety
shoes, gloves, high-vis vests

6.2 Slip, Trip & Fall 6.2.1 Housekeeping shall be a priority, 6.2.1.1 Removal of unnecessary
B 2 LOW walk and work areas shall be kept materials. B 1 LOW
free of materials and supplies.
6.3 Electric shock 6.3.1 Ensure all hand tools will be 6.3.1.1 Ensure tools are of correct
visually inspected prior to use, type, size and they are in good
kept in good repair and used only condition and color coded as
for intended purpose. required.
6.3.2 Check electrical equipment prior to
B 3 LOW use.Ensure it is properly B 1 LOW
inspected, color coded for the
month and properly documented.
6.3.3 Ensure all electrical equipment
were properly grounded and built
with ELCB at their source.
 6.4 Cuts injury 6.4.1 Ensure employee should wear
B 2 LOW correct leather hand gloves. B 1 LOW

6.5 Eye, hand & finger 6.5.1 Ensure employee wearing suitable
injuries safety gloves, safety glasses and
B 2 LOW safety shoes, safety helmet when B 1 LOW
handling steel pipe.
6.6 Overloading 6.6.1 Use safe rigging equipment for 6.6.1.1 The weight of such load will be
lifting of materials. Ensure that it is determined to ensure that
color coded for the month and overloading is prevented.
B 2 LOW properly documented and B 1 LOW
registered.
6.6.2 Loading will be closely supervised
with trained/certified banks men.
7 Welding works 7.1 Electric shock 7.1.1 Ensure100% grounding system. 7.1.1.1 Ensure all electrical equipment
Grounding cable must be clamped were properly grounded and
near the joint to be weld. Welding built with ELCB at their source.
cables, electrical cords must be 7.1.2.1 Don’t touch electrically live parts
properly insulated. with skin or wet clothing.
7.1.2 Ensure equipment is of correct 7.1.3.1 Insulate yourself from work and
type, size and they are in good ground.
B 3 LOW B 1 LOW
condition and color coded as 7.1.5.1 Don’t allow any live electrical
required. parts to touch the ground.
7.1.3 Ensure good electrical connection.
7.1.4 Ground the work being welded.
7.1.5 Maintain the electrode holder,
work clamp, welding cable and
welding machine.
7.2 Burn Injury 7.2.1 Wear appropriate protective
clothing, safety jackets, welding
apron, gloves, face shield.
B 2 LOW 7.2.2 Ensure work area properly B 1 LOW
barricaded and displayed warning
signs to warn the workers.
7.3 Electrocution and burns. 7.3.1 Do not weld on containers having 7.3.1.1 Maintained suitable fire
combustible materials (paints / extinguisher in the welding area.
thinner).
B 2 LOW 7.3.2 Do not weld on containers having B 1 LOW
combustible materials (paints /
thinner).
7.3.3 Keep a fire watch
7.4 Fumes & gases 7.4.1 Provisions for mechanical 7.4.2.1 Refer to MSDS.
ventilation. If not possible, use
7.4.2 correct respirator.
B 5 MED Ensure the right positioning of B 2 LOW
welders head & the used of
electrode.

7.5 Arc rays 7.5.1 Ensure employee wear a suitable 7.5.1.1 Only competent and trained
eye protection. employee will carry out the
B 3 LOW tasks. B 1 LOW

7.6 Slip, Trip & Fall from 7.6.1 Keep cables, materials, tools 7.6.1.1 Housekeeping shall be a
same level due to neatly organised. priority, walk and work areas
cluttered area. B 3 LOW shall be kept free of materials B 1 LOW
and supplies.