METHOD STATEMENT UPPER CONE ERECTION

REV. 1 DATE : 24-2-2012

CONTENTS SCOPE ERECTION OF UPPER CONE PROCEDURE INSTALLATIN OF WORKING PLATFORM AS BUILT HI-LO ALIGNMENT SUPPORTS RESTING CHAIRS GADGET PLATES 600T CRANE POSITIONING

SHIFTING & LIFTING ALIGNMENT & LEVELING FITUP & WELDING NDT REMOVAL OF ALL TEMPORARY ACCESSORIES PAINTING SAFETY / ENVIRONMENT AND ROLES / RESPONSIBILITIES

Annex;
1. 2. 3. 4. 5. 6. Rigging plans JSA Hierarchy of personnel from M/s Zealcon Erection plan Tools and tackles list with valid certification from Third party (M/s SGS) Daily Checklist of Crane and tools/tackle

METHOD STATEMENT UPPER CONE ERECTION

REV. 1 DATE : 24-2-2012

SCOPE This procedure outlines methods for the erection of Upper Cone at In-Situ Flue Gas Stack at BYCO OIL PAKISTAN LIMITED. The activities of the construction erection plan are attached for timeline and sequence of activities.

ERECTION OF UPPER CONE AT LOWER PART(0~37.5M) The procedure for the erection of upper cone with lifting tool and tackles (detailed in Table-1) used shall be carried out as per approve rigging plan.

PROCEDURE To be observed as below; INSTALLATION OF WORKING PLATFORM Installation of temporary ladder for safe access on working platform. Temporary working platforms will be installed with the help of Bracket Scaffolding inside and outside the lower part as per earlier practice at 36.5m height. Installation of cleats (eye plates) for the life line, for the hook up and harnessing to secure themselves before executing the job. AS BUILT At 37.5m as built of In-situ part (circumferential length and plumbness) minimum 12 locations and the same shall be verified with the upper before installation and submit to Byco for verification. HI-LO ALIGNMENT SUPPORTS 16 nos supports are installed through welding at the top edge of In-Situ shell inside & outside (supports are installed opposite to shell top edges). Supports are made as per sketch A & use for the rectify the hi-low, alignment & leveling between the In-Situ shell & upper cone for fit up/welding. RESTING CHAIRS 08 nos of resting chair are installed through welding at the top edge of In-Situ shell inside & outside (supports are installed opposite to shell top edge). Supports are made as per sketch B & use for maintaining the welding gap & positioning/alignment of both In-Situ shell & upper cone.

METHOD STATEMENT UPPER CONE ERECTION

REV. 1 DATE : 24-2-2012

Upper cone top flange level will be checked thru total station (mounted at 1C-1 top platform) and if required to level further adding shimming to 3 mm gap-plates will be carried out by crane. GADGET PLATES 02 sets of Gadget plates are installed through welding at two positions 90deg & 180 deg at the top edge of In-Situ shell & Upper cone as per sketch C. Gadget plates are made as per sketch C & use for maintain the first degree matching lines for the alignment of both parts. 600T CRANE POSITIONING Marked area should be leveled, compact and barricade before the foot-print of crane. The crane shall be positioned for its alignment and position on foot prints as per its approved rigging and lifting plan and shall be prior marked thru surveyor and shall be visible on ground. A lifting demo (without load) for the verification of the clearance, foot print and boom heights as per the approved rigging plan.

SHIFTING & LIFTING OF CONE Shifting & lifting of cone will be carried out on following steps, as per approved rigging plan. Before start of heavy Shifting/lifting job communication meeting held on job location for the right man for right activities. Before lifting & shifting of upper cone installed guide rope to control the movement of load & maintain the distance between working crew & load. Upper cone shift through crane from work shop to erection location. Placing of cone on leveled wooden logs to safe the beveled edge of upper cone. Before start of lifting wind speed should be confirmed. All communication of crane operator & rigging for lifting of upper cone shall be established and verified. Crane operator should get instructions from only signal man (signal man wear the green florescent jacket) for movement, shifting, lifting & positioning of upper cone from ground to In-Situ location (37.5m height). Crane holds the load & releases the load gradually till completion of upper cone at InSitu. Releasing & shifting of slings in safe manners from top to ground after erection of upper cone. . ALIGNMENT & LEVELING Alignment & leveling will be carried out on following steps.

METHOD STATEMENT UPPER CONE ERECTION

REV. 1 DATE : 24-2-2012

Alignment should be followed through gadget plates (already installed) to maintain the degree. Gadget plate part A (installed at upper cone) will be insert in Part B (Installed at In-Situ at edge of shell). Gadget plate will insured the marked line of degree for upper cone & In-Situ with 5mm tolerance. Joint gap for welding will be maintained thru 3 mm gap-plates which are seated on four resting chairs. Remove the hi-low between both shells with the help of alignment supports (already installed). Verticality will be checked by using the thredolite/total station using competent surveyor with the help of center line points. (already stenciled marked on upper cone shells at 90deg & 180 deg). Verification of level of flange (upper cone) through total station. Total station will be placed at 1C1 top platform to read the elevations of upper cone flange till leveling of upper cone flange.

FITUP & WELDING After fit up between both shell plate joint inspections will be carried out by client & then start the welding according to project specification. NDT The NDT of specified joints will be done as per project specifications. REMOVAL OF ALL TEMPORARY ACCESSORIES All temporary Platforms, supports, cleats and any other material will be removed after completion of job. PAINTING The painting shall be done as per project specification. Proper cleaning will be done before the application of final paint (welding seam area). Painting will be carried out as per project specification.

SAFETY / ENVIRONMENT AND ROLES / RESPONSIBILITIES

1. The hierarchy for personnel executing entire job shall be approved and authorities shall sign for the ownership of all the mentioned and approved activities and tasks. Further while executing no other person shall be allowed for any interference, change of activities, imposing of any decision or removal of site.

METHOD STATEMENT UPPER CONE ERECTION

REV. 1 DATE : 24-2-2012

2. All the documents pertaining to the activities of rigging/shifting/lifting/securing and position of upper cone, four number segments and venturi as per project drawings will be submitted for Byco approval after signing from M/s Zealcon Site Manager, rigging/HSE incharge and Crane Owner for the ownership. 3. The Cranes (lifting and trailing) along with all the tools and tackles shall be checked inspected and endorsed by SGS for visual, NDTs and any destructive testing required for conformance & verification of equipment specification, load test and performance tests. 4. No un-certified equipment and tools will be allowed for usage. 5. All the crew of mentioned jobs shall be inducted thru Byco EHS team. 6. All the activities of the subject method statement for the segments specified shall be executed in day-light only. 7. All works related to unloading and erection of Segments shall be conducted according to safe practices as per approved JSA 8. The loads imposed on slings, fittings, etc shall not exceed the safe working load. Open hooks shall not be used for hoisting. 9. Chains, belts, rope, etc Shall have valid certificates and inspected before use. 10. Particular care shall be taken to maintain and clean/safe working environment. 11. Housekeeping shall be continuously conducted and all wooden timber scrap/packing material removed from site. 12. Equipment shall be regularly maintained and kept free of fluid/oil leakages corrected. 13. All produced waste shall be disposed of according to approved Waste Management Plan. 14. Crane operator should get instructions from only signal man (signal man wear the green florescent jacket) for movement, shifting, lifting & positioning of segments & venturi from ground to In-Situ location 15. Before start of heavy Shifting/lifting job communication meeting to be held on job location for the right man for right activities and no activity will be allowed other than job executor. 16. Equipment / tools and tackles shall be checked before performing any activity thru approved checklist, signed and attached with rigging plan documents.

METHOD STATEMENT UPPER CONE ERECTION

REV. 1 DATE : 24-2-2012

17. It is to be noted that before lifting the in-charge shall have job file which contain its rigging plan, JSA and checklist.

18. Role of designated person shall be clearly defined for any emergency plan: arise during lifting or at any stage that can occur on any unseen technical fault during lifting or on any unforeseen change of weather / climate during handling the job. 19. No refueling of Crane during crane operation, top-up should be confirmed before start-up of the job and shall be part of the check-list. 20. Sufficient greasing / lubrication of crane shall be daily check and part of checklist.