Group Five Construction LLC METHOD STATEMENT

PROJECT NUMBER:

NDIA-2201-PRSSB

SUBMITTAL REF. No.: Rev No: Rev. Date:

NDIA-2201PRSSB/G5/MSS/MEP/V OL/005

PROJECT Passenger Rail System Station Box NAME: Construction Package No: NDIA-2201-PRSSB

01 14/05/2011

METHOD STATEMENT TITLE:

METHOD STATEMENT FOR INSTALLATION OF DUCT AND DUCT ACCESSORIES

AMENDMENT RECORDS
Rev. Date 04 Nov 2010 14 May 2011 Changes Issued for Approval Revised as per Comments Prepar ed by PP Deepak CV
Reviewed MEP Manager

Reviewed Logistics Manager

Reviewed QA/QC Manager

Reviewed HSE Manager

Reviewed Eng. Manager

Reviewed Project Manager

Issued to MACE PM MACE PM

00

01

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CONTENTS

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

PURPOSE SCOPE OF WORK PROJECT ORGANISATION (INCL. HEALTH AND SAFETY CONTROL) HEALTH AND SAFETY RISKS AND CONTROLS WORKPLACE ACCESS AND EGRESS WORKPLACE LIGHTING PLANT AND EQUIPMENT PERSONNEL TRAINING CERTIFICATION HAZARDOUS MATERIALS AND SUBSTANCES WASTE MANAGEMENT SPECIAL CONTROL MEASURES

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1.

PURPOSE :
This Method Statement aims at ensuring that the installation of Ventilation Duct Work and Accessories for the NDIA Railway Station meets the requirements of ventilation Specification Section 230000 and complies with Health and Safety procedures.

REFERENCES: o Project Specifications Volume II, Part -1, Section: 23000. o Approved shop drawings (latest revision) o Duct Work standard DW/144 Spec. o Duct work Air leakage test Procedure DW-143 . o o Method statement for Air Handling Unit ( MSS-MEP-VOL-004)- (Mace ref: MS-126) NDIA Design Basis Documents rev H (25045-x-3dr-x-1000_001) Dated on 08.05. 2006

2.

SCOPE OF WORK: Ventilation Duct Work generally includes all types of Supply Air Duct, Fresh and Exhaust Air Duct and their accessories such as duct elbows, offsets, transformation pieces, and branch off pieces, tee connections, access doors, Fire Dampers, Volume Control Dampers and Sound Attenuators. All the ventilation Ducting and accessories are suitable against corrosion from saline environment. The ducting and accessories will be painted with rubber acrylated anti corrosion paint before delivery to the site.

2.1 Pre Installation Procedures: 1. 2. Ensure that approved materials are available to carry out the work. Prior to Commencement of work , areas and access will be inspected to confirm that Site is ready to commence the work. 3. Check all the Duct work are pre-fabricated with tag number labelled and received at site in accordance with specifications and correct dimensions as per approved drawings. 4. All relevant documentation (Drawings) and Material applicable to particular section of works will be checked by Site Supervisor prior to commencement of work. 5. The Site engineer/ Site Supervisor will give necessary instructions to tradesmen (Duct erectors) and provide necessary approved construction/shop Drawings of latest revision along with coordinated layouts. 6. The Site Supervisor/Foremen will also check that proper tools and equipment are available to carry out the work and are in compliance with contract specification. 7. The Site Supervisor also explains the tradesmen regarding safety precautions to

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be observed. 8. Prior to Leak testing, Site Engineer will ensure that Calibrated test kit is available and in good condition.

2.2

Installation and Inspection Procedure :

Prior to commencement of work, coordination will be done with other services.

2.

Determine the position of duct supports as per approved construction drawing, coordinated layouts and specification.

3.

Prepare and fix the duct supports as per approved construction drawing and specification.

4.

Any cut edges of angles, channels or threaded rods will be touched up with Zinc rich paint.

5. 6.

Transport the Duct pieces and fittings to final location. Pre-assemble the Duct pieces and fittings as per approved shop drawing, ensuring the alignment.

7.

Raise the duct work on to the supports ensuring that each length is aligned and levelled with preceding length as per dimensions shown on approved shop drawings.

8.

Approved duct sealant shall be applied on the joints. Any excess sealant shall be removed so that the joint is left in clean and tidy condition.

9.

Ensure that duct work is clean and no tool/construction debris exists within duct work before proceeding to next length.

10.

All open ends of the duct works shall be temporarily sealed with polythene sheets/plywood before leaving the job site to prevent moisture and dirt.

11.

Ensure that all accessories like Volume Control dampers, Fire dampers, Access doors, Test points, Sensors are installed in accordance with approved shop drawings.

12.

Install Sound Attenuators, Diffuser and Louvers according to approved shop drawings.

13

Leak test will be carried out for duct work as applicable in DW144 standard.

14. 15.

Where duct work passes through fire rated wall/partitions, the gap between sleeve and duct work shall be filled with approved fire barrier. Bottom of the duct should be maintained as per the levels marked on the drawings.

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16.

All the ducts will be lifted by crane though the ventilation shaft opening to PRSSB and the horizontal movement will be carried by hand pallet track.

17.

Only trained workers will erect the scaffoldings and also the scissors lifts operators are to be trained , only trained work men should operate the scissors lifts.

18.

The ducting will be degreased inside and outside from the factory and the corrosive protection paint will be applied from factory itself before delivery to the site.

19.

The Painted duct work should be protected against damage in transit & storage . Touching up of paint to be done at site after delivery of the material if necessary.

20.

Duct work construction and installation should be as per the HVCA DW/144 & 143

2.3.

QUALITY CONTROL: 1. QCE along with Project Engineer and Site Engineer will monitor that all components are installed as per contract specifications and approved submittals and manufacturers recommendations. 2. Duct work Material inspection will be done as per standard QA/QC inspection procedure. Touching up of the paint should be done at site if necessary 3. Inspection Request (IR) shall be submitted to Main Contractor/Consultant for the following stages of work: 4. After completion of installation before leak test Leak testing of Duct work (as applicable) as per DW 143.

An activity specific Quality Control Plan (Inspection and Test Plans ITP) will be generated in accordance to this Method Statement and relevant Project Specifications, identifying suitable verification through Hold, Witness, Surveillance or Review points at appropriate stages of the process. The ITP will also indicate which records (relevant QC Forms) are to be generated to demonstrate that product realization has been achieved. The reference number for the relevant ITP is: QCP No.: NDIA-2201/ITP/026E This ITP will be submitted separately and will follow a separate approval process to that of this Method Statement.

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2.4.

SAFETY: 1. Work will commence as per safety regulations laid down in the contract specification and project safety plan. 2. Proper safety harness to be used and secured as required or as instructed by safety officer. 3. All personal protective equipment shall be used as appropriate according to the nature of the job. 4. Housekeeping shall be of good standard and all cut pieces and debris shall be removed. 5. Ensure that all lifting operations are carried out as per approved procedures and safety regulations.

2.5.

LIGHTING: 1. Workplace Lighting - G5 will have in place a temporary lighting system and ventilation system for other works to take place.

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3.0 3.1

PROJECT ORGANIZATION Group Five Construction - Organizational Chart

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3.2 Voltas Ltd. - Organizational Chart

VOLTAS LIMITED International Operations Business Group PO Box 23458 Doha, Qatar

ORGANISATION CHART FOR MEP WORKS PROJECT: NDIA-2201-PRSSB (PASSENGER RAIL SYSTEM STATION BOX)

DOHA BRANCH OFFICE BASED

NDIA SITE BASED

Regional Director Mr. C.D. Pant Project Director Mr. A. Tyler Secretary Mrs. L. Pineda Doc. Control Mr. R. Pontillias

PMO Mr. I. West

Procurement Cell Contracts Mr. A. Robertson Finance Mr. M. Deshmukh HR Manager Mr. R. Mazumdar Admin. Manager Mr. V. Guha Planning Eng. Mr. S. Haneef

MEP Project Manager Mr. P. Vlaicu

Construction Manager Mr. A. Alde

QS Mr. J. McMillan

QA/QC Eng. Mechanical Mr. R. Juelar

Seepage Water Drainage Works

Ventilation Works

Electrical Works

Storekeeper Mr. A. Ibrahim

QS Asst. Mr. T. Kumar

QA/QC Eng. Electrical Mr. R. Addatu

Project Mgr. (Plumb) Mr. D. Suresh

Project Eng. (Plumb) Mr. D. Veettil

Project Eng. (Ventilat) Mr.

P. Thangavelu

Site Eng. (Ventilat) TBA

Project Eng. (Electr) Mr. J. Marcelino

HSE Inspector Mr. J. Romero Site Superv. Electrical Mr. M. Abbas

Draughtsman Plumbing Mr. M. Karki

Site Superv. Plumbing Mr. Malkayah

Draughtsman Ventilation Mr. T. Baby

Site Superv. Ventilation TBA

Jun. Eng. Electrical Mr. N. Dhake

Ref. No: PRS/ORG-01 Date: 09 March 2011

Rev. 5

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4.0

HEALTH AND SAFETY RISKS AND CONTROLS

Below is an assessment of the risks involved for the surveying works? To evaluate risk: Likelihood (L) Severity (S) = Risk (R) Defined as High (11 - 25), Medium (6 - 10) or Low (1 - 5)

L = Likelihood
1 2 3 4 5 Very Unlikely Unlikely Likely Very Likely Certain

S = Severity
1 2 3 4 5 Minor Injury Lost Time Injury Major Injury Single Fatality Multiply Fatalities

Assessed by:

AC

Checked by:

PB

Date: 17 July 2010

Activity/ Element Work during summertime.

Potential Hazards Heat stress / Heat stroke during summer.

Consequence

Risk Rating L 3 S 3 R 9

Control Measures Specified

Residual Risk L 2 S 2 R 4

Workers overcome by heat problems, sunstrokes etc.

Work at night (if required).

Little light.

Injuries due to inadequate/ poor lighting.

1. All workers to be advised to drink at least 6 Liter minimum requirement of water per day (electrolyte solutions are highly recommended during the heat stress periods). 2. Rest hours during peak hot time, seasonal project break hours will be implemented. 1. Provision of adequate lighting. 2. In some circumstances, intrinsically safe lighting may be required.

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Activity/ Element Energising (connecting AHU control panel or power tools to the temporary power source).

Potential Hazards Electrical Shock.

Consequence

Risk Rating L 2 S 2 R 4

Control Measures Specified

Residual Risk L 2 S 1 R 2

Burns, injury and electrocution.

1. Instruction and toolbox talks given on use of tools. 2. Operatives to be tested for competence on the use of the tools. 3. Only double insulated reputable, branded manufactured tools to be used. 4. Conduct weekly tool inspections. 5. Functioning ELCB (earth-leakage circuit breaker) required on all circuits. 6. Ensure supply voltage conforms to operating voltage (240V single-phase or 415V three-phase at NDIA site).

Connecting extension leads for the power tools used for installing the AHUs

Electrical Shock.

Burns, injury and electrocution.

1. Use only matching colour coded industrial plugs and sockets. 2. Regular checks for polarity and serviceability. 3. Ensure that electrical equipment/tools are switched off prior to connecting to power supply. 4. Ensure 415V and 240V supply circuits include functioning ELCB. 5. Protect extension leads against damage. 6. Conduct relevant toolbox talks. 7. Conduct regular inspections.

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Activity/ Element Welding (if any).

Potential Hazards Fire.

Consequence

Risk Rating L 2 S 1 R 2

Control Measures Specified

Residual Risk L 2 S 1 R 2

Burns. Damage to property.

1. Hot Work Permit (Authority or Client) to be used. 2. Welding area to be free of flammable substances. 3. Ensure appropriate housekeeping practice/standards are followed. 4. Accessible fire extinguisher required. 1. Qualified personnel only to be involved in cutting, grinding activities with appropriate PPE and store keeper to ensure good condition of all tools& equipment before issue to site. Hot permit and Fire Extinguisher required at working area. 2. Defective/ damaged tools [broken handles, blunt edges, worn out heads, cracked parts etc.], homemade tools, make shift hand tools should be removed immediately & destroyed. 3. Technicians will be reminded regularly during Tool box talks about perils of misusing hand tools and the necessity of informing the defects found in the tools immediately. 4. Wear goggles while carrying out Chipping, hammering or similar operations. 5. Using proper tools for the right jobs to carry out the works. Do not use unsafe defective tool to do the works.

Hot welding (if any), cutting, grinding, drilling and handling of tools during installation of AHU and accessories or their supports

Hot work and improper handling of tools.

Fire hazard, electric shock and personal injury. Hit by sharp edges/ flying objects.

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Activity/ Element Operate an angle grinder for adjusting the length of threaded rods. Operate an angle grinder for installing the supports for AHU or its accessories.

Potential Hazards Hot sparks being air borne.

Consequence

Risk Rating L 3 S 3 R 9

Control Measures Specified

Residual Risk L 2 S 1 R 2

Eye injuries. Minor burn wounds to the body. Ignition of combustible materials, resulting in damage and loss of life through a fire. Eye and body injury. Start a fire.

1. PPE - Clear face shield visor. 2. Eye protection to be worn.

Hot sparks being air borne.

12

1. Areas are cleared of combustible materials. 2. Fire wardens do inspect the areas to ensure areas are cleared. 3. Site emergency plan deals with fire incidents.

Cutting and Grinding with abrasive wheels.

Flying particles and rotating blade. Sparks generated. Disc disintegration. Flying particles. Rotating blade.

1. Only fit good quality discs/wheels. 2. Avoid discs coming into contact with surroundings when not cutting/grinding. 3. Guards to be fitted. 4. Eye protection to be worn. 5. Keep work area clear of flammable material.

Cutting the support with a hand-held circular saw.

Eye and body injury / cut / amputation.

1. All power electrical tools to be fitted with dead man switch (trigger disconnecting the power supply if released). Trigger switch-lock not to be used. 2. Inspect tools regularly. 3. Guards are to be fitted and eye protection to be worn.

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Activity/ Element Drilling, cutting, grinding and chipping for Proper installation of AHU and Accessories Drilling, cutting, grinding and chipping for Proper installation of AHU and Accessories Drilling, cutting, grinding and chipping Proper installation of AHU and Accessories

Potential Hazards Dust generation.

Consequence

Risk Rating L 2 S 1 R 2

Control Measures Specified

Residual Risk L 2 S 1 R 2

Lung damage and eye injury.

1. Use of PPE to be enforced and controlled. 2. Operatives are to be issued with dust masks and eye protection.

Noise generation.

Loss of hearing.

1. Operatives to be issued with eye protection. 2. Limit / control the duration of noise exposure. 3. Noise levels to be checked at regular intervals, especially in confined spaces.

Vibration.

Hand / Arm Vibration Syndrome (HAVS). White finger Reynauds Disease.

1. Limited exposure duration to vibration. 2. Make use of relieve operator and rotate on a regular basis. 3. Use of heavy duty gloves is compulsory. 4. Inspect anti-vibration rubbers on equipment where applicable. 5. Monitoring of operators by Site Nurse on regular basis. 1. Projections from vehicles will not be permitted without red flag/lamp tied to the projection behind the vehicle. 2. Materials shall be stacked properly & should not obstruct the access of others.

Transportation & Storage of AHU and accessories .

Improper Transportation & Storage.

Damage of materials/ workmen/ vehicle.

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Activity/ Element Manual lifting of AHU and accessories.

Potential Hazards Incorrect Manual lifting.

Consequence

Risk Rating L 4 S 3 R 12

Control Measures Specified

Residual Risk L 2 S 2 R 4

Muscular skeletal injury.

1. Wherever possible mechanical handling devices shall be used. 2. Size of load shall be reduced when it is necessary to walk considerable distance in confined areas. 3. Heavy load shall be assessed before lifting and help obtained from other members of the site team.

Lifting of AHU and accessories and control panels by cranes or from vehicles.

Improper Lifting / Loading and off loading of tools & materials.

Lifting gear & loads / Worker struck by Falling object.

12

1. Working area to be barricade with warning tape and signage. 2. Clearly identify lifting capacity of plant/ equipment. Lifting plan to be uses/operated by competent person. 3. Check at regular intervals chains, slings, wire ropes will be certificated and colour coded. 4. Slung loads to be secure and balanced, use guide ropes use hard standing for reception. 5. Keep clear of slung loads; keep hands away from loads especially at point of landing. 6. Wear suitable PPE. 7. Use banks man. Maintain communication between banks man and driver. 8. Operatives to police the working area and to be aware of movements of public at all times.

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Activity/ Element General activity.

Potential Hazards Improper general site work.

Consequence

Risk Rating L 3 S 3 R 9

Control Measures Specified

Residual Risk L 1 S 3 R 3

Injury and tools/materials damage.

1. Attend site safety induction & method statement briefing to be given by G5 Engineer. 2. Comply with site rules and G5 safety policy. 3. Wear high visibility coat/waistcoat and PPE. 4. Carry out Daily STARRT talks for specific tasks. 5. Maintain exclusion zone around working area. 6. Do not permit public to enter site compound. 1. Noise should be reduced whenever possible, by using low noisy machines & shielding machine or distance. 2. Ear protectors must be provided for noise levels above 85 dbA. 1. All plant and equipment to be suitably serviced and maintained by competent fitters. 2. Check all plant certification. 3. Inspect equipment at the start of each shift. 4. Secure equipment in compound at the end of each shift.

General work.

Noise pollution.

Hearing damage.

General operation.

Improper operation of Plant and equipment.

Plant and equipment damage.

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5.0 WORKPLACE ACCESS AND EGRESS

5.1 All employees entering the construction area will do so by making use of the access provided. Only authorized employees will be allowed to gain access onto the construction site. 5.2 All employees will attend the NDIA health and safety induction prior to entering the area of operation. Access permits will only be issued to employees on completion of the induction. 5.3 Employees will be transported to the area of work and then back.

6.0 WORKPLACE LIGHTING

6.1 Installation and commissioning works will be conducted in day light; no work will be conducted after sunset unless during emergencies. 6.2 Proper lighting shall be provided when working in the night. Sufficient tower lights shall be operated should it be necessary. 6.3 Working hours will be from 07h00 to 18h00.

7.0 PLANT AND EQUIPMENT

The following plant and equipment shall be used during the plumbing works: Light torch Portable lights Extension leads Portable generator Portable drill machine Portable grinding machine Powder-actuated gun Electric cutter Tap & die set Hacksaw frame with blade Combination pliers Screwdriver set Spanner set

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Marker pen Measuring tape Spirit level Knife with retractable snap-off blade Vertical hydraulic jack 3 ton Ladder Scaffolding set Fork lift

8.0 PERSONNEL TRAINING CERTIFICATION

Copies of all relevant competency certificates will be kept on file in the G5C site HSE Advisors office. These documents will be made available for inspection on request from MACE Project Manager.

9.0 HAZARDOUS MATERIALS AND SUBSTANCES

Materials and substances used for the installation of Seepage Water Drainage System are nontoxic and non- hazardous.

10.0

WASTE MANAGEMENT

10.1 Waste management will be done as per the procedure set out in the G5C Project Health and Safety Plan.

11.0

SPECIAL CONTROL MEASURES

11.1 The safety of all personnel and other employees shall always be a high priority during all field operations conducted on the project. 11.2 All site operatives and staff working for this project shall attend the Main Contractors safety induction training / seminar prior to working at site. 11.3 The responsible supervisor will conduct a Safety Task Analysis Risk Reduction Talk (STARRT card) prior to start of work daily. The method statement shall also be discussed to all site operatives before commencing work. 11.4 Contractor is committed to ensure minimal risk for its employees, for the employees of subcontractors and consultants, and to protect the public exposed to construction operations. _____________________________________________________________________________________________ Page 17 of 18 G5C.IMS.001 Rev. 05 Dated: 26/11/2010

11.5 At a minimum, each site operative member will be equipped with PPE such as: high visibility reflective vest, safety shoes, hard hat, safety glasses. 11.6 When any operation becomes hazardous beyond reason due to unforeseen or uncontrollable circumstances, all affected operations will cease until safe working conditions have been restored. No operation will be considered as too important or urgent as to compromise the health and safety of any employee on site.

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