PROJECT PROCEDURE

WORK METHOD STATEMENT FOR

LEVLLING PAD INSTALLATION

DOC. NO. : IONE-AA00-MS-MS-0014

KARBALA REFINERY PROJECT Rev. 0 Page 1/12
Ref. FEED DOC. No. : N/A

WORK METHOD STATEMENT

FOR

LEVELLING PAD INSTALLATION

PROJECT : KARBALA REFINERY PROJECT

LOCATION : KARBALA, IRAQ
EMPLOYER : STATE COMPANY FOR OIL PROJECTS (SCOP)
PMC REVIEW STATUS CODE
Carmelo De Dominicis
2017.11.11 10:42:53 +03'00' CODE 1: REJECTED

CODE 2: REVIEWED WITH COMMENTS

CODE 3: NO COMMENTS

Please check minor form detail in

Refer to: IONE-AA00-PE-PM-0005 for code
page 8 description

ISSUED FOR
0 07 NOV 2017 Y.S.KIM K.B.LEE Y.S.KIM B.H.SHIM H.S.HWANG
CONSTRUCTION

A 23 OCT 2017 ISSUED FOR REVIEW Y.S.KIM K.B.LEE Y.S.KIM B.H.SHIM H.S.HWANG

REVD REVD APPRD CONFD

REV. DATE DESCRIPTION PRPD CHKD
(PQM) (PM) (PD) (SCOP)

Joint Venture of Hyundai Engineering & Construction Co., Ltd., GS Engineering & Construction Co., Ltd., SK Engineering &
Construction Co., Ltd., and Hyundai Engineering Co., Ltd.,

Note :
a) Revision bar(vertical line) shall be placed in the right hand margin to indicate where the changes has been made
b) PRPD = Prepared by, CHKD = Checked by, REVD = Reviewed by, APPRD = Approved by, CONFD = Confirmed by
 PROJECT PROCEDURE

WORK METHOD STATEMENT FOR

LEVLLING PAD INSTALLATION

DOC. NO. : IONE-AA00-MS-MS-0014

KARBALA REFINERY PROJECT Rev. 0 Page 2/12
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REVISION HISTORY

Rev. Date Description Page

A 23 OCT 2017 Initial Issue -

0 07 NOV 2017 Issued for Construction with Employer Comment -

 PROJECT PROCEDURE

WORK METHOD STATEMENT FOR

LEVELLING PAD INSTALLATION

KARBALA REFINERY
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TABLE OF CONTENTS

1. PURPOSE

2. SCOPE

3. DEFINITION

4. REFERENCE STANDARD

5. HSE REQUIREMENT

6. EQUIPMENT AND PERSONNEL

7. WORK METHOD

8. TOLERANCE TABLE FOR EQUIPMENT

9. ATTACHMENT
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WORK METHOD STATEMENT FOR

LEVELLING PAD INSTALLATION

KARBALA REFINERY
DOC. NO. : IONE-AA00-MS-MS-0014
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1.0 PURPOSE

The purpose of this work method statement is to establish a procedure for the padding works
of all foundations as guideline for the Subcontractor, EPC contractor and Company
representative. This document will serve as guide for the Construction management, HSE,
Quality and field personnel for the planning, control, installation and inspection in completing
the work in accordance to project requirements.

2.0 SCOPE

This method statement provides the instruction for levelling pad required for levelling pad
required for the erection of steel structures, pipe racks, pipe supports, static equipment and
rotating equipment on the Karbala Refinery Project.

3.0 DEFINITIONS

Company : State Company for Oil Projects (SCOP)

Contractor : HDGSK JV
PPE : Personal Protective Equipment
KRP : Karbala Refinery Project (Karbala City)
HSE : Health, Safety and Environment

4.0 REFERENCE STANDARD

Manufacturer's instruction Manual

IONE-AA00-MS-MS-0002 (Work Method Statement for Static Equipment
Installation)
IONE-AA00-MS-MS-0003 (Work Method Statement for Rotating Equipment
Installation)
IONE-AA00-MS-MS-0004 (Work Method Statement for Mechanical and Steel
Structure Grouting)
IONE-AA00-PE-QA-0001(Project Quality Plan)
IONE-AA00-PE-HS-0001(Project HSE Plan)
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WORK METHOD STATEMENT FOR

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IONE-AA00-ITP-CS-0005(Inspection and Test Plan for Steel Structure Work)

IONE-AA00-ITP-MS-0001 (Inspection and Test Plan for Equipment)
IONE-AA00-ITP-MS-0003(Inspection and Test Plan for Fired Heater/Reformer)
IONE-AA00-ITP-MS-0006(Inspection and Test Plan for Assembly of Boiler)

5.0 HSE REQUIREMENT

5.1. General
1) Appropriate PPE must be used by personnel doing the task.
2) Pre-job tool box must be conducted and all personnel assigned to do the task must
understand the hazards associated with the job and the control measures in place.
3) Safety induction must be given to all personnel prior to entering the site and adequate
supervision by Safety Officer and Site Supervisor shall be provided to ensure the job is
carried out in a safer way.

5.2. Hand Tools and Equipment

1) All tools shall be in a good condition and suitable to be handled.
2) Tools delivered by vendor shall be checked and made available by the supervisor of the
operation.
3) Operator shall be instructed and trained in the safe use of the equipment.

5.3. Environmental Issue

1) All machinery shall be kept in well maintained condition to reduce emissions.
2) Precautions will be taken to minimize the risk of fuel spillages. If there is any spillage, the
material will be removed in accordance to the spill contingency plan.

6.0 EQUIPMENT AND PERSONNEL

Following list shall be included but not limited to;

6.1. Tools & Equipment
1) Man-Lift (for elevated pedestals)
2) Air Compressor (for surface preparation)
3) Surveying instrument
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WORK METHOD STATEMENT FOR

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4) Chipping gun/chisel
5) Scaffolding
6) Generator set
7) Ladder
8) Trowel
9) Water container with measuring gauge

6.2. Staff and Supervisor

1) Mechanical Engineer
2) Mechanical Supervisor

6.3. Workers
1) Foreman
2) Mechanic
3) Millwright
4) Mason
5) Surveyor
6) Helper
7) Scaffloder
8) Man lift Operator(s)

7.0 WORK METHOD

Following sequence shall be followed for installation of Pad Plate.

7.1. General
1) Contractor shall have a full understanding on the scope of work, method statements, tools,
manpower and temporary works necessary to complete the work.
2) Contractor shall ensure the availability of approved vendor documents such as general
arrangement drawing, foundation drawing and procedure to follow all specific
requirements from the equipment vendor. If a levelling pad lay-out drawing is provided by
equipment manufacturer/vendor ensure details are understood and correctly followed.
3) Reference bench marks required for checking the levels shall be established from project
survey monuments and located on secured points near the work area.
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WORK METHOD STATEMENT FOR

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4) Levelling pads shall be installed to distributed loads without overstressing the base plate.

7.2. Materials
1) Non-shrink cement based grout shall be used to fix the levelling plates on top of the
foundation. Grout material must be of same or equivalent used for final base plate
grouting.
2) For levelling pads that are meant to be embedded in grout, the material is generally
carbon steel grade A36 steel or equivalent. Minimum cut size shall be 100mm, square or
rectangular shape and thickness may vary from 8mm to 25mm for embedded pad plate.
Surface must be smooth and plane particularly on top where base plate will be in contact.
3) Levelling pad materials may not be painted unless vendor specifies in the installation
procedure or supply the materials.

7.3. Preparation for Installation

1) Prior to installation of pad, foundation must be prepared on all surface area to come in-
contact with grout.
2) The concrete should be chipped to a rough bonding surface, remove all laitance and
exposing 50% of fractured course aggregate or chip down at least 25mm or deeper if
necessary to reach sound, uncontaminated concrete using a small chipping hammer or
equivalent. Avoid deep holes or grooves that could hinder the flow of grout.
3) Surface preparation shall be inspected and accepted first before installing the levelling
pads. If chipping exposes reinforcing bars, chip at least 20mm (or 2 times the maximum
aggregate size, whichever is greater) below the reinforcement and coat with approved
proprietary paint for weather protection incase final grouting will not take place
instantaneously.
4) Levelling plates shall be fixed on the foundation using non-shrink cement grout. Grout
shall be prepared/placed in dry pack (stiff) consistency. There should be only enough
water mixed into the grout to produce a near zero-slump mortar that will stick together
while being molded into a ball with the hands. Using a ramming device with a blunt end
(usually hammer or mallet), pack the mixed grout (together with the plate) into the mold
with sharp, quick blows building up material until the required level.
5) After leveling, cut the shoulders back at a 45° angle from the top edge of the levelling
plate to the foundation. Finish the grout shoulder with a trowel slightly dampening and
engraving the surface to have rough finish for bonding with the main base plate grout.
 PROJECT PROCEDURE

WORK METHOD STATEMENT FOR

LEVELLING PAD INSTALLATION

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DOC. NO. : IONE-AA00-MS-MS-0014
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6) Do not allow grout to remain above the levelling pad.

7) Consider the temperature conditions, working time and transporting/storing of grout on
site to accord with grout supplier recommendations.
8) Allowable tolerance shall be observed in setting the elevation (+/-3mm), however it is
good practice to keep the levelling pad elevation lower to allow final levelling if necessary.
9) During the installation, plate level and alignment shall be monitored using survey
equipment (dumpy level) to ensure compliance with drawings and fall within allowable
tolerance.
10) In general, and in the absence of manufacturer’s directions, begin wet curing immediately
after hardening. To prevent rapid surface drying, protect the grout from extreme drying
conditions by covering all exposed grout surfaces with continuously wetted burlap or
flannel rags for a minimum of three days. For pads supporting heavy equipment (more
than 50tons) and tall vessels or columns (more than 40meters) allow minimum seven
days of wet curing before erection.
11) Quantity of pad shall depend on the actual load of element to be supported, refer to
equipment vendor for any special requirements. Pad shall be installed in an arrangement
that will distribute the loads without overstressing locally the base plate and foundation.
Preferably, pads shall be located along side/s of anchor bolt however ensuring that it will
not hinder the flow of grout during pocket or base plate grouting.
12) Minimum two (2) pads shall be installed on equipment, in steel structure minimum one (1)
pad shall be installed center of the foundation. If not mentioned on vendor document,
additional pad shall be provided in between adjacent anchor bolts exceeding 800mm to
prevent skid frame member from bending. (Refer to distance B of Fig.4).
1) According to Manufacturer’s specification, grouting material compressive strength can
endure 15MPa (15ton/10cm2) after 1 day of padding and 40Mpa (40 ton/10cm2) after 3
days of padding. Using this properties, contractor shall decide quantity of pad. For more
details please refer to below informations.

Shouldn't be this
number 13?
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WORK METHOD STATEMENT FOR

LEVELLING PAD INSTALLATION

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Fig. 1 After Chipping

Fig. 2 Padding

Fig.3 Pad Installation

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Fig. 4 Pad Location Sample for Static Equipment

Fig. 5 Pad Location Sample for Rotating Equipment

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WORK METHOD STATEMENT FOR

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Fig. 6 Typical Pad for Steel Structure

8.0 TOLERANCE TABLE

Equipment Description Tolerance Remarks

Static Equipment
At the top of pad
(Horizontal and Padding ±3mm
plates
Vertical)

Rotating Equipment At the top of pad

Padding ±3mm
(General) plates

At the top of pad

Steel Structure Padding ±3mm
plates

Manufacturer’s
Package Item Padding
Instruction

9.0 ATTACHMENT

Risk Assessment and JHA [Chipping & Padding]

 Risk Assessment /JHA Form

Activity: *Hot Work Project / Site location: Karbala Refinery Project / Iraq

Department Involved:
Description of Work: Chipping, Pad Plate Installation & Grouting Works.
Job Supervisor:

Localized Shutdown: Required Not Required Supervisor:

Date: 31.05.2017 Sub-contractor: Ref No: KRP-HSE-JHA-2017-

Contractor supervisor: Rev No: 0

-HDGSK HSE Plan and safety procedures are to be followed at all times.
-Minimum PPE to be worn at all times.
-This JHA to be available at all points of work – operatives must be informed of this JHA and understand the risks involved in the
General safety condition
works.
requirements:
-Tool box talk / pre-job brief to be given at the start of each work shift and before starting a new task or activity.
-Summer and Ramadan working hours changes are to be observed and details posted at worksite.
-Paramedical or ambulance facilities to be available.

Minimum PPE required: Hard hat, safety glasses or goggles, hi-viz jacket, overalls, gloves, safety shoes

E – Environmental
LS Likelihood / Frequency
Consequence: H – Health
CS Severity of consequence
S - Safety

KARBALA REFINERY PROJECT

Analysis criteria:
Severity
Probability
Insignificant (1) Minor (2) Moderate (3) Major (4) Catastrophic (5)
Rare (1) 1 2 3 4 5
Possible (2) 2 4 6 8 10
Likely (3) 3 6 9 12 15
Often (4) 4 8 12 16 20
Frequent (5) 5 10 15 20 25
15 – 25 Extreme Risk (E) Activity must not proceed in current form.
8 – 12 High Risk (H) Activity must be modified to include further control measures and be subject to detailed HSE dept. assessment.
4–6 Moderate Risk (M) Activity can proceed subject to appropriate direct and continuous supervision and/or task modification.
1–3 Low Risk ((L) No action required. Activity can proceed subject to compliance with the specified control measures.
Descriptor Likely Frequency Probability
Environment Health and Safety
Frequent Continuous or will happen frequently. Occurs several times a year at location. 5
Often 5 – 12 times per year. Occurs several times a year in similar industries in Iraq 4
Likely 1 – 5 times per year. Has occurred at least once in Iraq 3
Possible Once every 5 years. Has occurred in industry (Worldwide). 2
Rare Less than once every five years Never encountered in industry. 1
Descriptor Consequence Severity
Environment Health and Safety
Catastrophic Long term severe / permanent impact on ecosystem Multiple fatalities 5
Major Significant widespread impact on ecosystem Fatality 4
Moderate Significant localized impact on ecosystem Serious injuries – off site medical treatment 3
Minor Minor changes to ecosystem Injuries – on site medical treatment 2
Insignificant Insignificant occasional change to ecosystem Minor injuries – first aid 1

KARBALA REFINERY PROJECT

 1st Risk 2nd Risk
Action
Consequence Assessment Assessment Residual
Activities Hazards Control Measures by
(E/H/S) risk
LS CS RATING LS CS RATING (Due date)

Preparation Manual handling Injury L L M 1. Conduct TBM. L L L HSE Sup. L

2. Issuing Permit to Work. Site
3. Safety Supervisor Petrol in Supervisor or
site. Foreman.
4. Check Ground Condition
before Work.
5. Check the Weather.
Condition before Work.
6. Before Starting the Works
Check the condition of
Calibrated tools and
equipment’s.
7. Plastic jersey Barricade
warning tape on both sides
with appropriate signboard
at working areas.
8. All tools and machineries
must be inspecting with
colour code.
9. Cable Management.
10. Provide proper working
platform.

KARBALA REFINERY PROJECT

Chipping Machine, 1) Falling/Flying Personal Injury M L H 1) Ensure work area is clear L L M HSE Sup. L
Debris Physical injury due of other workers. Site
2) Harmful Dust to incompetent for 2) User shall wear a hard Supervisor
(Silica) the job. hat, Double eye or
3) Tool Malfunction Overload voltage protection, heavy duty or Foreman.
4) Electric Shock which can cause anti-vibratory gloves, and
5) Loss of Control physical injury earplugs.
Over Tool (electrocution) 3) Use dust-free power
6) Vibratory tools that are equipped
Fatigue with a vacuum; watering
7) Excessive Noise to keep down the dust;
and have dust masks
available for workers who
might want to use one in
addition to the other
hazard controls.
4) Inspect and test drill and
cord prior to use.
5) Make sure all
manufacturer's
protective devices
(guards) are in place and
operational.
6) Make sure that cords are
not lying in water.

KARBALA REFINERY PROJECT

1) Falling/Flying Personal Injury M L H 7) The drill operator should L L M HSE Sup. L
Debris Physical injury due use any auxiliary handles Site
2) Harmful Dust to incompetent for that are on the drill to Supervisor
(Silica) the job. maintain control. or
3) Tool Malfunction Overload voltage 8) The drill operator should Foreman.
4) Electric Shock which can cause make sure that he sets
5) Loss of Control physical injury his feet properly before
Over Tool (electrocution) beginning to drill or chip.
6) Vibratory Fatigue 9) Take regular breaks from
7) Excessive Noise drilling or switch with
another worker (if drilling
for a prolonged period of
time) to relieve vibratory
fatigue.

M L H 10) Only competent and L L M HSE Sup. L

trained workers can Site
operate the Chipping Supervisor
machine. or
11) Only 220V with ELCB are Foreman.
Permitted to the working
area.

KARBALA REFINERY PROJECT

 1) Falling/Flying Personal Injury M L H 12) Working with proper L L M HSE Sup. L
Debris Physical injury due PPE’S. Site
2) Harmful Dust to incompetent for 13) Working with Supervisor
(Silica) the job. supervision. Or
3) Tool Malfunction Overload voltage 14) Use firefighting Foreman.
4) Electric Shock which can cause equipment’s.
5) Loss of Control physical injury
Over Tool (electrocution)
6) Vibratory Fatigue
7) Excessive Noise
Grouting. 1) Spilling. 1) Eye Injuries. L L M 1) Wear safety shoes and L L L HSE Sup. L
2) Quick drying. dust mask if needed. Site
3) Unclean areas. 2) After grouting, curing Supervisor
4) Not proper should be done for 3 days. or
grouting Tools. 3) Only such quantities of Foreman.
material for preparing
grout should be used, as
can be used within 15
minutes of its mixing.
4) Ensure work area is clear
of other workers.
5) User shall wear a hard hat,
eye protection, heavy duty
or anti-vibratory gloves,
and ear plugs.

KARBALA REFINERY PROJECT

Padding 1) Not Proper Level. Personal Injury L L M 1) Access Control of working L L L HSE Sup. L
2) Not Install the Areas Site
Proper Strictly. 2) Proper follow the manual Supervisor
3) Finger Injury of Instruction or
Workers 3) Proper Barricading, Foreman.
4) Before Starting the Works
check the concrete
foundation Levels.
5) Padding May be added or
reduced in Accordance
with Concrete Foundation
Size.
6) Top surface foundation
shall be cleaned and grout
properly Roughen to
ensure good Conduction.
7) Level base Plate shall be
Controlled Strictly.
8) Base plate and column
shall be fully grouted after
final level bracing of Steel
Structure.
9) Working with proper
PPE’S.
10) Working with supervision.

KARBALA REFINERY PROJECT

Housekeeping / Trauma Foot Injury Injury health L L M 1) Situational awareness, L L L HSE Sup. L
cleaning ( sweeping Inhalation gloves, protective Site
/ mopping / clothing. Supervisor
buffing ) 2) Wear safety shoes. Wear or
dust mask if needed. Foreman.

Prepared by: Sub- STL/STR Manager: Reviewed by: HSE Manager: Approved by: Discipline Manger:
Name: Name: Name:
Signature: Signature: Signature:

KARBALA REFINERY PROJECT