PROJECT PROCEDURE

WORK METHOD STATEMENT

FOR STATIC EQUIPMENT INSTALLATION

DOC. NO. : IONE-AA00-MS-MS-0002

KARBALA REFINERY PROJECT Rev. 4 Page 1/20
Ref. FEED DOC. No. : N/A

WORK METHOD STATEMENT

FOR

STATIC EQUIPMENT INSTALLATION

PMC REVIEW STATUS CODE

CODE 1: REJECTED

CODE 2: REVIEWED WITH COMMENTS

CODE 3: NO COMMENTS

PROJECT : KARBALA REFINERY PROJECT Refer to: IONE-AA00-PE-PM-0005 for code

description
LOCATION : KARBALA, IRAQ
EMPLOYER : STATE COMPANY FOR OIL PROJECTS (SCOP)
Carmelo De Dominicis
2018.03.12 08:30:54 +03'00'

ISSUED FOR
4 27 FEB 2018 Y.S.KIM K.B.LEE Y.S.KIM B.H.SHIM H.S.HWANG
CONSTRUCTION
ISSUED FOR
3 15 FEB 2018 Y.S.KIM K.B.LEE Y.S.KIM B.H.SHIM H.S.HWANG
CONSTRUCTION
ISSUED FOR
2 03 JAN 2018 Y.S.KIM K.B.LEE Y.S.KIM B.H.SHIM H.S.HWANG
CONSTRUCTION
ISSUED FOR
1 03 AUG 2017 Y.S.KIM S.R.KIM Y.S.KIM B.H.SHIM H.S.HWANG
CONSTRUCTION
ISSUED FOR
0 22 DEC 2015 M.K.PARK S.J.BACK Y.S.KIM B.H.SHIM H.S.HWANG
CONSTRUCTION

A 11 AUG 2015 ISSUED FOR REVIEW M.K.PARK S.J.BACK 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
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REVISION HISTORY

Rev. Date Description Page

A 11 AUG 2015 Initial Issue -

0 22 DEC 2015 Issued for construction

1 03 AUG 2017 Issued for construction

2 03 JAN 2018 Issued for construction

3 15 FEB 2018 Issued for construction

4 27 FEB 2018 Issued for construction

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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. GROUTING & BOLTING DOWN OF BASE PLATE

9. MOUNTING OF ACCESSARIES

10. OTHER WORK

11. TOLERANCE TABLE FOR EQUIPMENT

12. JOB SAFETY ANALISYS

13. RISK ASSESSMENT

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1.0 PURPOSE
The purpose of this work method statement is to ensure that a safe working environment is
achieved. Providing management control over the various areas carried out by the Contractor,
which may be potentially hazardous within the area known as Construction Areas.

2.0 SCOPE
This method statement provides the instruction for installation, erection, assembly, stack,
levelling and aligning of static mechanical equipment and related components, such as
Columns, Drums, Towers, Vessels, Heat Exchangers and Package Skids for 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-0001 (Work Method Statement for Lifting)
IONE-AA00-MS-MS-0004 (Work Method Statement for Mechanical and Steel
Structure Grouting)
IONE-AA00-ITP-MS-0001 (Inspection and Test Plan for Equipment)
IONE-AA00-MS-HL-0004 (Work Method Statement for Heavy Lifting)
IONE-AA00-MS-MS-0014 (Work Method Statement for Levelling Pad Installation)
Applicable Engineering documents and Design Code
IONE-AA00-PE-HS-0029 Lifting Safety

5.0 HSE REQUIREMENT

5.1. General
1) Appropriate PPE must be used by personnel doing the task.
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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 ensure the job is
carried out in a safer way.
4) Non-essential personnel will be kept in a safer area during lifting and bank-men will be
provided where necessary.
5) In case of tandem lift and equipment weight is over 50 ton, lifting work shall follow Work
Method Statement for Heavy Lifting (IONE-AA00-MS-HL-0004) and appropriate rigging
plan shall be submitted to the Employer for information with 24 hours advance notice.

5.2. Hand Tools and Equipment

1) All tools and lifting Equipment shall be in a good condition.
2) Tools such as Shackles, Spreader Beam, Slings, etc. 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.
4) All lifting Equipment and operator must be certified by TPA.
5) Capacity of lifting and tailing lugs/trunnions shall be checked before lifting, to ensure
design safety factor are not exceed. Where slings are used location to be verified against
vendor’s drawings. All this information to be at site during lifting operation as applicable.
Requirement of lifting spreader beams as applicable shall be follow in order to avoid lateral
loads on lifting lugs.
6) Lifting gear shall have TPC certification. All sling, cables and shackles shall be inspected
by the rigger in charge and by HSE inspector. Color coding shall be used.

5.3. Environmental Issue

1) All machinery and lifting Equipment 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 include but not limited to;

6.1. Equipment
1) Crane(s)
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2) Fork Lift
3) Trailer
4) Boom Truck

6.2. Tools
1) Man-Basket / Mobile Elevated Work Platform (MEWP)
2) Hammer Wrench
3) Theodolite / Dumpy Level
4) Cutting Gear
5) Vessels Lifting Shackles
6) Spreader Beams

6.3. Staff and Supervisor

1) Mechanical Engineer
2) Mechanical Supervisor
3) Lifting Supervisor

6.4. Workers
1) Foreman
2) Mechanic
3) Rigger
4) Helper
5) Crane Operator(s)

7.0 WORK METHOD

Before installation, all locations, elevations and orientations of the equipment foundations and
support structures shall be checked and verified in accordance with installation drawings and
specifications.

7.1. Installation of Levelling Pads

Refer to IONE-AA00-MS-MS-0014 (Work Method Statement for Levelling Pad Installation).
Before equipment erection, Mechanical Superintendent or Field Engineer should confirm
leveling pads installation layout in accordance with the design requirement for vertical
equipment, over 30 meter in height or over 30 ton in weight. A field sketch is preferred to
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indicate pad arrangement and number required.

7.2. Installation of Equipment

1) The equipment shall be thoroughly inspected for any damage that may have occurred
during transportation to site. The orientation and center of gravity marks on the equipment,
base level from the datum line of the foundation and the condition of the anchor bolts shall
be thoroughly inspected.
2) The height of the bottom surface of the equipment or base plate is within the specified
project elevation and centerline tolerances at a minimum of four locations that are
diametrically opposite.
3) Liners, wedges and jack screws are standard erection aids for use during base plate/skid
levelling operations and shall be prepared for use. Final choice depends upon site
requirements and vendor installation manual. Recommended sizes for liners and wedges
are based on general industrial practices.
4) Installation of the Equipment to be done as per vendor requirements, if applicable.
5) The foundation must be prepared in accordance with paragraph WMS for levelling pad
installation (IONE-AA00-MS-MS-0014).
6) The placement of Equipment onto the foundation shall be done by using approved lifting
methods comply with manufacturer’s requirements. The lifting supervisor in charge to
identify and mark the lifting points as per the design of the Equipment to be lifted.
7) Adequate measures shall be taken so that the anchor bolts and the foundation are not
damaged.
8) When anchor bolts with sleeves are used, the inside of the sleeve hole are cleaned before
placing the Equipment onto the foundation.
9) When anchor pockets are used, the pocket grouting will be done after making the levelling
alignment of the Equipment.
10) Stacked Heat Exchanger
a) Ensure that bottom heat exchanger preliminary centering and alignment, saddles
base plate are in full bore contact with pad plates on foundation, before anchor bolts
tightening.
b) Release the nitrogen of the both units, remove provisional shipping blind flanges of
the interconnecting nozzles. Check flanges face conditions, and clean thoroughly using
WD 40 or equivalent with clean cloth.
c) Install upper heat exchanger with the vendor supplied shim plates and gaskets on the
bottom heat exchanger top saddles and pre fasten the setting bolts.
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d) Ensure upper heat exchanger preliminary centering, levelling and alignment

(elevation and connecting nozzles gap vendor tolerances). Gap shall be checked by
taper gauge. (min. 4 point for each nozzle considering the gasket thickness)
e) Levelling and alignment using jacks, chain blocks or cranes removing or adding
calibrated shim plates as required, and ensuring the required tolerance gap between
flanges interconnecting nozzles.
f) Install stud bolts of the interconnecting nozzle flanges.
g) Flange stud bolts tighten following the project flange management procedure with the
calculated torque value or value recommended by vendor.
h) After interconnecting flange tightening, upper heat exchanger saddles with bottom
heat exchanger saddles support setting bolts and anchor bolt final tight.
i) Reinstatement of nitrogen on both units in line with the Vendor preservation
procedures.
* If required torqueing tools or torque value are not available for final flanges tightening
completion, provisional hand tool tight leak free to be implemented and record for final
torqueing later during system mechanical completion phase or before.

7.3. Levelling & Alignment

1) Alignment of the Equipment shall be carried as follows;

a) Elevation shall be measured on the basis of level marked on the foundation.
b) Following order of priority shall be given during alignment.
Horizontal/Vertical
Position
Elevation
Orientation
c) Contractor surveyor will verify all supporting calculation and results are in accordance
with allowable tolerances.
d) The equipment shall be inspected visually from two directions, about 90 degrees apart.
The Surveyor shall sight the top and bottom of the vessel shell to ascertain if it is
plumb. Very tall equipment shall be checked for verticality early in the morning.
Reference points shall primarily be side profile reading, the centerline datum markings
of the vessel may be taken in some cases.
e) The equipment shall not be out-of-plumb by more than 1.0 millimeter per one meter of
height up to allowable tolerance (max. 15mm up to 15 meter height, max. 15mm +
0.5mm/m for over 15meter) for the entire height, whichever is less.
2) Elevation of the Equipment shall be verified using dumpy level, graduated straight edge,
steel rule and set square as appropriate.
3) The Equipment horizontal and vertical alignment/plumbing will be checked using a
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theodolite or suitable instrument to the permissible tolerance limits indicated in tolerance

table 11.0 (Tolerance Table for Equipment), and surveying instrument shall be to the
minimum accuracy as specified.
If the equipment inclination is outside the acceptable tolerance, it shall be corrected
providing additional shim liners in accordance with the project requirements. However, in
line with industry custom practice, cases where leveling and alignment accuracy cannot
be achieved as per defined tolerance, deviations will be considered and corrected utilizing
the field fit allowance for piping during erection works (Typ. 50mm in 3 planes X, Y, Z).
3) Horizontal equipment elevation, levelling and location shall be checked by two (2) points
for each saddle (total four (4) points), these points should be positioned between saddle
ribs and symmetrically on each saddle.
In case where the measurement on the saddles or base plate is not practical or possible,
such as typical small drums, vessels, hairpin exchangers or coolers, verification of the
alignment and level within required tolerances, can be checked using the equipment
longitudinal shell edge length. Equipment elevations verified and confirmed with the use
of a Dumpy/Auto Level instrument.
4) Alignment cases of vertical tall columns or vessels using its shell edge, and with diameter
reduction from bottom skirt to the top, deviation check can be verified considering the
longest distance of the shell section with the same diameter only.

Set Datum Point

TL

TL
Check Deviation at
this Point

Figure 1
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5) Alignment of vertical vessels/columns with configuration as shown in Fig. 2, using its shell
edge case can be completed by the following procedure:
a. Based on vessel dimension, identify the center line using measuring tools such as
steel straight rule at the base block.
b. Set the center line with graduated straight edge, steel rule or set square as
appropriate at center line and check variation using surveying instrument from the top
edge of the vessel shell.
c. Repeating similar procedure indicated in point “a” and “b” identify and mark on the
skirt (see Fig.2), the vessel edge OD and use it to check the alignment in accordance
with defined tolerances.

TL

TL
b. Steel rule will be set to
a. Set centerline compare Vessel OD

Figure 2

Note : It is common for some manufacturers to mark the center line of the vessel with a
punch pop mark on a none pressure part of its base plate. Installer should always check for
this for use in aligning.

6) Alignment of vertical vessels where its total straight length between tangent lines is two (2)
meters and below, the use of theodolite instruments is impractical and time consuming
based on the level of accuracy required. Therefore, the leveling of the vessels under this
category can be completed using a professional Spirit Level (Stabila or similar) as shown
in Fig. 3.

Figure 3
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7) The anchor bolt shall be tightened at 4 points in across manner and inclinations are
rechecked using theodolite/spirit level. If the total inclination is within the tolerance level,
then all the anchor bolts are to be snug-tight in a criss-cross pattern as shown in Fig.4.

Figure 4.

Note: None of the methods indicated above are precise engineering and are the
industry custom & practice for equipment leveling and alignment. Any additional
deviations will be considered and corrected utilizing the field fit allowance for piping
during erection works (Typical 50mm in the 3 planes X, Y, Z).

8.0 GROUTING & BOLTING DOWN OF BASE PLATE

8.1. General
1) Visually check foundations and chipping conditions.
2) The foundation surface shall be moistened for minimum 24 hours before start grouting with
water after checking there is no foreign contaminants such as oil and cleaning the area by
compressed air.
3) If drain pipe, oil exhaust pipe, etc. are buried in the grouting mortar, necessary protection
such as winding cupboard around the pipes shall be considered.
4) Build a formwork around the foundation first to grout.
5) Holes are provided in the base plate to permit pouring the grout and stirring for large skid
package. They also act as air vents. Fill under the base plate completely. Stir to assure
proper distribution of the grout flows under the 3 edge of the base plate evenly.
6) Where the grouting mortar is poured into a gap between the bottom of base plate of the
Equipment and the top of the foundation, it shall be sufficiently filled. When the grouting
thickness exceeds a certain value (depending on the grouting material) vibration is needed.
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Expansion joints for epoxy grouting skids of large area of skid packages shall be
considered.
7) Non-shrink grout shall be mixed and placed according to the manufacture's Instruction.
8) After the grouting has set, hardened and cured anchor bolts shall be checked and
tightened fully. Bolt & nut requirements shall be checked.
9) Washer plates shall be welded as per drawing requirements.

8.2. Types of grout

Sand-Cement grout, non-shrink grout. A proper method of grout shall be applied for
grouting as per WMS (Refer to IONE-AA00-MS-MS-0004, WMS for Grouting). Vendor
requirements shall be strictly observed.

8.3. Anchor Bolts Final Tightening

While in most of the static equipment anchor bolts “snug-tight” is in line with industry practice,
for tall towers over 30m height or with height/diameter ratio of 15 or more, sensitive to wind
loads, pre-tensioning is required. And the recommended pretension load is one-third the
tensile strength of the bolt unless otherwise is specified.

CASE 1 - Static equipment (Towers, Drums, Exchangers) not requiring pre-tensioning.

1) Grout the base plate or ring.

2) After the base plate or ring has been grouted and cured, anchor nuts shall be brought to a
‘snug tight’ condition. NOTE: At the sliding end of exchangers or horizontal drums (if plate is
slotted hole end) first nuts shall be hand tightened and counter nut ‘snug tight’ with the first
nut.

CASE 2 - Static equipment requiring pre-tensioning or torqueing (generally towers over 30 m

in height or with height/diameter ratio of 15 or more).

1) Where Anchor Bolt Pre-Tensioning is required, it has to be specified by engineering.

Pre-tensioning information with the list of equipment requiring anchor bolt pre-tensioning to
be available.

Pre-Tensioning Sequence:

a) Before grouting all anchor bolts shall be in a “snug tight” condition to insure good contact
between mating surfaces.
b) Grout the base ring.
c) After 7 days re-tighten the bolts.
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Methods for Pre-Tensioning:

a) Torque wrench.
Only when is physically possible and practical (Bolt/Nut size, torque wrench/tool availability)
or Supplier (Engineering) request torque value for anchor bolt tightening

Torque value, calculated as follow or directly provided by supplier:

T= K*D*P
where:
T = Tightening torque, (kN-mm)
K = Torque coefficient, dimensionless (usually 0.2 for regular bolts)
D = bolt diameter (mm)
P = required bolt tensile load, (kN) - Provided by supplier or Engineering

b) Turn of Nut
Most commonly industry custom & practice, easiest to perform by a construction crew, and
demonstrated accurate result.
- Ensure that all anchor bolts are in a “snug tight” condition.
- Nuts marked with crayons or chalk to show the location in the “snug tight” condition
- All bolts additionally tightened by a nut rotation between 90° to 180°.

Note: If the bolt is to be retightened to compensate for any loss of pre-load, this method
requires that nuts be loosened, brought to a “Snug tight” condition, and then turned the
number of degrees above specified.

9.0 MOUNTING OF ACCESSORIES

1) Accessories shall be checked for quantity, damage, etc. to meet the requirement in the
manufacture's drawings and/or part list.
2) Sort and prepare the material such as insulation, platform, ladder, handrail, pipe support
and riser pipe.
3) Accessories shall, as a rule, be attached in the order from lower to upper parts of the
Vessel.
4) For assembly of the platforms, brackets shall be attached first, and all the bolts and nuts
shall be finally tightened after adjustment has been completed.
5) When staircase and ladder are mounted, attention shall be paid to the location of long bolt
holes and step bolts, considering by operating temperature. Further details shall conform to
the manufacture's drawings.
6) Accessories, if not fitted to the vessel, shall be mounted with necessary modifications with
approval of engineering and shall be handled through site engineering modification request.
7) As a rule, the accessories shall be mounted after centering of the vessel.
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8) Where such apparatus are to be installed at site, it shall be handled carefully to avoid
damage. Pre-assemble can be considered before erection, if applicable.
9) Attached piping and instruments shall be installed as per the manufacturer's instruction.
10) No welding, hammering etc. shall be carried out on the Equipment marked with PWHT or
any vessel in general, unless instructed and certified by manufacturer.
11) Contractor check the requirement of pre-dressing large vertical columns, in order to
reduce requirement of scaffolding for installation of insulation, piping, ladders and platforms.
Dressed load not to exceed design limits.

10.0 OTHER WORK

1) Electrical and instrumental work will be treated in other electrical and instrumental
Instruction.
2) Piping furnished by the equipment manufacture as part of the purchase order shall be
installed according to the equipment manufacture's drawing and piping instruction.
Desiccants or foreign materials shall be removed before pipe connection.
3) Temporary cap removal shall be strictly done as per drawing and manufacturer instruction
to avoid nozzle cutting instead of cap removal only.
4) Painting on the equipment which is described in equipment list shall be performed
according to the painting instruction.
5) Welding as part of the installation of the equipment furnished by the manufacture shall be
done according to technical manufacture's drawing and instructions and welding procedure.
6) Insulation on the equipment described in the equipment list shall be performed according
to the insulation instruction.

11.0 TOLERANCE TABLE FOR EQUIPMENT

Equipment Description Tolerance Remarks

Padding ±3mm At top of pad plate

Horizontal Elevation ±6mm At top of base plate
Vessel Location ±10mm At center of foundation
Levelling ±1mm/m (Max 6mm) At top of base plate or
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longitudinal shell / vessel length

edge
Padding ±3mm At top of pad plate
Elevation ±6mm At top of Equipment base plate
Location ±13mm At center of Foundation
Plumbing ±1mm/meter, On one of either side or centerline
Vertical
(1) max. 15mm of vertical
Vessel
(Height 15meter) Ex) 30 meter height column
(2) max. 15mm + 0.5mm/m tolerance is 22.5mm
for over 15meter =15mm + 7.5mm
(Height > 15meter) ((30m -15m) x 0.5mm/m)

Padding ±3mm At top of pad plate

Package
Level
items
Centering Manufacturer’s Instruction
Alignment

12.0 JOB SAFETY ANALYSIS

Ste Work Responsible

Hazard Control Measures
p Activity/Step Person

- Sufficient hardwood bearers, or equivalent,

have been provided for loading. HSE Engineer,
Transportation - Vehicle collapsing into a hole Supervisor,
1 from Laydown to (if the site isn’t adequately - The area for unloading is firm and level and Workers,
Site compacted) checked for load capacity and where
applicable or necessary, ground Drivers
computations.

- Supervisor to check weather forecast and

monitor on a continual basis and have a HSE Engineer,
- Weather makes erection hazardous
contingency plan in place in the event of Supervisor,
extreme weather.

Installation the - Topple of crane, Failure of crane. - Set up barrier and warning signs.
2
Equipment - Falling object - Inspected & certified Crane and lifting gear Supervisor,
- Improper loading and overloading. with color coded HSE Engineer,
Competent
- Unauthorized personnel setting up - Licensed & authorized operator & Crane to Rigger
cranes of slinging loads be confirmed.

- Personnel struck by moving plant - Rigging with communicating for crane by

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resulting from lack of attention or
being unable to hear due to
background noise.
- Sprains and strains from lifting and
handling lifting equipment.
- Simultaneous activities(Interface) of
other workers in area which
exposes additional danger of
workers being injured
3 Working at height - Falling from height
- Overloaded lifting or crane down
4 Lifting equipment
- Hook, Shackle with crane and break
- Equipment Lifting
Rev. 4 Page 16/20
qualified rigger only.
- Conducted TBM and sharing information with
direct involved workers.
- All workers involved in the work operation to
wear the approved PPE.
- Area around the working operation and the
lifting activity to weld to be properly
barricaded.
- No one will be allowed under suspended
unload.
- The lifting of vessel will be carried out in
accordance with the approval of the Rigging
Supervisors.
- Lifting will be closely supervised by
competent people in attendance.
- Assigned Competent Rigging Supervisor and
Riggers.
- Checking for PPE;
- Installing static line for attaching Safety
harness.
- Wearing Safety harness with Double Lanyard
- Anchor the hook with proper guard rail or life
line during working at height HSE Engineer,
Supervisor
- Ensure to proper access for working at height
- Installed fall protection for working at height
such like a guard rail or life line or additional
life line
- Use a ladder shall be required to install with a
fall arrestor
- Crane must be guaranteed with the weight
and in authorized area
- Do not work overloading or exceeding radius Supervisor,
capacity at any time.
Foreman,
- Lifting gear must frequently be checked Crane driver,
undamaged and passed the color changing
test through every month HSE Engineer
- Proper clap with valid certificate will be used
for lifting.
- To ensure following approved document and Supervisor,
drawing are in place and approved by
Foreman,
relevant parties prior to lifting operation
Crane driver,
- To conduct visual checks to ensure all loose
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materials are removed. HSE Engineer

- It is necessary to installed 2 tag line in order
to hold the equipment turbulence or rotating
- Rigger/signal man should be present and
wore luminous vest during lifting.

- No one is allowed to work under suspended

load with barricaded in lifting zone. Supervisor,

- Reflected light wire must be tied round Foreman,

- Crane area
craning area and it must be put the notice Crane driver,
- To ensure work area for the operation is free HSE Engineer
of obstruction and protruding hazard.

- Man-lift operator shall be trained and

- Unqualified personnel operation of
man-lift
- Struck By or Pinch Point
- Man-lift failures
- Personnel thrown from or ejected
from man-lift man-basket
- Tip-over of man-lift during
Man Lift / equipment operation
5 Operator
Man basket - Operation of man-lift during high
wind Conditions
- Striking ground personnel, or other
object that results in personnel
injury, property damage, or damage
to equipment
- Man-lift failure or occupied man lift
becoming disabled with personnel at
elevated positions
qualified.
- Personnel awareness of objects that could
strike the body or result in a whole body pinch
point type of injury
- Manufacturer’s operation manual shall be
present and followed. Conduct a daily
documented pre-use inspection
- All workers involved in the work operation to
wear the approved PPE and Safety harness
- Follow manufacturer’s operating
requirements for operating man-lifts during
windy conditions.
- Check the surrounding work area for hazards Supervisor
before utilizing the man lift do not exceed
manufacturer’s allowable side-slope and Foreman
grade requirements while operating man-lift.
Workers
- Keep All non-operating personnel away from
aerial lift during all driving and swing HSSE
operations. Engineer
- A dedicated support person shall be
assigned and operate man lift on the ground
- Man basket shall use by certified product
- Man basket is required to use a life line on
crane hook directly
- Man basket wire shall be used only for lifting
man basket, it should not to use other
purpose
- Man basket connected with certified O-ring
- Do not anchor the safety belt hook on Man
basket, only accepted anchoring position on
crane hook with separated additional wire
sling from man basket wire.
 PROJECT PROCEDURE

WORK METHOD STATEMENT

FOR STATIC EQUIPMENT INSTALLATION

KARBALA REFINERY
DOC. NO. : IONE-AA00-MS-MS-0002
Rev. 4 Page 18/20
PROJECT
Ref. FEED DOC. No. : N/A

- Man basket held by 2 tag line from each side

- While man-lift or man basket operation, no
one allowed come under operation.
- Do not exceed SWL(Safety working load) on
Man basket or man lift
- Man-lift must moving by boom down position

- Confined spaces should only be entered by

suitably trained people.
- Test the atmosphere for lack of oxygen,
flammable or toxic atmosphere.
- Re-test the atmosphere at regular intervals
- Personnel should inspect ladders prior to
their use and use safety equipment when
needed.
- Inspect areas where debris or slick surfaces
are present to prevent tripping and slipping
accidents. Good housekeeping
- Lack of Oxygen
- Arrange fan for ventilation. Supervisor,
- Flammable or toxic atmosphere
- Arrange watchmen for record all person in Foreman,
6 Confined Space - Heights and Ladders
and out Workers
- Slipping and Tripping potential
- Safety staff must stand by with gas detector
- Temperature extremes
- Inside of confined space shall use a halogen
type lamp only
- Ensure the sufficient oxygen (18.5% ~
23.5%)
- Arranged oxygen cylinder near from access
for emergency providing oxygen
- Workers must wearing proper PPE inside of
confined space
- While worker in/out must recorded on entry
sheet and working time is not more than
20minute with changed team members.

- It must be put in order when taking the hook

- Cable’s
down
Supervisor,
- Gathering the derrick and crane’s legs in to
- Crane truck
the beginning status Foreman,
7 Working finishing
Crane driver,
- Gathering the barrier and notice and do the
sanitation before leaning crane area HSE Engineer
- Around area
- Conducted housekeeping of tools and any
other material which used in work location
 PROJECT PROCEDURE

WORK METHOD STATEMENT

FOR STATIC EQUIPMENT INSTALLATION

KARBALA REFINERY
DOC. NO. : IONE-AA00-MS-MS-0002
Rev. 4 Page 19/20
PROJECT
Ref. FEED DOC. No. : N/A

13.0 RISK ASSESSMENT

Hazard Mitigation /
N Work Residu
Classifi Hazards Identified Impact Initial Risk Action By
o Activity/Step Control Measure al Risk
cation

R
H S E P E A R S P RF S P
F

- Sufficient hardwood bearers, or

equivalent, have been provided
- Vehicle collapsing HSE
for loading.
Transportation into a hole Engineer, L
Med - The area for unloading is firm
1 from Laydown (if the site isn’t 4 2 Supervisor, 1 1 o
ium and level and checked for load
to Site adequately Workers, w
capacity and where applicable Drivers
compacted)
or necessary, ground
computations.

- Supervisor to check weather

forecast and monitor on a HSE L
Installation the - Weather makes Med
2 2 3 continual basis and have a Engineer, 1 1 o
Equipment erection hazardous ium
contingency plan in place in the Supervisor w
event of extreme weather.

- Topple of crane, - Set up barrier and warning

Failure of crane. signs.
- Falling object - Licensed & authorized operator
- Improper loading to be confirmed.
and overloading. - Signaling to be done by
- Unauthorized experienced and trained person
personnel setting only.
up cranes of - All workers involved in the work
slinging loads operation to wear the approved
- Personnel struck PPE.
by moving plant - Area around the working Supervisor,
resulting from lack operation and the lifting activity HSE L
of attention or Med
3 3 to weld to be properly Engineer, 2 1 o
being unable to ium
barricaded. Component w
hear due to Rigger
background noise. - No one will be allowed under
suspended unload.
- Sprains and strains
from lifting and - The lifting of vessel will be
handling lifting carried out in accordance with
equipment. the approval of the Rigging
Supervisors.
- Simultaneous
activities(Interface) - Lifting will be closely
of other workers in supervised by competent
area which people in attendance.
exposes additional
danger of workers - Assigned Component Rigging
being injured Supervisor and Riggers.

- Checking for PPE; HSE L

Working at Med
3 - Falling from height 4 2 - Installing static line for Engineer, 1 1 o
height ium
attaching Safety harness. Supervisor w
 PROJECT PROCEDURE

WORK METHOD STATEMENT

FOR STATIC EQUIPMENT INSTALLATION

KARBALA REFINERY
DOC. NO. : IONE-AA00-MS-MS-0002
Rev. 4 Page 20/20
PROJECT
Ref. FEED DOC. No. : N/A

Hazard Mitigation /
N Work Residu
Classifi Hazards Identified Impact Initial Risk Action By
o Activity/Step Control Measure al Risk
cation

R
H S E P E A R S P RF S P
F

- Wearing Safety harness

- Crane must be guaranteed with

the weight and in authorized
area L
Lifting - Overloaded lifting Site
4 5 2 High 1 1 o
equipment or crane down - Do not work overloading or Engineer
w
exceeding radius capacity at
any time.

- Hooks must frequently be

checked undamaged and
passed the color changing test L
- Hook, Shackle with Med through every quarter
4 2 1 1 o
crane and break ium
- Proper clap with valid w
certificate will be used for
lifting.

- To ensure following approved

document and drawing are in
place and approved by relevant
parties prior to lifting operation
- To conduct visual checks to
ensure all loose materials are L
Med removed.
- Equipment Lifting 4 2 1 1 o
ium
- It is necessary to tie 2 ends in w
order to keep the equipment
not to move
- Rigger/signal man should be
present and wore luminous
vest during lifting.

- No one is allowed to work

under suspended load.
- Reflected light wire must be
L
Med tied round craning area and it
- Crane area 2 3 1 1 o
ium must be put the notice
w
- To ensure work area for the
operation is free of obstruction
and protruding hazard.