Method Statement for Tower Erection & Stringing within Switchyard METHOD STATEMENT @ DOCUMENT TITLE ACCESSIBILITY. coneibenrial [] ‘Approved By Ajendra Agarwal M, Sivaprosad ResrRicreD CI controueo CI UNCONTROLLED 6 Prepored By sunilOubey Sa 0 At Noyok Reviewed By Sushil Krishnan S.PDas G.$ Thokur GE T&D India Limited DATE NAME SIGNATURE Doc No: sHeeT | SH. END 1 1 This document is the exclusive property of GE T&D India Limited and shall not be used, copied or communicated to third parties without prior authorization Pago totMETHOD STATEMENT @ Amendment Sheet REVIND. PURPOSES OF THE MODIFICATION. first Issue with Derogation - Applicable Til 30" Nov 2017 Lifting & Stringing arrangement with Winch Machine TABLE OF CONTENTS 1.0 2.0 10 Purpose 2.0 Scope of Work 3.0 Definitions 40 Plant & Equipments 5.0 Safety 60 Receipt & Storage 7.0 Site Inspection 80 Planning & Pre-requisites 9.0 Installation Procedure 10.0 Responsibilities 110 Declaration Purpose 1.1 To ensure the Stringing Works, Lifting of Tower & Beom parts is executed Safely and 12 13 in accordance with EHS guidelines and contract requirement. To ensure implementation of approved Field Quality Plan, This Method Statement is Only for Stringing & Lifting works within Switchyard area and shail not be used for Transmission Line works or any works outside switchyard area Scope of Work 21 22 23 2m Material Hondiing ond Storage Inspection of Moteriat Stringing Works Lifting Works Page 20423.0 4.0 5.0 QD alee STATEMENT @ Definitions 31 GEPM GE Project Manager 32 GESM GE Site Manager 33 GESE GE Site Engineer 34 GESO GE Safety Officer 35 CSM Contractor Site Manager 36 CSO Contractor Safety Officer 37 CSE Contractor Site Engineer 38 RA Risk Assessment 39 FOP Field Quality Plan 3.10 EKD Erection Key Diagram Plant & Equipment 4l 42 43 4a 4s 46 ar 48 49 410 411 412 413 414 415 Safety 51 52 Motorised Winch Machine ISWL - 5 Ton or above} Tractor with Trolley - 01. No {not for pulling/pushing works) 4/2 Sheave Pulley (STon SWL ~ 02 Nos (with TPH Single Sheave Pulley (5Ton SWLI - 01 No (with TPI) Come Along Clamp (5 Ton SWL or Suitable for respective Conductor) D~ Shackle (5 Ton SWL) - 02 Nos {with TPH Wire Rope Pulley (Min 12mm of 1,75 Ton SWU (with TP) Spanners Set / Wrench Set Cable Drum Jack F15 / Hydra - 12 T/ 14 T (with trained Banksmen) LOTO Kit along with VAV Equipment Personal Protective Equipment IPPE -15,CE,EN standard only} Collective Protective Equipment (CPE -IS,CE,EN standard only) Rescue Kit ‘12mm Dia Wire Rope with TP All workforce and Engineers exposed to hazards related to "Work at height” shall have valid “Green Safety Poss’ & if exposed on Electrical Risk shall have valid "RED Safety Pass". All the workers involved in the job must have gone through induction training followed by the job specific training. Page sot 12METHOD STATEMENT @ 6.0 53 GESE shall ensure availabilty of Safety barriers, warning tape, signage, and watchman lif required), scaffolding / CPE's / test certificate of Winch Machine Hydra, Pulleys, D - Shackles, Wire Rope, Licence of Tractor Operator, Competency of Winch Machine Operator, etc. in coordination with GESO. 54 Physical verification of the lifting equipment and tools/tackles shall be ensured at site before commencement of the job. Tagging and color coding of the samme shall be ensured. 55 GESM shall conduct Risk Assessment & preparation of SOD jointly with GESO and shall ensure the communication of hazards & implementation of corrective actions to the Working Team. 5.6 Lifting plan shall be prepared and communicated. Lifting Permit to be taken. 5.7 Area beneath the suspended load shall be protected for restricting the access of other workers in the vicinity 58 Work Permit for Work at Height” & "Lifting Activity” shall be obtained prior to the activity commencement 59 Prior to the commencement of any activities, Tool Box Talk on the hazards related to an activity shall be delivered to workforce jointly by GESE & CSO. 5.10 Work shall be carried out in compliance with GE Operating Instructions, EHS & Project EHS Plan. 5.11 On-site emergency response plans shall be prepared and communicated with all the stake holders With the change of working condition, the procedure shall be amended and persons shall be trained accordingly. Receipt & Storage 6.1 Receiving & Storage of the material shall be done strictly as per Approved FOP. 62 Ensure that Insulator String / Long Rod is handled carefully and stored separately. 63 Check Clamp and Connectors received as per Approved EKD_ 64 Check the quantity of conductor received from Vendor, damages to drums /turns of conductor & conductor ends are sealed properly. 65 Ensure proper use of Equipment like Hydra / Crone shall be used for loading / unloading the Conductor Drum on / from to the trolley. 66 Old generation Hydra is a very dangerous equipment. It topples rapidly. Use it carefully with trained Banksmen only, No tandem lfting/shifting is allowed with it Try to use F15 crane. Page ot 12METHOD STATEMENT @ 7.0 8.0 67 68 69 6.10 Ensure that after loading the Conductor drum on Tractor Trolley, drum is tied properly to ensure No Toppling of the same. Ensure availability of Drum Jack at site for unwinding the conductor, Conductor Drum should always be rolled in the direction of arrow marked on the drum, Strictly follow the instructions given by the Supplier for unloading & handling of ony materia Maintain all records as per approved FOP and intimate to HO immediately for damages / defects, if any. Site Inspection 7 72 73 Before starting any Stringing Activity, carry out thorough inspection of site and ensure following; Ensure to make Lifting plan (Refer GE crane manual 2003), 7.1.1 Check for torque tightness of Gantry Structure / Support Structure, 7.1.2 Check all T&Ps as mentioned above are available and are in good state of condition to use. 7.13. Check and ensure the area is dry. Stringing ‘activity shall be avoided during rain or in wet conditions, 7.1.4 Check the around stability / compactness before using crane on it. 7.15 Check and ensure that anchoring points, if provided are firm to the ground, 7.1.6 In case of non-availability of anchoring point, anchoring shall be done with the Tower foundation and the foundation shall be checked for firmness before being used Before Starting any Lifting activity, check site and ensure following: 7.21 Check all T&Ps os mentioned above and are in Good state of condition and have valid TPI, if required, 7.2.2 Check and ensure anchoring points, if provided are firm to the ground. 7.2.3. In case of non-availability of anchoring point, anchoring shall be done with the Tower foundation and the foundotion shall be checked for firmness before being used, Specific checks to be carried out for below scenarios used for Lifting or Works: Planning & Pre-Requisites The following are the pre-requisites before start of Stringing / Lifting Activity. 81 Ensure the availability of approved Method Statements for the above activities, 82 HIRA & PTW for the above activities shall be jointly prepared by GESM, GESE, GESO & CSM and communicated to the workforce. Pogo of 12METHOD STATEMENT @ 83 Ensure, check and obtain necessary site clearance, 84 Ensure the availability of all Tools and tackles as Listed above and other material, 85. Ensure all Tools, required for Stringing / Lifting activity, are tested and certified by Approved Inspection Firms and necessaty certificates are available. 8.6 Ensure Lifting Plan and RA associated with work should be prepared in consultation with sag-tension chart for the said span prior to commencement of the work, jointly with GESM, GESO & CSM and is communicated to workforce. 87 Ensure all requisite Permits are obtained 88 Ensure availabilty of approved Sag - Tension Chart. Installation Procedure Stringing / Lifting activity shall be executed using ST Winch Machine with 12mm Dio Wire rope or Manual with 24mm Dia PP rope only. Do not use PP rope with Winch Machine. Keep a close eye on Pulley movement during operation. Standord pulley to be used. Colour coding to be done. GESM along with GESO & CESM shall jointly conclude for the best methodology to be adopted with necessary check points as detolled in each methodology, Before start of any stringing / lifting activity, maximum pull required for Stinging / Lifting shall be calculated w.t the load For Lifting works, below details are required to get maximum Pull required: 1. Wire rope to be used for Pulling ~ 122mm SWI of above Wire Rope ~ 2.5 Ton (Vertical Hitch) Max Length of Wire rope for the highest part of 765kV Gantry Tower (Section 4 / Peak) = (40Mx4 ~ ffor Double Sheave Pulley] + (50 ~ (Pulling Lengthil= 210M Weight of Wire rope - 0.7 Ko/Mtr Total weight of wire rope - 0.7 x 210 = 147Kgs 2. 2 Sheave Pulley with latch (5 Ton SWL)- 02 Nos 3. D-Shackle (5 Ton SWL} - 03 Nos 4. Wire Rope - 12mm for tying Derrick with the Tower Leg - 03 Nos at an equal distance ‘Note: 24mm Dia PP Rope with TP! to be used for manual erection with all barricading, etc. Page 6 of 12METHOD STATEMENT @ Maximum Pulling load including above Fabricated members and lifting accessories will be between 15 T to 2 T {To be calculated from BOM) Total Load = Line Pull x Angle Factor {@ 30Deg, Angle Factor is 193. @ 90Deg AF - 141, @ 120Deg AF - 1) Pull Required = Weight To be Lifted / Mechanical Advantage (Mechanical of 2 Sheave Pulley is FA) Calculate the load of each section prior erection and maximum load should not exceed 2 ‘Tons at any point of time. Pulling of the above assembly sections shall be done using Manual or Winch only. Use of Tractor/Hydra as pulling equipments strictly prohibited. Fix spacers as per specification/ drowing. Use horizontal ife ine (12mm Wire rope} during spacer fixing and jumpering / droppers fixing and if practical use MEWP for same activity Papo 70112METHOD STATEMENT @ ‘Typical Erection Methodology for Erection of 765KV Gantry Tower Section - 3 Section - 2 Section - 1 Erection of 765kV Gantry Tower is divided in various Parts as highlighted in the above drawing, ‘A, Erection of Section - 1 1. Erection of Section -1, shall be carried out using F-15 or similar equipment. All Lifting accessories and Lifting Equipment shall undergo valid Third-Party inspection certification. 2. Method Statement for Section -1 shall be similar to Method Statement used for erection of Low Height Equipment Lattice Structure. Page wot t2BE METHOD STATEMENT @ 8. Erection of Section - 2 1 For Erection of Section - 2 as highlighted in the above picture of Gantry Tower, Derrick shall be used. Detailed Load Calculation of Derrick and details of other Lifting Accessories ta be used for this are as mentioned below. Weight of Section - 2 shall be calculated as per 8OM without legs. Legs of this section shall be erected using Derrick separately. Once all legs are erected, assemble section - 2 each side separately, Main Members (with step bolts fitted on one of the members) of the bottom section are placed on foundation and cross bracing are assembled. Next section main members (with step bolts fitted on one of the members| are lifted one by one manually or with Winch machine arrangement, Remaining sections are erected in the same manner, C. For erection of balance Section - 3, follow the steps used for Erection of Section - 2. D. Erection of Section - 4 / Tower Peak or Cross Arm. 1. Weight of Fabricated members of above Tower Peak or Cross Arm varies between 13T to 15 Ton. All Lifting Accessories and Derrick as mentioned in Erection Methodology of Section ~ 2 shall remain same for the erection of Tower Peak / Cross. Maximum Pull required for the above section will be approx 1000 Kgs. Tower Peaks assembled on ground and lifted either manually or with Winch Machine. Erection Procedure for Gantry Beam For Erection of Gantry Beam, two sides of Beam are assembled on ground and lifted from both Gantry Tower with 2 Winch machines or manually using 2 Sheave Pulleys tied on Top of Gantry Tower. Page wotMETHOD STATEMENT @ Complete assembled one side of Beam shall be lifted from both sides parallelly to avoid any jerks. Proper co-ordination shall be maintained to ensure smooth operation. Procedure for Stringing works. to get maximum Pull required: In addition to the above detai's, additional detoi’s os mentioned below are required for stringing ‘works to calculate maximum Pull required, 1 2. 3. 4 5. Weight of String Hardware Gantry Span Length Weight of the Conductor No. of Conductor required for Stringing Weight of insulator String / Long Rod Insulator GESM/GEEE/GESO shall ensure that above details are within permissible limit as described above. Typical Picture for Winch Machine - ST ‘Typical Anchoring Arrangement of Winch Machine Pape 10 012METHOD STATEMENT @ 10.0 Responsibilities 10.1 10.2 103 10.4 GEPM/GESM will ensure that the necessary resources to implement the approved Method Statement have been allocated to the task, The GESM will ensure that the site preparation activities are conducted According to the approved Method Statement. The GEPM will ensure that the materials being used are in accordance to the Project Specifications, the approved Material Submittals. Itis the GESM and GESO responsibility to organize the work in « safe Manner to ensure that safety and protective equipment are being properly utilized. itis responsibilty of GE & SC staff to ensure that necessary action are initioted every time any deviation is observed and stop works in any Paget ot 12METHOD STATEMENT stage, if any deviation is observed wrt Method statement, RA & Lifting Plan. 11.0 Declaration by Site Execution Team (GE + Subcontractor) This is to certify that we have read the method statement completely and commit to comply it in full for safe and timely execution of respective activity Ais prepared ond shall be reviewed and communicated to the members of Working party as and when required prior to starting any related works Name of the authorized | Designation/Organization | Signature Date and person time Page 20112