Additional Sample Poster

Risk Assessment / Method Statement / Technical Description
Clients Name : SLTEC/SPSI, Calaca, Batangas

Task of Operation : DRY-OUT OF J Valves01and Ignition2019
August Ducts Unit 1
Project No. : O.1911991
Date : 01 August 2019
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TECHNICAL DESCRIPTION
METHOD STATEMENT
RISK ASSESSMENT
A STATEMENT OF INTENT OUR OBJECTIVES AND COMMITMENT TO HEALTH & SAFETY
We understand the importance of Health and Safety throughout our company, in our office
environment, factory and on site.
Our Directors and team give health and safety the same priority as other business objectives.
Over the last year we have looked at all of our company procedures and systems throughout our
organisation developing and improving all of our procedures from quality control to training.
Introducing changes and more structure where needed. We have paid special attention to its
Health and Safety throughout the company.
We have reviewed all the risks in every area of the company, and are introducing changes in
control measures where they were seen to be necessary thus developing a no blame culture
throughout our organisation.
We have endeavoured to encourage employees to report even the smallest of incidents, hazards
and accidents, so in their and our interest we could improve, implementing remedial measures to
cut down on hazards and risks that could potentially cause harm.
Throughout toolbox talks, safety meetings and training, we have communicated these findings to
all of our workforce, consulting all of our team on Health and Safety issues, involving them where
possible in a proactive, positive way.
We monitor daily our working conditions for our employees.
Through consultation instruction and training we have made all our team aware of their
responsibilities to Health and Safety for themselves and others and our responsibility to provide
them with safe systems of work as far as responsibility practicable.
Our Directors have encouraged co-operation from their employees with the basic objective to
develop effective relationships between employer and employee, encouraging participation from
them in matters regarding their development, mental and physical well-being.
Work can make a positive or negative contribution to an individual’s health. Both physical and
mental health may be affected if people are exposed to harm.
We have found, that if the workplace is safe with good welfare facilities, and if people are
interested and involved in their work, job satisfaction can increase and so can production for the
company.
Health and well-being can be a result for the employee. In return we have a happy, enthusiastic,
competent and committed team with a great performance record.
As time moves on so does the industry which is changing rapidly every day. Today, there is a much
greater emphasis on Health and Safety and Safety Management in the workplace. A greater
understanding we felt was required by us all to manage and understand Health and Safety to
develop the correct safety culture in our workforce.
We believe training is very important so that we have a competent qualified workforce.
We have a proactive strategy monitoring and evaluating our Health and Safety performance. We
have set goals and offer incentives to the team if they can meet targets we set out. We have
introduced safe systems to make all our team aware of their responsibilities for themselves and
others to be safe at the workplace as far as reasonably practicable to achieve excellence with our
Health and Safety Performance.
Occupational Health and Safety needs to be managed properly. Failure to do so might result in a
prosecution in a criminal court or claims for compensation in a civil court.
Accidents that result in personal injury obviously cause pain and suffering to the victim, family,
friends, colleagues and the company, suffering that could be avoided through instruction, training,
consultation, induction and supervision we can introduce a positive safe working culture for all.
As a company constantly strives to achieve excellence in all we do, from the manufacturing of
goods, design, workforce, management, technical abilities, professionalism and now Health and
Safety.
Yours sincerely
Marcia Heideliza Lopez Bernard Carpio

Director – Asia Pacific Technical Director – HWI Inc.
Task of Operation : DRY-OUT OF J Valves and Ignition Ducts Unit 1
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CFB Dry Out
Technical Description
and
PROCEDURE
Task of Operation : DRY-OUT OF J Valves and Ignition Ducts unit 1
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CFB Boiler Dry Out
Where a component of a process is to be subjected to excessive temperatures during operation, then

they are usually lined with Refractory bricks or cements.
The Refractory linings used will hold an amount of water and if the process switched on using the
process burners then the water would expand and cause the linings to explode off the furnace wall.
To prevent this from happening, the company which produces the refractory lining will recommend
rate of temperature increase during commissioning, that will remove the water without any damage
occurring. This Rate of increase is identified within a DRY OUT CYCLE.
The service is achieved by the strategic placement of High Velocity burners into the furnace which
operate by producing excessive hot air as opposed to a direct flame. The aforementioned is achieved
by using a higher ratio of air input than fuel.
On this project Hotwork International shall use Oil Burner Units.
Made by : Approved by : Accepted by :
Name: Bernard Carpio Name: Marcia Lopez Name: ______________________
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Schedule
Arrival of the Hotwork equipment.

Arrival of Project Engineer
Arrival of complete Hotwork team
Day 1 to Day 3
Orientation of Hotwork team
Uploading and putting equipment on place/levels.
Area inspection.
Burner Installation and test equipment.
Day 4 till finish

Start the Burners.
Increase temperature following the dry out curve, until 62 hours
Temperature measurement
Adjusting fire power.
Last Days on site ….

Dismantle equipment and loading to container
Cleaning up and post dry out inspection
Travelling back of Hotwork equipment and Engineers
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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IMPORTANT PREPARATION
The client should prepare the following before arrival of Hotwork engineers:
a. Supply of power to HWI Electrical Distribution Box

Each Ventilator has a capacity of 15kW and 7.5kW, motors are direct starting and require
individual protection by circuit breaker 63A. Hotwork Ventilators are equipped with 63A CEE
Plugs. Please refer to section Connection specification for more information.
b. Fuel Oil supply
The client has to supply sufficient fuel on a 24h, 7 days a week basis. The line should be as
discussed.
c. Openings for High Velocity Burners
Openings should be min. 220x220mm but better 400x400mm allowing alteration of the burner
angle.
The client must provide sufficient ceramic fibre blanket and isolation bricks to close the opening
around the burner.
d. Supply of 220V Connection.
To be used for HWI recorder and temporary lighting on all HWI working areas.
e. Preparation and cleaning
The areas to be dry out should undergo the usual preparation.
f. Supply of Compressed Air.
Compressed air connection must be provided near the burners area.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Responsibilities
Operation Description Responsibility Date
Fire Extinguisher Total 6 sets of extinguishers in a range of 20m HWI

from the working position for each level
Compressed Air Dry compressed air at 7bar, 250cfm in a range SLTEC
of 5m to the working position
Fuel Oil Supply of diesel fuel and connection from client SLTEC
take off point.
Electric connection Connection of the electric distribution boards HWI
of Hotwork International and Cables till the
main source
Electric distribution Ventilators, please refer to 7. Electrical HWI
boards equipment
Supply of the electric Cables between the main source and HWI
cables Hotwork's distribution board
Lighting Illumination of working areas SPSI
Cutting / Weld Hotwork will supply the tools and equipment’s HWI
equipment
Fork Lift Truck/ Elevator To unload the equipment from the truck and SPSI/SLTEC
or Hoist lifting on level positions on the boiler area
Rain Protection for HWI Provision of rain protection or covering for HWI SPSI
Equipment equipment and personnel
Safety PPE’s HWI will provide PPE’s for its personnel and HWI
safety signages and warnings
Hard Barricade Client should provide hard barricade around SPSI
designated areas
Safety and Security Introduction into plants health and safety plan, SLTEC
Induction site organisation etc.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Unloading the Unloading of all equipment’s and placing it on SPSI/HWI

equipment position / levels
Installation of the Dry Hotwork technicians will install all High Velocity HWI
Out equipment Burner, electrics and fuel supply under a final
Test
Installation of the Hotwork technicians will install temporary HWI
Thermocouples thermocouples to supervise temperature
throughout the dry out operation.
J valve, Ignition duct Dry Hotwork technicians will do the actual drying HWI
Out out operation, following the client’s curve and
specification (as discussed and agreed)
Remove Burners Removing step by step the Hotwork burners HWI
after the cooldown
Dismantling all Hotwork technicians will dismantle all HWI
equipment & accessories equipment and conduct clearing and cleaning
Loading of equipment on HWI
the Truck for return
shipment
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Resources, Connections, Points of Take Over (POT)

J valves and Ignition Ducts Dry out
Electrical Power: Ventilators

Each Ventilator will be connected to HWI’s distribution board. Each board
can be connected with 6 Ventilators. Each HWI distribution board will be
tie in to the generator terminal. Please refer to 7. Electrical Equipment for
more Information.
Attention! Ventilators start direct!
Recorder / Computer Control System
220V extension board for our recorder and control Instruments at our
temporary control base.
Compressed Air: Main source for compressed is from client.
Fuel: High Velocity Burners

Each Burner has a max. Flow of up to 187l/h fuel oil. The fuel oil line will be
supplied and installed by Hotwork. The client will supply the connections
from the main burner fuel skid to connect Hotwork to equipment. Can be
connected on 2 locations.
Oil return will be established at burner main skid. No return line is required
for HWI temporary line.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Connection specifications
Oil Connection
3/4" outside
thread connection
Compressed Air connection
Electric CEE Plugs

Please refer to 7. Electrical Equipment:
16A CEE Plugs and Sockets 5 Pins
32A CEE Plugs and Sockets5 Pins
3 pins for 220V for lighting connection
Distribution boards have to be connected
directly.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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High Velocity Burners
Our special heat-up technology is based on the use of Hotwork International High Velocity Burners
operating on an excess air basis, which have been especially developed for the heat up of all types and
sizes of boilers. The system has been developed to ensure that precise temperature control of hot gas
emissions from the burner can be effected at all stages between 60°C and 1300°C, simultaneously
eliminating the potentiality of hot-spots or stagnant areas within the furnace.
Our Equipment:
• Uses high volumes of high velocity (emission speed ca. 180 metres/second) hot gases which permits
a positive vessel pressure to be established and maintained and assists in assuring good temperatures
during the dry out.
• The velocity of the hot gas emissions simultaneously promotes a turbulent atmosphere providing
uniform temperature distribution throughout the boiler.
• Combustion air fans are silenced to 83 dba.
• Our equipment complies with DIN-EN 746-2 specifications
• Our Combustion Air Fans are under VDE controls.
• Safety-Shot Off valves are in use
• Ignition and flame supervision system are used in compliance with DIN-EN 746-2 specifications
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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High Velocity Burners – Oil fired
Our burners have a max. capacity of 187 l/h fuel oil EL and max 4.500 Nm³/h combustion air as well as 4 Nm3/h
atomising air with 3 bar. Flames supervision by UV-cells. In case of flame failure, oil supply will be stopped
within 2 s by safety shut-off electro valve.
Pos. 6 Combustion Air Fan
current consumption: 15 kW, directly starting
voltage: 220/440 V, 3 phases, neutral, earth, 63 A
dimensions: 800 x 1000 x 1320
(L x W x H), installed on wheels
weight: 460 kg
sound absorbing: 83 dba
Pos. 7 High Velocity Burner Chambers for Fuel-Oil
Length: 2,0 m
Shape: cylindrical
Max. Diameter: 380 mm

Cone Diameter: 160 x 160 mm or 210 x 210 mm
Weight: 40 kg
Connections at the Burner: Oil 1/2" Quick Acting coupling
Atomising Air 3/4" claw coupling
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Thermocouple Recorder
Hotwork shall record temperatures using a paperless recorder 30 channel. Calibration certificate for recorder
and certification of conformity from the manufacturer for thermocouple and cables shall be submitted.
Thermocouples and Cables
Hotwork-INTERNATIONAL Ni-Cr-Ni-thermocouples have a 3,2 mm diameter.
Stainless Steel Thermocouple

Type : K
Material : Stainless Steel
Diameter: 3.2mm
Length : 2m long
Connection : Type “K” TC Plug
Wire TC
As previously identified, where access is not possible then
Hotwork shall install Wire TC / Type "K" into the unit at
specific points to record the temperatures.Thermocouple wire
Type K nickel chrome/nickel aluminium thermocouple wire,
insulated with high temperature glass braid. Recommended
maximum temperature 800oC.A consumable item, which is
used to convert the thermal energy at the hot junction of the
thermocouple to an electrical mV signal which can then be
used by
temperature control and recording instruments to accurately
record temperatures
Conforms to:
BS EN 60584-1: 1996 part 4
BS EN 60584-2: 1993 class 1
And ANSI-MC96
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Compensating Cable - Type "K"

Compensating cable is attached to the outlet socket of a
Type "K" Thermocouple and carries the signal to the
Type : "K"
Material : PVC Coated RED or GREEN
Diameter : 3mm
Length : 25Mtrs Long
Connections : Type "K" TC Plug & Socket
Connections : Type "K" TC Plug & Socket
Stainless wire shall be prepared by

HWI in case we need to install in
inaccessible areas.
Locations for the installation of Thermocouples can only be identified by taking into account the
locations and sizes of openings available in the unit.
Further issues taken into account are the shape and dimensions of off ducts and components which
are to be included in the Dry Out.
Client will give sufficient openings on existing instrument nozzles for thermocouples.
Type "K" Thermocouples or Type "K" Thermocouple Wire will be used into. It has been
decided that Thermocouples & Thermocouple Wires shall be installed as within the following
locations:
J valve A 3 TC’s
J valve B 3 TC’s
Ignition duct A 5 TC’s
Ignition duct B 5 TC’s
-------------------------------------------
TOTAL- 16 TC’s Possible adjustment of location and
quantity of thermocouple to be added as
per actual site condition during
preparation. Can be added by suppliers
recommendation.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Bulkhead
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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A bulkhead shall be required to install into the unit as identified

on the below drawing
Notes:
Flue Gases : Flue gases contain soot and are humid – therefore
they should not be conducted through the filter system
Hotwork is not responsible for any pollution caused by derivate

flue gas.
Cooling : The client is responsible for the cooling of all parts

and or units which cannot resist the maximum temperature during the
dry out.
Possibility of fumes and heat can come out in the furnace area. It
is advisable that no activity on the furnace area going to the
inlet and outlet.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Electric Equipment
Regular checks are made to ensure there are no loose wires or damaged components.
All electrical equipment’s are checked and tested. Any hired electrical equipment must
be delivered with a guide to its safe use. All site workers are familiar with the safe use
and working practices using electrical equipment. The main Power supply from the
clients switch board have to be connected by a certified electrician for high voltage, the
clients or its subcontractors Risk assessment and method statement applies.
The equipment which may be used on site includes:
Distribution Boards
• Electrical Distribution boards for Ventilators 7.5kW-15kW; CEE sockets
6 x 63A ( about 32-35A during operation )
Total load 250A, cable dimension suggested: 70mm² ; IP54
460V, 3phase, earth
Ventilators
• 7.5 kW; 16A; 440/380V/3Phase, earth; 60/50Hz; CEE Plugs
• 15 kW; 32A; 440/380V/3Phase, earth; 60/50Hz; CEE Plugs
Extension and Main Power Cables

• 16A; CEE Plugs; 5m long
Welds
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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• Electric Welds for electrodes; 5-140A; 220V or 440V; up to 32A; CEE Plugs
Grinders
• Different sizes for stones/bricks and steel; 220V; 16A; 50Hz
Tools/Lightning/Miscellaneous
• Different tools at 220V to be connected to our electrical board
• Lighting up to 2kW per unit
• If required other miscellaneous tools and system will be used
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Setting-Up
All Setting up and installation of the equipment will be done by Hotwork engineers.
Upon arrival of the Hotwork truck or its logistic partner, the Client should provide a fork lift with driver
to unload and transport the material near by the furnace.
Before equipment assembly, the Hotwork project leader will discuss with client exactly how they intend
to make the installation and verify that all the necessary requirements are available. At this point the
client should also inform the Hotwork about safety regulations on site
An initial inspection will be made to evaluate the actual situation of the boiler and the accessibility.
The openings will be approved or modifications might be necessary.
The ventilators are installed within 3 m from the burner.
Burners are suspended with chains from the metal work or held by supports.
The burners are then connected by Hotwork engineers to the oil take off points.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Burner Installation
Locations for the installation of Burners can only be identified by taking into account the locations
and sizes of openings available in the unit.
Further issues taken into account are the shape and dimensions of off ducts and components which
are to be included in the Dry Out.
Following review & discussions with site and identification that 6 x Burners will be adequate for
the purpose. It has been decided that burners shall be installed as within the following installation
positions.
It is usual for a client to require that a Target Temperature is achieved throughout the unit. But where
shape, size and burner openings dictate the flow of air and heat then it is not unusual for
temperatures lower in the unit to be driven to slightly higher temperatures in order to achieve the
required temperatures throughout. Where the situation lends itself to this being a requirement then
the Client will usually be requested to confirm the acceptability of this and max temperatures to
which this can be driven.
For one(1) unit:
J valve A 1 or 2 burners
J valve B 1 or 2 burners
Ignition Duct A 1 burner
Ignition Duct B 1 burner
-----------------------
TOTAL 6 burners
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Dry Out Curve
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Fuel Oil
Client Scope – Provide diesel fuel to complete the dry out. The following is an estimation of fuel
requirements:
Estimated fuel consumption for J-Valves A and B
Estimated fuel consumption for Ignition Ducts

Notes. Fuel consumption forecasts should only be used as a guideline.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Method Statement
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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1. Site Conditions and Organization
Hotwork International Inc is able to overcome most problems relating to site conditions.
We have a thorough system for identifying possible hazards and introducing controls to
reduce the risk of injury. We might require mechanical handling during installation on
specific structures. Should the need arise, due to working in the close proximity of other
contractors, to use mechanical handling the relevant precautions have been allowed for.
Areas of Public Access will generate a certain public interest, but during the installation,
operation and dismantle period, in Hotwork working area, there should be no access for
the general public and usual site rules will apply. General means, no working as welding,
grinding and any metal worker closer then 10m to Hotwork equipment is allowed.
Adequate security must be maintained by the client, to prevent theft, abuse or damage
to Hotwork equipment.
Usually a site inspection has been done prior to job execution. All discussed points for
site preparation have to be fulfilled. Please refer to operational responsibilities. Anyway,
the client has to provide clean and free access to the building, CFB Boiler and installation
position of equipment. The Boiler condition has to be ready to start installation and all
required points of take over should be ready. Keep electric welding machine and oxygen
cutting torch ready stand by if required. Our normal Terms and Conditions apply.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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1.1. Organizational Structure – Company
Department Hotwork International AG Hotwork International Inc. HWI Contact No.

MANAGEMENT Benjamin Koester Marcia Heideliza N. Lopez +63 917 546 8189
ENG’G/TECHNICAL Marcelo Pires Bernard E. Carpio +63 9190892957
FINANCE/ACCOUNTING Eva Wuillemin Francis S. Arcilla +63 977 154 3092
OPERATIONS Gyeong-Jin Yoon Franco Antonio D. Arcilla +63 998 970 7624
SALES Rui Fontes Giovanni P. Villahermosa +63 967 588 9950
EQPT SUPPLY & LOGISTICS Ernesto Vinagre Glenn Mark Anthony B. Lopez +63 977 109 6659
EMPLOYEES: Less than 50 fixed emp

Head-Office: Asia Pacific Office:
HOTWORK INTERNATIONAL AG HOTWORK INTERNATIONAL, INC.
ROMANSHORNERSTRASSE 123 HUMAY-HUMAY,
9322 EGNACH SWITZERLAND LAPU-LAPU CITY, CEBU PHILIPPINES
1.2. Project Structure

Name Position Function
Jeefriel Sarte Project Manager Site Responsible
Nipsey Carpio Project Supervisor Supervisor
Lloyd Posadas Technician Electrician
Glenn Acierto Technician Technician
Nelson Dugan Technician Technician
Kyle Delarmente Technician Technician
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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1.3. Working Hours
Operation Period Working Shifts

Hours/Day
Arrival of HWI team
Orientation and Site 1st day 8 hours 08:00 – 17:00
Assessment
Installation 2nd to 3rd day 8 hours 08:00 – 17:00
J Valves and Ignition Ducts Dry 4th to 6th day 12 hours/shift 08:00 – 20:00
Out (24 hours op.) 20:00 – 08:00
Dismantling of Equipment/ 7th day 8 hours 08:00 – 17:00
Post Inspection
Travelling of HWI Team
1.4. Entry
Each technician will present themselves at the site entrance and undergo the usual
formalities and - if required - the safety induction, provided by the client or it’s
subcontracted responsible to receive entry permission.
1.5. Circulation, Parking

The Hotwork International technicians will respect the circulating rules on site and
will only park the vehicles in the designated parking areas.
1.6. Site Container

Hotwork International will not have bungalows or site container. The client will
provide access toilets/washrooms and resting facilities , if necessary.
1.7. Equipment
Hotwork International will provide the equipment described within the Risk
Assessment, Method Statement and Technical description on hand. All parts of the
equipment delivered to site are listed in the delivery
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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1.8. Working Area

Around the CFB Boiler.
2. Loading / Unloading
The use of heavy plant machinery required for such tasks as the loading and unloading
of materials and equipment, will give rise to certain obvious hazards: load shift/load
collapse/falling objects etc. All persons working on behalf of Hotwork International Inc.,
to operate such machinery, are qualified, and appointed to do so. All works should use
a Banks man to assist the driver. Equipment’s delivered on a truck or in a container are
secured safely. All forklifts and cranes are supplied by the client, as specified and initially
agreed. Automatically their Risk Assessment and Method Statement applies for the
operation.
The equipment is loaded on the lorry under supervision of the lorry driver and foreman.
Carriage to and from the lorry is to be, as much as possible, by forklift truck, trolley truck
and sack trolley. The driver is responsible for the strapping and tying down of the load
in thus its security.
3. Method Statement - Procedure
SEQUENCE OF OPERATIONS – Electrical Setup
All distribution boards are placed in position.

1.
Hotwork International will supply the main cables to connect the main board. The actual
2. connection both sides has to be done by HWI certified electrician.
The client should have cable trays available or any kind of holder / support to allow the cables
3. installation out of the way of main traffic.
Cables will be pulled manually and secured with straps.
4.
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SEQUENCE OF OPERATIONS – High Velocity Burner with Light Oil
Each Oil Burner is installed with a light oil supply and compressed air supply. The compressed air
1. supply has an adjustable pressure reducer. The light oil amount has a special designed needle
valve to adjust the flow.
Oil flexible hoses are made especially for the use with shut-off couplings to prevent any leakage.
2.
The main Oil line – supplied be the client – should be fitted with a return line and a pressure
3. stabiliser to prevent pressure fluctuation during the operation.
It is necessary to use a special designed ignition system. The Burner will be ignited with the
4. smallest amount of light oil. During its start up the technician will manually check the flame and
adjust the atomisation – light oil compressed air relation.
All temperature adjustments are made in the same way to assure a proper atomisation of oil.
5. This have to be checked during all temperature stages manually.
Protective function test shall be done prior to burner operation
6.
SEQUENCE OF OPERATIONS Dry out
After all equipment’s have been unloaded off the lorry, our team will place ventilators, burners,
1. pressure regulators and all flexible connections on the agreed burner position.
Flexible oil hoses will be distributed to each burner position and connected with the Safety-Shut
2. Off valves.
Burners will be mounted with front nozzles and shifted into position and fixed with double
3. chains or burner stands.
The Boiler openings around the burner has to be closed with ceramic fibre wool or isolations
4. bricks airtight.
Burners will be connected with combustion air flexible, electricity for burner control and oil
5. hose. Ventilators will be connected to the distribution board.
The distribution board and cables to the clients switch board have to be connected from the
6. client’s electrician, all systems and ventilators will be tested for rotation.
Thermocouples will be installed on the defined position. Extension cables will be connected till
Hotwork Internationals recorder and tested.
7.
Thermocouple
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Ventilators have been checked for rotation and Burners for ignition, flame supervision and safety
8. valves for operation. Fuel lines are bleed off air until the burner.
The Team leader will bleed the oil line till the shutoff valve and oil burner, afterwards the system
9. is ready for ignition.
To start the burner a small combustion air flow is required. After detecting the flow, the pilot
10. flame can be ignited manually. The pilot can be kept in operation until all burners has been
started.
Afterwards the combustion air amount can be increased to supply a positive furnace pressure.
11. To increase the temperature, the main flame will be ignited.
If required the combustion air fan is equipped with a silencer / filter. If required the filter has to
12. be changed during operation.
The Thermocouple reading is made contentiously during the complete Drying out. The recording
13. is made on computer control system or recorder. Beside hourly logs will be taken and reported
manually.
If the temperature does not comply with the required temperature curve, manual adjustments
14. will be taken on the burner fuel supply.
In case of flame failure or electric failure the safety valves will stop the fuel supply in less then 2
seconds. On bigger boilers it might be that the temporary control area of our team is too far
15.
away to see the failure. Anyway the temperature drop will show in a very short time ( a
continuous drop of a few °C ).
Checks will be made on the burner / ventilator and the team member will ignite the burner again
16. as described above.
4. Adverse weather conditions
In very strong winds or stormy weather, it may be necessary to cease or delay the
installation outside the building for safety reasons. Likewise, light or heavy rain may
create a danger to personal, equipment and machinery. The client have to provide
sufficient clearing of the affected area. Regular checks are made with the meteorological
office to avoid, so far as reasonably practicable, adverse weather conditions. All
Hotwork International team / project leaders have the authority to make such decisions,
as they deem appropriate and necessary, with regard to the erection because of unsafe
situations arising from adverse weather conditions.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Page : 32 of 44
5. Personal safety clothing, tools and equipment
Personal protective and safety clothing

Hotwork International Inc. must be informed of any special requirements!
The following P.P.E. will be worn:

5.1. Hard Hats
5.2. Hi-Visibility vest or gray Jacket
5.3. Protective Footwear
5.4. Overalls
5.5. Gloves – Where the risk of injury or greasy work is present
5.6. Ear protection – Where Noise is present
5.7. Eye protection. Use clear glasses. Dark glasses not allowed. – Where risk of eye damage
is present
5.8. Breathing protection – Where dust is present
5.9. Safety Harness – When working over 1.8m
5.10. Kevlar Gloves – When working in hot conditions
5.11. Kevlar and high Temp. clothing – When working in very hot conditions
Foot Hearing Safety Hand Protective Breathing

Protection Protection glasses Protection Clothing Protection
Personal Equipment
Sufficient, suitable, equipment in good conditions must be supplied to allow the job to be done safely.
All equipment must be checked and / or serviced before it leaves the depot. Faulty equipment, including
ladders and steps must not be delivered on site.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Page : 33 of 44
Personal Tools
The correct tools for the job must be provided, and they must be used in the correct manner. Each
employee is personally responsible to keep its tools in a good condition. Lost and faulty tools have to be
replaced individually.
Regular checks are made within the depot by the designated team or project leader.
First Aid
A First Aid Kit should always be available on site. On larger sites this could be in the site office but on
smaller sites it may be more practical to place a kit permanently in the team leader’s car or lorry as
appropriate. Measures must be also taken to ensure that the emergency services can be alerted if
required.
Anyway for bigger injuries, the client have to supply emergency assistance and First Aid in each factory.
6. Allocated Equipment conformance certificate
This is to certify that all equipment issued to the referenced project has been subjected to
Maintenance / Testing / Calibration in accordance with the requirements of Hotwork International
Inc Safety and Quality Management Procedures.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Page : 34 of 44
Risk Assessment
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Page : 35 of 44
Risk Assessment
Task for Operation DRY-OUT OF J Valves and Ignition Ducts
Client Name SLTEC/SPSI
Clients Address / Site SLTEC, Calaca, Batangas
Assessors Name Bernard Carpio

Date of Assessment 01 August 2019
Equipment to be used Forklifts, Crane (if necessary), Welding Machine,

Grinder, Ventilator, Burner
Working Environment CFB Boiler Area

J valve, Ignition duct, Furnace
Hazards Welding, Grinding, working in heights
Safety Equipment to be used PPE, hard hats, gloves, hi-viz clothing, goggles,
safety footwear, Safety harness, protection
clothing
Experience of involved employees All staff are experienced and aware of the
involved risks. Only qualified personnel are
allowed to operate the equipment.
Employees especially at risk New persons, persons with medical condition
Non Employees who may be at risk Clients staff, other contractors, visitors, general
public.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Task of Operation : DRY-OUT OF J Valves and Ignition Ducts Unit 1
Page : 36 of 44
L - Likelihood Rating (1-5) S - Severity Rating (1-5) RM - Risk Magnitude (LxS)
1-6: Low Risk Magnitude 7-12: Medium Risk Magnitude 13-25: High Risk Magnitude
Process/ Hazard Residual Risk

Activity/ Additional Controls
Hazard Effect Uncontrolled Risk Existing Controls Existing Risk
Workplace
L S RM Low, Medium L S RM Low, Medium Required Low, Medium
Factor
or High or High or High
Only certified
personnel to drive any
vehicle around site.
All driving riles to be
Moving vehicles Cuts, bruising, broken adhered to. Use
2 2 4 Low 1 1 1 Low
around site bones Banksman to escort
when positioning
vehicle during works.
All staff to wear HI-
VIZ
Ensure good house
Cuts, bruising, broken
Slips Trips and Falls 2 2 4 Low keeping, Tidy site as 1 1 1 Low
bones
work progress
Ensure all equipment
on platforms is secure
at all the times. Ensure
General Cuts, bruising, broken
hazard signs are
Falling Objects bones, possible head 2 2 4 Low 1 2 2 Low
presented or area
injuries
underneath is closed.
Ensure hard hats war
worn all the times.
Exclude public from
site all visitors to be
escorted in specified
Cuts, bruising, broken
Site Public access 2 2 4 Low corridors or off the 2 1 2 Low
bones
workplace. Apply
barriers or corridor off
work place.
Check weather
Exposure, cuts,
forecast, stop outside
Weather bruising, broken 2 2 4 Low 1 1 1 Low
working if not in
bones, injuries
condition.
Page : 37 of 44
All materials /
equipment used meet
current government
specifications of fire
Burns, Smoke
Fire 3 1 3 Low redundancy. Use PPE 1 1 1 Low
inhalation, Death
specified in point 6.
Personal safety
clothing, tools and
equipment.
Ensure only trained
personnel use
equipment’s in height,
ensure safety harness
is worn and lanyard is
fastened and anchored.
Cuts, bruising, broken Ensure Banksman in
Working at height 2 4 8 Medium 1 1 1 Low
bones, possible death sight and area is clear
of stuff. Collective
protection
(scaffolding, stairs,
and guards) must be
provided before the
use of harness.
Ensure only trained
and certified personnel
General connects electrical
equipment. Respect
and meet government
specifications. Ensure
power off during
Electric shock, burns,
Electrics 2 4 8 Medium work. Check all 2 1 2 Low
possible death
electric cables and
equipment. Client has
to provide electric
connection between
their EDB and
Hotwork machines or
its EDB.
Certified personnel to
Personal Injury, Burns use welder, safe work
Welds 2 2 4 Low 1 1 1 Low
and fume inhalation procedure, wearing
PPE, manual handling
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Page : 38 of 44
Pro check: welding,

power cables, correct
Eye sight damage –
filter for the task,
welding flash 2 2 4 Low 1 1 1 Low
correct shade welding
Faulty equipment
lens, adjust shade
setting
Remove combustible
materials such as
flammable liquids,
rags, flammables
Potential fire hazards 2 2 4 Low units, long dry grass 1 1 1 Low
when working outside.
Provide fire
extinguisher close to
the work place.
Ensure any person in
the vicinity has their
eye protection and
Eye injuries to others 2 2 4 Low welding masks. 1 1 1 Low
Provide physical
barriers (panels or
canvas).
Ensure the correct
electrode in use,
Damage to equipment connect earth lead, do
2 1 2 Low 1 1 1 Low
being welded not work in wet areas,
use PPE specified in
point 6.
Protect welding /
power cables. Check
Electrical hazard 2 2 4 Low all cables and machine 1 1 1 Low
and use only if in good
condition.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Page : 39 of 44
Electrical test
equipment will be
insulated and
calibrated. All circuits
to be worked on will
be treated as live until
verified dead. There
are no exceptions.
Live work is only to
be carried out by
authorised electricians
1 4 4 Low under direct 1 2 2 Low
supervision. Don’t
Electrocution remove protection
Electrical Work Up to
Electrical Burns from equipment.
415V
Fire Assure personal
protection. Cables
using double
protection insulation.
All equipment
General equipped with
differential circuit
breaker 30mA.
Adequate PPE and
2 2 4 Low first are made 1 1 1 Low
available.
All persons are
1 2 2 Low qualified, competent 1 1 1 Low
and certified.
Comply with
regulations for
electricity at work,
2 2 4 Low equipment manuals 1 2 2 Low
and regulations.
General Electrical Electrocution, Company Health and
Equipment Electrical Burns, Fire safety policies.
Disconnect all panels
from power supply.
1 2 2 Low Display Warnings. 1 1 1 Low
Keep records of
maintenance.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Page : 40 of 44
Operatives to be
Falls from height; back experienced, good
strain; eye injuries, 2 2 4 Low working practices with 1 1 1 Low
minor injuries tools. Pre-Planning to
Pipe Work Installation ensure access.
Reasonable lightning,
Minor injuries, back protect skin and eyes,
strain
1 2 2 Low
two operators required
1 1 1 Low
for pipes over 4m.
Assure all tools are
Follow erection secured (lanyard or use
sequence on hangers. toolbox. If necessary
2 1 2 Low 1 2 2 Low
Use lifting equipment scaffold and platforms
Back strain, sealants where required. with guard rails will be
( lungs, eye, skin ). provided.
General Ductwork Installation
Fall objects Access to each work
Fall from height area should be safe
and suitable for Assure nobody is below
2 2 4 Low 1 1 1 Low
movement of the the installation position.
ductwork.
Wear PPE.
Contact with Isolate and shut off the
electricity, 2 2 4 Low ventilator. Check all 1 2 2 Low
electrocution switches.
Wait till rotation stops
Work with Ventilators completely, Isolate
Contact with rotating system. Never remove
2 2 4 Low 1 2 2 Low
parts. Noise. protection of rotating
equipment or other
movable parts.
Visually examination
for any undue noise,
vibration or
Contact with rotating
General Work with Ventilators 2 2 4 Low overheating, check for 1 1 1 Low
parts
grid. Check that motor
ventilation airways is
clean.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Page : 41 of 44
Certified personal to
use grinder, safe work
procedure, wearing
PPE, manual handling
Personal Injury, burns,
grind not in direction
fume inhalation, 2 1 2 Low 1 1 1 Low
of furnace or
Projected particles
flammable. Use face
shield. Provide panels
around working area,
Grinding avoid projection.
Follow procedure,
wear PPE, use tools
Cuts, bruising 2 2 4 Low 1 2 2 Low
and work benches if
required.
Protect cables from
cuts. Check cables
Electrical hazard 1 2 2 Low before use. Remove all 1 1 1 Low
damaged equipment
from site.
Following the
instruction and
wearing PPE. Only
Damage to the body personal with training
Using the Fork Lift 1 3 3 Low 1 3 3 Low
Personal injury can use fork lifts.
Following FPS 04
Material mechanical handling
unloading of cargo.
Follow Instruction.
Respect the charge
Placing equipment Equipment Fall onto
1 1 1 Low capacity of the 1 1 1 Low
around the furnace man
equipment. Assure all
the cargo is secured.
Work Carefully, wear
PPE and hot work PPE
Working in Heights Equipment or man Fall 2 4 8 Medium 1 4 4 Low
Work only in
restricted areas. Use
Set Up of Platforms and stairs.
equipment
Wearing PPE,
Welding/ Grinding Burn on the body 2 3 6 Low 2 3 6 Low
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Page : 42 of 44
Wearing Ear
Welding / Grinding Hearing damage 1 2 2 Low protection – PPE 1 2 2 Low
Wearing Glasses –
Welding / Grinding Damage to the eyes 2 3 6 Low PPE specified in point 2 3 6 Low
6.
Follow instruction,
Working on a Gas Burns and damage on wear PPE, check the
1 4 4 Low 1 2 2 Low
Line equipment gas line first, check
pressure, close lines
Follow instruction,
Installation of Burns and damage on wear PPE, check the
Working on a Oil Line 1 4 4 Low 1 2 2 Low
Oil Burners equipment gas line first, check
pressure, close lines
Follow instructions,
Working on a Pressured equipment, wear PPE, check the
1 2 2 Low 1 1 1 Low
Compressed Air line personal injury pressure and open
slowly
Bleed the line till the
burner, follow
instructions, wear
PPE, start the burner
Start up of Burns and damages, only when ventilator
Working with Gas or
Gas or Oil explosion, personal 4 2 8 Medium or combustion air is 2 2 4 Low
Oil Burners
Burners injury available. Use min.
fuel, check UV
supervision and
Ignition, increase fuel
slowly.
Work Carefully, wear
PPE and hot work
PPE, work only in
Dismantling
Working in Heights Equipment or man Fall 2 4 8 Medium restricted areas. 1 4 4 Low
of equipment
Provide scaffolding.
Assure that all
material is tied off.
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Page : 43 of 44
Welding/ Grinding Burn on the body 2 3 6 Low Wearing PPE 2 3 6 Low
Wearing Ear
Welding / Grinding Hearing damage 1 2 2 Low protection – PPE 1 2 2 Low
Wearing Glasses –
Damage to the eyes PPE specified in point
Welding / Grinding 2 3 6 Low 2 3 6 Low
Projected particles. 6. Provide Panels or
equal.
Following the
instruction and
wearing PPE specified
Damage to the body in point 6. Only
Using the Fork Lift 1 3 3 Low 1 3 3 Low
Personal injury workers with specific
training can use
forklifts. Following
FPS 04 instructions.
Material Follow Instructions,
loading Shift equipment , load Personal injury, wear PPE, secure
1 1 1 Low 1 1 1 Low
on to the truck bruising, cuts equipment’s, use
lifting equipment
Secure equipment
when loaded, drive
Personal injury,
Equipment fall 1 2 2 Low carefully. Follow 1 1 1 Low
bruising, cuts
FPS01 and or
instructions.
*PPE – specified in point 11 “Personal safety clothing, tools and equipment”
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Page : 44 of 44
RISK MAGNITUDE
Severity Rating
Likelihood Rating
• 5 - Likely - Not unusual to occur in normal operating conditions • 5 - Fatality
• 4 - Probable - Is likely to occur in normal operating conditions • 4 - Major Injury
• 3 - Possible - May occur in normal operating conditions, but is unlikely • 3 - Greater than 3 day injury
• 2 - Remote - Will result only from an unforeseen event • 2 - Minor Injury
• 1 - Improbable - Is believed too unlikely to require consideration • 1 - No Injury
Likely Probable Possible Remote Improbable

5 4 3 2 1
Fatality 5 25 20 15 10 5
Major Injury 4 20 16 12 8 4
> 3 Day Injury 3 15 12 9 6 3
Minor injury 2 10 8 6 4 2
No Injury 1 5 4 3 2 1
13-25 : High Risk Magnitude
7-12 : Medium Risk Magnitude
1-6 : Low Risk Magnitude
Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

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Risk Assessment / Method Statement / Technical Description

Clients Name : SLTEC/SPSI, Calaca, Batangas

We monitor daily our working conditions for our employees.

We believe training is very important so that we have a competent qualified workforce.

Marcia Heideliza Lopez Bernard Carpio

CFB Dry Out

CFB Boiler Dry Out

Where a component of a process is to be subjected to excessive temperatures during operation, then

On this project Hotwork International shall use Oil Burner Units.

Made by : Approved by : Accepted by :

Name: Bernard Carpio Name: Marcia Lopez Name: ______________________

Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Arrival of the Hotwork equipment.

Day 4 till finish

Last Days on site ….

Made by : Approved by : Accepted by :

Name: Bernard Carpio Name: Marcia Lopez Name: ______________________

Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

a. Supply of power to HWI Electrical Distribution Box

Made by : Approved by : Accepted by :

Name: Bernard Carpio Name: Marcia Lopez Name: ______________________

Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Operation Description Responsibility Date

Fire Extinguisher Total 6 sets of extinguishers in a range of 20m HWI

Made by : Approved by : Accepted by :

Name: Bernard Carpio Name: Marcia Lopez Name: ______________________

Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Unloading the Unloading of all equipment’s and placing it on SPSI/HWI

Made by : Approved by : Accepted by :

Name: Bernard Carpio Name: Marcia Lopez Name: ______________________

Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Resources, Connections, Points of Take Over (POT)

Electrical Power: Ventilators

Compressed Air: Main source for compressed is from client.

Fuel: High Velocity Burners

Made by : Approved by : Accepted by :

Name: Bernard Carpio Name: Marcia Lopez Name: ______________________

Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Compressed Air connection

Electric CEE Plugs

Made by : Approved by : Accepted by :

Name: Bernard Carpio Name: Marcia Lopez Name: ______________________

Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

High Velocity Burners

Made by : Approved by : Accepted by :

Name: Bernard Carpio Name: Marcia Lopez Name: ______________________

Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

High Velocity Burners – Oil fired

Max. Diameter: 380 mm

Made by : Approved by : Accepted by :

Name: Bernard Carpio Name: Marcia Lopez Name: ______________________

Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Thermocouples and Cables

Hotwork-INTERNATIONAL Ni-Cr-Ni-thermocouples have a 3,2 mm diameter.

Stainless Steel Thermocouple

Made by : Approved by : Accepted by :

Name: Bernard Carpio Name: Marcia Lopez Name: ______________________

Date: 01.08.2019 Date: 01.08.2019 Date: ____ / ____ / ________

Compensating Cable - Type "K"

Stainless wire shall be prepared by

Ignition duct A 5 TC’s

Ignition duct B 5 TC’s

Made by : Approved by : Accepted by :

Name: Bernard Carpio Name: Marcia Lopez Name: ______________________

Date: 01.08.2019 Date: 01.08.2019 Date: / / ____

Date: 01.08.2019 Date: 01.08.2019 Date: / / ____

Date: 01.08.2019 Date: 01.08.2019 Date: / / ____

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