1、精選優(yōu)質(zhì)文檔傾情為你奉上精選優(yōu)質(zhì)文檔傾情為你奉上專心專注專業(yè)專心專注專業(yè)精選優(yōu)質(zhì)文檔傾情為你奉上專心專注專業(yè)METHOD STATEMENT FOR BATCHING PLANT ERECTION WORKSDISCIPLINECivilMechanicalElectricalGeneralContactDocument controlNAME: M.S for Batching Plant Erection WorksTel:Action RequiredFor informationFor ApprovalContents TOC o 1-3 h z u 8. emergency Plan

2、.21PURPOSEThis Document explains the detailed procedure for Erection of Batching Plant using Hydraulic Mobile crane 50T/60T.SCOPEThis method statement details the erection and commissioning of:2.1Batching plant with Silos and Assembly.REFERENCES DOCUMENTS / SPECIFICATION / STANDARD3.1 Batching Schwi

3、ng Stetter M-1T3.2SHE conditions of contract.3.3SHE manual of contract.3.4Project EHS plan.3.5Project Quality Plan.RESPONSIBILITIES:Following are the responsibilities and reporting structure of personnel involved in the scope of the procedure:PositionReporting / ResponsibilitiesProject ManagerShall

4、be responsible for safe and timely erection of batching plant in his supervision.Shall be responsible for assuring quality to be maintained.Deputy Project ManagerShall be responsible for control, supervision and direction for implementation and execution of construction plans in regard of erection o

5、f batching plant.Manager (Casting Yard)Shall also be responsible for supervision of erection of batching plant and other assemblies. Ensuring of construction activities and preparation of records, procedures required to be completed in regard of batching plant erection.Sr. Engineer (Execution)Shall

6、report to manager casting yardShall be responsible for day-to-day planning and progress of site.Getting the foundation ready as per required drawings for safe and early plant erection.Responsible to finalize the location of batching plant and get it approved by manager (casting yard). SurveyorShall

7、report to Manager (Casting yard)Shall be responsible to coordinate with Manager (Casting yard), understand the drawing, planning & carrying out of survey activities at site along with the preparation of survey records based on the approved drawing.PositionReporting / ResponsibilitiesQA/QC In chargeS

8、hall report to Project Manager.Shall be responsible for overall control of QC activities and sub- contractors QC activities as per approved ITP and implementation of Project Quality Plan.Shall be responsible for carrying out Inspection as per specification.Chief SHE ManagerShall report to Project Ma

9、nager.Shall be responsible for overall control of SHE Activity as per approved Safety Methodology.Ensuring the approval of Method statement by the client.Responsible to Ensure to provide Risk Assessment involved in erection of Batching Plant. Monitoring of safety requirement and its compliances from

10、 time to time.SHE EngineerResponsible for completing all the documents needed for erection of Batching Plant. Responsible for provision of risk assessment.Responsible for ensuring crane documents.Responsible for making lifting plan and commencement of all safety measures required before lifting oper

11、ations starts.SHE StewardShall report to SHE Engineer/SHE Manager.Monitoring of Tool Box (TBT) at site before erection of plant starts.To provide and ensure the correct use of PPEs & safety devices as per the working condition.Ensure safe work at erection location. Responsible to make sure no workme

12、n shall be allowed to site without PPEs and Safety Induction.P&M In chargeShall report to Project Manager Responsible for safe and timely erection of batching plant.Responsible to ensure all the equipments shall be TPI by approved TPI vendor.Responsible for the selection of crane to be deployed for

13、safe erection of batching plant.Monitors the erection of batching plant at site.Coordinates with the Project Manager for all plant and equipment requirements. To meet the deadline ofr safe and timely erection of batching plant.Electrical/Mechanical In chargeShall report to P&M In charge.Responsible

14、for safe electrical power supply and distribution at site during lifting operation.Responsible to provide optimum working light at erection location.Responsible for ensuring no cable shall get punctured or pass through the lifting area.Responsible to Co-ordinate with Electrical Contractor for Electr

15、ification, Execution, Erection & Commissioning.Ensuring proper cable routing of batching plant after erection and commissioning, i.e through trench.Responsible for to ensure all documents related to erection of plant has been submitted.Responsible for ensuring lifting plan of batching plantResponsib

16、le to use tag line while lifting of heavy equipment of batching plant. Responsible to ensure the lifting is being carried out with in crane limits.To ensure the ground condition before finalizing the crane location.To ensure for availability of TPI approval for crane and lifting equipments to be use

17、d for erection of batching plant.Site SupervisorShall Report to Engineer.Ensure all work is completed as per the responsibilities of Engineer.Direct and supervise the Work man, operators and riggers for the desired work to be done.MACHINERY, TOOLS, EQUIPMENTS AND MATERIALSSr noEquipmentNos.Remarks1H

18、ydra Crane IInd Generation (F-15)01As per requirement2Hydraulic Crane (77 T at 75% din rated)02As per requirement4Welding Machine02As per requirement5Gas cutting set01As per requirement6Grinder01As per requirement7Hand tools , JackAs per requirement8Wire rope slings & Chain Slings (10T, 6T, 2T)04 Se

19、tAs per requirement9D Shackles (17T, 9.5T)06+02As per requirement10Nylon rope, 28 mm dia turn buckles15 mtrAs per requirement11 Web slings 5 T4 NoAs per requirementMATERIALSMajor materials to be used in the Erection of Batching Plant 6.2.1Structural Steel as per IS 2062 shall be used 6.2.2Suitable E

20、lectrodes of grade 6013 or other grade as recommended by Designer / Design drawing shall be used. 6.2.3Concrete of specified grade shall be used as per approved design & drawings. 6.2.4Bolts with washers as per the approved design & drawings. 6.2.5Suitable grout materials.MACHINERY, TOOLS, EQUIPMENT

21、S AND MATERIALS6.1Silo 3200dia. Weight 6T-04nos., (100Ton capacity) 6.2 Batching Plant (Main structure) weight approx. 17 Ton.6.3Aggregate hopper and belt conveyor.6.4Operation Cabin.6.5Cement Screw.6.5Dust Controller System.WORK METHODOLOGYWhether the lifting operations are repetitive or if they ar

22、e a one off, a safe system of work must be established and followed for the operation to be both safe and successful.In order to provide a safe system of work the following items are to be included in the lift plan / AssessmentThe sequential activity and corresponding methods are detail below7.1GENE

23、RALErection of batching plant with 04 no. silos and Assembly, Make- Schwing Stetter, Model- M-1T, Capacity- 54 Cum/Hr. 7.2 SELECTION OF CRANE:The selection of suitable crane and work equipment must be carried out.A crane team has to be deployed at site for pre inspection of soil condition and make t

24、hem aware of their responsibilities before the commencement of the job.All certifications, reports of thorough examination and other documents including manufacturers manual are to be retained and available.CRANE OPERATIONSOnly authorized & experienced Operator shall be permitted to operate the cran

25、e.Assembling, maintenance and disassembling on the equipment shall be done as per the manufacturers manual and Third-party certified crane shall only be deployed for the jobOverloading shall never be allowed at site. Weight of load being lifted and the lifting radius of all major components are prov

26、ided in the method statement. Same will be incorporated in the daily erection permit also and Crane shall be stationed on a firm level ground.The operator shall ensure the area is good enough for the crane before marching or parking it. Proper boom angle and radius shall be followed to lift the load

27、. Refer the load chart given in the crane manual or fixed inside the crane cabin. Cranes shall not be parked near the edges of pit or excavations. Limit switch of cranes shall be tested frequently for ensuring its proper functioning. The swinging area of the crane shall be cordoned. The Crane helper

28、 shall ensure no trespassers enter in this vicinity and a trained signalman shall give the signal for crane operation. The operator shall have a clear view of the operation throughout the hoisting period. The banks man shall be always at the visibility of the crane operator. If the operation is such

29、 that the banks man must stand at an obscure location then more banks man shall be posted to have an effective communication. A competent rigging gang shall do material handlingClear passages shall be left for easy handling and transportation structures.All persons shall stand clear when a crane is

30、sorting or shifting materials.7.4OrganizationChartBelow staff should be available at the time of erection-KEC P&M in charge/ P&M in charge (For Supervision).KEC Electrical/ Mechanical Engineer.Schwing Stetter (OEM) service engineer (Erection activity).Skilled Rigger for erection work.Unskilled workm

31、en.Electrician Mechanic.WelderGENERAL SAFETY MEASURESOnly skilled & experienced gang (specialised) will be deployed.Only tested & certified tools & tackles should be used.Cranes being used for erection activities should have valid 3rd party inspection certificate.All the workmen have to wear full bo

32、dy harness and fall arrestor at the time of working at above 3 meters height Soft barrication the area of batching Plant during erection, no unauthorised workmen will be allowed in the erection area.Ensure proper communication & continuous supervision by P&M and Safety staff.Weight of load being lif

33、ted and the lifting radius of all major components are provided in the method statement.Lifting plan to be prepared for each Lifting with Reference to load chart of crane and weight of material.Detailed sketch to be made for each lifting.TBT with Dynamic HIRA to be prepared every day before start th

34、e work.No heavy lifting activity will be carried out after 06:00 PM.RIGGINGKnow the safe working load of the equipment and never exceed this limit.Barricade the working area, no unauthorized workmen should enter working area. No workmen should stand under suspended load or crane operating area.Exami

35、ne all hardware, equipment, tackle and slings before using it and destroy defective components.Caution must be exercised when working near overhead power lines. Minimum safe distance should be maintained.Rapid swinging of suspended loads also subjects the equipment to additional stresses, which can

36、cause collapse. Load must always be kept directly below the boom point or upper load block The rated loads of most hoisting equipment do not generally account for the weight of hook blocks, hooks, slings, material handling equipment and other elements of lifting tackle. Their combined weight must be

37、 subtracted from the load capacity of the equipment to determine the maximum allowable load to be lifted. Sharp bends, pinching and crushing must be avoided. Never use kinked or damaged slings or hoist ropes should be cut and removed from site.Never allow wire rope to lie on ground for any length of

38、 time or on damp or wet surfaces, rusty steel or near corrosive substances. Avoid dragging rope slings from beneath loads.Keep all ropes away from flame cutting and electric welding operations.Never wrap a wire rope completely around a hook. The sharp radius will damage the sling. Ensure that the sl

39、ing angle is always greater than 450. If horizontal distance between the attachment points on the load is less than the weight of the shortest sling leg, then the angle is adequate one. In this case angle is greater than 600. When using choker hitches, do not force the eye down towards the load once

40、 tension is applied. Rope damage is inevitable. All loads must be rigged properly to prevent the dislodgement of any partThe load must always be kept under control. Loads must be safely landed and properly blocked before being unhooked and unsung. Keep hands away from pinch points as the slack is be

41、ing taken up.Lifting beams should be plainly marked with their weight and designed working loads and should only be used for the purpose for this they were designed.Wear gloves when handling wire rope and never ride on a load that is being lifted.Avoid impact loading. Lift the sling gradually until

42、the slack is eliminated.SIGNALLING The signalman must be qualified by experience with the operations.Signalman shall wear high visibility clothing.Use hand signals only when his signals are clearly visible to the operator.Signalman should be in constant communication with the crane operator, either

43、visually with hand signals or audibly by radio throughout the operation. If the operator loses contact with the signalman for any reason, he must stop the movement of the crane until communication is restored. Hand signals can be used effectively when the signalmen are clearly visible to the operato

44、r; but 2-way radios should be used when the distance or atmospheric conditions prevent clear visibility. Adequate lighting and signaling arrangements must be available during night work and equipment must not be operated when either one is inadequate. When two or more cranes or hoist are used to lif

45、t one load, one qualified person should be responsible for the operation. He should analyze the operation and instruct all personnel involved in the proper positioning, rigging of the load, and the movement to be made.Crane operator, signalmen and rigger should not use mobile phone during the workin

46、g time.WIRE ROPE AND SLINGSWire ropes and slings shall be purchased to a specification and shall be accompanied by a certificate of quality and strength.Terminal attachments must be properly fitted or they may seriously reduce the efficiency and ultimate breaking strength of the rope.LIFTING GEARLif

47、ting gear like, Slings, lifting lugs/pad-eyes, shackles, etc. shall be inspected when they are brought to site and then once a month. The inspected lifting gears shall be colour coded for identification. A Competent Person shall be identified for carrying out the inspection. He shall inspect the lif

48、ting gears and put the colour code on each item inspected: Any lifting gear, which do not bear the respective colour code for the month, shall not be used. Each item shall be marked with its safe working load, colour code.Slings shall be inspected on a monthly basis with a colour coding system appli

49、ed to indicate month of inspection and Inspection records shall be maintained. 7.6.4 Lifting EquipmentWhether the lifting operations are repetitive or if they are a one off, a safe system of work must be established and followed for the operation to be both safe and successful.In order to provide a

50、safe system of work the following items are to be included in the lift plan / Assessment.WORK PROCEDURE / ERECTION SEQUENCE:STEP 1:Placing of 77 ton Hydraulic Mobile Crane upon compacted ground. Soil condition to be inspected before placing the crane & report for the same will be submitted along wit

51、h pre work starting. STEP 2: Silo Erection upon civil foundation & fixing with nut bolt installed in foundation having 6 Ton Weight, 3200 mm dia. After erection one skilled rigger will climb up to silo with Double lanyard safety harness to remove the lifting gears.Four nos. Silos (03 nos. Cement & 0

52、1 no Fly ash) will be erected in same process.Sample Picture of erection of siloSTEP 3:Erection of batching plant (Main Structure Approx weight 14 ton) with aggregate bins having the weight of 17 Ton by using the 77 Ton Hydraulic crane upon civil foundation. After erection M40 grade concrete to be d

53、one in given pockets Erection of 4 Nos. Aggregate Compartment & Mixing Unit to be Unfolded Using 70 Ton Crane.Aggregate bins to be unfolded after shifting upon foundationTo be unfolded after shifting upon civil foundationPresent condition of M1T Batching PlantSample picture of Lifting & Erection of

54、batching plantSTEP 4Conveyer Belt to be lifted by 77 ton crane and 15 ton Hydra crane & Base support of conveyor to be fixed by using 15 Ton hydra crane before lifting of conveyor after fixing of Base support Conveyor to be erected upon civil foundation & M40 Grade concrete done in given pocket. (Ap

55、prox Weight 8 Ton)Base Support to be fixed for conveyorPresent condition of aggregate conveyorConveyor support after erectionSample picture of aggregate conveyor erectionSTEP 5 Aggregate Hopper to be erection upon civil foundation and fixed with nut bolts. (Approx. weight 0.7 Ton)Present condition o

56、f HopperSample picture of hopper after erectionSTEP 6Screw Conveyer (09mtr. Long & 01 Ton weight) assembled on ground level after assembling will be lifted with Crane & Erected between Silo & Cement weigh and fixed with nut bolts. 04 nos. Screw conveyor will be erected in same procedure.Lifting Poin

57、ts of Screw conveyor, can be lifted according to center of materialPresent condition of Screw conveyorCement & Fly ash Screw Conveyor after ErectionSample Photo of Screw conveyor after erectionSTEP 7Erection of Dust Collector with Accessories at ground level. (Height 2.5 mtr Weight 1.1 Ton).Sample p

58、hoto of Dust collectorSample Photo of Dust CollectorEmergency Plan:All Site location should have proper emergency plan and minimum requirement is given belowa. Always emergency vehicle available at site location were dismantling work is going on.b. Sufficient quantity of first aid medicine and First

59、-aider available at site.Emergency Contact numbers and nearby hospital numbers, to be displayed.Risk assessmentRisk Assessment Sheet Attached as Appendix-02 shall be followed. Safety Training Requirement: All the employees engaged for Plant Erection should be properly screened and safety induction about CCECC KEC JV safety standards and requirement to be done. All employees engaged should be provided with mandatory and work related