DRUM DRYER 11T53 & 11T03

METHOD STATEMENT FOR

PROJECT: OMAN SUGAR REFINERY COMPANY

JOB: 66729 – EQUIPMENT AND PIPING ERECTION
FORGES TARDIEU Ltd Tel +230 206 52 00
PO Box 20-31 Fax +230 240 71 59
31 Nicolay Road, Email project@forgestardieu.mu
Port Louis Web www.forgestardieu.com
Republic of Mauritius
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 FT-MST-EQ-001

METHOD STATEMENT
FOR THE INSTALLATION OF SUGAR DRUM DRYER
AT OMAN SUGAR REFINERY COMPANY

DISCLAIMER
The information contained in this manual remains the property of Forges Tardieu Ltd and as such must not be
copied, reproduced or communicated to third parties without their written permission.

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Table of Contents
INTRODUCTION .....................................................................................................................................4
OJECTIVE & PURPOSE ............................................................................................................................4
SCOPE OF WORK....................................................................................................................................4
RESPONSIBILITIES ..................................................................................................................................5
4.1 Site Manager/ Equipment Coordinator .................................................................................................5
4.2 Site Engineer ..........................................................................................................................................5
4.3 HSE Officer .............................................................................................................................................5
4.4 QC Officer ..............................................................................................................................................5
GENERAL HEALTH & SAFETY PROCEDURES ...........................................................................................6
5.1 Procedures prior to commencement of work .......................................................................................6
5.2 Documentation required for starting of work .......................................................................................6
5.3 Precaution at the time of work .............................................................................................................6
5.4 Tasks after completion of work .............................................................................................................6
SCAFFOLDING ........................................................................................................................................7
BARRICATION & SAFETY SIGNAGE .........................................................................................................8
DRUM DRYER TECHNICAL DATA ............................................................................................................9
METHODOLOGY .................................................................................................................................. 10
9.1 Pre-requisites and initial condition .................................................................................................... 10
9.2 Sequence of operation ....................................................................................................................... 10
Transport movement and installation of roller supports ................................................................... 10
Transport movement and installation of drum dryer ........................................................................ 13

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 INTRODUCTION
This method statement is intended to provide Forges Tardieu Ltd. with recommended procedures for the
lifting operations to be executed and completed without injury to working personnel, their health and
damage to asset and environment on Oman Sugar Refinery site in Sohar Port – Oman.

OJECTIVE & PURPOSE

The objective and purpose of this method statement is to establish a work sequence on how the sugar
drum dryer (11T53 and 11T03) and the roller supports will be transported from current storage area to
installation on site. The statement also, includes work methodology, sequence of activities,
responsibilities, documentation and safety measures for the installation of the drum dryer.
If there is any deviation from the approved plan, the site manager/ engineer is responsible to ring this
matter to the attention of the client and approved changes must be communicated to the responsible
site supervisor and workforce then only, work can be started.

SCOPE OF WORK
The main scope of work pertaining to the activities for the installation of the sugar drum dryer are as
follows:
 Taking over of roller supports from client prior to lifting
 Taking over of drum dryers prior to lifting
 Installation and inspection of scaffolding on site
 Transport movement of roller supports from current storage area to installation site
 Installation of front and rear roller supports for both dryers
 Inspection of roller supports after installation
 Transport movement of dryer from current storage area to installation site
 Installation of drum dryers
 Inspection of drum dryers after installation

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 RESPONSIBILITIES
4.1 Site Manager/ Equipment Coordinator

The site manager/ equipment coordinator shall be having the overall responsibility of the lifting and
installation involved. He shall ensure, not limited to: -

 Responsible for control and operation and ensure that the works are carried out according to
specifications, shop drawings, erection manual and method statement.
 Organizing tools and equipment required for the work.
 Activities are executed as per the scheduled programme.
 Liaison with client for the daily activities on site.
 Initiate the completion of corrective/ preventive actions.

4.2 Site Engineer

The site engineer shall be responsible for the day to day activities of the site and shall be responsible
for: -

 Confirming the installation locations from latest approved

 Sequence of activities to be carried out for the work as per the method statement.
 Stage inspection & surveillance.

4.3 HSE Officer

The HSE officer in coordination with the site team shall be responsible for the implementation of the
company approved HSE plan. Further, the health & safety officer shall ensure, not limited to: -

 All works are carried out as per approved HSE plan.

 Relevant inspections are carried out.
 To carry out risk assessment associated with the work and provide mitigation measures.
 The compliance with all required legislation.
 To monitor and maintain all implemented safety measures.

4.4 QC Officer

The responsibilities for the quality control officer include the following, not limited to: -

 Inspection of the equipment to be installed prior installation and after installation.

 Monitoring, reporting and controlling quality related to the work activities.
 Raising quality alerts, improvement notice and non-conformities as applicable.
 Routine inspections, technical queries if any with regard to works to be carried out.
 Establishment and use of a quality related control and reporting system.
 Preparation of red-line drawings.

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 GENERAL HEALTH & SAFETY PROCEDURES

5.1 Procedures prior to commencement of work

 Give 1st day HSE Induction to all the new workers and maintain record.
 Check PPE and maintain record.
 Work method statement will be explained to all workers, drivers and crane operators by supervisor.
 Conduct TOOL BOX TALK to all the workers explaining about all hazards and risk by HSE officer.
 Conduct TAKE – 5 to workers by supervisor.
 Verification of Safe access and egress for worker’s movement.
 Verification of Access and egress for vehicle movement.
 To inform and provide support if required for other contractors before starting any related work.
E.g. Diversion of walk ways, vehicle movement & Information about overlapping of works at same
work location which comes under high risk activity etc….
 Pre inspection of all the tool & tackles by Foreman / Supervisor & verification of documents by HSE
officer.
 Pre inspection of all the equipment’s and machinery’s by Foreman / Supervisor & verification of
documents by HSE officer.
 Working area and working platform to be inspected by supervisor.
 Proper barrication should be done.
 Sign boards should be available at work location.
 Housekeeping should be done before starting of work.

5.2 Documentation required for starting of work

 Approved HSE plan.

 Approved Emergency Plan.
 Approved HIRA.
 Work permit.
 Tool box talk.
 Take-5.
 Tools and tackles certificates.
 Equipment and machinery certificates.
 Operator and riggers certificates.

5.3 Precaution at the time of work

 No access for unauthorised persons.

 Work should be done under the supervision of Foreman or Supervisor.
 Follow the work method statement procedure.
 Ensure no entry or stand under the suspended load.

5.4 Tasks after completion of work

 Barrication and sign boards to be removed, if it is not required.

 Housekeeping to be done after completion of the work.

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SCAFFOLDING

 Prior to the installation of the roller supports, scaffolding will be installed around the concrete
bases to make work at height safer and easier.
 The scaffolding will be installed under the supervision of the supervisor and will be inspected by
the same after its completion.
 No work should be performed until the scaffoldings have been inspected and verified by the
HSE officer.
 The scaffolding should be tagged “safe for use” before its utilisation.
 Figure 1 below shows the position and arrangement of the scaffoldings around the concrete
bases.
 For more details of the scaffolding arrangement, refer to scaffolding layout drawing.

Scaffolding for
drum dryer 11T53

Concrete base

Concrete base

Scaffolding for
drum dryer 11T03
Figure 1: Scaffolding layout

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BARRICATION & SAFETY SIGNAGE
 Prior to commencement of any related work, the work location will be barricaded with warning
tape to prevent access for unauthorised persons.
 Sign boards will be placed at specific location to inform occupants about the danger associated
with the related works.
 Figure 2 and Figure 3 illustrate the barrication area that’s need to be done prior to
commencement of any related work.
 For more detail refer to layout of barrication area drawings.

Figure 2: Barrication for storage area

Figure 3: Barrication on work location site

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DRUM DRYER TECHNICAL DATA

DRUM (11T53 & 11T03) SPECIFICATION

Diameter of drum (nominal diameter) 3600 mm
Length of drum (nominal length) 11000 mm
Diameter of riding ring 3910 mm
Width of riding ring 430 mm
Pitch diameter, chain wheel 746.14 mm
Pitch diameter, chain gear segments 3881.28 mm
weight 31000 kg

SUPPORT STRUCTURE WITH RIDING AND SPECIFICATION

LOCATING ROLLERS (INTAKE END)
Length 3950 mm
Width 1600 mm
Height 1150 mm
Weight 4750 kg

SUPPORT STRUCTURE WITH RIDING SPECIFICATION

ROLLERS (DISCHARGE END)
Length 3950 mm
Width 1000 mm
Height 1150 mm
Weight 4000 kg

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 METHODOLOGY

9.1 Pre-requisites and initial condition

 All equipment & tools within this lifting plan is to have current valid certification at the time of
use.
 All the equipment shall be inspected prior to mobilisation by the HSE and lifting supervisor for its
good condition.
 All machine operators should have valid documented evidence of competency to do the work
and for operating any machinery that they will be using.
 Prior to commencement of work, carry out area setup and demarcate using rigid or soft barriers.
 Ground should be compacted and be able to withstand load from mobilisation of heavy
machineries.
 Check for weather condition; if the condition is not good, the lifting should be postponed until
the further notice.
 Approved lifting plan should be with the lifting supervisor on site.

9.2 Sequence of operation

The sequence of operation for installing the drum dryer will consist of 2 phases:

1. Loading, transport movement and installation of roller supports from current storage area to site.
2. Loading, transport movement and installation of drum dryer from current storage area to site.

Transport movement and installation of roller supports

9.2.1.1 Transport movement of roller supports for drum dryer 11T03 and 11T53
 Firstly, the 4 roller supports for the 2 sugar drum dryer 11T03 and 11T53 will be transported
from the current storage area to the site.
 An 80T crane will load all the roller supports on a trailer from their current storage locations.
 The trailer will then deliver the rollers support at the required location on site.
 The same 80T crane will be used to unload and install the roller supports.

9.2.1.2 Installation of roller supports for drum dryer 11T53

 The trailer and the 80T crane will be positioned as shown in Figure 4.
 The 80T will then extend its boom to the required position to lift the rear roller support for the
drum dryer 11T53.
 The crane will lift the rear support and place it on its concrete base as shown in Figure 4.
 Riggers will instruct and guide the crane operator to position and lower the roller support at the
required anchor bolt position.
 After installation of the rear roller support, the crane will carry out the same operation for the
front roller support as shown in Figure 5.
 The supports will then be levelled to required height and aligned to each other.
 For technical details of the lift, refer to lifting plan document ref: FT-LP-EQ-003.

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 Figure 4: Installation of rear roller support for drum dryer 11T53

Figure 5: Installation of front roller support for drum dryer 11T53

9.2.1.3 Installation of roller supports for drum dryer 11T03

 After the installation of the roller support for the drum dryer 11T53, the crane will do the same
operation for the roller supports of the drum dryer 11T03.
 The supports will then be levelled to required height and aligned to each other same as for the
roller support 11T53.

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 Once all lifting has been completed, the trailer will move out of the process house and the crane
operator will lower its hook block to ground and all lifting gears will be removed.
 Crane will then derig and move off site.

Figure 6: Installation of rear roller support for drum dryer 11T03

Figure 7: Installation of front roller support for drum dryer 11T03

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 Transport movement and installation of drum dryer

9.2.2.1 Transport movement of drum dryer 11T53 and 11T03

 Prior to lifting of the drum dryer, the position of the crane and that of the low bed trailer will be
marked on the ground with road marking chalk.
 A crane capacity of 80T will be used for the loading of the drum dryer on the low bed trailer.
 The crane will be positioned within a working radius of 7m with the drum dryer and the low bed
trailer as illustrated in Figure 8.
 The crane will be driven into position under the control of a banksman/ slinger or signaler.
 After positioning of crane and low bed trailer, the lifting area will be barricaded with warning
tape.
 The crane will first lift the drum dryer 11T53 and load it onto the low bed trailer as illustrated in
Figure 8.

Figure 8:Loading of drum dryer 11T53

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 After loading of the drum dryer 11T53 on the trailer, part of the barricade will be temporary
removed to make access for the trailer to move out. The barricade will be put back after the trailer
has move out.
 The trailer will then transport the drum dryer 11T53 and deliver it on site using the indicated
route as shown in Figure 9.
 For more details, refer to transport movement layout for sugar drum dryer.

OSRC
OFFICE
Initial position
of drum dryers

White sugar warehouse Process house

Offloading position
of drum dryers

Figure 9: Trailer movement route

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  Meanwhile, the crane operator will position the 80T crane within a working radius of 7m with the
drum dryer 11T03 and will wait for the trailer to come back to fetch the second drum dryer.
 After delivery of the drum dryer 11T53, the trailer will come back and will be positioned as shown
in Figure 10. The crane will then lift the second drum dryer 11T03 and load it onto the trailer.
 The trailer will use the same route as for the drum dryer 11T53 to transport and deliver the second
drum dryer on site.
 For technical details of the lift, refer to lifting plan document ref: FT-LP-EQ-002.

Figure 10: Loading of drum dryer 11T03

9.2.2.2 Installation of drum dryers 11T53

 The installation of drum dryer 11T53 will consist of 4 major steps.

 Firstly, after fetching the drum dryer 11T53 from the storage area, the low bed trailer will be
positioned at a centre to centre distance of 9m from the 160T crane.
 Slinger will instruct and guide the crane operator to carry out the motion required for the lifting.
 The 160T crane which was initially already in position, will extend its boom to the required
position to lift the drum dryer from the low bed trailer as illustrated in Figure 11.
 The crane will then lift the drum dryer to a minimum work safety height and will make a 154°
anti-clockwise rotation to temporarily place the drum on the roller supports of the drum dryer
11T03 as shown in Figure 12.

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 Concrete base for
drum dryer 11T03

Initial position
of 160T crane

Drum Dryer 11T53

Final position of
low bed trailer
Figure 11: Step1 - unloading of drum dryer 11T53

Drum Dryer 11T53

Figure 12: Step2 - Lifting and positioning drum dryer on 11T03 roller supports

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  After the crane have temporarily placed the drum dryer 11T53 on the roller supports, the crane
will go inside the process house using the route shown in Figure 13.

Initial position of crane

Forward route
for crane
Drum dryer 11T53

Reverse route for crane

Forward route for crane
Final position
into process house
of crane

Figure 13: Crane mobilisation route inside process house

 After the crane have been positioned inside the process house, it will extend its boom to lift the
drum dryer 11T53 from the roller supports of drum dryer 11T03 as illustrated in Figure 14.

Drum dryer 11T53

Figure 14: Lifting of drum 11T53 from roller supports

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  The crane will then lift the drum dryer to a minimum work safety height and will make a 77°
clockwise rotation to finally place the drum on its roller supports as shown inFigure 15.
 For technical details of the lift, refer to lifting plan document ref: FT-LP-EQ-001.

Drum dryer 11T53

Figure 15: Final position of drum dryer 11T53

9.2.2.3 Installation of drum dryers 11T03

 The installation of drum dryer 11T03 will consist of 2 steps only.

 After installing the drum dryer 11T53, the crane will be removed from the process house and
will be positioned outside.
 Then after fetching the drum dryer 11T03 from the storage area, the low bed trailer will be
positioned at a centre to centre distance of 9m from the 160T crane as illustrated in Figure 16.
 Slinger will instruct and guide the crane operator to carry out the motion required for the lifting.
 The crane will then lift the drum dryer to a minimum work safety height and will make a 154°
anti-clockwise rotation to finally place the drum its roller supports as shown in Figure 17.
 For technical details of the lift, refer to lifting plan document ref: FT-LP-EQ-001.
 Operations will cease once equipment has been put into position to enable supervisor to check
position, level and orientation.
 Once all lifting has been completed, crane operator will lower hook block to ground and all
lifting gears will be removed.
 Crane will then derig and move off site.

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 Concrete base for
drum dryer 11T03

Final position
of 160T crane

Drum Dryer 11T03

Final position of
low bed trailer
Figure 16: Step1 - unloading of drum dryer 11T03

Drum Dryer 11T03

Figure 17: Step2 - Lifting and positioning of drum dryer 11T03 on its roller supports

A proper housekeeping will be done after all lifting operations have been ceased.

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