METHOD STATEMENT OF TOWER CRANE INSTALLATION

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1.Purpose

To expedite the progress of erection activities of ESP Casing Structure, Casing Wall Panel,
Hopper, Roof Structure, etc…
The preassembly of ESP auxiliaries, equipments and material handling to be done safely and
accordance with good practices as per job specification.
The procedure to intended to provide standard practices, General Application guidance.

2.Storage components of Tower crane

To Ensure healthiness of received parts of Tower Crane, material to be stored and kept as per
MEL Standard. Electrical items to be stored in closed area or converted Area.

3.Excavation for Civil Foundation

a) This work will consist of cutting, removing and disposing of all materials such as
trees, bushes, shrubs, stumps, roots, grass, weeds, rubbish, top organic soil, etc. to be
done as OEM Manual. Foundation Details to be incorporated.
b) All materials arising from clearing and grubbing operations will take over and dispose
of at suitable disposal sites. The disposal shall be in accordance as per MEL
guidelines.
c) Ground levels will be taken prior to and after Clearing and Grubbing, excavation up
to required level as per drawing
d) Foundation to be casted as per OEM Supplied Drawing.
e) Foundation curing to be done for 7 days after casting.

4. EQUIPMMENT ERECTION AND COMMISSIONING:

1. Tower Crane erection will be done by 150T Crawler Crane (TPI No …… Valid Up
to……).
2. Permit to work to be issued by MEL
3. Position the Foundation leg assembly near the Crawler crane and start lifting after
slinging properly.
4. Lift the leg assembly in vertical position near the marked foundation area where
Tower crane is to be installed.
5. After reaching required height, install them to concrete reinforcing bars and check the
verticality along with the Elevation.
6. After ensuring the Alignment of the Leg Assembly, Concreting works are to be
carried out.
7. After the required Curing period, Remaining erection to be carried out.

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8. Sectional Mast of Dimension 2.5 mtr x 2.5 mtr of Length 11.960 mtr each to be
shifted near the crane area.
9. Tie PPE rope at the end of the Mast for maneuvering while lifting.
10. Lift the Assembled Mast and after reaching required height lower it in position on the
correct position on Leg Assembly. Then lock the Mast to Leg Assembly with 8 pins
by using 4 Cotter pins.
11. Repeat the process 3 times until the Mast reaches the height of 48 mtr.
12. After this, Lift the Climbing frame assembly and place it at the height of 48 mtr. This
Frame assembly is placed around the Mast.
13. Next, Swing unit is lifted and installed just above the Climbing Frame.
14. Then, Cabin Assembly is lifted and installed in Swing unit.
15. Then, Tower head is lifted and installed above the Swing unit.
16. Then, Counter balance boom of 19.18 mtr is lifted and connected to Swing unit by
using Lock pins.
17. Now, Pull rods to be connected between Tower head and Counter balance boom.
18. Now, place counter block of 3MT (2nos) in counter balance boom.
19. Now, lift the assembled Lifting boom of length 65 mtr and connect to Swing unit and
connect with lock pins.
20. Now, Pull rods to be connected between Tower head and Lifting boom.
21. Then, Balance counter weights of 3.8MT (4nos) and 2MT (2nos) to be placed in
Counter balance boom.
22. After completing the installation of above total setup, increase the height of the mast
up to 48 mtr by using Hydraulic power pack jack system.
23. Then, Electrical connection and Roping works to be carried out.
24. Lay the Main power cable & miscellaneous electrical equipment as per drawing.
25. Electrical Power withdrawal from MEL Source to Tower crane. Sketch to be
incorporated. Provision for both side cable routing arrangement to be made ready.
26. Fit MCC, main switch, limit switch for Hoist equipment. Fix the actuators for limit
switches at proper places after checking the hook approaches as per drawing.
27. Complete the wiring and earthling should also be completed on Assembly etc.
28. Properly clamp the cables with Aluminum strips and dress up.
29. Carry out insulation test with megger and improve the value if necessary, prior to
giving supply to the crane.
30. Give supply to control panel, check all sequences of control panels.
31. Arrange for first fill of oil for gear boxes. Carry out greasing at required places. Take
up lubrication system work as required in the drawings.
32. After this is carried out and necessary changes made carry out no load test on each
motion.
33. Set all limit switches and brake.
34. Record all speed, current for all motors. Attend to deviation if observed. Record
voltages obtained at no load.
35. Arrangement for loads to be arranged by PMPL. Load test for SWL to be carried out
with proper duly tested slings.

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 36. Carry out load test. Record speed, current for all motions. Check breaks and limit
switches operation on load. Deviations found should be attended by modifying
resistance tapping suitability.
37. Lift 125% SWL as overload, just checks all motions on this load. No recording of
speed and current is required to be done. Identification NO………………..TPI
No……
38. All people will use full body harness attached to lifeline or any secure anchor point at
the work place

5. Precautionary Measure

Safety rules & procedure are used to ensure the health and safety of all persons
involved in the erection work to prevent loss of lives and damage to property.
Ensure safe working practice and create safe working environment by:
 Compliance, implementation and enforcement of factory safety rules.
 Accident prevention by having pre planning, instruction and constant training
and education.

6.Personal protective equipment (PPE’s)

All workmen and staff shall wear appropriate PPE like Safety shoes, Safety jackets, Safety
Helmets, Ear plugs, masks, Safety glasses etc. Site Engineer/ Supervisor will be ensure.

 Site Induction and toolbox talks should be given prior to start job..
 Equipment to be used should be inspected and must be safe for use.
 Permit to work system should be followed by all supervisors and engineers.
 Full body harness must be used for height work
 All workmen at the site must wear high visibility vest.
 Use of hand gloves for material handling
 Full body harness must be used for height work
 Safety shoes must be at the time of work.
 Face guard/face shield for grinding work
 Safety goggle should be used at the time of work
 Welders must use appropriate PPE’s for welding work

7.Mobile Equipment (Cranes/Hydra)

 Crane operator will ensure that no one can get on or off equipment
while it is in motion
 Operator ensures, boom of crane must be at down position at the time
of movement.
 Supervisor on site must look after, that there will be provision of
signalman with Farana/Crane.
 At the time of material shifting, job will be provided with guide ropes.
 Nobody allowed to below suspended load.

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  All lifting hook will be provided with safety latch lock.
 All area will barricade with caution tape where dismantling is going
on.
 Maintain safe distance between man lift and Crane.
 Boom lift checked by competent person before start the work.
 Site Engineer ensures that crane operator must be competent & having
through knowledge of crane & dismantling methodology by crane.
 All cranes to be checked by competent person before entering to
factory.
 Regular inspection to be carried out by safety dept. for crane and other
mobile equipments.
 Supervisor in charge ensures that no one remains in position of
danger.
 When two cranes are operating independently, must to ensure that
they must maintain safe distances from each other.
 Engineer/Supervisor will take care & ensure safe operation when two cranes
lift a single load. PTW to be issued from MEL for tandem Lifting.

 Arear Engineer/Supervisor ensures that at the time of lifting load, load

& angle chart will be follow by the crane operator.
 Supervisor in charge ensures that all limit switches and other electrical
& mechanical devices are in proper condition.
 Loads will be raised and lowered smoothly avoiding jerk

8. Guy lines / Tagline

 All guy lines will be checked before they are firstly introduced to work and
also regular inspection will be carried out at regular interval.
 Defective and damaged ropes will be cut immediately to prevent further use.
 Guy lines will be flagged where they cross any path or roadway.
 For all rigging or lifting by rope Supervisor ensures that it is capable to take
load.

9. Lifting Tackles (wire rope slings, Chain Blocks etc.)

 Area Engineer/Supervisor will ensure that all lifting tackles are in accordance
with standard
 List of T&P to be used.

Si. T&P Description Purpose Validity Remarks

NO
1 32 mm wire rope Lifting
sling 12mtr-2 Nos.
2 1inch wire rope sling Trailing
6 mtr-2 Nos.
3 Chain block/Hand Locking
Rachet 5T-2Nos.
4 D shackle 17T-4Nos. Lifting
5 D shackle 12T-4Nos. Trailing

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 6 PP Ropes 20mm Lifting

 Wire Rope will not over load beyond safe working load.
 When weight of an object is in doubt, lifting of higher safe working load
capacity will be used.
 Belt with worn out, damage or defect will not be used.
 While using belt over sharp corner supervisor to ensures, padding of gunny
bags, rubber packing.
 Engineer/Supervisor ensures that no one will carry any repair or change in
defective belt or slings work.
 Regular inspection will carry out by safety dept for ensuring good quality of
belts and slings.
 Engineer/Supervisor will look after to avoid sudden jerk or pull to the belt.
 All defective belts will be discarded, cut off to avoid re use.

10.Work at Height
 Work at Height Tool box talk to be conducted among with riggers &
helpers before start the work. PTW to be issued from MEL.
 Only authorized and trained riggers will be allowed to work at height.
 Only approved and certified ladders will be allowed for access.
 Full body harness required for personnel those who are involved in
erection.
 Supervisor and site in charge will do arrangements of lifeline for height
work.
 All people will use full body harness attached to lifeline or any secure
anchor point at the work place

Prepared By Reviewed By Approved By

Name :
Company : PMPL MEL MEL
Designation :
Date :
Location :

Signature :

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