SAFE WORK METHOD STATEMENT (SWMS)

Activity – Surface Condenser Flash Tank SIEMENS

Installation and Welding

Released by: Mr. Abhishek Srivastava Project Manager

Reviewed by : Mr. Peter Antony Site Manager
Created by : Mr. Yogesh k Mishra Execution Engineer
Name Org.-Unit
The approvals of all involved persons are recorded in the document management system.

age 1 RC IN PG EHS - SWMS – Aug 2017

 Contents

1. PURPOSE -------------------------------------------------------------------------------------------------------------------- Page 3

2. SCOPE -------------------------------------------------------------------------------------------------------------------- Page 3

3. REFERENCE DOCUMENTS --------------------------------------------------------------------------------------------------------------- Page 3

4. ABBREVATIONS AND DEFINITIONS ---------------------------------------------------------------------------------------------------- Page 3

5. PROCEDURE ---------------------------------------------------------------------------------------------------- Page 4
5.1 Receipt and unloading of Lighting Materials at Lay down area. ------------------------------------------------------------ Page 4
5.2 Shifting the material to site. ----------------------------------------------------------------------------------------------------- Page 4
5.3 Inspection ------------------------------------------------------------------------------------------------------------------------------ Page 4
5.4 Assembly of Standpipe. ------------------------------------------------------------------------------------------------------------ Page 5
5.5 Assembly Flash Box /Flash Tank: --------------------------------------------------------------------------------------------- Page 5
5.6. Installation -------------------------- -------------------------------------------------------------------------------------------- Page 6
6. Welding detail for Neck & Dome with Shell Assembly: ----------------------------------------------------------------- ------ Page 9
7. Welding detail for Bottom Hotwell with Shell assembly ----------------------------------------------------------------------- Page 9
8. Check list ------------------------------------------------------------------------------------------------------------------------------- Page 10
9. RESOURCES, MANPOWER, EQUIPMENT PLANNING:- --------------------------------------------------------------------- Page 10
10. SAFETY PRECAUTIONS ------------------------------------------------------------------------------------------------------------- Page 11
10.1. General Precautions ------------------------------------------------------------------------------------------------------------- Page 11
10.2 Monsoon Preparation ------------------------------------------------------------------------------------------------------------- Page 11

age 2 RC IN PG EHS - SWMS – Aug 2017

 General
1. PURPOSE:

This document describes the methodology for the Surface condensers Flash tank, Flash Box, Stand pipe installation, Welding and Garb Spring
Installation activity and to ensure that all concerned persons are familiar with the sequence of activities, utilization of resources and execution of the
works in compliance with applicable safety and quality procedures, reference documents and specification

2. SCOPE:

This method statement describes the Surface Condenser Flash tank, Flash Box, Stand Pipe Installation and welding and garb Spring Installation activities.
The activities involved such as movement of the material inside the construction site, unloading of the material at lay down area, shifting of material to
installation designated area, Flash Tank, Flash Box, Stand Pipe installation with the general safety and necessary control measures are described in detail.

3. REFERENCE DOCUMENTS:
DESCRIPTION
1.General Arrangement Drawing
2.Equipment's Foundation Drawing
3.P&I Drawing
4.Risk assessment sheet

4. ABBREVATIONS AND DEFINITIONS:

PTW: Permit to Work
FBSH: Full Body Safety Harness
SWMS: Safe Work Method Statement
MS: Method Statement
RA: Risk Assessment
DP Dye Penetration
QC Quality Control
age 3 RC IN PG EHS - SWMS – Aug 2017
 5. PROCEDURE:
5.1 Receipt and unloading of Lighting Materials at Lay down area.
After receiving material and completing inward formalities, Surface Condenser Materials are shifted to lay-down area in truck and unloading
is done manually/ Mechanical. Material will be inspected as per packing list for approved make, quantity and any external damages is to be
checked and information is to be given to back office and supplier. Damages should be noted by digital pictures.

1. The Flash Tank, Flash Box, Stand Pipe, And fittings to be stored on hard surface in the open yard.
2. The light fixtures and material to be stored in the closed store on flat surface above the ground.
3. The outside stacking must be lower than 2 metres.
4. The inside stacking must not be overloaded and protected from climatic effects.

5.2 Shifting the material to site.  

a) Shifting of material will be done by Farana and trailer.
b) The approach and area of unloading is to be selected and make suitable for working.
c) The pipe and Fittings specification and the type to be checked by the responsible engineer.
d) The Flash Tank, Flash Box, Stand Pipe and Pipe to be secured on the trailer to prevent any fall. The vehicles must adhere to the speed
limit of max. 20 km/h or as per client’s instruction.
e) The material to be unloaded manually/ mechanically and shifted to the work area.

5.3 Inspection
f) Before starting of the Flash Tank, Flash Box and Stand Pipe installation, the specification must be checked and ensured.
g) The PPEs and other tools tackles of the workers to be inspected for healthiness before starting of the job.

age 4 RC IN PG EHS - SWMS – Aug 2017

 5.4 Assembly of Standpipe.

1. Lift the stand pipe with the help of lifting aid (Chain Pulley Block).
2. Align the stand pipe with upward measuring Standpipe connection provided in shell & downward measuring
Standpipe connection in Hotwell.
3. Check the dimensions given in the G.A Drawing .Record the same. Fit stand pipes with all valves and instruments
to the condenser shell and hotwell. Refer the condenser GA drawing for orientation/ position of the component.
4. Please refer below sketch for arrangement of stand pipe.

5.5 Assembly Flash Box /Flash Tank:

5. Lift the Flash Box / Flash Tank with the help of lifting aid (chain block).
6. Align the with upward Flash Box / Flash Tank connection provided in dome & downward Flash Box / Flash Tank
connection provided connection in Hotwell.
7. Check the dimensions given in the G.A Drawing, Record the same. Refer the condenser GA drawing for
orientation/ position of the component. Fit flash box /Flash Tank to condenser neck and Hotwell and weld all
connection.
8. Please refer below sketch for arrangement of Flash Box/Flash Tank.

age 5 RC IN PG EHS - SWMS – Aug 2017

 5.6. Installation
Aspect On surface/On Elevation levels
Access
1. Clear all obstructions (if any) in the way to
the work location.
2. Clean the nearby area before starting of
the job.
Lifting
1. The Flash Tank and Stand Pipe materials
are generally to be carried manually.
2. In case of higher elevations, Flash Tank
And Stand Pipe can be lifted by using
pulley’s arrangement and a guide rope.
age 6
At Height
1. Clear all obstructions (if any) in the way to the work location.
2. Scaffolding gang will construct required length of Scaffolding platform depending on
the Flash Tank and Stand Pipe.
3. Working platform will be certified by the Scaffolder and all authorized persons will be
allowed to access the working platform.
4. Wherever Required, lifeline must be used.
1. The Flash Tank, Stand Pipe and all other accessories are generally to be carried
manually.
2. In case of higher elevations, Flash Tank And Stand Pipe can be lifted by using pulley’s
arrangement and a guide rope.
3. All materials must be lifted to the installation point by using proper rope with bag
arrangement for carrying the small parts.
RC IN PG EHS - SWMS – Aug 2017
 5.6 Installation (Fabrication & Inspection)

Aspect Fabrication & Inspection

Installation Fabrication
Marking shall be done according to drawing requirement and the same shall be checked by concerned supervisor prior to cutting.
The cutting shall be generally done as following:
a) Carbon Steel pipes           -          By gas cutting & grinding.
1. End preparation and fit-up shall be done at shop as per the approved Specification and WPS.
2. Care shall be taken to make sure that longitudinal seams on the joining pipes will not come in one line in a butt joint. Seams will be
staggered at least 100mm apart and also will clear the branch connections. Care shall be taken to make sure that longitudinal seams
are not resting on the steel structure.
3. Welding of the joint will be done after getting QC fit-up Inspection clearance and the same shall be offered for Client inspection
randomly.

age 7 RC IN PG EHS - SWMS – Aug 2017

 5.6 Installation

Aspect On surface/On Elevation levels

Flash Tank, Flash box and Stand Pipe

Installation 1. Check the route, illumination, hazards and access for starting the job.

2. Start the work on proper and valid PTW and availability of competent manpower and supervisor.

3. Measure the route and distribution of the Flash Tank and Stand Pipe installation.

4. Ensure use of inspected and safe tagged equipments only.

5. Make proper bends and angles in the cut pieces as per requirement.

6. Take proper power connection from safe source and using proper cables and DBs.

age 8 RC IN PG EHS - SWMS – Aug 2017

 6. Welding detail for Neck & Dome with Shell Assembly:

Procedure:
1) Refer the condenser GA drawing for orientation/ position of the component.
2) Before welding match the Neck & dome edge with marked / painted welding line on shell.
Sequence:
3) Tack-weld the Neck & Dome to the Condenser shell assembly (without cut the shell) and check the dimension/orientation/levels
once again and record the same, weld the assembly from outside.
4) All around fillet argon root [GTAW_Gas tungsten-arc welding (TIG) ASME SFA 5.18 AWS ER70S-2].
5) 100% DP test.
6) Fillet welding with 3.15mm (SMAW_Sheild Metal-Arc welding ASME SFA 5.1 AWS ER 7018).
7) Subsequent; fillet welding (SMAW) with 3.15 OR 4 mm should be up to 12 mm.
8) 100% DP OR water filled test (min 300mm above the welding joint line).
Caution: Before fill the water please lock the spring support

7. Welding detail for Bottom Hotwell with Shell assembly

Procedure:
9) Refer the condenser GA drawing for orientation/ position of the component.
10) Before welding match the Hotwell outer edge with marked / painted welding line on shell.
Sequence:
11) Tack-weld the Top Hotwell to the Condenser shell assembly & Neck & Dome (Without cut the shell) and check the dimension/
orientation/ levels once again and record the same, weld the assembly from out side.
12) All around fillet argon root [GTAW_Gas tungsten-arc welding (TIG) ASME SFA 5.18 AWS ER70S-2].
13) 100% DP test.
14) Fillet welding with 3.15mm (SMAW_Sheild Metal-Arc welding ASME SFA 5.1 AWS ER 7018.
15) Subsequent; fillet welding (SMAW) with 3.15 OR 4 mm should be up to 12 mm.
age 9 16) 100% DP OR water filled test (min 300mm above the welding joint line). RC IN PG EHS - SWMS – Aug 2017
 8. Check List:

8.1 House keeping

Plastic & All un-useful material is to be kept in scrap area on daily basis after completion of work.
Nails, metallic waste, cut pieces of pipes, etc should be collected and disposed off in designated scrap area.
The installed light fixtures shall be cleaned using cotton cloth if required.

8.2 Final Inspection

End of the shift it will be ensured by the Supervisor that the fixtures which are partially completed must be secured properly.
Ensure that no loose material/ tools & tackles or installation fixtures are left at the work area.
Ensure that fire watch for any Hot work area to be completed 30 minutes after last work. This must be done by the Supervisor

9. RESOURCES, MANPOWER, EQUIPMENT PLANNING:

Note: Actual Resource Plan both Tools & tackle and manpower will be review & finalized by Site in- charge .
List of resources and material to be prepared at site.

age 10 RC IN PG EHS - SWMS – Aug 2017

 10. SAFETY PRECAUTIONS

10.1. General Precautions

1. All personnel to be inducted by Siemens .
2. All power tools to be inspected before use must green tagged.
3. Competent Site Supervisor shall be deputed during the Work Progress.
4. The method statement and risk assessment form the basis of the TBT initially
5. Tool box talk shall be conducted on daily basis for manual understanding of the workers involved in the installation process & same is to be submitted to Siemens.
6. Identified hazards and control measures shall be explained to erection team/work men through tool box talks every day in the morning before the start of the activity till the
completion of job.
7. Risk assessment shall be done well in advance by site engineer/supervisor and the same shall be reviewed & approved by Safety officer, Site in charge.
8. Keep fire extinguisher at the work location. All Hot work shall be controlled with hot work permit. Welding screen are to be used for any welding activity.
9. Work permit to be obtained before starting work.
10. Unauthorized person shall not be allowed to enter the work area during the work.
11. All lifting tools & tackles shall be inspected visually for safe use.
12. Appropriate PPE's such as helmet, gloves suitable for the task High visibility vests, and safety shoes shall be used.
13. Conduct regular or daily check of the equipment & machineries prior to use. Check for "safe for use" tag .
14. Conduct regular medical fitness of all workers.
15. Mandatory use of safety PPE is a must while welding and installation activities.
16. All tools and tackles shall be secured in a bag suitably tied to person.
17.Only trained and competent persons shall be deployed for working at height.
18. Working area to be barricaded with warning tape to avoid the entry of unauthorized persons.
19. Installation/Work area shall be properly barricaded with proper signage.
10.2 Monsoon Preparation
1. In Rainy Condition welding and cutting work shall be carried out in covered area with roof arrangement.
2. Gum Boots shall be used for working on wet ground with steel toe.
3. Heavy material shall not be shifted in rainy atmosphere with hydra or crane.
4. Erection of pole shall not be done in rainy atmosphere.
age 11 RC IN PG EHS - SWMS – Aug 2017