Classification: Public

Company: Thermax ltd

Work Method Statement Completed by:

Date completed:
Ratan Singh

30th NOV 2023

METHOD STATEMENT FOR Assembly & Erection of ESP Casing box up

LOCATION of work (as specific as possible): Near Boiler house ESP (Electrostatic Precipitator) Area (Package-2).

DESCRIPTION of work (as specific as possible): Erection of ESP Penthouse

Start of work (date & time) 16 th oct 2023 @ 10:00 Expected duration of work: 15 th NOV 2023 @ 12:00
Scope of Works & S &H information received from site? √ Yes No
Risk assessment completed and reviewed? √ Yes No
Name of Contractor Performing Authority: Thermax ltd

HOW will we do the work?

1. INTRODUCTION:

 This method statement describes the work procedure to be followed for Assembly & Erection of ESP (Electrostatic Precipitator)
Casing box up Phase-2 (Package-2). Nestle, Sanand.

2. SCOPE:

 The scope of work involves the following:

 Ground assembly of ESP Casing

3. DETAILS OF MATERIAL:

 At ground Assembly time- Length with nozzle<14.5mtr> width<8.692 mtr>Height<3.692 mtr> weight-14 ton
 Dimensions after assembly along with Inlet and outlet nozzle
 Length with nozzle<14.5 mtr> width<3.692 mtr>Height<8.910 mtr> weight-14 ton for vertically position.

4. REFERENCES AND STANDARD:

As per Good Engineering Practice and Nestle standard of OHSE guidelines.

5. TOOLS & EQUIPMENT REQUIRED:

 One Farhana <SWL-15MT>

 Crane as per requirement.
 D-shackle <SWL-5MT > 4 nos’ for assembly
 D-shackle <SWL-17MT > 4 nos’ for Erection
 Web Sling/steel sling <5WL> 4nos.
 Steel sling as per requirement
 Rope <Nylon rope, only for guiding>.
 Gas cutting set.
 Welding machine
 Grinding machine
 Full body harness
 Hand tools
 Scaffolding staging (ITL)
 Man lift
 Chain block
6. PERSONAL SAFETY EQUIPMENT REQUIRED:

 Safety helmets, safety shoes, cotton hand gloves, safety goggles, leather hand Gloves.

7. Assembly work at ground crew to be present:

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 Construction team Engineer – 01
 Foremen – 01
 Rigger -02 Nos
 Signalman-01.
 Welder-02
 Gas cutter -01
 Helper-02
 Man lift/crane/farana operator-4
8. SEQUENCE OF ACTIVITIES: (attached snaps).

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Previous site Photo after assembling:

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Crane Positioning:

Crane position place

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GROUND BEARING PRESSURE CALCULATION

 Weight of 160MT Crane = 55MT

 Weight of Counterweight= 20MT
 Weight of Load = 14 MT
 Weight of Rigging equipment and accessories = 1 MT
 Gross Weight = 90 MT
 Weight on each outrigger = 0.66X 90 = 59.4 MT

A = 59.4 MT/40 t/msq = 1.48 msq

A (reqd.) = √1.48 msq = 1.21m X 1.21m
Available plate size at site = 6.25msq.

Crane load chat

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Load chart of Farana

ESP

Casing box up weight details

Weight of Accessories = 800KG

Weight of Load = 14 MT
Weight of Rigging = 200Kg
Total Weight = 15 MT
10.PREPARATORY WORKS BEFORE STARTING THE ACTIVITY:

 General work permit, height work, Hot work & Critical lifting work permit to be taken before starting the job by
performing authority.

 All Tools & tackles to be used before starting the job once confirmed TPI done & Green tag has been either done or not

 TPI certification hard copy also to be checked before commencing the job.

 Before the work is started, a brief safety talk Shall be given on the scope of work and hazards associated with the work
to all the concerned for safety awareness.

 Display of cautionary signboards.

 Barricading of the work area shall be done by caution tape to avoid unauthorized persons entering the work area.

 Housekeeping is to be done before starting the work.

 Ensure Safety compliance. (PPE’s, barricading, toolbox talk, medical fitness of operator, Test certificates (T.P.I.) of lifting
tools and tackles)

 Keep the proper tools, which we need to be used during unloading.

 Check the web sling, wire rope sling & Rope.

 Ensure Crane jacks should be placed on 2.5 X 2.5 m X 25 mm plates.

 Used chain block for ESP casing assembly work.

Description of work
9. ESP Casing Assembly & Erection.

 Prepare the Bed for ground assembly of ESP casing structure.

 Complete the water level of Bed with additional support for fixing if required.

 Do the ground assembly of ESP casing column structure with Top girders, bottom girders, side panels, Nozzle, Collecting
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and Di-Emitting plate.

 Do the complete welding of casing /nozzle panels.

 Fixing Collecting and Di-Emitting plates at ground.

 After welding work complete inspection work to be done for any leakage.

 After inspection work complete fixing lifting hook for Erection work.

 Ensure Loose material removing at casing before Erection work start.

 Crane positioning for the erection of casing panel

 Sling fixing work at the assembled ESP Casing for the erection & guide rope will be fixed at ground on structure.

 Properly fixing of tag line rope to control the assembled casing box up while lifting & erection.

 Lifting of assembled casing for erection with Crane and 2 no’s Farhana will use for toeing & positioning vertical.

 Lifting & positioning of assembled structure at top of base columns at 6-meter elevation.

 Manpower will access by scaffold/man lift at 6-meter elevation for fastening bolts & welding to arrest ESP casing
structure at position.

 After Securing the casing column properly, person will access through man lift for de slinging of structure and releasing
load from crane.

 Gas cutting set is to be used for plate/column cutting work.

 If required grinding set will be used.

 Used chain block for ESP casing assembly work.

 Scaffolding staging (ITL) use for casing plate fixing at ground.

 Fire extinguisher and fire blanket shall be placed at workplace.

 Deploy fire watcher near the hot work Area.

 Arrangement of skilled manpower for the job.

 Supervisor shall ensure, during whole activity workers hand or any body part should be out of material that it could not
create any Injury to workers.

 Avoid line of fire & flagman shall be deployed & area to be barricaded.

12.STEPS AFTER COMPLETING THE ACTIVITY:

 After completing the erection activity at nearby ESP area, ensure the Web sling & rope shall be removed from the
material.

 Ensure remove the barricades.

 Housekeeping is to be done before leaving the area.

 Specific job location all permits shall be closed.

WHO will do the work?

Thermax ltd agency is doing this ESP Casing box up Assembly & Erection job at nearby ESP area.

1. DESCRIPTION of materials (materials, consumables, quantities, hazardous properties)

WHAT EQUIPMENT will we use?
Ladder Cutter machine if required.
Mobile Scaffold Tower Material Movement vehicle, Truck/Trailer
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Mobile Elevating Working Platform Excavator
Scaffolding Powered Hand Tools

Farhana/crane

Additional equipment to be used: Telescopic Crane

Will we need a PERMIT-TO-WORK…?
High-
Confined Hazardous Mode 4 Critical
Work at Hot hazard Ground
Space Line Machinery Lifting Demolition
Height Work Electrical Disturbance
if Entry Breaking Intervention Operation
Work
required

What services will need to be ISOLATED…? (Electricity, Compressed Air, Hydraulics, Gravity, Springs, Other stored energy)
SERVICES TO BE ISOLATED: Not Applicable

How will we prepare BEFORE STARTING THE JOB?

PRE-JOB MEASURES to be taken:
Ensure statutory safety compliance & Vehicle fitness, use appropriate PPE’s, obtain work permit, Unauthorized entry
restriction, Area to be proper levelled and compacted and also area should be proper barricading.
What precautions will we take DURING THE JOB?
PRECAUTIONS required:
Before the work is started, a brief safety talk Shall be given on the scope of work and hazards associated with the work to all the
concerned for safety awareness.
Close eye supervision.
Check the medical fitness of operators.
Check the cherry picker vehicle or fixed scaffolding tower.
Safe lifting procedures should be planned by a competent person.
Periodically maintenance of Crane& Farhana should be carried out.
Training in safe lifting is given to all involved persons.
Display of cautionary signboards.
Barricading of the work area shall be done by caution tape to avoid unauthorized persons entering the work area.

WHAT PPE will we use?

if Face
Safety Reflective Eye Ear Protective Respiratory Respiratory Personal fall Protective
required Helmet
footwear vest protection
protection
protection gloves protection protection arrest system clothing
)
√ √ √ √
If using gloves or respiratory protection cotton mask or if any other, indicate type: Cut level 1 hand gloves

How will we PROTECT OTHERS?

Measures to protect OTHERS (eg other workers, members of public)
No unauthorized entry, close supervisor and ensure use of PPEs and hard barricading with Signage boards.
Communication shall be done through email to Nestle project team one day prior to the activity on Mixer tower area
access blockage, as crane shall be placed on road going towards Mixer tower.

What if things GO WRONG?

EMERGENCY PROCEDURES, such as first aid, Contact with emergency number like OHSE center Safety and fire team.
According to site emergency response plan.
First aid kit, Nearest OHC.

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