PROJECT PROCEDURE

WORK METHOD STATEMENTS

FOR LIFTING
DOC. NO. : IONE-AA00-MS-MS-0001
KARBALA REFINERY PROJECT Rev. A Page 1/15
Ref. FEED DOC. No. : N/A

WORK METHOD STATEMENTS

FOR

LIFTING

PROJECT : KARBALA REFINERY PROJECT

LOCATION : KARBALA, IRAQ
EMPLOYER : STATE COMPANY FOR OIL PROJECTS (SCOP)

A 11 AUG 2015 ISSUED FOR REVIEW M.K.PARK S.J.BACK Y.S.KIM B.H.SHIM H.S.HWANG

REVD REVD APPRD CONFD

REV. DATE DESCRIPTION PRPD CHKD
(PQM) (PM) (PD) (SCOP)

Joint Venture of Hyundai Engineering & Construction Co., Ltd., GS Engineering & Construction Co., Ltd., SK Engineering &
Construction Co., Ltd., and Hyundai Engineering Co., Ltd.,

Note :
a) Revision bar(vertical line) shall be placed in the right hand margin to indicate where the changes has been made
b) PRPD = Prepared by, CHKD = Checked by, REVD = Reviewed by, APPRD = Approved by, CONFD = Confirmed by
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REVISION HISTORY

Rev. Date Description Page

A 11 AUG 2015 Initial Issue -

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WORK METHOD STATEMENTS

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1.0 SCOPE

2.0 REFERENCE

3.0 CLASSIFICATION OF ITEM

4.0 SAFETY

5.0 UNLOADING AT THE JETTY

6.0 PROCEDURE

7.0 REQUIREMENTS

8.0 APPENDIX

1.0 SCOPE
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The purpose of this document is to define the construction method statement

for in-land transportation, unloading at site, rigging and lifting of equipment.

2.0 REFERENCES

The document applicable for the lifting procedure is the requirements of the
contract and all necessary documents for the completion of the works.
However here under is the mechanical part of the specification, drawing,
codes and standard specification;

2.1. ANSI B 30, Safety Standards for Cable ways, Cranes, Derricks, Hoists,
Hooks, Jacks and Slings.

2.2. PIP/ API REIE 686 recommended practices for machinery installation and
installation design.

2.3. Safety, Health and Environmental requirements.

2.4. Manufacturers Manual of Handling Equipment.

1. CLASSIFICATION OF ITEM

3.1. Classification of Permanent Plant Equipment

The requirements for activities covered by this procedure are based on

classifying the Items into four (4) categories according to their important
physical characteristics, as defined in the following sections.

3.1.1. Category “A” (Critical Lifts: Exceeding 100 tons or exceptional

conditions)

(1) Require two or more cranes to make lift.

(2) Are located such that the load, crane boom or rigging could fall on
electrical lines, transformers, pipe racks or pipe bridges, vessels or
operating units containing flammable, explosive or hazardous
gases
and liquids or etc.

(3) Are specially designed and designated to handle specific loading

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that are require the use of lifting equipment, such as, but not limited
to, riggers, towers, poles, cableways, etc.

(4) Vertical vessels that exceed 100 ton erection weight, 20 meter
overall height

(5) Horizontal vessels that exceed 100 ton erection weight.

(6) Vessel that is located within a structure or is supported by a

structure 10 meters or higher from ground level.

(7) Thin wall thickness of vessels that may require temporary

shipping support and loading slings shall install auxiliary spiders,
struts, bands or stiffening rings to prevent shell out-of roundness
during transportation.

(8) Transportation, unloading of any piece of equipment by ship, or

otherwise, exceeding 2 meter in diameter, 20 meter in length or 100
ton in weight.
Note: Crane configuration as used in this procedure refers to such
variables of the crane as boom length, boom angle,
counterweight outriggers extended and set/tracks
expanded or retracted and attachment (Jib, headache ball,
load block, lofting devices etc). All above items affect the
gross capacity of the crane and shall be taken into
consideration prior to lift.

(9) Category “A” (Critical lifts) shall be submitted to company

representative for review prior to conducting lifting activity.

3.1.2. Category “B” (Heavy Lifts); 50 to 100 tons.

Items classified as Category “B” are those that are handled with
standard manufactured handling components and commercial
standard designed equipment, but those susceptibility to damage,
cost,
or long lead time to replace may necessitate the use of a detailed
procedure, as determined by the Contractor–Category B (Heavy Lifts)
shall be submitted to company representative for review prior to
conducting lifting activity.

3.1.3. Category “C” (Mean size lifts); 10 to 50 tons

3.1.4 Category “D” (Minor lifts); Up to 10 tons

 Static, Rotating Equipment
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 Ladder and Platform

 Internal Material
 Miscellaneous

Note: Items classified as Category “C” and “D”, those that may be handled
with conventional equipment, using standard rigging practices, by
qualified personnel without heavy lift and erection plan.

3.2. Lifting and movement plan shall be submitted in order to review by company
Representative prior to the lift and movement to the site.

4.0 SAFETY

4.1. General
1) On all locations where work is performed, the Contractor shall be
responsible for ensuring at his own cost the health, safety and welfare of
all personnel involved in the performance and/or inspection of the work,
including personnel of Company and designated third parties, and in
particular for ;

 Providing all necessary information in respect of any

potential hazard associated with the performance of the
work and measure to be taken to confront it/to prevent it.
 Providing appropriate safety equipment, gear and
protective clothing.

 Taking adequate safety, prevention, health and

firefighting measures such as, but not limited to following;
Use tag lines to the direct load, watcher and area to be
taped off.

2) The Contractor shall also take all necessary appropriate to protect the
Company’s Property at work- site and its environment and avoid or
reduce to a minimum inconvenience to the public and to other
contractors.

4.2. Construction Equipment

4.2.1. Standards of Construction equipment

(1) The Contractor shall provide all construction equipment
necessary for the performance of the work. Such construction
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equipment shall be suitable for its intended use and maintained

at all times in good operating condition that keeps appropriate
and uninterrupted valid certification in accordance with
applicable laws and Contract requirements.
(2) Upon the company’s request, the Contractor shall provide the
Company with the technical characteristics and the operating and
maintenance conditions of the major items of Construction
Equipment, as well as the names of the owners of the
Construction Equipment.

4.2.2. Certification for Cranes and Lifting Gears will be kept available at all
times during the performance of the work, subject to implementation
of applicable laws and regulations. Certifications for cranes and lifting
Gears shall be issued / updated prior to the requirement of operations
and s hall be kept valid for a period of a minimum of three (3) months
following the date of operation and the Contractor shall provide all
relevant documents and certificates as proof thereof. Colour coding
system for lifting and handling of lifting equipment should be
implemented on site. Certification shall be issued by TPA.

5.0 UNLOADING AT THE JETTY

5.1. For the heavy weight equipment, an unloading method shall be

determined on investigation the following items and an unloading plan
shall be made out prior to the work.

(1) Size, weight and shape of the equipment.

(2) Unloading facilities of the jetty.

(3) Accessible distance to the jetty for transporting column and Drum, etc.

(4) Time of Sunrise and Sunset.

(5) Time of Tides.

(6) Meteorological condition, such as wind wave at the jetty.

(7) Condition of ground at unloading point.

(8) Means of communication with the transport Column and Drum.

5.2. The ground at the unloading point, if it is not firm, shall be thoroughly
reinforced to prevent of the equipment turning over etc.
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5.3. Prior to unloading, the orientation and position of the equipment after
unloading shall be confirmed in relation to the orientation of installation

6.0 PROCEDURE
6.1. Frequent Check Requirements

(1) Check delivery date of the applicable equipment periodically.

(2) Access road to the installation place or lay-down area shall be cleared.

(3) Contact to the marine transportation company transferring the

equipment.

6.2. A thorough study shall be done in order to store safely in the storage area in
case that the equipment could not be installed immediately upon arrival on
site.

6.3. Obstacles / Crossing shall be identified well in advance along the access
road in order to clear the way prior to arrival of equipment. Reinforcement
shall be made around permanent or temporary facilities such as pipes or
conduits to withstand heavy weight.

6.4. The Contractor shall obtain the relative Authority’s approval for crossing
public roads.

6.5. To unload as well as in-land transportation of the Equipment, the soil or

ground shall be level and compacted properly to support the weight of
construction equipment and permanent plant equipment.

6.6. The width and the radius of rotation of transportation road shall be
checked and modified, if necessary, to transport the equipment from jetty
to site.

6.7. The Contractor shall develop and submit to the Company representative
a listing of all lifts exceeding 50 tons. The Contractor shall update this list
monthly or as required.

6.8. The use of lifting lugs shall be governed by the following requirements. All
lifting lugs shall be designed to meet ANSI/ASME B30, 20 allowable
design stresses. This may be done with using 1/3 of yield point or AISC
allowable stresses with a load factor.
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6.9. The manufacturer shall provide the necessary certified rigging gear to
use all designed lifting points on fabricated equipment, unless directed
otherwise by Company representative.

6.10. Temporary lifting lugs are sometimes attached to the component at the
vendor’s shop to be used for shop assembly only, if these lugs have not
been removed before shipment, they must be removed in the field or
clearly tagged with instruction that they are not to be used.

6.11. Any lugs not shown on the approved drawing must not be used.
Temporary lifting lugs are not allowed on any vessel or equipment unless
designed, fabricated and installed by the manufacturer prior to shipment.

6.12. Jib or hook and link or makeshift fasteners, formed from bolts, rods etc.
Other such attachments shall not be used.

6.13. For all crane lifts, the total load lifted by the crane shall not be exceed
eighty percent (80%) of the allowable capacity of the crane tipping chart,
and the clearance between the boom and load or other obstruction shall be
a minimum of the three (3) feet.

6.14. Before a crane transports a load, the load shall be tied back or secured
to the crane to prevent swinging.

6.15. Load charts for crane boom lengths, radial angle and optional
configuration shall be available with the crane at all times and ensure
that such lifting devices are properly inspected, maintained, and affixed
with TPA sticker.

6.16. Crane mats shall be used under all crane outriggers and when the load
exceeded 60% of the allowable capacity under crawler crane trucks,
unless calculation of the actual versus allowable soil loading show they
are required.

6.17. When crane mats are used they shall be made of hardwood timbers
(bolster) a minimum of eight (8) inches thick and arranged to spread
the load to the soil. In conditions of poor soil, more than one layer may
be required to spread the load sufficiently

6.18. Under no circumstances will be laminated “truck mats” be used to spread

the load to the soil

6.19. Crane booms one hundred (100) feet in length, or greater, should be
either lowered to the ground during overnight or the load block should
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be anchored to secure an object and a slight load placed on the crane

block.

6.20. The Contractor shall provide documentation on all cranes brought on to

the site. Lifting work shall not be permitted unless the cranes are certified
by TPA

6.21. All custom-designed rigging equipment, such as spread bars, beams,

links, and any other device which carries all or part of the load being
lifted, shall designed to meet ANSI/ASME B30, 20 (below - the – hook
lifting device) allowed design stresses. This is may be done by using 1/3
of yield point or AISC allowable stresses with a load factor of 1.8.

6.22. All shackles shall be in good condition, with the capacity permanently
marked on the shackle and color coding should be implemented.

6.23. All slings shall be in good condition identified as to size and capacity,
with a permanent identification stamp or an approved identification
alternative and color coding should be implemented.

6.24. All slings shackles and/or lifting appliances shall have a test certification
issued either by third party or approved manufacturer stating the safe
working load size, and identification, thus identifying the individual sling
and color coding should be implemented.

6.25. All signals shall be controlled by the qualified signalman in charge of

the lift.

6.26. The Company Construction Manager or his designated representative

shall be retain the right to halt the operation any time he seems an
unsafe act or situation developing and not allow the operation to
continue until the condition is corrected. Stoppages of this nature to
Contractor account.

6.27. Night rigging work will be done with artificial light sufficient to permit the
work to be carried out on efficiently and safely.

6.28. The Contractor will rope off or barricade areas beneath the load to prevent
personnel from entering.

6.29. The execution of the lift must not deviate from the rigging plan and
procedure.
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6.30. Prior to making the lift, the Contractor shall thoroughly brief all personnel
involved with the lift as to their duties and responsibilities.

6.31. The Contractor shall designate a representative who shall be the single
point of contact for all lifting operations.

6.32. Lifting lugs must be inspected prior to the lift. The inspection shall include
the followings;

(1) The size and quantity of all component of the lifting lug shall be checked
making sure that all parts, such as gussets and reinforcing plates, have
been installed.

(2) The location and orientation of lifting attachment shall be checked for
conformance to drawing and specifications.

(3) Weld sizes shall be checked for conformance to drawing and

specifications.

6.33. Dimensions, finishing and alignment of lifting holes shall be checked for
conformance to drawing and specifications.

6.34. Rigging appliances (ropes, slings, shackles, lifting beams, hooks etc.)
shall be visually checked prior to each major lift. Unacceptable rigging
appliances will be tagged and removed from the site.

6.35. Contractor shall confirm that forecast weather conditions throughout the
duration of the lift are acceptable before the lift of any item with a large sail
area. When wind velocities approach action levels, velocities shall be
monitored continuously.
Also the following should be considered prior to any lift.

(1) The Contractor shall confirm forecast weather condition with operations
personnel whether access to anemometers. The Contractor shall be
familiar with wind velocity action levels for the protection of cranes from
high winds.

(2) A wind velocity action level for termination of lifting activities.

(3) An inspection required for cranes that have been subjected to weather.

6.36. Specific lifting instruction supplied by equipment manufacturer to be use

when applicable. The Contractor shall review these instruction prior to
use when applicable to Category “A” and “B”
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7.0 REQUIREMENTS
7.1. Prior to any lift or movement being performed the following minimum
conditions must be fulfilled:

 Certificates of all cranes, slings, shackles, lifting

appliances, operators etc. must be available.

 Approved lifting study

 Supervisor and safety officer approved by Contractor to

perform the particular lift.

 Risk assessment to be completed.

7.2. For heavy or critical lifts, special precautions must be taken and no “go
ahead” for lifting will be given prior to all following conditions being fulfilled ;

7.2.1. Detailed lifting study with a drawing to scale of;

- Crane and crane layout

- Equipment to be lifted and sketch / drawing at the each critical

lifting position of equipment or vessel.

- Lifting accessories

- Tail crane

- Clearance between crane and other equipment.

- Access to area for the crane and equipment to lifted.

7.2.2. Unloading and transportation study inside and outside the plant for
the crane and the equipment to be lifted.

7.2.3. Approval by the safety manager and site logistic coordinator for the
necessary road closures.

7.2.4. Review of supplier’s recommendation concerning lifting and handling.

7.2.5. Soil bearing load calculation

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7.2.6. North marking of drawing on foundation and equipment to avoid

orientation errors. (Confirm true north & plant north)

7.2.7. Checking of anchor bolt and placing of shimming plates.

7.3. The Contractor shall submit to the Company Representative a detailed

rigging plan and procedure for the rigging operation before the major lift
(either heavy or critical) is to take place. The rigging plan submitted by
the Contractor must include the following;

(1) Total weight to be lifted including load blocks and rigging gear.
(2) Identity boom length, radius, capacity of all crane.

(3) Scale plot plan which shows location of lifting equipment, lifted items,
and their relationship with any potential obstructions.

(4) Scale elevation view which shows the relationship and clearness
between the lifting equipment and lifted items.

(5) Identity the specification of all shackles, slings, and other rigging gear.

(6) Detailed written description that adequately describes any part of

the erection procedure not made obvious by the drawings.

(7) A set of crane charts and equipment procedure for equipment

being used.

7.4. During lifting, after obtaining work permit, the Contractor shall be present
to make sure that lifting is performed as per approved procedure. Other
works in the danger zone will be prohibited during all lifting activities.

7.5. The list of critical lift will be given to the Subcontractor prior to Subcontract
award and detail of the Contractor’s lifting organization and equipment will
be checked for consistent with the company’s requirement. The feasibility
of the means for the installation of heavy equipment shall be studied in
details.

7.6. During the feasibility of the means for the installation of heavy equipment is
being reviewed, the detailed plot plans, foundation and structure drawings,
heavy equipment layouts, transportation road / access and routing will be
checked to guarantee that lifting can be performed with safety and
efficiently
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8.0 APPENDIX
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