Brazing Procedure

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DELEVOPMENT MANAGER: J ohn Buck CompanyP.O. Box: 63737, ABU DHABI, UAE

Tel: (+971) 2 414 6699 - FAX: (+971 2 4146756

Internet: www.johnbuckinternational.com

ARCHITECTS: Goettsch Partners224 S. Michigan Ave, Suite 1700 Chicago, IL 60604

GenslerAldgate House, 33 Aldgate High St,

London EC3N 1AH

CONTRACTOR: OGER ABU DHABIP.O. Box 35656, ABU DHABI, UAE

TEL: (+971) 3 7555745 - FAX: (+971) 3 7555732

ARCHITECTURE & OGER INTERNATIONALENGINEERING: 70 RUE SAINT-DENIS - 93582 SAINT OUEN - FRANCE

UNITED ARAB EMIRATES

ABU DHABI

ABU DHABI FINANCIAL CENTER

: -

INTERNET: www.ogerinternational.com

SUBCONTRACTOR: THERMO L.L.C.

5 DONE BY: CHECKED BY: APPROVED BY:

4 DATE & VISA: DATE & VISA: DATE & VISA:

3

2

1

ORGANIZATION PHASE TRADE UNIQUE NUMBER

TITLE:

PROJECT

005004

CONCEPT DESIGN

DESIGN DEVELOPMENT

CONSTRUCTION DEVELOPMENT

FLOOR

P H A S E S

MTS9000

AS BUILT

0Z

AREA23/09/09

2 PWS

DATE:

0Z

BUILDING

METHOD STATEMENT BRAZINGPROCEDURE

TRM

SCHEMATIC DESIGN

00

REV

0Z

Written document cover sheet template, rev 029/07/09



Contact: 5004SOWW AH SQUARE PROJ ECT

REF.No: 5004- TRM-2-~.s- 0z- .M1>~00ABU DHABI, UNITED ARAB EMmA TES

Rev. No. : 00

METHOD STATEMENT FOR Date: 19-5ept.-2009BRAZING PROCEDURE

Page: 1of 15

METHOD STATEMENT

FOR

BRAZI NG PROCEDURE

PREPAREDBy

HANY

CHECKEDBy

APPROVEDBy

GEaR

DESCRIPTION &PAGE NUMBERSOFREVlSION

UBMITlED FOR APPROVAL

~~ jC 4=? g l

O G E R A B U D H A B I

T H E R M OSUB CONTRACTOR

THERMO L .L .C.



Contact: 5004SOWWAH SQUARE PROJECT

REF. No: 5004- TRM-2·Q W 5 - 02.-nr,..~·000ABU DHABI, UNITED ARAB EMmA TES

Rev. No.: 00

METHOD STATEMENT FOR Date: 19-5ept.-2009BRAZI NG PROCEDURE

Page: 2 of 15

METHOD STATEMENT: Mrn THODSTATEMENTFOR THEBRAZWG

PROCEDURE

CONFIRM THAT THOSE PEOPLE LISTED BELOW HAVE BEEN MADE

AWARE OF THE REQUIREMENTS OF TillS METHOD STATEMENTAND UNDERSTAND THE CONDITIONS LISTED WITHIN.

~~1C4:?91

O G E R A B U D H A B I

T H E R M OSUB CONTRACTOR

THERMO L.L.C.



SOWWAH SQUARE PROJ ECTABU DHABI, UNITED ARAB EMIRATES

Contact:5004

REF. No: 5004-TRM-2-PWS-0Z-MTS9000

Rev. No. : 00

METHOD STATEMENT FORBRAZING PROCEDURE

Date : 19-Sept.-2009

Page : 3 of 15

CONTRACTOR

OGER ABU DHABI MEP CONTRACTOR

SUB CONTRACTOR

THERMO L.L.C.

TABLE OF CONTENTSS.NO DESCRIPTION PAGE NO.

01 Scope & Purpose 4

02 Reference & Related Documents 4

03 Abbreviations 5

04 Safety 7

05 Responsibilities 8

06 Equipment / Tools 10

07 Materials requirements 10

08 Work Sequence & Methodology 11

09 Procedure 12

10 Attachments 15




Contact:5004


Rev. No. : 00



Page : 4 of 15

CONTRACTOR


SUB CONTRACTOR

THERMO L.L.C.

1. SCOPE & PURPOSE

1.1. This “Method Statement” covers the nature and type of work for the BRAZINGPROCEDURE.

1.2. This method statement gives guidelines contained herein so as to ensure that the job executioncomplies with the requirement of the Specifications and the authorities concerned and servesthe intended purpose to satisfactory level.

2. REFERENCES& RELATEDDOCUMENTS

2.1 Project Quality Plan

2.2 Contract No:- 5004

2.3 Manufacturer Product Data Sheets

2.4 OGER HSE Manual.




Contact:5004


Rev. No. : 00



Page : 5 of 15

CONTRACTOR


SUB CONTRACTOR

THERMO L.L.C.

3. ABBREVIATIONS

EMPLOYER : MUBADALA DEVELOPMENTS

EMPLOYER REPRESENTATIVE : FLUOR

CONSULTANT : SEREX

CONTRACTOR : OGER ABU DHABI

SUB CONTRACTOR : THERMO L.L.C

PM : Project Manager

SE : Site Engineer

ITL : Independent Testing Laboratory

PQP : Project Quality Plan

QCP : Quality Control Procedure

MS : Method Statement

QA/QC : Quality Assurance / Quality Control.

ITR : Inspection and Test Request

NCR : Non-Conformance Report

MAR : Material Approval Request

MIR : Material Inspection Request

BPS : Brazing Procedure Specification

BPQR : Brazing Procedure Qualification Record




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Rev. No. : 00



Page : 6 of 15

CONTRACTOR


SUB CONTRACTOR

THERMO L.L.C.

PPE : Personal Protective Equipment

COSHH : Control Of Substances Harmful To Health




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Rev. No. : 00



Page : 7 of 15

CONTRACTOR


SUB CONTRACTOR

THERMO L.L.C.

4. SAFETY

4.1. All staff will have a safety induction carried out by the contractor before commencing anyactivities on site.

4.2. Prior to commencing any activity, labor force shall receive a tool box talk on the project sitesafety regulations from the subcontractor safety officer on a weekly basis on topicsappropriate to the activities being undertaken. A Method statement briefing will be given toall staff before the commencement of the work and a record kept.

4.3. Any process that is adopted that may have particular safety risk will be assessed andaddressed as required.

4.4. All activities will be subject to a risk assessment by the subcontractor safety officer before thecommencement of work which will be forwarded to the contractor safety department forapproval. Appropriate measures will be taken following the R/A to minimize the risksidentified.

4.5. Ensure only trained persons shall operate the power tools.

4.6. Ensure all concerned personals shall use PPE and all other items as required and full

specifications of equipment to be used including BSI standard will be provided.

4.7. Ensure adequate lighting and adequate space is provided in the working area at nighttime.

4.8. Ensure that in all areas where there is a risk of falling from height preventative measures willbe taken and identify them.

4.9. Ensure service shaft opening are provided with barricade, tape, safety nets.




Contact:5004


Rev. No. : 00



Page : 8 of 15

CONTRACTOR


SUB CONTRACTOR

THERMO L.L.C.

5. RESPONSIBILITIES

5.1 Project Manager

The CONTRACTOR/SUB CONTRACTOR Project Manager will have full authority and overallresponsibility to manage, supervise. He will. control the works and will have direct responsibilityfor ensuring safe working practices and compliance with regulatory authorities requirements. Co-ordinate with the engineers and the EMPLOYER REPRESENTATIVE for execution of theContract Scope of works. Implement the project quality systems to be the satisfaction of the projectrequirements. Review changes and variations to evaluate impact of those on time and schedule.

5.2 Project Engineer

Is responsible for ensuring that all works are carried out as per thespecifications, approved shop drawings, Method Statement, manufacturerinstructions and coordinate with other works.

5.3 QA/QC Engineer

1) Is responsible for monitoring the works are in fulfillment with the specifiedrequirements, that all quality records related to the works are complete.

2) He will carry out all the inspections with the EMPLOYER representatives

and notice will be given to EMPLOYER RE PRESNTATIVES within 3 daysand ensure that no work will be executed/covered up withoutinspection/testing.

5.4 Site Engineer

1) The site Engineer shall co-ordinate all the site activities according to work schedule,installation according to the project Specifications, Manufacturer Data Sheet and approvedshop drawings.

2) Shall Liaise with site representatives of EMPLOYER and CONTRACTOR and co-ordinatesafety procedures with site supervisors and site foremen.

3)

To Co-ordinate and explain the work to be carried out to the Supervisors / Site Foreman.




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Rev. No. : 00



Page : 9 of 15

CONTRACTOR


SUB CONTRACTOR

THERMO L.L.C.

4) He will ensure the compliance of works with the related approved Quality ControlProcedure and co-ordinate with the CONTRACTOR QA/QC Engineer to advise for theareas to be issued for inspection.

5.5 Site Supervisors and Site Foremen

1) The project team of experienced Supervisors and Foremen shall ensure the quality of theinstallation work carried out, and shall also ensure that it is as per the latest approvedconstruction shopdrawing issued for installation and according to instructions receivedfrom the Site Engineer.

2) He will provide his subordinates (charge hand and technicians) adequate information tocarry out their duties.

3) To ensure that he has adequate resources of machinery, labor and materials to carry out allthe activities efficiently and to discuss with the Site Engineer.

4) To ensure safe and clean working environment to enforce a safe working habit.

5.6 Safety Engineer/Officer

The SUB-CONTRACTOR Safety Engineer/Officer is responsible forimplementing the risk assessment and he will ensure that all controlmeasures and necessary safety/health precautions are effectively completedprior to start the activity. He is responsible for carrying out training,monitoring the work activities, carrying out inspections and reporting to thePrincipal contractor safety department and carrying out accident and incident

investigations.

5.7 Stores controller:

5.7.1 Review the documents with approved MAR and verify the items with thepacking list for any shortage or description from approved.

5.7.2 Responsible for proper storage as per site requirement.

5.7.3 Verify all documents are forwarded with the item as per the requirement of purchase order.

5.7.4 The unapproved material shall not be received and storage in store.




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Rev. No. : 00



Page : 10 of 15

CONTRACTOR


SUB CONTRACTOR

THERMO L.L.C.

6. EQUIPMENT & TOOLS

6.1 Tool Box for Mechanical6.2 Leveling Instrument6.3 Ladders.6.4 Brazing Torch set6.5 Oxy Acetylene Set6.6 Brazers safety equipment

7. MATERIALS:

7.1. Brazing Filling Rod

7.2. Oxygen cylinder

7.3. Acetylene cylinder

7.4. Pipe Cutters

7.5. Line up, external line up clamps or jigs

7.6. Other consumable item as per site requirement




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Rev. No. : 00



Page : 11 of 15

CONTRACTOR


SUB CONTRACTOR

THERMO L.L.C.

8. WORK SEQUENCE & METHODOLOGY

8.1 Check all material delivered to site is inspected properly by QA/QC Engineer and check it isstored properly as per manufacturer recommendations.

8.2 MIR shall be issued, for the inspection.

8.3 Work shall be carried out by the site staff under strict supervision and guidance of the concernedSupervisors / Foremen’s / Engineers.

8.4 The SUB CONTRACTOR QA/QC Engineer shall check all the installations.

8.5 RIA shall be prepared by SUB CONTRACTOR QA/QC Engineer and will be submitted toCONTRACTOR for their inspection and approval of the consultant.

8.6 SUB CONTRACTOR QA/QC Engineer shall coordinate with CONTRACTOR and arrangeinspection for installation and testing of piping.

8.7 SUB CONTRACTOR QA/QC Engineer is responsible for all installation activities for getting the work inspected / approved by CONSULTANT/ EMPLOYER REPRESENTATIVE.

8.8 SUB CONTRACTOR QA/QC Engineer is responsible to ensure that LEED requirements arefulfilled.




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Rev. No. : 00



Page : 12 of 15

CONTRACTOR


SUB CONTRACTOR

THERMO L.L.C.

9. PROCEDURE

9.1 PREPARATI ON OF BRAZING J OINTS:

1) Prior to alignment of pipes for brazing, each length of pipe will be inspectedthoroughly to ensure that no visible defects are present. Check the materials as per thestandard and specification and get approval from the CONSULTANT/ EMPLOYERREPRESENTATIVE.

2) Each pipe shall be thoroughly cleaned from the rust, paint, oil scale or other foreignmaterials, which are harmful for brazing quality.

3) Each length of pipe shall be thoroughly cleaned by polishing with abrasive paper.Protect and cover the openings of pipe with suitable cap or polythene sheet in order toavoid any foreign material entering.

4) Approved shop drawings and site measurements are to be taken before starting theinstallation of the pipe work.

5) The brazing joints clearance to be 0.05mm to 0.5 mm. Piping braze joint alignmentshall be done properly.

6) For proper line-up, external line up clamps or jigs shall be used.

7) Brazing filler metal to be as per Material Submittal which has been approved by TheConsultant.




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Rev. No. : 00



Page : 13 of 15

CONTRACTOR


SUB CONTRACTOR

THERMO L.L.C.

9.2 BRAZING:

1) Brazing of piping shall be performed in accordance with the approved BPS based onproject specifications and applicable codes.

2) All Brazers performing under these specifications are fully qualified in accordancewith the test requirements of ASME SEC IX.

3) Brazer Certificates will be provided to CONSULTANT/ EMPLOYER REPRESENTATIVE

4) Brazing shall not be permitted when weather conditions are bad viz. rain, high windsor any other climatic condition that may hamper the quality of brazer. Proper windprotection closures shall be provided for brazer during brazing.

5) All the equipments used for brazing shall be in good condition.

6) For brazing of copper pipes to copper fittings, silver brazing alloy to BSEN 1044 CP2shall be used, (N164). The silver content of the alloy shall be 2%.

7) Cleaning shall be done as per the Brazing Procedure. Specification. All slag / fluxremaining on the bead of brazing shall be completely removed.




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Rev. No. : 00



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CONTRACTOR


SUB CONTRACTOR

THERMO L.L.C.

9.3 INSPECTION:

1) Conformity to Drawing shall be done for all the lines checking that all the components,supports etc are installed / erected as per the approved drawings.

2) Installation and Pressure testing of the piping systems shall be done as per therequirements of the project line list.




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Rev. No. : 00



Page : 15 of 15

CONTRACTOR


SUB CONTRACTOR

THERMO L.L.C.

10. A TTACHMENTS:

10.1 Risk Assessments for the Brazing Procedure10.2 COSSH Assessments10.3 Accident and Reporting Procedure10.4 Work Permits10.5 Plant Machinery and Equipment Check list10.6 List of Personal Protective Equipment required for carrying out the job10.7 List of Fire Extinguishers that will be present when the welding is carried out.10.8 Removal of Combustible Materials

10.9

Risk Assessments and Safety Plan10.10 Brazing Procedure Specification10.11 Brazing Procedure Qualification Record



10.1 RISK ASSESSMENT FOR THE

BRAZING PROCEDURE



Oger Abu DhabiManagement System Level 7

Standard Forms

Probability (P) Severity Conclusions:1 =Improbable 1 =Negligible A=Hazard MUST be avoided (or level of risk reduced significantly and reli2 =Remote 2 =Minor B=Hazard SHOULD be avoided (or level of risk reduced significantly and r3 =Possible 3 =Severe C=Risk to be controlled as far as reasonably practicable.4 =Probable 4 =Extreme D=Risk is controlled as far as reasonably practicable.

- =No control measures necessary

RISK LEVEL

P/S

S1 S2 S3 S4

P1 ‐ ‐ D C

P2 ‐ D C B

P3 D C B A

P4 D B A A

CLIENT: Mubadala Developments CONTRACT No: 5004

PROJ ECT: S0WWAH SQUARE

RISK ASSESSMENT PLAN FOR THE BRAZING PROCEDURE

Ref No.

Task Significant HazardsRisk

Assessments

(No controls)

Training Remarks SpecialEquipme

P S R

1. Arrange the gas cylinders in work

place in vertical condition.

1.Hand injury

2. Back pain

3.Fire Hazard

3 2 D 1 Handling manual

procedure

2 Safety induction

1. PPE for suitable work

2. A proper PPE

3. Work area to be

barricaded

4. Fire extinguisher to be

used



Oger Abu DhabiManagement System Level 7

Standard Forms

Probability (P) Severity Conclusions:1 =Improbable 1 =Negligible A=Hazard MUST be avoided (or level of risk reduced significantly and reli2 =Remote 2 =Minor B=Hazard SHOULD be avoided (or level of risk reduced significantly and r3 =Possible 3 =Severe C=Risk to be controlled as far as reasonably practicable.4 =Probable 4 =Extreme D=Risk is controlled as far as reasonably practicable.

- =No control measures necessary

RISK LEVEL

P/S

S1 S2 S3 S4

P1 ‐ ‐ D C

P2 ‐ D C B

P3 D C B A

P4 D B A A

2. Test of cylinder for any leak 1. Hand injury

2. Eye injury

3. Body injury

4. Fire Explosion

3 1 D 1. Proper PPE/Induction

2. Flush back arrestor to

be present

3. Fire extinguisher

3. Brazing Pipe Joints 1.Burn

2. Fire

3. Hand injury

3 3 C 1..Use proper PPE

2. Hand gloves

3. Face shield

4. Fire Blanket

5. Fire extinguishers

4. Housekeeping in the work place,

before start the work.

1. Fall

2. Slip

3. Trip

3 2 C 1. Proper PPE

2. Hand Gloves

3. Dust Musk

6. Lifting / Handling of pipes 1. Hand injury.

2.Body injury

3 3 B 1. Proper PPE

2. Hand Gloves

3. Dust Mask

4. Proper Tools

Originator: Reviewed: Approved:



10.2 COSSH ASSESSMENTS



Oger Abu Dhabi

Management System Level 7

Standard Forms

SF193

Issue : 001

Date: Mar 2008

Page 1 of 5

COSH - ASSESSMENT FORM

Site: ADFC Contract No: 5004

WorkplaceLocation:

AL SAWA ISLAND

WorkplaceOperation:

Number of WorkersExposed:

ExposureTime:

Others whomay be Exposed:

SUBSTANCE

Trade Name:

Physical State:

Colour:

Odour:

Quantities to be used:

Mode of Exposure:

Toxicity Class:

***SAFER ALTERNATIVE AVAILABLE (YES/NO) NAME

TOXIC EFFECTS of Hazardous Components within Substance

Substance Gas No Target Organs OES/MEL

HEALTH SURVEILLANCE



Oger Abu Dhabi


Standard Forms

SF193

Issue : 001

Date: Mar 2008

Page 2 of 5

Employees Record Keeping Required YES/NO: _____________________________

(If “yes” include historical record of previous exposures)

Skin Check Required YES/NO: _____________________________

Lung Test Required YES/NO: _____________________________

Urine Test Required YES/NO: _____________________________

Blood Test Required YES/NO: _____________________________

VENTILATION (Type Required to Provide Control)

Natural Ventilation ADEQUATE/YES NO: _____________________________

General Ventilation ADEQUATE/YES NO: _____________________________

Forced Ventilation ADEQUATE/YES NO: _____________________________

Local Exhaust REQUIRED/YES NO: _____________________________

Air Sampling REQUIRED/YES NO: _____________________________

RESPIRATORY PROTECTIVE EQUIPMENT

Disposable (Dust, Mist, REQUIRED/YES NO: _____________________________Fume) (to EN 149)

SPECIFY TYPE/MAKE _____________________________

Vapour Masks (Organic/ REQUIRED/YES NO: _____________________________Inorganic vapour) (to EN 140)

SPECIFY TYPE/MAKE: _____________________________

Full Face Mask (Toxic Gases, REQUIRED / YES NO: _____________________________Particulates) (to EN 136)

SPECIFY TYPE/MAKE: _____________________________

Fresh Air Feed (Specialist work, oxygen deficient) Contact Safety Department.

EYE PROTECTION - Goggles (to EN 166 BS 2092)

Type 1 REQUIRED/YES NO: _____________________________

Type 1 (Chemical) REQUIRED/YES NO: _____________________________

Type 1 (Dust) REQUIRED/ YES NO: _____________________________

Type 1 (Molten) REQUIRED/ YES NO: _____________________________

Face Visor (to BS 2092)

Type 1 REQUIRED/YES NO: _____________________________



Oger Abu Dhabi


Standard Forms

SF193

Issue : 001

Date: Mar 2008

Page 3 of 5

HAND PROTECTION

Barrier Cream REQUIRED/ YES NO: _____________________________

GlovesREQUIRED/ YES NO: _____________________________

SPECIFY TYPE : _____________________________(see note)

Note: Gloves/Protection; (PVC general use) (PVA, solvent, not water) (Nitrile, lubricating) (Neoprene, greases, organic

acids, hydrocarbon) (Butyl acids and corrosives) Viton benzene) (Rubber water borne hazards)

PROTECTIVE CLOTHING

Normal working clothing ADEQUATE/YES NO: _____________________________

Overalls (clean each shift) REQUIRED/YES NO: _____________________________

ApronREQUIRED/YES NO: _____________________________

Boots Safety REQUIRED/YES NO: _____________________________

Boots Safety and Impervious REQUIRED/YES NO: _____________________________

HYGIENE

Smoking Prohibited YES/NO: _____________________________

Eating Prohibited YES/NO: _____________________________

Drinking Prohibited YES/NO: _____________________________

WELFARE

Washing exposed skin (end of shift) REQUIRED/YES NO: _____________________________

“ “ (during shift) REQUIRED/YES NO: _____________________________

Shower (end of shift) REQUIRED/YES NO: _____________________________

Decontamination Unit REQUIRED/YES NO: _____________________________

WORK PRACTICES

Containers to be kept closed YES/NO: _____________________________

Substance to be stored in closed container YES/NO: _____________________________

Is substance compatible with others YES/NO: _____________________________

(Provide information on above) ____________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

HOUSEKEEPING



Oger Abu Dhabi


Standard Forms

SF193

Issue : 001

Date: Mar 2008

Page 4 of 5

Can substance be swept up dry YES/NO: _____________________________

Work areas to be damped before sweeping YES/NO: _____________________________

Should a vacuum cleaner to be used YES/NO: _____________________________

Details: _______________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

STORAGE AND DISPOSAL

No special storage, controlled waste only YES/NO: _____________________________

Special Storage Requirements YES/NO: _____________________________

Special Waste YES/NO: _____________________________

Provide details on above, to include nature of hazard, eg. harmful, corrosive, toxic, flammable, type of container,ventilation, type of storage required eg, lockable and fire proof store:-

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

FIRST AID - PROVIDE DETAILS;

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

FIRE PRECAUTIONS - PROVIDE DETAILS;

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________



Oger Abu Dhabi


Standard Forms

SF193

Issue : 001

Date: Mar 2008

Page 5 of 5

SPILLAGE - PROVIDE DETAILS;

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

TRAINING - PROVIDE DETAILS; (INCLUDE TRAINING PROVIDER)

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

INFORMATION AND INSTRUCTION

Following assessment is work instruction sheet required. YES/NO: _____________________________

Name of Person to provide: ___________________________________________

Records of instruction required YES/NO: _____________________________

Assessment to be updated YES/NO: _____________________________

REMARKS/ESTIMATION OF RISK

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

Assessors Name (Print): _______________________________________________________________________

Assessors Signature: __________________________________ Assessment Date _____________________

Position __________________________________ Date _____________________



10.3 ACCIDENT AND REPORTING

PROCEDURE



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10.4 WORK PERMITS



WORK PERMITS

HOT WORKS RECORD & CHECKLIST

OGER Hot Works Permit No …………………………………………………..…

(Original must be available on site at all

times)

For the “METHOD STATEMENT FOR THE BRAZING PROCEDURE”.

Method Statement No : 5004‐TRM‐2‐MTH‐MTS‐MDP‐8000

Building/Site: T1, T2, T3, T4, STOCK

EXCHANGE, CENTRAL RETAIL AREA, NORTH

CAR PARK, SOUTH CAR PARK.

Exact Location: To be mentioned later

From (Time/ Date) ……………………….. Until ………………................................(Time/ Date)

1. Notification 4. Other precautions required: a) Area cleared of combustiblematerials and swept

b) Local smoke/heat detectors isolated

c) Combustible

floors

covered

with

sand

or

other non combustible materials

a) Logged in with Station Supervisor d) Floor and wall coverings covered and sealed

b) Trans4m Site Manager informed



2. Portable fire fighting equipmentrequired in place

Minimum : 2x AFFF 1x CO2 and 1x Fire

Blanket

e) Other sides of walls or partitions checked to

ensure there are no combustible materials

which may ignite

3. Operatives instructed regarding f) Gas cylinders stood upright and secured

b) Location of nearest alarm call point if

applicable

h) Gas detection test taken place (in the event

of working in inverts/sumps and confined

c) Means of communication agreed and

rovided

i) Local Exhaust Ventilation required

d) Escape routes and Fire exits j) Additional Information

e) Fire Watchperson certification valid (to

be checked by Site Person in Charge)

Declaration

I the Fire Watchperson, certify that it is safe to carry out Hot Work at the location stated above and that the

safety precautions detailed above have been implemented.

Name…………………………………………………….. Signature…………………………………………………

Clearance

I the Fire Watchperson certify that the Hot Work stated above has been completed/suspended and I confirm:

a) The final check for smouldering material and fire was carried out at (state time)……………………………

b) All waste material and work equipment removed from area

Signed:………………………………………………………………………….

Time…………………………………………………Date………………………………………………….



10.5 PLANT MACHINERY AND

EQUIPMENT CHECK LIST



OGER ABU DHABIManagement Syst Oger Abu Dhabi

System Level 7Standard Forms

SF249Issue : 001Date: Mar 2008

Page 1 of 1

PLANT MACHINERY & EQUIPMENT CHECKLIST

PROJECT NO:- C2807

SITE LOCATION:- AL SAWA ISLAND

PROJECT MANAGER:-GEORGE S KAMEL

DATE:-23/09/09

TYPE:-

OWNER:-

MAKE/MODEL:-

DURATION OF HIRE:-

Proposed use:-

Is it suitable? Yes / No

Is it in good condition?

Are there any visual defects?

Yes / No

Yes / NoIf yes, report defects to Line Manager.

Are test/calibration certificates required? Yes / No

If certificates are required:-a) Are they available?b) Are they valid?

Yes / No Yes / No

If machine is accompanied by an operator, hashe/she a valid training certificate?

Yes / NoIf yes keep a copy of the certificate for filing.

NOTE:-AnyNO responses, the plant machinery and equipment arenot to be used until remedial action

is taken.

I confirm the above information to be correct:-

Signature:- ………………………………………….

Print Name:- ………………………………………..

Position:- ……………………………………………



10.6 LIST OF PERSONAL PROTECTIVEEQUIPMENT REQUIRED FOR

CARRYING OUT THE J OB



List of Personal protective Equipment required carrying out the job 1. Safety Apron 2. Hand Gloves 3. head Protection ( cowl) 4. Safety Goggles 5. Safety Mask 6. Fire Blanket 7. Safety shoes and Gaiter



10.7 LIST OF FIRE EXTINGUISHERS

THAT WILL BE PRESENT WHEN THE

WELDING IS CARRIED OUT



List of fire extinguishers will be present when the brazing is carried out • Dry Powder Fire extinguisher (6 Kg) • Co2 Fire extinguisher (6Kg) • Bucket of Sands



10.8 REMOVAL OF COMBUSTIBLE

MATERIALS



Removal of Combustible Materials

Al l combust ib le mater ials such as oi l, pain t, rags etc , Should be:

• Cleared from where brazing and burning operations are likely to be conducted.

• Fire blankets shall be used to contain sparks and molten metal’s within the floorand should not be allowed to fall from height.

• Areas below brazing or burning should be barricaded.• Suitable fire extinguisher shall be ready for instant use in any location where

brazing and burning is taking place.• Hot works permit must be obtained and filled in before any brazing or burning has

commenced.• Gas cylinders should be kept up right position and properly secured.• Anti flashback arrestor shall be used in all gas burning sets.

• Hoses shall be of approved type and should be free from any defects, leaks etc.• All regulators should be in good working order and only cylinder keys/spanners

shall be used to open them. Before doing any hot works in drains, sump-pits,• Excavation pits and confined spaces a hot works permit must be obtained for

explosion risk.• At the end of the job before leaving the place of work, smoldering fires should be

put out.



10.9 RISK ASSESSMENT AND SAFETY

PLAN



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Risk Assessment and Safety planPage : 1

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Ref. No. HSE PROCEDURES MANUAL Risk Management

Risk Management1.1 Identification of Risk

All HSE hazards within Thermo LLC operational areas shall be highlighted and periodicallyreviewed to ensure findings remain valid. Hazards will initially be identified by the company’saudit/inspections programme.

Each operation should identify all HSE hazards within each respective area together withevidence to show that risks and consequences are clearly understood.

• The hazards shall be reviewed whenever major changes should apply.

• The Risk Assessment will be carried out and finalized by the safety dept according to themethod statement submitted by the Engineers involved.

• All hazards identified shall be fully investigated and evaluated by a Management team,controlled by supervisor of relevant department.

• Input from field personnel should be encouraged during identification evaluation.

1.2 Risk Assessment

• Risks association within current and future operations should be understood through writtenassessment of all hazards using the Risk Matrix to calculate the level of risk to people,assets and the environment.

• Risk Assessment will be made based on the method statement and a discussion along withthe engineers and supervisors. The responsible safety personnel will record it and

communicate to the relevant work force• Changes (If Any) will be recorded in the due course of time.

• Evaluate all options for preventing and controlling risks.

• All new techniques and working practices requested shall be evaluated for potential hazardsto equipment and personnel.

• Risk Assessment should follow a logical systematic format.

1.3 Control of Risk

• All risks should be reduced to as low as reasonably practicable (ALARP) and risksacceptable to customers concerned and justified.

• The Risk Assessment study result/recommendation of customer is to be studied andimplemented.



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1.4 Risk Matrix

High risk - Take action to reduce, immediately

Medium risk - Reduce risk As Low As Reasonably Practicable

Low risk - Acceptable

PROBABIL ITY L EVELS

SEVERI TY LEVELS Improbable

1 in

100,000 yrs

Remote

1 in

10,000 yrs

Occasional

1 in

1,000 yrs

Probable

1 in

100 yrs

Frequent

1 in

10 yrsPeople Assets Environment Reputation

C a t a s t r o p h i c

Multiplefatalities orpermanent

totaldisabilities

Extensivedamage Massiveeffect Internationalimpact

HIGH RISK

S e v e r e

Singlefatality orpermanent

totaldisability

Majordamage

Major effect Nationalimpact

MEDIUMRISK

C

r i t i c a l Major

injury orhealtheffects

Localdamage

Localizedeffect

Considerableimpact

M a r g i n a l Minor

injury orhealtheffects

Minordamage

Minor effect Minor impact

LOW RISK

N e g l i g i b l e Slight injury

or healtheffects

Slightdamage

Slight effect Slight impact



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1.5 Work Permit system

The relevant Work Permit forms are attached along with the Health & Safety forms

1.6 Thermo Safe Systems of Work

Thermo Safety Officers will ensure that the procedures laid down in the safe system of work arebeing carried out and are effective and that any changes in circumstance, which requirealterations to safe system of work, are taken into account.

1.6.1 Safe Working Procedures for Brazing and Cutting:

Main hazards and the Precautionary measures are as follows:

a. Fire and explosion hazard

Precautionary Measures

• All combustible materials such as oil, paint, rags etc, should be cleared from wherewelding and burning operations are likely to be conducted. Fire blankets shall be used tocontain sparks and molten metals within the floor and should not be allowed to fall fromheight. Areas below brazing should be barricaded. Suitable fire extinguisher shall beready for instant use in any location where welding and burning is taking place. Hotworks permit must be obtained and filled in before any brazing has commenced. Gas

cylinders should be kept up right position and properly secured. Anti flashback arrestorshall be used in all gas burning sets. Hoses shall be of approved type and should be freefro any defects, leaks etc. All regulators should be in good working order and onlycylinder keys/spanners shall be used to open them. Before doing any hot works indrains, sump-pits, excavation pits and confined spaces a hot works permit must beobtained for explosion risk. At the end of the job before leaving the place of work,smoldering fires should be put out.

b. Personnel exposed to hazardous heat and fumes.

Precautionary Measures

• Screens, shields and other safe guards shall be provided for the protection of personnel,equipment and materials against molten material. Brazers shall wear eye protection aswell as suitable protective clothing and gloves. Brazers and helpers shall wear a hardhat while performing brazing and burning operations. Adequate ventilation shall beprovided while carrying out hot works in confined spaces.

• Before starting any brazing activity, technician needs to confirm the brazing equipment istested and the periodical inspections are done. A trained and experienced person is the



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only authorized person to conduct a brazing task. To confirm the technician’scompetency, adequate certification to prove should be verified in advance.

• Before commencing any hot work a risk assessment will be held by the engineer and thesafety officer to ensure that the area is clear of any combustible material. A hot workpermit system will be followed and issued before commencing any hot work; this permitwill be recorded and filed for any needed information.

• Gas Cylinders and Flammable Material Storage: Gas Cylinders should be stored safelyand secured properly, a chain should be used to prevent their falling, good ventilation,separate oxygen from acetylene cylinders at least 6 m, label all Full and empty cylinders.All flammable materials should be stored in proper storing area well ventilated and fireextinguishers to be provided, all flammables should be clearly labeled, MSDS to bepresented at all the times. Weekly check list will be done and submitted to the safety

dept, as far as reasonably practicable the minimum quantity of flammables should be inthe site.



10.10 BRAZING PROCEDURE

SPECIFICATION





10.11 BRAZING PROCEDURE

QUALIFICATION RECORD







