Brazing Procedure

ABU DHAB DHABII FINAN F INANCIAL CIAL CENTE C ENTER R ABU DHABI UNITED ARAB EMIRATES ohn Buck Buck Comp Company any DELEVOPMENT MANAGER: MANAGER:  J ohn P.O. Box: 63737, ABU DHABI, UAE  Tel:  Tel: (+ (+971 971) 2 414 669 6699 - FAX: FAX: (+ (+971 971 2 4146 41467 756 Internet: www.johnbuckinternational.com Goettsch Part P artners ners

ARCHITECTS:

224 S. Michigan Ave, Suite 1700 Chicago, IL 60604

Gensler Aldgate House, 33 Aldgate High St, London EC3N 1AH

OGER ABU DHABI DHABI

CONTRACTOR:

P.O. Box 35656, ABU DHABI, UAE  TEL: (+ (+971) 71) 3 7555 755574 745 5 - FAX: FAX: (+971) 71) 3 7555 755573 732 2

OGER INTERNATIONAL

ARCHITECTURE & E NG NGINE ER ERING:

70 R UE UE SAINT-DE NI NIS - 93582 SAINT OUE N - F RA RANC E : INTERNET: www.ogerinternational.com

 THERMO L.L.C. L.L.C.

SUBCONTRACTOR:

TITLE:

METHOD STATEMENT STATE MENT BRAZ BR AZING ING PROCEDURE       S       E       S       A       H       P

5

CONCEPT DESIGN

DONE BY:

CHECKED BY:

AP P ROVED BY:

4

SCHEMATIC DESIGN

DATE & VISA:

DATE & VISA:

DATE & VISA:

3

DESIGN DEVELOPMENT

2

CONSTRUCTIONDEVELOPMENT

1

AS BUILT

0Z

0Z

FLOOR

AREA

DATE:

23/09/09

005004

TRM

2

PWS

0Z

MTS9000

00

PROJECT

ORGANIZATION

P HASE

TRADE

BUILDING

UNIQUE NUMBER

REV

Written document cover sheet template, rev 0 29/07/09

Contactt: 5004 Contac SOWW AH SQUAR QUARE E PRO PROJJ ECT ABU DHABI HABI,, UNITED AR ARAB AB EMm EMmA A TES

REF EF.. No: 5004- TR  TRM M-2-~.s-

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Rev. No. : 00 METH ETHO OD STATEMEN ENT T FO FOR R BRAZING BRAZ ING PRO PROCED CEDURE URE

Date: 19-5ept.-2009 Page:

1 of 15

METHOD STATEMENT F OR BRAZII NG PROCED BRAZ PROCEDURE URE

PREPAR REPARE ED

By

CHE CH ECKED

APPROVED

By

By GEa R

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AGE E NUMBERS &PAG

OFRE OFR EVlSION UBMITlE UBMITl ED FO FOR R APPRO APPROVAL VAL

THERMO SUB SU B CONTRACTOR

OGER A BU DHA BI

DESCRIPTION

 THERM  THE RM O

L .L .C.

Contactt: 5004 Contac SOWW AH SQUAR QUARE E PRO PROJJ ECT ABU DHABI HABI,, UNITED AR ARAB AB EMm EMmA A TES

REF EF.. No: 5004- TR  TRM M-2-~.s-

0z-

.M1>~00

Rev. No. : 00 METH ETHO OD STATEMEN ENT T FO FOR R BRAZING BRAZ ING PRO PROCED CEDURE URE

Date: 19-5ept.-2009 Page:

1 of 15

METHOD STATEMENT F OR BRAZII NG PROCED BRAZ PROCEDURE URE

PREPAR REPARE ED

By

CHE CH ECKED

APPROVED

By

By GEa R

HANY HA NY

~~ j jCC 4=? ~~ 4 =? g l

AGE E NUMBERS &PAG

OFRE OFR EVlSION UBMITlE UBMITl ED FO FOR R APPRO APPROVAL VAL

THERMO SUB SU B CONTRACTOR

OGER A BU DHA BI

DESCRIPTION

 THERM  THE RM O

L .L .C.

Contact:: 5004 Contact

SOWWAH SQUARE PRO PROJJ ECT ABU AB U DHAB ABI, I, UN UNITED ITED ARAB EMmA TE TES S

REF EF.. No: 5004 5004-- T  TR RMM-2 2· Q W 5 - 02.-nr, -nr,...~·000 Rev. No.: 00

METHOD STA METHO STATEM TEMEN ENT T FO FOR R BRAZI NG PRO PROCEDU CEDURE RE

Date: 19-5ept.-2009 Page:

METHO METH OD STATE TATEMEN MENT: T:

2 of  15

Mr n THODSTA STATEM TEMENTFOR T  THE HEBR BRAZ AZW W G PROCEDURE

CONFI FIR RM THAT THOSE PEO EOP PLE LIST LISTED ED BELO ELOW W HAVE BEE EEN N MAD MADE E AWA AW ARE OF TH THE E REQUIR IRE EME MEN NTS OF Ti TillS llS ME METH THO OD STA TATE TEME MEN NT AND AN D UN UNDE DERS RSTAND TAND THE COND CONDITI ITIO ONS LI LIS STED WITHIN.

~~1 C4:?91

THERMO SUB SU B CONT NTR RACT ACTO OR

O G E R A BU DH ABI

 THER  TH ERMO MO L. L.L. L.C C.

Contact: 5004

SOWWAH SQUARE SQUARE PROJ ECT ABU DHABI, DHABI, UNI UNI TED ARAB EMI RATES RATE S

REF. No N o: 5004-TRM-2-PWS-0Z-MTS9000 Rev. No. : 00

MET HOD STAT EME NT FOR BRAZING PROCEDURE

Date : 19-Sept.-200 19-Sept.-2009 Page: 3 of 15

 TABL  T ABL E OF CONTENTS CONTE NTS DESCRIPTION

S.NO

PAGE NO.

01

Scope & Purpose

4

02

Reference & Relate elated Documents

4

03

A bbrevi bbreviat atiions

5

04

Safety Safety

7

05

Respons sponsibili bil itie ties

8

06

Equipmen quipmentt / Tools ools

10

07

Materi terials als requi requirements ents

10

08

Work Work Seque Sequence nce & Methodology ethodology

11

09

Procedure

12

10

A ttachments

15

CONTRACTOR

OGER ABU DHABI SUBC SUB C ONTRACTOR

 THERM  TH ERM O L.L.C.

ME P C ONTRACTOR

Contact: 5004

SOWWAH SQUARE SQUARE PROJ ECT ABU DHABI, DHABI, UNI UNI TED ARAB EMI RATES RATE S

REF. No N o: 5004-TRM-2-PWS-0Z-MTS9000 Rev. No. : 00

MET HOD STAT EME NT FOR BRAZING PROCEDURE

1.

Date : 19-Sept.-200 19-Sept.-2009 Page: 4 of 15

SCOPE & PURPOSE

1.1.  This  This “Met Method Statement” covers the nature and type of work for for the BRAZING BRAZING PROCEDURE. 1.2.  This  This method statement give ives guide ideline lines containe ined herein so as to ensure that the job job execution ion compl compliies with with the requirem requirement of the Specif Specifications cations and the authori authoriti ties es concerned and and serves the intende ntended d purpose purpose to satisfactory satisfactory leve levell.

2.

REFERENCES & RELATED DOCUMENTS

2.1 Project Quality Plan 2.2 Contrac ontractt No:No:- 50 5004 04 2.3 Manufacture anufacturerr Produ Product ct Dat Data a Sheets 2.4 OGER HSE Manual.

CONTRACTOR

OGER ABU DHABI SUBC SUB C ONTRACTOR

 THERM  TH ERM O L.L.C.

ME P C ONTRACTOR

Contact: 5004

SOWWAH SQUARE PROJ ECT ABU DHABI, UNITED ARAB EMI RATES

REF. No: 5004-TRM-2-PWS-0Z-MTS9000 Rev. No. : 00

MET HOD STAT EME NT FOR BRAZING PROCEDURE

3.

Date : 19-Sept.-2009 Page: 5 of 15

A BBREVIATIONS

EMPLOY ER

: MUBADALA DEVELOPMENTS

EMPLOY ER 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-ConformanceReport

MAR

: Material Approval Request

MIR

: Material Inspection Request

BPS

: Brazing Procedure Specification

BPQR

: Brazing Procedure Qualification Record CONTRACTOR

OGER ABU DHABI SUBC ONTRACTOR

 THERM O L.L.C.

ME P C ONTRACTOR

Contact: 5004

SOWWAH SQUARE PROJ ECT ABU DHABI, UNITED ARAB EMI RATES

REF. No: 5004-TRM-2-PWS-0Z-MTS9000 Rev. No. : 00

MET HOD STAT EME NT FOR BRAZING PROCEDURE

Date : 19-Sept.-2009 Page: 6 of 15

PPE

: Personal Protective Equipment

COSHH

: Control Of Substances Harmful  To Health

CONTRACTOR

OGER ABU DHABI SUBC ONTRACTOR

 THERM O L.L.C.

ME P C ONTRACTOR

Contact: 5004

SOWWAH SQUARE PROJ ECT ABU DHABI, UNITED ARAB EMI RATES

REF. No: 5004-TRM-2-PWS-0Z-MTS9000 Rev. No. : 00

MET HOD STAT EME NT FOR BRAZING PROCEDURE

4.

Date : 19-Sept.-2009 Page: 7 of 15

SAFETY

4.1. All staff will have a safety induction carried out by the contractor before commencing any activities on site. 4.2. Prior to commencing any activity, labor force shall receive a tool box talk on the project site safety regulations from the subcontractor safety officer on a weekly basis on topics appropriate to the activities being undertaken. A Method statement briefing will be given to all 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 and addressed as required. 4.4. All activities will be subject to a risk assessment by the subcontractor safety officer before the commencement of work which will be forwarded to the contractor safety department for approval. Appropriate measures will be taken following the R/A to minimize the risks identified. 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 night time. 4.8. Ensure that in all areas where there is a risk of falling from height preventative measures will be taken and identify them. 4.9. Ensure service shaft opening are provided with barricade, tape, safety nets.

CONTRACTOR

OGER ABU DHABI SUBC ONTRACTOR

 THERM O L.L.C.

ME P C ONTRACTOR

Contact: 5004

SOWWAH SQUARE PROJ ECT ABU DHABI, UNITED ARAB EMI RATES

REF. No: 5004-TRM-2-PWS-0Z-MTS9000 Rev. No. : 00

MET HOD STAT EME NT FOR BRAZING PROCEDURE

5.

Date : 19-Sept.-2009 Page: 8 of 15

RESPONSIBILITIES

5.1 Project Manager  The CONTRACTOR/SUB CONTRACTOR Project Manager will have full authority and overall responsibility to manage, supervise. He will. control the works and will have direct responsibility for ensuring safe working practices and compliance with regulatory authorities requirements. Coordinate with the engineers and the EMPLOY ER REPRESENTATIVE for execution of the Contract Scope of works. Implement the project quality systems to be the satisfaction of the project requirements. Review changes and variations to evaluateimpact of those on time and schedule. 5.2 Project Engineer Is responsible for ensuring that all works are carried out as per the specifications, approved shop drawings, Method Statement, manufacturer instructions and coordinate with other works. 5.3 QA/QC Engineer 1)

Is responsible for monitoring the works are in fulfillment with the specified requirements, that all quality records related to the works are complete.

2)

He will carry out all the inspections with the EMPLOY ER representatives and notice will be given to EMPLOY ER RE PRESNTATIVES within 3 days and ensure that no work will be executed/covered up without inspection/testing.

5.4 Site Engineer 1)

2) 3)

 The site Engineer shall co-ordinate all the site activities according to work schedule, installation according to the project Specifications, Manufacturer Data Sheet and approved shop drawings. Shall Liaise with site representatives of EMPLOY ER and CONTRACTOR and co-ordinate safety procedures with site supervisors and site foremen.  To Co-ordinate and explain the work to be carried out to the Supervisors / Site Foreman.

CONTRACTOR

OGER ABU DHABI SUBC ONTRACTOR

 THERM O L.L.C.

ME P C ONTRACTOR

Contact: 5004

SOWWAH SQUARE PROJ ECT ABU DHABI, UNITED ARAB EMI RATES

REF. No: 5004-TRM-2-PWS-0Z-MTS9000 Rev. No. : 00

MET HOD STAT EME NT FOR BRAZING PROCEDURE

4)

Date : 19-Sept.-2009 Page: 9 of 15

He will ensure the compliance of works with the related approved Quality Control Procedure and co-ordinate with the CONTRACTOR QA/QC Engineer to advise for the areas to be issued for inspection.

5.5 Site Supervisors and Site Foremen 1)

2) 3) 4)

 The project team of experienced Supervisors and Foremen shall ensure the quality of the installation work carried out, and shall also ensure that it is as per the latest approved construction shop drawing issued for installation and according to instructions received from the Site Engineer. He will provide his subordinates (charge hand and technicians) adequate information to carry out their duties.  To ensure that he has adequate resources of machinery, labor and materials to carry out all the activities efficiently and to discuss with the Site Engineer.  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 for implementing the risk assessment and he will ensure that all control measures and necessary safety/health precautions are effectively completed prior to start the activity. He is responsible for carrying out training, monitoring the work activities, carrying out inspections and reporting to the Principal 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 the packing 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 theitemas per therequirement of  purchase order.

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

CONTRACTOR

OGER ABU DHABI SUBC ONTRACTOR

 THERM O L.L.C.

ME P C ONTRACTOR

Contact: 5004

SOWWAH SQUARE PROJ ECT ABU DHABI, UNITED ARAB EMI RATES

REF. No: 5004-TRM-2-PWS-0Z-MTS9000 Rev. No. : 00

MET HOD STAT EME NT FOR BRAZING PROCEDURE

6.

Date : 19-Sept.-2009 Page: 10 of 15

EQUIPMENT & T OOLS

6.1  Tool Box for Mechanical 6.2 Leveling Instrument 6.3 Ladders. 6.4 Brazing Torch set 6.5 Oxy Acetylene Set 6.6 Brazers safety equipment

7.

M ATERIALS :

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 itemas per site requirement

CONTRACTOR

OGER ABU DHABI SUBC ONTRACTOR

 THERM O L.L.C.

ME P C ONTRACTOR

Contact: 5004

SOWWAH SQUARE PROJ ECT ABU DHABI, UNITED ARAB EMI RATES

REF. No: 5004-TRM-2-PWS-0Z-MTS9000 Rev. No. : 00

MET HOD STAT EME NT FOR BRAZING PROCEDURE

Date : 19-Sept.-2009 Page: 11 of 15

8. WORK  SEQUENCE & M ETHODOLOGY 8.1

Check all material delivered to site is inspected properly by QA/QC Engineer and check it is stored 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 concerned Supervisors / 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 to CONTRACTOR for their inspection and approval of the consultant.

8.6

SUB CONTRACTOR QA/QC Engineer shall coordinate with CONTRACTOR and arrange inspection 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 are fulfilled.

CONTRACTOR

OGER ABU DHABI SUBC ONTRACTOR

 THERM O L.L.C.

ME P C ONTRACTOR

Contact: 5004

SOWWAH SQUARE PROJ ECT ABU DHABI, UNITED ARAB EMI RATES

REF. No: 5004-TRM-2-PWS-0Z-MTS9000 Rev. No. : 00

MET HOD STAT EME NT FOR BRAZING PROCEDURE

9.

Date : 19-Sept.-2009 Page: 12 of 15

PROCEDURE

9.1 PREPARATI ON OF BRAZING J OINTS:

1) Prior to alignment of pipes for brazing, each length of pipe will be inspected thoroughly to ensure that no visible defects are present. Check the materials as per the standard and specification and get approval from the CONSULTANT/ EMPLOY ER REPRESENTATIVE. 2) Each pipe shall be thoroughly cleaned from the rust, paint, oil scale or other foreign materials, 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 to avoid any foreign material entering. 4) Approved shop drawings and site measurements are to be taken before starting the installation of the pipe work. 5)  The brazing joints clearance to be 0.05mm to 0.5 mm. Piping braze joint alignment shall 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 The Consultant.

CONTRACTOR

OGER ABU DHABI SUBC ONTRACTOR

 THERM O L.L.C.

ME P C ONTRACTOR

Contact: 5004

SOWWAH SQUARE PROJ ECT ABU DHABI, UNITED ARAB EMI RATES

REF. No: 5004-TRM-2-PWS-0Z-MTS9000 Rev. No. : 00

MET HOD STAT EME NT FOR BRAZING PROCEDURE

Date : 19-Sept.-2009 Page: 13 of 15

9.2 BRA ZING: 1) Brazing of piping shall be performed in accordance with the approved BPS based on project specifications and applicable codes. 2) All Brazers performing under these specifications are fully qualified in accordance with thetest 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 winds or any other climatic condition that may hamper the quality of brazer. Proper wind protection 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 CP2 shall be used, (N164). The silver content of the alloy shall be 2%. 7) Cleaning shall be done as per the Brazing Procedure. Specification. A ll slag / flux remaining on the bead of brazing shall be completely removed.

CONTRACTOR

OGER ABU DHABI SUBC ONTRACTOR

 THERM O L.L.C.

ME P C ONTRACTOR

Contact: 5004

SOWWAH SQUARE PROJ ECT ABU DHABI, UNITED ARAB EMI RATES

REF. No: 5004-TRM-2-PWS-0Z-MTS9000 Rev. No. : 00

MET HOD STAT EME NT FOR BRAZING PROCEDURE

Date : 19-Sept.-2009 Page: 14 of 15

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 the requirements of the project line list.

CONTRACTOR

OGER ABU DHABI SUBC ONTRACTOR

 THERM O L.L.C.

ME P C ONTRACTOR

Contact: 5004

SOWWAH SQUARE PROJ ECT ABU DHABI, UNITED ARAB EMI RATES

REF. No: 5004-TRM-2-PWS-0Z-MTS9000 Rev. No. : 00

MET HOD STAT EME NT FOR BRAZING PROCEDURE

Date : 19-Sept.-2009 Page: 15 of 15

10.A TTACHMENTS: 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11

Risk Assessments for the Brazing Procedure COSSH Assessments Accident and Reporting Procedure Work Permits Plant M achinery and Equipment Check list L ist of Personal Protective Equipment required for carrying out the job L ist of Fire Extinguishers that will be present when the welding is carried out. Removal of Combustible Materials Risk Assessments and Safety Plan Brazing Procedure Specification Brazing Procedure Qualification Record

CONTRACTOR

OGER ABU DHABI SUBC ONTRACTOR

 THERM O L.L.C.

ME P C ONTRACTOR

10.1 RI SK ASSESSM ENT FOR THE BRAZI NG PROCEDURE

SF276 Issue : 001 Date: OCT 2008

Oger Abu Dhabi Management System Level 7 Standard Forms

CLIENT:

Mubadala Developments

PROJ ECT:

S0WWAH SQUARE

CONTRACT No:

5004

RISK ASSESSMENT PLAN FOR THE BRAZING PROCEDURE Ref  No.

 Task

Significant Hazards

Risk Assessments

 Training

Remarks

(No controls) 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

Severity 1 =Negligible 2 =Minor 3 =Severe 4 =Extreme

Risk Assessment (With Control)

1 Handling manual procedure 2 Safety induction

Probability (P) 1 =Improbable 2 =Remote 3 =Possible 4 =Probable

Special Equipment

1. PPE for suitable work 2. A proper PPE 3. Work area to be barricaded 4. Fire extinguisher to be used

P

S

R

2

2

D

Conclusions: A=Hazard MUST be avoided (or level of risk reduced significantly and reliable by controls) B=Hazard SHOULD be avoided (or level of risk reduced significantly and reliable by controls) C=Risk to be controlled as far as reasonably practicable. D=Risk is controlled as far as reasonably practicable. - =No control measures necessary

RISK LEVEL P/S S1

S2

S3

‐ ‐

‐

D

C

P2

D

C

B

P3

D

C

B

A

P4

D

B

A

A

P1

S4

SF276 Issue : 001 Date: OCT 2008

Oger Abu Dhabi Management System Level 7 Standard Forms 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

2

2

D

3.

Brazing Pipe Joints

1.Burn 2. Fire 3. Hand injury

3

3

C

2

2

D

4.

Housekeeping in the work place, before start the work.

1. Fall 2. Slip 3. Trip

3

2

C

1..Use proper PPE 2. Hand gloves 3. Face shield 4. Fire Blanket 5. Fire extinguishers 1. Proper PPE 2. Hand Gloves 3. Dust Musk

2

1

D

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

2

1

D

Originator:

Reviewed:

Approved:

Page:2 Revision No.:0 Date:16.09.09

Probability (P) 1 =Improbable 2 =Remote 3 =Possible 4 =Probable

Severity 1 =Negligible 2 =Minor 3 =Severe 4 =Extreme

Conclusions: A=Hazard MUST be avoided (or level of risk reduced significantly and reliable by controls) B=Hazard SHOULD be avoided (or level of risk reduced significantly and reliable by controls) C=Risk to be controlled as far as reasonably practicable. D=Risk is controlled as far as reasonably practicable.

SF276 Issue : 001 Date: OCT 2008

Oger Abu Dhabi Management System Level 7 Standard Forms 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

2

2

D

3.

Brazing Pipe Joints

1.Burn 2. Fire 3. Hand injury

3

3

C

2

2

D

4.

Housekeeping in the work place, before start the work.

1. Fall 2. Slip 3. Trip

3

2

C

1..Use proper PPE 2. Hand gloves 3. Face shield 4. Fire Blanket 5. Fire extinguishers 1. Proper PPE 2. Hand Gloves 3. Dust Musk

2

1

D

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

2

1

D

Originator:

Reviewed:

Approved:

Page:2 Revision No.:0 Date:16.09.09

Probability (P) 1 =Improbable 2 =Remote 3 =Possible 4 =Probable

Severity 1 =Negligible 2 =Minor 3 =Severe 4 =Extreme RISK LEVEL P/S

S1

S2

S3

‐ ‐

‐

D

C

P2

D

C

B

P3

D

C

B

A

P4

D

B

A

A

P1

S4

Conclusions: A=Hazard MUST be avoided (or level of risk reduced significantly and reliable by controls) B=Hazard SHOULD be avoided (or level of risk reduced significantly and reliable by controls) C=Risk to be controlled as far as reasonably practicable. D=Risk is controlled as far as reasonably practicable. - =No control measures necessary

10.2 COSSH ASSESSM ENTS

Oger Abu Dhabi

SF193 Issue : 001 Date: Mar 2008

Management Syst em Level 7 Standard Forms

COSH

- ASSESSMENT FORM

Site:

ADFC

Contract No:

5004

 AL SAWA ISLAND Workplace Location:

Workplace Operation:

Number of Workers Exposed:

Exposure Time:

Others who may be Exposed:

Trade Name: Physical State: Colour: Odour: Quantities to be used: Mode of Exposure: Toxicity Class:

Substance

Gas No

Target Organs

OES/MEL

Page 1 of 5

Oger Abu Dhabi

Management Syst em Level 7 Standard Forms

SF193 Issue : 001 Date: Mar 2008

Employees Record Keeping Required

YES/NO:

_____________________________

Skin Check Required

YES/NO:

_____________________________

Lung Test Required

YES/NO:

_____________________________

Urine Test Required

YES/NO:

___________________________ __

Blood Test Required

YES/NO:

_____________________________

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:

_____________________________

Disposable (Dust, Mist, Fume) (to EN 149)

REQUIRED/YES NO:

___________________________ __

SPECIFY TYPE/MAKE

_____________________________

REQUIRED/YES NO:

_____________________________

SPECIFY TYPE/MAKE:

_____________________________

REQUIRED / YES NO:

_____________________________

SPECIFY TYPE/MAKE:

_____________________________

Type 1

REQUIRED/YES NO:

_____________________________

Type 1 (Chemical)

REQUIRED/YES NO:

_____________________________

Type 1 (Dust)

REQUIRED/ YES NO:

_____________________________

Type 1 (Molten)

REQUIRED/ YES NO:

_____________________________

Type 1

REQUIRED/YES NO:

_____________________________

 Vapour Masks (Organic/ Inorganic vapour) (to EN 140)

Full Face Mask (Toxic Gases, Particulates) (to EN 136)

Page 2 of 5

Oger Abu Dhabi

Management Syst em Level 7 Standard Forms

Barrier Cream

SF193 Issue : 001 Date: Mar 2008

REQUIRED/ YES NO:

_____________________________

REQUIRED/ YES NO:

_____________________________

SPECIFY TYPE : (see note)

_____________________________

Normal working clothing

ADEQUATE/YES NO:

_____________________________

Overalls (clean each shift)

REQUIRED/YES NO:

_____________________________

REQUIRED/YES NO:

_____________________________

Boots Safety

REQUIRED/YES NO:

_____________________________

Boots Safety and Impervious

REQUIRED/YES NO:

_____________________________

Smoking Prohibited

YES/NO:

_____________________________

Eating Prohibited

YES/NO:

_____________________________

Drinking Prohibited

YES/NO:

___________________________ __

Washing exposed skin (end of shift)

REQUIRED/YES NO:

_____________________________

“

REQUIRED/YES NO:

_____________________________

Shower (end of shift)

REQUIRED/YES NO:

___________________________ __

Decontamination Unit

REQUIRED/YES NO:

_____________________________

Containers to be kept closed

YES/NO:

_____________________________

Substance to be stored in closed container

YES/NO:

_____________________________

Is substance compatible with others

YES/NO:

_____________________________

Gloves

 Apron

“

(during shift)

(Provide information on above) ____________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________

Page 3 of 5

Oger Abu Dhabi

Management Syst em Level 7 Standard Forms

SF193 Issue : 001 Date: Mar 2008

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: _______________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________

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:_____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________

_____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________

_____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________

Page 4 of 5

Oger Abu Dhabi

Management Syst em Level 7 Standard Forms

SF193 Issue : 001 Date: Mar 2008

_____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________

_____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________

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:

_____________________________

_____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________

 Assessors Name (Print):

___________________________ ______________________________ ______________

 Assessors Signature:

________________________________ __

Assessment Date _____________________

Position

_______________________________ ___

Date

_______ ______________

Page 5 of 5

10.3 ACCI DENT AND REPORTI NG PROCEDURE

 ACC DENT AN

REPORTING PROC

REPORTIN

DURE:

PROCEDURES

FOR CCIDE NT, NE R MIS & PO LUTIO

INCI ENTS

FOR NON‐LOSS TIME ACCIDENTS CO PLETE T E ACCIDENT BOOK .

EMEMBER TO INCLUDE FIRST AI AT TENDANCE AT H FAX A COP OF THE ACCIDENT BOO SPECI LISED EDICAL

INFOR ATION ND OR SPITAL. ENTRY  TO MID LE EAS CENTER ON

971 44674 6

IN TH EVENT OF A FA ALITY, AJ OR I  J URY, L SS TIM ACCID NT, OR ANGER US OCCURRENCE, NOTIF YOUR INE MA NAGER F  TH ACCID NT OR I CIDENT. ALL LINE MANAGERS

ILL ENSU E THAT ALL RELEVANT PERSONNEL ARE

INFO MED, TH T THE FO M IS CO PLETED ND FAXE WITH A OPY OF THE ACCIIDENT BO K ENTRY O MIDDLE EAST SP CIALISED MEDICAL ENTER ON

971 44674 6

ALL FORMAL / S ATUTORY REPORTI G REQUIREMENTS

ILL BE C RRIED OUT BY

HSEQ.

ALSO NOTIF ANY I CIDENT, INCLUDING POL UTION ND NEA R MISS  Y CONT CTING MIDDLE EAST SPECIALIS D MEDI AL CEN ER N THE PHO E NUMBER 971 44674 6

OR SEND AN E MAIL T : mesm @emiar es.net.ae SHOULD Y O HAVE NY QUE IES, PL ASE CA L DA

FREE O

971 44674 6

10.4 WORK PERM I TS

 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

Exact Location : To be mentioned later

EXCHANGE, CENTRAL RETAIL AREA, NORTH CAR PARK, SOUTH CAR PARK.

From (Time/ Date) ………………………..

1. Notification

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

4. Other precautions required:

a) Area cleared of combustible materials 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 b) Trans4m Site Manager informed

d) Floor and wall coverings covered and sealed

2. Portable fire fighting equipment required in place Minimum : 2x AFFF 1x CO2 and 1x Fire

e) Other sides of walls or partitions checked to ensure there are no combustible materials which may ignite

Blanket 3. Operatives instructed regarding

f) Gas cylinders stood upright and secured

b) Location of nearest alarm call point if 

h) Gas detection test taken place (in the event

applicable

of working in inverts/sumps and confined

c) Means of communication agreed and

i) Local Exhaust Ventilation required

rovided 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 PL ANT MACHI NERY AND EQUI PMENT CHECK L I ST

OGER ABU DHABI Management Sys t Oger Abu Dhabi System Level 7 Standard Forms

SF249 Issue : 001 Date: Mar 2008

PLANT MACHI NERY & EQUI PMENT CHECK L I ST PROJECT NO:- C2807

PROJECT MANAGER:-GEORGE S KAMEL

SITE LOCATION:- AL SAWA ISLAND

DATE:-23/09/09

 TY PE:OWNER:-

MAKE/MODEL:DURATION OF HIRE:-

Proposed use:Is it suitable?

Y es / No

Is it in good condition?

 Y es / No

Are there any visual defects? Are test/calibration certificates required?

 Y es / No If yes, report defects to Line Manager. Y es / No

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

 Y es / No  Y es / No

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

 Y es / No If yes keep a copy of the certificate for filing.

NOTE:Any NO responses, the plant machinery and equipment are not to be used until remedial action is taken.

I confirm the above information to be correct:Signature:- …………………………………………. Print Name:- ……………………………………….. Position:- ……………………………………………

Page 1 of 1

10.6 L IST OF PERSONAL PROTECTIVE EQUIPMENT 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 L I ST OF FI RE EXTI NGUISHERS  THAT WI L L BE PRESENT WHEN THE WEL DI NG IS CARRI ED OUT

List of fire extinguishers will be present when the brazing is carried out •

Dry Powder Fire extinguisher (6 Kg)

•

Co2 Fire extinguisher

•

Bucket of Sands

(6Kg)

10.8 REM OVAL OF COM BUSTI BL E MATERIALS

Removal of Combustible Materials

 Al l c om bu st ib le m ater ial s s uc h as oi l, p ain t, r ags etc , Sho ul d b e:

• •

• •

•

• • • •

•

•

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 floor and 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 RI SK ASSESSM ENT AND SAFETY PLAN

Thermo L LC

Rev:

02

Page : 1

Risk Assessment and Safety pl an SOWWAH SQUARE

Risk Management 1.1

Identification of Risk

All HSE hazards within Thermo LLC operational areas shall be highlighted and periodically reviewed to ensure findings remain valid. Hazards will initially be identified by the company’s audit/inspections programme. Each operation should identify all HSE hazards within each respective area together with evidence 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 the method 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 Ass essment

Risks association within current and future operations should be understood through written assessment 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 with the 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 hazards to 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 risks acceptable to customers concerned and justified. The Risk Assessment study result/recommendation of customer is to be studied and implemented.

Ref. No.

HSE PROCEDURES MANUAL

Risk Management

Rev:

Thermo L LC

02

Page : 2

Risk Assessment and Safety pl an SOWWAH SQUARE

1.4 Risk Matrix PROBABIL ITY L EVELS

SEVERI TY L EVE L S

People

Assets

Environment

Reputation

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

Multiple fatalities or permanent total disabilities

Extensive damage

Massive effect

International impact

Single fatality or permanent total disability

Major damage

Major effect

  e   r   e   v   e    S

National impact

   l   a   c    i    t    i   r    C

Major injury or health effects

Local damage

Localized effect

Considerable impact

   l   a   n    i   g   r   a    M

Minor injury or health effects

Minor damage

Minor effect

Minor impact

  e    l    b    i   g    i    l   g   e    N

Slight injury or health effects

Slight damage

Slight effect

Slight impact

High risk

-

I mprobable

Remote

Occasional

Probable

Frequent

1 in

1 in

1 in

1 in

1 in

100,000 yrs

10,000 yrs

1,000 yrs

100 yrs

10 yrs

HIGH RISK

MEDIUM RISK

LOW RISK

Take action to reduce, immedi ately

Medium risk -

Reduce risk As Low As Reasonably Practicable

Low risk

Acceptable

Ref. No.

-

HSE PROCEDURES MANUAL

Risk Management

Thermo L LC

Rev:

02

Page : 3

Risk Assessment and Safety pl an SOWWAH SQUARE

1.5 Work Permit s yst em

 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 are being carried out and are effective and that any changes in circumstance, which require alterations to safe system of work, are taken into account.

1.6.1 Safe Working Procedures for Brazing and Cutti ng: Main hazards and t he Precaution ary measures are as f ollow s:

a. Fire and explo sion hazard Precautionary Measures •

All combustible materials such as oil, paint, rags etc, should be cleared from where welding and burning operations are likely to be conducted. Fire blankets shall be used to contain sparks and molten metals within the floor and should not be allowed to fall from height. Areas below brazing should be barricaded. Suitable fire extinguisher shall be ready for instant use in any location where welding and burning is taking place. Hot works 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 arrestor shall be used in all gas burning sets. Hoses shall be of approved type and should be free fro 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.

b. Personn el exposed to h azardous heat and fu mes. Precautionary Measures •

•

Ref. No.

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 as well as suitable protective clothing and gloves. Brazers and helpers shall wear a hard hat while performing brazing and burning operations. Adequate ventilation shall be provided while carrying out hot works in confined spaces. Before starting any brazing activity, technician needs to confirm the brazing equipment is tested and the periodical inspections are done. A trained and experienced person is the

HSE PROCEDURES MANUAL

Risk Management

Thermo L LC

Rev:

02

Page : 4

Risk Assessment and Safety pl an SOWWAH SQUARE

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

•

Ref. No.

Before commencing any hot work a risk assessment will be held by the engineer and the safety officer to ensure that the area is clear of any combustible material. A hot work permit system will be followed and issued before commencing any hot work; this permit will be recorded and filed for any needed information. Gas Cylinders and Flammable Material Storage: Gas Cylinders should be stored safely and 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 fire extinguishers to be provided, all flammables should be clearly labeled, MSDS to be presented 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 in the site.

HSE PROCEDURES MANUAL

Risk Management

10.10 BRAZI NG PROCEDURE SPECIFICATION

10.11 BRAZI NG PROCEDURE QUAL I FI CATI ON RECORD