Site Methodology & Risk Assessment

1. Method statement — piping installation

Scope: cutting, welding, fitting, aligning and testing of process piping at site as per isometrics and project drawings.

Key activities

• Review piping isometrics and approved fabrication drawings
• Prepare pipe supports and hangers
• Cut and bevel pipes to specification
• Weld using qualified procedures and welders
• Non-destructive testing (NDT) of welds
• Hydrostatic or pneumatic testing for integrity
• Cleaning and flushing of pipelines
• Pickling & passivation for stainless steel; blasting & painting for carbon steel
• Final inspection and handover

Safety measures

• PPE: gloves, helmets, apron, shoes, eye protection, welding shields
• Gas flow monitoring during welding / cutting
• Fire-watch procedures and extinguishers on site
• Confined space entry protocols
• Proper lifting and rigging techniques

2. Risk assessment — piping installation

Hazards: fire and burns from welding/cutting, falling objects or pipe sections, trips and falls, exposure to fumes and gases, manual handling injuries.

Controls: strict hot-work permits and firefighting readiness, scaffolds and barricades, ventilation and respiratory protection, mechanical lifting aids and team lifting, comprehensive training and supervision.

3. Method statement — structural steel erection

Scope: assembly, alignment and fixing of structural steel including columns, beams and bracing.

Key activities

• Verify structural drawings and levels
• Prepare foundations and anchor bolts
• Lift and position members by cranes
• Install temporary bracing
• Final welding / bolting and torque checks
• Surface preparation and coating application

Safety measures

• Fall protection systems (harnesses, nets)
• Crane operation by certified operators only
• Ground personnel exclusion zones
• Lifting guides and tag lines
• PPE: helmets, gloves, high-visibility vests

4. Risk assessment — structural steel erection

Hazards: falls from height or scaffolds, crane accidents and dropped loads, pinch points and crush injuries, welding fumes and sharp edges.

Controls: fall arrest systems with regular inspection, crane pre-operation checks and load tests, clear communication via radios or signals, PPE and safe work zones around lifting areas.

5. Method statement — thermal insulation

Scope: application of thermal insulation materials on piping, structural elements and equipment.

Key activities

• Surface cleaning and preparation
• Cutting and fitting insulation (fibreglass, mineral wool, etc.)
• Securing insulation with bands, wires or adhesives
• Applying vapour barriers or jacketing
• Final inspection for completeness and integrity

Safety measures

• Respiratory masks and protective clothing
• Handling adhesives and sealants as per MSDS
• Avoiding dust inhalation during cutting
• Safe scaffold and work-platform use

6. Risk assessment — insulation work

Hazards: respiratory irritation from fibres and dust, skin irritation, chemical exposure from adhesives, working-at-height risks.

Controls: PPE including gloves, masks and eye protection, training on safe handling and material hazards, good ventilation and wet-cutting methods, fall protection equipment.