Cathodic Protection Installation
Cathodic Protection Installation
10230
SUBCONTRACTOR / PO No.
10230-25303
CONTRACTOR review comments do not indicate either responsibility or liability for accuracy and
completeness of this Document or alter any contractual terms and conditions.
REVIEW DATE :
This document is property of UTE TR Marjan md TR Saudi arabia for Services and Contracting Co Ltd.
Its repmduction without previous permission in writing is strictly forbidden.
10230-00-082-PD-0004-TMP02
Project:
Marjan Increment Program - Tanajib Gas Plant Project Package 9
Owner:
Saudi Aramco
Contractor:
Technicas Reunidas
Subcontractor
China Eleventh Chemical Construction Company Limited
00
Rev Date Description Prepared By Checked By Approved By
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CONTENTS
1.PURPOSE.............................................................................................………….3
2.SCOPE................................................................................……………………….3
3.REFERENCE....................................................................………………………...3
4.DEFINITION...................................................................................……………….7
5.RESPONSIBLITIES…………………………………………………………………...7
6.TOOLS.......................................................................................................……... 9
7.HANDLING PROCEDURE FOR EQUIPMENT & MATERIALS...................…...9
7.1. Storage........................................................................................................………….… 9
7.2. Site Transport.......................................................................................………………..10
7.3. Material Storage......................................................................................………………10
7.4. Handling..................................................................................................………………11
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15.Safety Precaution………………………………………………………………..33
15.1.Additional Traininig Required…………………………………………………………..35
15.2.Emergency(Scenario base Emergency Rescue Plan)……………………..……….35
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1.PURPOSE:
The purpose of this method statement is to set out the procedures and precautions to be observed
during carrying out of Cathodic Protection Installation activity as per the sequence mentioned in
Marjan Increment Program Tanajib Gas Plant Project package 9 specifications, ITP, Drawings and
relevant standards.All works shall be carried out in accordance with site safety procedures and
regulations as guided by project HSE Plan.
2.SCOPE:
This method statement including limited to the activity of Cathodic Protection installation works as
following:
Cathodic Protection material handling
Installation of Cathodic Protection anodes, pipes or other equipment
Installation of above ground or underground CP cables
Thermo weld, thermite welding, or pressure crimping of CP cables
Testing for CP system
All activities of Cathodic Protection system in this project should be carried out according to the
descripted requirement in this method statement.
3.REFERENCE:
The latest revision of Saudi Aramco standard shall be use as per the below given reference
and its part of this method statement for execution.
10230-00-091-PD-0005 CONTRACTOR SITE SAFETY PROGRAM
10230-00-091-PD-0009 EMERGENCY RESPONSE PLAN
10230-00-091-PD-0019 HEAT STRESS PROGRAM
INT-10230-00-091-PD-001 SPECIFIC FALL PROTECTION PLAN
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SAES-X-600
CATHODIC PROTECTION OF EXTERNAL SURFACES OF
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SAES-X-700
CATHODIC PROTECTION OF ONSHORE WELL CASINGS
17-SAMSS-018
REMOTE MONITORING SYSTEM (RMS) FOR CATHODIC
PROTECTION
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4.DEFINITIONS:
5.RESPONSIBILITIES:
Site Manager:
Site Manager is responsible for supporting and encouraging the related staffs and workers, so as
for them to participate dynamically as work site Cathodic Protection Installation and
implementation of HSE requirements.
Construction Manager:
This Method Statement and shall ensure to review contract documents and provide all resources
necessary to effectively implement throughout Monitor the quality and Cathodic Protection
Installation progress of the work and ensure that occupation aim is achieved. Construction
Manager is responsible for complying with HSE requirements.
QA/QC Manager:
Prepare and submit Method of statement Cathodic Protection Installation for Saudi Aramco
review and approval. Provide latest revision of IFC drawings, material specifications, procedures,
drawings ,standards and technical specifications. Responsible for the overall discipline of QA/QC
Inspection, verification of the project specification, documentations and QC records for final
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acceptance.
HSE Manager:
HSE Manager shall monitor related works under carrying out, and advising supervisors for
corrective measuring of particular area, ensure holding of pre task HSE meeting / daily tool box
talks explain details of specification tasks and specification job risks and JSA involved to the work
force involved Cathodic Protection Installation . Ensure appropriate mode of communication in
case of emergency at Site.
Electrical Supervisor:
Ensure relevant work permits are raised and received prior to commencement of work, with full
compliance by all associated Foreman, quality control supervisor and Instrument supervisor to the
requirements of this procedure, Quality Control Procedures, reference the updated drawings, and
Aramco Specifications for the Cathodic Protection Installation work.
Electrical Foreman:
Ensure relevant permits are raised and received prior to commencement of work, with full
compliance by all associated Electrical supervisor ,foreman & quality control supervisor to the
requirements of this procedure. Responsible for the execution of the work, skilled Technicians and
manpower assignments and every day hourly monitor the work done and preparing the work
activities for the technician/Electrician.
Quality Control Supervisors:
Shall be responsible for monitoring, surveillance, inspection and reports as required and issue an
inspection request to Saudi Aramco Project Inspection Department as defined by the ITP.
The QC Inspectors shall accompany the SAPID representative to carry out routine inspection. To
Ensure the work activities are in compliance with the applicable standards and procedures.
To initiate the request for inspection, issue the hold point and closes the requested inspection
activities in the system.
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All handling, storage and maintenance shall be performed in a safe manner as to avoid
mechanical damage and corrosion.
7.1. Storage:
It is important to avoid exposure to moisture, dust, oil, and lubricant in order to
prevent rust.
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The materials listed above should be securely stored within a scaled storage facility local to
the work site.
The storage facility should provide the materials protection from dust and direct sunlight.
Temperatures within storage facility should not exceed +30°C (air-conditioning may be equired).
1) Reference electrodes
2) Heat shrink tube for the positive and negative connections
3) Transformer rectifier.
7.4.Handling:
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Cables
Individual cable drums shall be provided for the positive, negative and instrument negative
connections. Care should be taken when lifting and transporting the Cable Drums and cable
jacks should be used while removing cable. Care should also be taken not to score or
damage the cable insulation during the cable removal installation.
Anode ribbon mesh
Care should be taken when lifting and transporting the boxes of anode. It is also
recommended that gloves to bed used when directly handling the anode material due to
the stamp edges of the anode ribbon.
Conductor bar
The conductor bar is supplied individual rolls. There are no direct hazards when handling but
care should be taken not to damage the conductor bar during installation.
Reference electrodes
Each reference electrode is supplied with a length of cable attached. The sensor head for
each reference electrode is protected with PVC cap. The cap should not be removed until batch
testing or the encapsulation process is to be undertaken. Care should also be taken not to
damage the cable insulation during installation.
Heat shrink tube
Positive, negative and instrument negative connections shall be encapsulated with a suitable,
mechanically strong, adhesive lined heat shrink tube. Care shall be taken to ensure no damage
results to the cable insulation or heat shrink tube during heat application. Time should be allowed
for the connection to cool to ambient temperature after this procedure.
Power supplies
Care should be taken when lifting and transporting the self – contained power supply units in
order to avoid damage to the electronic components. There are no direct hazards for this item.
Junction boxes
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The junction boxes will be supplied pre-fabricated in the original shipping carton. Upon
receipt the boxes shall be removed from their cartons and checked against approved drawing
and specifications. After the checks are complete and recorded, the junction boxes shall be
returned to their cartons and stored in a secure area until installed at Site.
Prior to work, the Contractor shall review and become thoroughly familiar with the cathodic
protection drawings, applicable project specifications, and HSE policies.
The project drawings show the general arrangement of the cathodic protection equipment and can
be revised, if necessary, to meet site conditions. Any changes require prior approval from the
appropriate authority and must be noted on as-built drawings.
For Civil Work the schedule for installation of the cathodic protection equipment shall be
coordinated with the civil contractor. The anode grid shall be installed directly in the clean sand
between the HDPE liner and the tank bottom plates. The anode grid shall be surrounded by clean
sand, free from stones and debris.
The use of oiled sand or asphalts in the tank foundations is not allowed. The cathodic protection
equipment will be installed at two elevations. The anode grid shall be installed slightly above the
HDPE liner. The reference electrode and monitoring / calibration tubes shall be installed slightly
below the tank bottom plates.
It is recommended that the location where the sumps and other protrusions below the tank be
“blocked out” with wooden forms. The backfilling operation shall be in accordance with civil
specification.
An impressed current system using a grid system will be used for cathodic protection of the
external surfaces of the bottom plates for the tanks included in the scope of this project. Each
system will be similar and generally consist of a transformer rectifier, titanium / MMO anode
system, power feeds, junction boxes, reference electrodes and associated cabling.
The negative output terminal of the rectifier will be connected to the tank and the positive output
terminal will be connected to the anode feeder cable.
When the transformer rectifier is energized, current will be discharged from the anode grid, flow
through the sand to the tank bottom plates and return to the rectifier through the negative structure
cable. When adequate current densities are achieved on the tank bottom, corrosion is mitigated.
The anode grid is installed directly under the tanks in the sand backfill which ensures a very
uniform distribution of the cathodic protection current. The grid consists of titanium ribbon anode
which has Mixed Metal Oxide (MMO) coating on it and uncoated titanium conductor bars.
The anode ribbon is installed in multiple parallel anode chords evenly spaced under the entire area
of the tank. Titanium conductor bars are installed perpendicular to the anode ribbons. The anode
ribbons are resistance welded to the conductor bars at every crossing.
The anode ribbon will be connected to conductor bar by multiple feeder cables, which will minimize
the voltage drop across the anode grid. This configuration provides a uniform anode grid
throughout the entire pad of the tank bottom, which will promote a very uniform current density to
the tank bottom.
Positive cable connection to anode i s achieved by spot welding a factory assembled power feed
assembly to the conductor bar. This avoids any field splices.
Permanent copper / copper sulfate reference electrode will be installed under the tank to adjust
and monitor the performance of the cathodic protection system. In addition, slotted pipe will be
installed under the tanks bottom to monitor the tank bottom potential by using portable reference
electrode.
It is necessary to installation of the cathodic protection equipment in different phases of the project
as follows:
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Unrolling of MMO ribbon anode from coils and positioning at the spacing required
on drawing.
MMO ribbon anode should hold in place with sand bags to keep rising above the
compacted sand.
The total installed ribbon anode length shall not be less than the total length on
approved drawing.
Conductor bar from coils shall be uncoiled and positioned at the spacing required.
Spot welding at each MMO ribbon anode and conductor bar (at least three (3)
welds required on
25mm intervals), according to vendor procedure. (refer to attachment 1)
Connect the conductor bar and the power feeder cable according to the approved
drawing. Titanium rod to power feed cable will be compression crimped to the
positive cable and sealed with an appropriate splice kit and filled with epoxy resin.
Ensure sufficient time (More than 2 hour) is allowed for the resin to set.
The following inspection and tests shall be performed for the anode grid system
and related accessories on approved drawing:
8.2.2. Before Backfilling:
Anode spacing (within ±5%).
Anode depth with respect to the tank bottom.
electrodes, etc.)
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Perforation shall be installed toward tank bottom plate and Joining of pipe section
is by PVC glue which is supplied by subcontractor.
PVC cap shall be installed at both sides of pipe.
PP rope stopper will be provided to secure pulling rope.
Installation polypropylene rope inside monitoring pipe for connection to retractable
electrode, in case of future measurement.
Visual and dimension check (within Typ. ±10%).
Check the smooth operation of passage through the monitoring pipe with
temporary electrode instead of retractable reference electrode.
The inspection result shall be recorded on the form.
8.5.Cable to tank connection:
The material of steel plate shall be same as tank shell.
The interval between negative connection and test cable connection shall be Min.
1m.
Before connection, paint of steel plate shall be removed. Resistance between tank
and negative cable shall be tested. Measured resistance shall be less than 1ohm.
Above ground cable to tank connections shall be carried out by lugging the cable
on a steel plate. l The cable shall be connected to the threaded stud bolt by using
a lug, nut and washers.(See figure 1) l Cable lug shall be suitably sized to fit the
cable cross-section.
After connection, connection point shall be protected with grease
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8.6.Backfilling:
During backfilling of clean sand, attention to be paid to avoid damages to MMO
anode, cables, permanent reference electrodes and monitoring pipes.
If any damage to C.P materials is detected (cable cutting, welding damage etc),
backfill shall be interrupted and prompt repair actions shall undertake.
8.7.Temporary Protection and Tagging of CP Cables:
The reference electrode and power feed cables installed under the tanks cannot be permanently
installed until after the tanks are erected and the junction boxes are installed.
Subcontractor shall devise a method to protect the cables from damage during tank construction
activities. This may be accomplished by coiling the cables and temporarily burying them or placing
them in an above ground box where they will not be damaged during construction of the tank.
Please note that the ends of the power feed cables need to be accessible for resistance testing
during tank construction. The end of all cables shall be identified with permanent cable labels.
8.8.Resistance Testing During Tank Construction:
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It is extremely critical that the anode grid is electrically isolated from the tank and all other metallic
structures. A short circuit between the anode and other metallic structures including; the tank
bottoms plates, tank sumps, electrical conduits, reinforcing steel, instrumentation lines, piping,
ground rods etc., will render the CP system non-functional.
Therefore, it is recommended that the electrical resistance be measured between the power feeds
and the tank bottom plates. A measurement should be made immediately after the installation of
the first plate. Subsequent periodic measurements should be taken during installation of the tank
bottom plates - especially if it is suspected that a bottom plate has contacted the anode grid (i.e.at
sumps that protrude below the tank bottom plates)
The measurement technique involved using a megger to measure the electrical resistance (in
Ohms) between the steel tank bottom plates and the power feed cables. The electrical resistance
should be significant and any drastic reduction of the initial resistance value should be
investigated.
8.9.Site Clean-up:
All work areas including access and storage areas shall be restored to their original condition.
Excess materials, as well as all scrap and debris, shall be removed. All clean up shall be approved
by the Saudi Aramco representative.
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The anode installation will be checked to ensure the fixing by hook is secure and
there is no interference or contact with the tank internal surfaces. If anode is
contacted with shell, bottom & pipe inside tank, CP system cannot be operated.
Check the resistance between anode and tank. If measured resistance is low,
check all anode status.
Install anode JB and terminate each anode cable ensuring that each cable is
correctly labeled.
An All cable routes inside and outside of tank shall be defined at site in order to
achieve shortest run to TR/Rectifier.
During hydro test, CP system for tank internal shall be energized using temporary
power supply and checked the performance before other work.
The following inspection and tests shall be performed for suspended anode
system and related accessories on approved drawing.
① Location of suspended anode (±5%).
② Elevation of suspended anode (±5%).
③ Anode quantity (Not less than approved quantity).
④ Connection of rope to concrete ballast (Visual)
⑤ No secondary interference (Visual).
⑥ Visual and dimension check of suspended system accessories (Visual)
⑦ Anode rope and hook (Visual).
The inspections and test should be recorded on Inspection and test sheet
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- Prepare supplied Ag/AgCl ref. electrodes and calomel ref. electrode. (See
Figure 2)
- Fill a bucket with seawater or (3 to 3.5% sodium chloride solutions)
- The permanent Ag/AgCl ref. electrode shall be in the left side of the bucket
- The calomel ref. electrode shall be in the right side of the bucket.
- Measure potential difference between the two electrodes as shown on
below diagram.
VOLTMETER
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The cable shall be connected to the threaded stud bolt by using a lug, nut and
washers.(See figure 4)
Cable lug shall be suitably sized to fit the cable cross-section.
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- Prepare supplied Ag/AgCl ref. electrodes and calomel ref. electrode. (See
Figure 7)
- Fill a bucket with seawater or (3 to 3.5% sodium chloride solutions)
- The permanent Ag/AgCl ref. electrode shall be in the left side of the bucket
- The calomel ref. electrode shall be in the right side of the bucket.
- Measure potential difference between the two electrodes as shown on
below diagram.
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~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
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Be careful at the time of anode junction box installations. It is highly recommended to install the
anodes power feeder cables first and then select the anode junction box location where all
associated anode power feeder cable tails can reach, because cable joint in anode cable is not
allowed. Therefore, select the anode junction box location very carefully to avoid any problem
related to short anode length.
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a)Equipment supports will be inspected to ensure they are fabricated as per the
approved detail drawing.
b)Base plates, fixings, concrete foundations etc, will be checked for locations and
level and the fixings.
c) Cables to boxes shall be checked against the approved drawing for correct
routing and termination.
d) Nameplate shall be checked.
Check the connection.
The inspection result shall be recorded on the form.
12.INSTALLATION OF TRANSFORMER/RECTIFIER:
The designated location for installation shall be verified on site prior to installation works taking
place. Oil immersed rectifiers shall be mounted a minimum of 300 mm above ground to minimize
sand accumulation against the rectifier.
The unit shall be securely grounded prior to connection of A.C. and D.C. cables. It shall be
assured that the applicable A.C. breaker at the associated sub-station is locked off prior to
connection of A.C. cables. It shall be assured that the D.C. cables are connected with the correct
polarity.
The transformer rectifiers shall be connected to plant grounding system at nearest
Install guardrails for unfenced rectifiers for protection against vehicular traffic (IF ANY)
Prior to installation, the foundations shall be checked for level and civil
clearance shall be obtained.
Fix transformer rectifier to base utilizing anchors and the fixing holes
provided. Great care to be taken in identification of polarity of all cables
ensuring they match the polarity of the marked terminals.
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c) Where oil immersed unit has been supplied oil filled, the oil level will
be checked to ensure no leakage.
d)Prior to installation, the foundations will be checked for level and civil clearance
will be obtained.
e)Installed unit will be witnessed to ensure correct orientation and alignment for
cabling.
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Spot welding will be used for connection of M.M.O ribbon anode and conductor bar which is very
thin metallic as shown the below.
Spot welding is a resistance welding process for joining metal sheets by directly applying opposing
forces with electrodes with pointed tips. By one or two electrode
The current and the heat generation are localized by the form of the electrodes. The weld nugget
size is usually defined by the electrode tip contact area. Spot welding for CP work also used to
connect electrical conductivity without force of tension and other reason.
Spot welding is simple and different with strict SMAW because the spot welding is no need free of
leakage, force of tension and other strict requirement. Spot welding generally is doing like
resistance spot welding procedure without strict test and special qualification.
For each unique type of weld to be produced, a minimum of 5 sample welded connections shall be
produced for an initial procedure qualification.
The qualification sample set shall be acceptable to all of the following 3 levels of quality control as
applicable, for successful qualification:
A) Visual inspection, B) Conductivity (Resistivity) testing,
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All weld specimens shall be visually inspected and tested for electrical conductivity
(resistivity). The
resistivity of each connection shall meet the drawing requirements or if not
specified by the drawing, shall measure up to 1.0.
C) Destructive testing
Five (5) weld samples shall be tested prior to start. Spot weld is by making a triangle and
the weld is acceptable if the weld is not falling out when rubber hammering (1kg) to
welding points.
14.QA/QC REQUIREMENT:
14.1.General
ELECO will follow this project itself QA/QC plan, TR QA/QC plan, and Saudi Aramco relate
documents.
14.2. Inspection
While construction is processing and/or when the job finished, ELECO will submit relate RFI to
QA/QC department for inspection. Items should be like below:
Material Receiving Inspection should be execution; all materials comply with drawing or
specification.
Supports, Equipment, Anode and conductor, Bus bar, Conduit, Cable Installation are all
comply with drawing or specification.
CP System spot welding joints and thermo welding joints Installation (clamps, bounding
jumper, etc.) comply with drawing.
Resistance Test Checked and should be inspection.
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certificate, or other factory technical documents and specifications. All type, size, and
materials must comply with design.
Strict implementation of approved ITP.
Full time quality inspection personnel to inspect the quality of construction for a nice job in
the record, the unqualified items should also make in record and rectification immediately.
CP cable installed and routed according to the latest drawing (AFC) and specifications.
Grounding Cables and Electrode are buried the depth as per drawing (AFC) and
Specifications.
Underground conduits stub up are properly installed according to drawings (AFC) and
specifications
Ensure the installation of ground bus bar is the same as approved drawing (AFC)
CP resistance welding joints and thermo welding joints visual check (cadwelds, clamps,
etc), and pressure connections must be tighten, and all should be follow drawings and
specifications.
15.SAFETY PRECAUTIONS:
Cathodic Protection Installation work will be undertaken in accordance with ARAMCO
CSM requirement.
Work Permits must be obtained prior to any work being carried out and work will
commence in accordance with the specific measure itemized on the permit.
All necessary (PPE) Personal Protection Equipment will be provided and worn in
accordance with Procedure of ARAMCO Construction Safety Manual.
Unloading of construction material must be initiated by competent person (SA
certified Rigger and SA certified Crane operator)
Area barricading, sign boards placing, safety personnel presence checking and
stopping all on-going activities within the operating radius.
All personnel connected to the job shall have a Toolbox meeting & each one shall be
apprised of the total work procedure, individual responsibilities, and safety aspects.
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The load test certificate of the crane shall be checked. All the tools, tackles, shackles,
slings, auxiliary tools, spanners etc. being used for the erection shall be of good
quality and must be inspected before using them on daily basis.
All Personnel shall be familiar with the location and use of safety devices located in
the area such as Fire Extinguishers, first aid kits.
All electrical equipment shall be properly earthed, color coded and inspected as per
project Requirement.
All safety precautionary signboards must be visibly posted.
Electrically driven power tools shall be properly grounded to prevent work. When
working at heights use only approved (green tagged) scaffold working platforms and
attain 100% tie-off safety policy.
A specific site Job Safety Analysis will be required prior to start the work in order to
assess the specific risk arisen in work location, which will include all HSE
requirements and the specific safety measures to perform the work safely.
Ensure that only authorized and competent personnel are allowed working in the
area.
Maintained Work Permit and JSA at worksite by work Supervisor, requirements shall
be discussed in daily TBT
The use of Electrical safety, Are Flash safety grounding, and Lock Out Tag out
Procedure should always be followed during Installation, Servicing and Uninstalling
electrical.
If possible, use mechanical equipment to eliminate the ergonomic hazards.
Frequent job rotation shall be implemented to minimize fatigue to the personnel.
Positioning on line of fire shall be prohibited.
If ever use of Forklift:
Load must be secured, Load must not exceed beyond the manufacture capacity,
Only SA certified operator with valid Gov, License operator shall operate the forklift.
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Scenario base Emergency Rescue Plan for Victims using manlift for, Injured or
Trapped Worker or suspended workers: If a worker is injured or trapped during
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equipment installation at height, immediately cease all work and initiate the following
actions:
Scenario base Emergency Rescue Plan for Victims using Rescue pulley and man
basket, for Injured or Trapped Worker or suspended workers: If a worker is injured or
trapped or suspended during equipment installation at height, immediately cease all work
and initiate the following actions:
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Inform coworkers and supervisors about the situation so they can aid and cooperate
with emergency personnel. Evacuate the area to nearest assembly point.
Assist with Rescue Efforts:
Upon the arrival of ERT follow the instruction of ERT while using rescue pully and
man basket for lowering the victim, cooperate with ERT and follow their instructions.
Scenario base Emergency Rescue Plan for Victims using Rescue from work area
using stair access or floor below, Injured or Trapped Worker: If a worker is injured
during equipment installation at height, immediately cease all work and initiate the
following actions:
Upon the arrival of medical team cooperate with medical team and follow their
instructions.
Stay at the assembly area until all clear announcements.
10.ATTACHMENT:
a) JSA.
b) Scenario based Risk assessment.
c) High angle rescue team members (ERT) (Approved 3rd Party).
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