TENDER No: N-11038

REHABILITATION AND PROTECTION WORKS FOR 132 kV

OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
METHOD STATEMENT FOR
CLEANING, WELDING AND
PAINTING OF STEEL ANGLES &
CASINGS
TENDER NO: N-1103
REHABILITATION AND PROTECTION
WORKS FOR 132 kV OHTL TOWER
FOUNDATION AND CORRODED STEEL
LEGS
CLIENT : TRANSCO
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
CONTRACTOR :KEC INTERNATIONAL LTD$
1.0 Specifc work Activity and Scope:
The purpose of this Method Statement is provide the methodology
to carry out cleaning, welding and painting of steel angles and
casings. It will be assured that the work is done in line with good
engineering practices and is compliance with engineering standard
practices , nation & local codes.
2. Terminology!
OHL ! "ver #ead Transmission $ine.
Welding : Manual metal arc welding!
Danger:
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
%anger is a risk to #uman health, &roperty and 'nvironment
damage.
Danger Notice:
( notice of an approved type conveys a warning of the
%anger. These notices are also displayed at the limits of safe
working areas, calling attention to the ad)acent %angers.
The Text on Danger Board i a !ollow!
DAN"#$
STO%
O&#$ H#AD T$ANS'(SS(ON L(N# WO$)S *ND#$
%$O"$#SS
"eneral Sa!ety:
The provision and maintenance of safe access to and from the
place of work, a safe place of work, a safe working
environment, safe methods of work and the correct use of
e*ective personal protective e+uipment.
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
S+perviion:
The control and direction e,ercised by a -ompetent &erson
who is present at the point of work at all times during the
progress of the work.
3.0 $ole and $eponi,ility:
%ro-ect 'anager!
"verall control and &ro)ect Management of all activities at
&ro)ect level. %istribution of resources & .nance. /eview
and implement procedure for meeting statutory and +uality
re+uirements. -o0ordination with pro)ect co0ordinators and
customer 1 consultant 1 sub contractors 1 sub vendors 1 local
statuary bodies at the &ro)ect level and shall have the .nal
responsibility on #S'.
Site #ngineer!
2or ensuring all the activities are undertaken and
constructed as per the drawings, co0 ordinate for necessary
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
work permits, all approved 3- re+uirements are met by the
construction team and ensure that all necessary resources are
available to meet the schedule targets.
Sa!ety O.cer!
2or ensuring all the activities are undertaken and
constructed in a safe manner as per the T/(4S-"5s
approved Method Statement, /isk (ssessment & #S'
Manual.
Site S+pervior!
2or ensuring that all the works are e,ecuted meeting
T/(4S-"5s #S' & 3- re+uirements, allotment and
supervision works to individual groups, conduct Tool 6o,
Talks, 7uide and Monitor the work force for progress,
report to the Site 'ngineer on regular basis.
/01 Doc+2ent re3+ire2ent4 Drawing4 Sa!ety Doc+2ent: 5
Technical speci.cations of materials used for cleaning,
welding and painting.
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
Material Safety %ata Sheet 8MS%S9 documents of &aint.
&roduct %ata Sheet of &aint
601 'ain Tool 7 #3+ip2ent
:elding M1-, welding rod and :elding Tool kit
7enerator
&aint and &ainting tool kit
801 Step By Step %roced+re !or Steel angle
6.1 S+rvey
(ll the locations of "#$ will be surveyed.
%egree of corrosion across steel cross0section will be estimated
8whether less than ;< or greater than ;<9
Methodology of recti.cation will be classi.ed depending upon
the degree of corrosion found.
&reparation of design and re+uired drawing for fabrication will
be done and submitted for approval.
6.2 S+r!ace %reparation :
(ll steel plates shall be cleaned with potable water1 tool
cleaner to remove all traces of dirt, =inc salt etc.
-lean the surface starting with a steel wire brush. Sand again
with a .ner grit sandpaper, and .nish the sanding with a 2>
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
grit sandpaper. :ipe with a damp rag to remove all traces of
dust. /emove corrosive salts, chalks, marks, soil or other
contaminants and foreign matter by brushing the steel with a
sti* .bre or wire brush or a combination of both.
'nsure that all white =inc o,ide and other surface
contaminants are removed by abrading with abrasive paper.
/emove all traces of wa,, oil grease and other coating applied
for protection by solvent cleaning, 6erger Tool -leaner.
809 'ethodology o! painting i! the teel cro ection i
red+ced ,y le than :1; then !ollowing proced+re o!
painting hall ,e carried o+t : 5
Application o! #tch %ri2er
Mi, $u,aprime ;?, base ! #ardener in the ratio of > ! ; by
volume. @ou may add upto ?< thinner. Solvalu, ?0A for
application. (pply one coat of $u,aprime ;? by brush 1 roller to
a dry .lm thickness of upto B microns. &lease ensure that the 2
nd

coat of &rimer, 'pilu, ;C is applied after one hour or ma,imum
the same day of application of $u,aprime ;?. %o not apply after
pot life e,pires ie after >0? hours of mi,ing of base! hardener.
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
Application o! #poxy %ri2er
Same day mi, 'pilu, ;C. 6ase ! #ardener in the ratio of A ! ; by
volume. (dd always hardener to the base at the time of mi,ing and
not otherwise. (dd ;0;? < Solvalu, D0>? 8Thinner9 for
application of mi,ed paint after induction time of ;0;? minutes of
the mi,ed paint. Then apply by brush or roller to a dft of ?
microns.
Application o! <irt =oat <inih
4e,t day, Mi, 'pilu, ? 6lack. 6ase! #ardener in the ratio of A ! ;
by volume. (dd always hardener to the base at the time of mi,ing
and not otherwise. (dd ;0;? < Solvalu, D0>? 8Thinner9 for
application of mi,ed paint after induction time of ; minutes of the
mi,ed paint. Then apply by brush or roller to a dft of ;2? microns
Application o! Second =oat <inih
4e,t day, Mi, 'pilu, ? 6lack. 6ase! #ardener in the ratio of A ! ;
by volume. (dd always hardener to the base at the time of mi,ing
and not otherwise. (dd ;0;? < Solvalu, D0>? 8Thinner9 for
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
application of mi,ed paint after induction time of ; minutes of the
mi,ed paint. Then apply by brush or roller to a dft of ;2? microns.
80/ (! the teel cro ection i red+ced ,y 2ore than :1;
then deign o! tower hall ,e verifed ,e!ore carrying o+t
2an+al 2etal arc welding > no0 o! ? 22 teel plate
ti@ener aro+nd da2aged portion4 with overlap length A
91122Bda2aged lengthB811220 hall ,e carried o+t0 (n
cae the da2aged portion i in connection ,etween
concrete pile and t+, angle4 concrete hall ,e ,roken +p
to 911 22 +ntil a healthy ection i reached0
Welding to ,e carried o+t a per the !ollowing
proced+re: 5
C.>.; &reparation for :elding
It will be necessary to provide for temporary alignment of the
ad)acent components which are to be welded together, and to
hold them in position until they are welded. The methods
adopted for alignment may have to be able to carry the weight
of the components and in some cases a substantial load from
the structure.
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
Safe means of access and a secure working platform must be
provided for the welder and his e+uipment. The working
platform may also have to incorporate weather protection,
since wind, rain and cold can all adversely e*ect the +uality
of the weld.
The design of the weld and the preparation of the components
to be )oined must take into account the position of those
components in the structureE the method statement for the
erection and the welding procedure for each )oint must take all
these factors into account.
(ll the welding must be carried out by +uali.ed welders in
accordance with approved procedures.
( detailed welding plan must be made for the more important
structural )oints as well as for structures to which special
speci.cations apply.
The earth return of the electric current must never be made
through the steel frame of installations but must be directly
connected to the construction part being welded.
The surface of the =one to be welded must be clean and dry.
80/0> Welding e3+ence
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
I. -onsideration is to be given to the assembly se+uence and the
e*ect on the overall shrinkage of plate panels, assemblies, etc.,
resulting from the welding processes employed. :elding is to
proceed systematically, with each welded )oint being
completed in the correct se+uence, without undue interruption.
II. :here practicable, welding is to commence at the centre of a
)oint and proceed outwards, or at the centre of an assembly
and progress outwards towards the perimeter so that each part
has freedom to move in one or more directions.
III. =oolingC%ot Weld =leaning
&ost heat may be re+uired to relieve internal stresses caused
by the concentration of heat in the weld area. &ost heating aids
in slow down of the cooling process to minimi=e cracking.
This is a good procedure to use when )oining thick metals.
Shielded metal arc and Fu, cored welding leaves a slag
residue on the weld. /emove slag with a chipping hammer or
by grinding.
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
A!ter 8 ho+r o! welding getting co2pleted4 a2e a,ove
2entioned proced+re o! painting hall ,e !ollowed0
D. =leaning o! teel caing
-leaning of steel casings shall be carried out for height G 2
mm from top level and following steps for surface cleaning
and painting shall be carried out !0
7.1 Surface &reparation !
/emove the loose laitance and gla=ing if any, by thorough wire
brushing, rubbing stone and then clean the surface with 6erger Tool
-leaner prior to application of ;
st
-oat as primer.
7.2 (pplication of &rimer
Mi, 'pilu, ? 6lack. 6ase! #ardener in the ratio of A ! ; by
volume. (dd always hardener to the base at the time of mi,ing and
not otherwise. (dd ;0;? < Solvalu, D0>? 8Thinner9 for
application of mi,ed paint after induction time of ; minutes of the
mi,ed paint. Then apply by brush or roller to a dft of ;2? microns
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
7.3 (pplication of 2inish
4e,t day, Mi, 'pilu, ? 6lack. 6ase! #ardener in the ratio of A ! ;
by volume. (dd always hardener to the base at the time of mi,ing
and not otherwise. (dd ;0;? < Solvalu, D0>? 8Thinner9 for
application of mi,ed paint after induction time of ; minutes of the
mi,ed paint. Then apply by brush or roller to a dft of ;2? microns.
(bove mentioned 2 coatings of coal tar epo,y paint have to be
coated on foundation cap in total 8 including appro,imately ? cm
of vertical surfaces of the foundation9.
?01 Sa!ety %reca+tion !or %ainting
Technicians and personnel engaged in painting shall wear
proper coveralls, hand gloves, shoes & safety helmets.
'ach person engaged in painting must wear dust mask and eye
protector.
&aints & chemicals shall be covered1sealed o* suHciently to
prevent from spillage during transport from one tower location
to another.
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
'nvironmental ha=ards shall be checked as follows!
aD (ll paints & chemicals spilt shall be cleaned immediately.
'nsure that there is always e+uipment and supply of absorbent
materials readily available to absorb 1 breakdown or where
possible, where encapsulate paint1chemical spillages.
,D -ontrol measures for storage of painting materials at site!
"nly approved containers 1 portable tanks shall be used for
storage and handling. (pproved metal safety cans shall be
used for the handling and use of paints, etc.
&aints1chemicals shall not be stored in areas used for e,its or
normally used passage of people. Ieep them in an appropriate
and safe location such as away from sources of ignition.
&aints and chemicals shall be kept in closed containers when
not actually in use. -over the opening of the paint can with
plastic wrap before closing the lid. This will help create an
additional seal when the can is closed.
Store paint away from e,treme heat and cold. ',tremes in
temperature will spoil paint and make it unusable. Ieep away
from free=ing and hot temperatures in sheds. #ot temperatures
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
near furnaces and direct sunlight can also a*ect the +uality of
leftover paint. Store in a cool, dry area.
Segregate used and unused paint containers at one side and
mi,ing of paints with proper care.
Solvent4 che2ical 7 paint tripper +tiliEed d+ring cleaning
ho+ld ,e dipoed o! properly a!ter +e a !ollow:
They shall not be dumped onto the ground, into storm sewers
or seawater, or into sanitary sewer system.
(ll wastes shall be disposed of o* site at an approved land.ll
site. It may be a separate waste disposal area which shall be
designated on the construction site which contain clearly
demarcated skips and bins.
SuHcient water and soap will be kept at each location for
treatment in case of paint in contact with skin and eyes.
:ork area will be declared as J4o Smoking (reaJ.
Stand0by vehicle shall be at site at always to attend any
emergency.
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
&rovision of 2ire e,tinguisher & 2irst aid bo, in stand0by
vehicle at all times.
(ll electrical e+uipment to be properly maintained and earth
protected and all conductive ob)ects in the painting1spraying
area shall be grounded as well.
"nly +uali.ed painter having enough e,perience and training
in tower painting should be assigned.
%roced+re to ,e !ollowed in the event o! Tra.c Accident:
A0 (! yo+ are frt to arrive on the cene o! an accident:
;. Inform Safety %epartment1 -all "perator K Dial 1615
9F?>>/: C1>589F/??8 by any communication means
giving following information!
a9 4ature of incident
b9 $ocation of incident
c9 4ame and employment number
2. If safe to do so, turn o* the engine of a crashed vehicle.
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
A. Make the area safe by putting safety cones, warning
triangles etc.
>. &ark your vehicle safely.
?. (ssist any in)ured.
C. :ait for 'mergency Team to arrive.
B0 (! yo+ are involved in an accident:
;. Inform Safety %epartment1 -all "perator 0 Dial
161C9F?>>/:4 1>C89F/??8 by any communication means
giving following information!
a. 4ature of incident
b. $ocation of incident
c. 4ame and employment number
2. /emain at the scene of any road accident until police
give permission to go
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
A. :ait for 'mergency Team to arrive
Note: 5 Do not handle the ca+alty i! yo+ are not +reC3+alifed4
to avoid !+rther da2age to the in-+red peronnel0
=0 O@ G Site HaEardo+ #2ergency:5
"* site #a=ardous emergencies may include the following! 0
;. (ny o* K Site .re likely to a*ect on K site operations.
2. Severe weather conditions are likely to a*ect on site
operations.
A. $aw enforcement emergency alert.
'mployee must report any sighting of severe weather such as heavy
winds, /ain Fooding etc. immediately. &lease identify the condition,
appro,imate speed and direction of the weather patterns.
On Site #3+ip2ent!0
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
&ick up Truck
2ire 2ighting '+uipment
'mergency 1 2irst (id '+uipment
'mergency /escue Iit.
F01 Sa!ety preca+tion !or Welding
2or protection from in)ury it is essential that the following safety
precautions are followed!
*e protective clothing and e3+ip2ent H%%#D
This includes!0
overalls or heavy drill cotton long trousers & long0sleeve shirt
made from non0Fammable material
safety footwear
leather gauntlet gloves
standards approved safety goggles with correct .lter lens shade
wearing standards approved safety glasses when working near
Fame cutting, gouging and heating operators
Note: Other safety issues relating to clothingE
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TENDER No: N-11038
REHABILITATION AND PROTECTION WORKS FOR 132 kV
OHTL TOWER FOUNDATION AND CORRODED STEEL LEGS
METHOD STATEMENT FOR CLEANING, WELDING AND
PAINTING OF STEEL ANGLES & CASINGS
clothing worn by the operator should be in good repair. 2rayed
clothing is a .re ha=ard
leather clothing such as spats, aprons or leather )ackets may be
necessary for some Fame cutting, gouging and heating
applications
lightweight clothing is not suitable for the intense heat emitted
from Fame cutting, gouging and heating operations
Warning : Never leave ,+tane cigarette lighter in yo+r pocket
whilt Ia2e c+tting4 go+ging and heating a thi can re+lt in an
exploion ca+ing erio+ in-+ry or death0
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