Vasava Engineering Private Limited

Project: Construction 9000TPD Integrated Cement Plant At Jamul, C.G. For ACC

Method Statement

SHIFTING, ASSEMBLY AND

ERECTION OF CLINKER SILO
EXTRACTION SYSTEM

ACC Jamul Expansion Project – Bhilai (C.G))

30-MAY-2014
 Vasava Engineering Private Limited
Project: Construction 9000TPD Integrated Cement Plant At Jamul, C.G. For ACC
Method Statement: Shifting, Assembly and Erection of Clinker Silo
Extraction System

PROJECT: ACC JAMUL EXPANSION PROJECT

Client: ACC Limited.

Drawings Ref No: 244-024-100035 (Clinker Transport and Storage)

1 Document details :

Re
Date Prepared by Designation Signature Approved by Signature
v
0 28-5-2014 Vimal Singh Asst. Mgr.
1
2

2 Individual/s responsible for implementing supervising the activity and the safety
supervision of the activity (Whether line manager /safety personnel of the
Contractor)

Occupation /
SN Name Surname Signature Company
Designation
1 Satendra Singh Site Incharge
2

3. Preface

This Method Statement refers to Shifting, Assembly, Erection of Clinker Silo Extraction
DPC & Structure and Equipment at ACC Jamul Expansion Project, Chhattisgarh.

4. SCOPE OF WORK

The scope of work will be Shifting, Assembly and Erection of Clinker Silo Extraction DPC
Structure and Equipment.

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 Vasava Engineering Private Limited
Project: Construction 9000TPD Integrated Cement Plant At Jamul, C.G. For ACC
Method Statement: Shifting, Assembly and Erection of Clinker Silo
Extraction System

Detailed step-by-step sequence of activities and tasks involved in performing the

task: (Work procedure)

Shifting, Assembly and Erection of Clinker Silo Extraction DPC Structure and
Equipment.

A-Shifting of Materials-

1. Shifting of Extraction materials like Discharge chute, pin gate,

Pneumatic/Hydraulic/Motorised gate, Rail & Steels under Clinker Silo Building from
Equipment yard. All tools & tackles to be shifted from store by tractor/pick-
up/manually nearby working place.
2. Maximum & Minimum weight of shifting material will be 3 MT, 0.200 MT respectively.
3. Shifting the material near erection place for assembly purpose by
Crane/Hydra/Manually as per requirement.

B-Stacking of Materials-

1. Firstly area development will be carried out.

2. After completion of area development material will be stacked in the developed area
with proper packing.

C-Erection of Assembled Materials-

1. Marking and checking of the centre line and checking the water level and chipping of the
insert plate for post erection.
2. Parallel erection of discharge chute for DPC, 51A-AC1(4 nos), 51A-AC2 (4 nos), 51A-
AC3( 4 nos), Scaffolding Erection done to wherever required as per the ACC Standard.
3. Erection of Pin gate for 51A-AC1—DFC, DFF, DFJ, DFM.
4. Erection of Pin gate for 51A-AC2—DFB, DFE, DFH, DFL
5. Erection of Pin gate for 51A-AC3— DFA, DFD, DFG, DFK
6. Erection of the Post for erection of Pan conveyer structure
7. Erection of Head drives structure and Discharge chute.
8. Erection of Head and Tail Drive and Alignment of the motor, gearbox and drive.
9. Erection of Chain drive and locking of the chain.
10. Erection of bucket manually and locking to be done by bolts as prescribed
11. Area to be barricaded before commencement of the job.
12. Slings will be used as per load, and all lifting items should be tested by competent

3
 Vasava Engineering Private Limited
Project: Construction 9000TPD Integrated Cement Plant At Jamul, C.G. For ACC
Method Statement: Shifting, Assembly and Erection of Clinker Silo
Extraction System

person.
13. Proper packing will be done to avoid the damage to the wire rope with the sharp edges.
14. No standing under suspended load.
15. Tool box talk to be conducted first before work start.
16. For dismantling the sling proper ladder with fall arrestor will be used.
17. After completion of erection aligned the structure & tightened with nut.
18. After completion of alignment erect the floor members at different levels, afterwards
fixing of chequered plate / Gratings & hand rail will be carried out.
19. Then erect the staircase as per drawing.
20. After completion of this side runner will be lifted one by one.
21. Bolting & welding work at height will be done by Cherry Picker Arrangement.

Method statement for Welding:

1. Only qualified & approved welder will perform welding work. Before starting the
welding work, the welder will check
2. The welding cable is properly connected with the rectifier by lugs and it is also properly
tightened with welding machine.
3. He will also ensure the common connection lead is connected through the clamp as per
required polarity.
4. The welder will restore the consumable electrode in a dry place after get it issued from
store.
5. Before starting any welding activity the welder will contact to welding supervisor and
electrician to conform all the connection is made as per safety norms and technically
and electrically safe,
6. And also will take clearance from welding supervisor .The welding supervisor will
ensure that the machine and weld bed is connected with the earthling pit and weld bed
is absolutely dry, weld able object if free from paint grease, oil, plastic etc.
7. Before performance the welder will adjust current range by doing welding on a separate
object.
8. Starter may be used in case of V Butt weld. The welder will follow sequential welding
process i.e. after root weld subsequent cross will be made and welding supervisor will
confirm the zone, will be welded as shown in the shop drawing.
9. Above 8 mm thick weld multiple pass welding will be done and welding supervisor will
keep control on root gap and fit-up as per general engineering practice as stipulated in
code a practice and also will take care to maintain the interpose temperature of welding.
10. Electrodes will be preserved in a dry covered packet or box.
11. After finishing root run the welder will instruct to his helper to clean the welded
surface by cheeping & brushing before starting subsequent run.
12. After final run the welder will instruct to his contact welding supervisor to confirm weld

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 Vasava Engineering Private Limited
Project: Construction 9000TPD Integrated Cement Plant At Jamul, C.G. For ACC
Method Statement: Shifting, Assembly and Erection of Clinker Silo
Extraction System

thickness, weld length and also to check final weld surface. For usage of E7018 class low
hydrogen electrode baking is required as mentioned by the manufacturer and also the
welder will be keep the consumable item in a portable oven maintaining 80° C to 100° C
during work period and the welding supervisor will keep control on it.
13. The welded surface should be free from slag, spatter, porosity, excess weld sagging
cross weld etc and it will be responsibility of welding supervisor to identify and rectify
it instantly on also he will try to minimize the error in welding on a regular basis. Finally
the welded surface will be offered for final inspection to the client engineer.

Method statement for Grinding:

1. Gridding will be done manually, necessary (PPE's) will be used by grinding operator.
Angle grinder will be used to grind material from different angle.
2. Grinder will ensure before commencing of any grinding activity, he will contact site
electrical person to ensure for the right connection of the grinding machine.
3. After getting ensure for electrical personal as the connection is made properly through
ELCB. The operator will check the direction of rotation of grinding wheel an also
ensure the guard is in place and tightened properly.
4. The grinding machine operator will have a control one machine by using of dry gloves
with sufficient grip also will ensure usage of face guard an apron which is essential
while doing grinding work and also ensure not use any damaged or broken.
Method statement for Gas cutting:

1. Gas cutter will issue O2 cylinder and LPG/DA cylinder from store and will be shifted to
cutting zone keeping the cylinder in upright and fasten it by chain with cylinder trolley
to prevent it from sudden fall. Regulator and flash back arrester will be attached with
cylinder before connecting it with flexible hose pipe, generally red collared hose for LPG
and blue colured hose for oxygen is used to connect the cylinder with torch to reach gas
with certain desired pressure.
2. LPG gas flow will be adjusted proportionately through the knob in cutting torch and for
additional pressure.
3. During cutting will be realized through cutting nozzle by pressing the liver attached in
cutting torch.
4. Before operation the gas cutter will ensure that the hose is free from chocking, damage,
cut, etc, and also ensure nozzle of torch is properly clean.
5. Gas cutter will confirm before light up the torch that the complete connection circuit is
made an ensure it; the complete system is free from leakage.
6. Gas cutter also checks that the object will be cut, is properly supported and it will not be
dislocated or fall suddenly just after getting detached from its main segment. In this

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 Vasava Engineering Private Limited
Project: Construction 9000TPD Integrated Cement Plant At Jamul, C.G. For ACC
Method Statement: Shifting, Assembly and Erection of Clinker Silo
Extraction System

method steel is heated by a pressurized mixture of oxygen and combustible gas such as
liquid petroleum gas (LPG) the heat is focused on to a very narrow band and steel melts
at 1500° when a jet of high pressure oxygen is released on to a narrow separate hole in
the centre of the nozzle to blast away the molten metal in globules. The desired cuts are
obtained quickly by this process. The cutting will start along with the marking drawn by
filter of fabricators; cutting will be done by keeping nozzle down words or inclined in
position.

Potential hazards and risks associated with the work activities and control measures – to be
detailed in the Risk Assessment form:

Note - In the event of a sudden change in original scope of work/activity - re-submit a

new method statement and Risk Assessment for the activity:

Plans and drawings required for this job (attach as necessary)

Drawing reference
Particular / Description
number
244-024-100035 Clinker Transport and Storage

Identify all equipment required to perform the task and inspections required:

Required Inspection Frequency

item Equipment type
YES NO Daily Weekly Monthly Quarterly
1 JCB
2 Roller
3 Dumper/Tractor
4 Crane 1
5 Hydra 1
6 Trailor 1
7 Cherry Picker

Responsible Person:
1- MR. Satender Singh (Site Incharge)

Emergency Rescue Plan:

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 Vasava Engineering Private Limited
Project: Construction 9000TPD Integrated Cement Plant At Jamul, C.G. For ACC
Method Statement: Shifting, Assembly and Erection of Clinker Silo
Extraction System

 In case of any incident, call to paramedical staff’s on their mobile number by the site
supervisor.
 All emergency contact number is displayed at site for immediate communication
around the clock.

VASAVA MBE ACC