Doc No : SEN-MECH-01

METHOD STATEMENT FOR Rev : 00

FABRICATION WORKS FOR ROD MIL- Page : Page 1 of 8
01 Date : 07 Feburary 21

JOB NO 4300547081

PROJECT TITLE Fabrication Works for Rod Mil-01

CLIENT SAUDI IRON AND STEEL COMPANY (HADEED)

LOCATION ROD MIL 1

METHOD STATEMENT
FOR
FABRICATION WORKS FOR ROD MIL-01

00 For Approval Feb. 07, 2023 USMAN FURQAN

Rev. No. Details of Revision Date Prepared by Checked by Approved by

 Doc No : SEN-MECH-01
METHOD STATEMENT FOR Rev : 00

FABRICATION WORKS FOR ROD MIL-01 Page : Page 2 of 8

Date : 07 Feb 23

TABLE OF CONTENTS

S.NO Description Page No.

1 OBJECTIVE 3

2 SCOPE 3

3 REFERENCES & DRAWINGS 4

4 ABBRIVATION/DEFINITIONS 4

5 RESPONSIBILITIES 4

6 PROCEDURE 4

7 TOOLS & EQUIPMENT 17

8 HSE INSTRUCTION 17
 Doc No : SEN-MECH-01
METHOD STATEMENT FOR Rev : 00

FABRICATION WORKS FOR ROD MIL-01 Page : Page 3 of 8

Date : 07 Feb 23

1 OBJECTIVE:
The purpose of this method statement is to define the procedure for fabrication activity for Rod Mil-01
during May 2023 Turnaround.

SCOPE:
Scope of this method statement covers the following activity,

1. Material & equipment shifting.

2. Scaffolding platform erection (for lifting arrangements and execution work).
3. Existing Scrap Chute (Shear#07).
4. Installation of new water seal troughs in section with Hoppers.
5. Installation of new Dipper Plates.
6. Replacement of Furnace open circuit cooling water piping as per defined battery limits
7. Replacement of Scale & inspection Doors of reheating furnace.
8. Levelling & Alignment of furnace walking platform as per the scope.
9. Replacement of protection plates with supporting legs of the mil stands 1-15.
10. Replacement of protection covers of the stands 1-15 clamping cylinders.
11. Replacement of protection covers with supporting legs of NTM modules # 1-10.
12. Replacement of steel structure for troughs before and after shear # 7.
13. Replacement of grating underneath Pre-cooling zone.
14. Scaffolding dismantling
15. Housekeeping

2 REFERENCE & DRAWINGS:

Project Drawings
1. JS-SAJ 0201,1100 Slew Bearing Base Foundation
2. JS-SAJ 0221,7000 Fixed Gantry Structure Lifting Cylinder
3. JS-SAJ 0221,7020 Fixed Gantry Structure Supporting Ring
4. JS-SAJ 0221,7060 Fixed Gantry Structure Supporting Column

4. ABBRIVIATIONS/DEFINITIONS:
CL Client
PM Project Manager
SM Site Manager
DE Discipline Engineer
QA/QC Quality Assurance & Quality Control
 Doc No : SEN-MECH-01
METHOD STATEMENT FOR Rev : 00

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Date : 07 Feb 23

QCI Quality Control Inspector

PQP Project Quality Plan
PPE Personal Protection Equipment
HSEP Health Safety & Environment Plan

5. RESPONSIBILITIES:
1. It is overall responsibility of PM/SM to organize resources to perform the activities in this method
statement as per project specifications, in compliance with quality, schedule & HSE requirements.
2. The relevant DE and Supervisor will ensure that dismantling is conducted in accordance with this
method statement, project specifications and safely.
3. HSE inspector will be responsible for the HSE-related matters and shall facilitate the site teams for the
implementation of HSE plan.

6. PROCEDURE:
Premises
 During the working at site, paramount importance will be given to HSE in all works.
 Work permit should be secured before commencing any work at site.

6.1 Material & Equipment Shifting

a) Material & equipment (scaffolding, tools, air compressor, welding machine, temporary
supports etc.) to be shift near the work location EAF 1 slew bearing by fork lifter, trailer and
overhead crane.

6.2 Scaffolding platform erection (for lifting arrangements and execution works)
a) Erect the scaffolding platform around the scrap chute for dismantling and installation works.
b) Erect the scaffolding platform for installation water seal troughs in section with hoppers.

6.3 Existing Scrap Chute (Shear#07)

c) Dismantling of existing facilities around Scrap Chute.
d) Removal of existing scrap flap.
e) Demolition of existing scrap chute and will be removed using overhead crane.
f) Repair works shall be carried out as per site condition and will be inspected by CL.
g) Installation of new scrap chute (Shear#07) using overhead crane.
h) Re-installation of existing scrap flap.

6.4 Installation of new water seal troughs in section with hoppers

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METHOD STATEMENT FOR Rev : 00

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Date : 07 Feb 23

a) De-Bolting and demolition of existing dross hopes (8 No’s)

b) Removal of Hoppers from area using overhead crane and by manual rigging (Chain blocks etc.
…)
c) Dismantling of existing piping around trough and structural supports for rigging of water seal
trough.
d) De-bolting of water seal trough in segments to remove from area using overhead crane and
manual rigging.
e) Installation of new water seal trough in segments using overhead crane and manual rigging
f) Bolt torquing of water seal trough Segments.
g) Reinstatement of pipeline and structural supports in parallel to trough installation.
h) Installation of new dross hoppers and connection with new water seal trough.
i) Bolt Torquing of connection plates.

6.5 Installation of new Dipper Plates

a) De-Bolting and Demolition of existing identified dipper plates as per client inspection and
survey.
b) Adjustment of plates size as per site condition.
c) Bolt tightening and inspection of new installed dipper plates.

6.6 Replacement of furnace open circuit cooling water piping

a) Demolition of existing cooling water piping.
b) Installation of new Supply & Return pipeline.
c) 100% Dye Penetration testing of all weld joints at site.
d) Service Test to be performed for the complete replaced pipe circuit.

6.7 Replacement of Scale & Inspection doors of re-heating Furnace

a) De bolting and removal of existing furnace inspection doors.
b) Cutting and removal of existing furnace door frames.
c) Grinding and preparation for installation of new door frame.
d) Welding of new hinges on the door frame.
e) Installation of new door supplied by Hadeed.
f) 100% Dye Penetration testing of all weld joints at site.

6.8 Replacement of protection plates with supporting legs of the Mil Stand (1-15)
a) Demolition of existing protection covers plates in Sequence from Mil Stand-01 to Mil Stand-
15.
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Date : 07 Feb 23

b) Placement of new chequer plates parallel to removal sequence from Mil Stand-01 to Mil Stand-
15.
c) Cutting, grinding of plates to adjust as per site condition.

6.9 Levelling & Alignment of furnace walking platform as per the scope.
a) Alignment and levelling of walking platform by using chain blocks and temporary supports.
b) Placement of supports under the alignment platform.
c) Welding of newly placed supports.
d) 100% Dye Penetration testing of all weld joints at site.
e) Removal of temporary supports.

6.10 Replacement of protection covers with supporting legs of NTM modules # 1-10
a) Demolition of existing protection cover plates in sequence from NTM Module#01 to
Module#10.
b) Placement of new protection covers parallel to removal sequence from NTM Module#01 to
Module#10.
c) Cutting, grinding of new plates to adjust as per site condition.

6.11 Replacement of steel structure for troughs before and after Shear#07
a) Removal of Support#2940 and placement of new support of Shear Crank.
b) Alignment and Bolt torquing of new Support#2940.
c) Removal of Support#2930 and placement of new support of Shear Crank.
d) Alignment and Bolt torquing of new Support#2930.
e) Removal of Support#6014 and placement of new support of Shear Crank.
f) Alignment and Bolt torquing of new Support#6014.
g) Removal of Support#90101 and placement of new support of Shear Crank.
h) Alignment and Bolt torquing of new Support#90101.
i) Removal of Support#80101 and placement of new support of Shear Crank.
j) Alignment and Bolt torquing of new Support#80101
k) Support# 7290 shall be subjected to changed based on client survey during TA.

6.12 Replacement of grating underneath Pre-cooling zone

a) Removal of existing pre-cooling zone grating panels one by one and placement of new grating
panels.
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METHOD STATEMENT FOR Rev : 00

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Date : 07 Feb 23

b) Adjustment of grating panels sizes by cutting grinding.

c) Installation and tightening of grating clamps.

6.13 Housekeeping
a) Removal all material, equipment from the area.

7. TOOLS & EQUIPMENT:

7.1 Execution
7.1.1 Overhead Crane
7.1.2 Trailer
7.1.3 Fork Lifter
7.1.4 Air Compressor
7.1.5 Chain Blocks
7.1.6 Lifting Gears
7.1.7 Bolt Tightening/Nut Splitter/Bolt Tensioner Unit
7.1.8 Drill/Hilti Machine
7.1.9 Gas Cutting Torch
7.1.10 Gas Cylinders
7.1.11 Welding Generator
7.1.12 Jack Pallet Trolley
7.1.13 Hand Tools
7.1.14 Fire Blankets
7.1.15 Fire Extinguisher

7.2 HSE
7.2.1 Safety helmet
7.2.2 Safety Goggles
7.2.3 Safety Shoes
7.2.4 Leather Gloves
7.2.5 Full Body Harness
7.2.6 Face Shield
7.2.7 Welders Helmet

7.2.8 Ear Plugs/Muffs

7.2.9 Dust mask

8 HSE INSTRUCTIONS:
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METHOD STATEMENT FOR Rev : 00

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Date : 07 Feb 23

8.1 Covid-19 golden rules will be strictly followed.

8.2 During execution of the job all measure shall be adopted to ensure safe working.
8.3 All personnel involved will use necessary PPE as required.
8.4 The workers will be made aware of HSE requirements related to this activity through daily,
weekly and monthly toolbox and HSE talks.
8.5 HSE (SENDAN) prior to use will inspect all equipment.
8.6 During transportation of structure, the material shell be properly supported and tied on the
Trailer.
8.7 Ensure that structure is properly wedged or blocked.
8.8 Properly insulated and nonconductive tools should be used for electric work.
8.9 Access and good housekeeping should be maintained in all working areas.
8.10 Fire extinguisher should be available in all working areas.
8.11 Proper storage, handling and use of gas cylinders will be observed.
8.12 All cylinders shall be kept in trolleys and in an upright position.
8.13 Gas cutting sets should be checked and maintained regularly for wear and tear.
8.14 Waste Management should be strictly followed to keep the job site neat and clean.