SCD-GR-FM-074 - SOW - EAF Process Optimization SMP1 Rev-02

EMIRATES STEEL
SoW Contracted Engineering Services Requirements SCD-GR-FM-074
PR No: 4909103292
Work/Service Title: EAF Process Optimization System
Name of Requisitioner: Manoj Kumar Agrawal Date: 1.11.2021
End User Focal Point):
Table of Contents
1. Description ................................................................................................................................................. 2
2. Contractor Deliverables............................................................................................................................. 3
3. Relevant Designs and Specifications ....................................................................................................... 22
4. Work Location.......................................................................................................................................... 23
5. Time/Schedule Requirements ................................................................................................................. 23
6. Relevant ES Management and Coordination Roles and Responsibilities .............................................. 23
7. Equipment and Materials Requirements................................................................................................ 23
8. Quality Requirements ............................................................................................................................. 24
9. Security Requirements ............................................................................................................................ 24
10. Contractor Staffing (Management, Supervisory, Technician and Helper) Requirements .................... 25
11. Reporting and Documentation Requirements ....................................................................................... 26
12. Other Requirements ................................................................................................................................ 26
13. HSE Requirements for the Work ............................................................................................................. 27
Issue No.: 3 1 Issue Date 15.02.2021

EMIRATES STEEL
1. Description
Emirates Steel (ES) is in Mussafah, Industrial City Area (ICAD1), on the North East of Abu Dhabi, UAE and
currently comprises of an integrated steel making facility (Phase 1, Phase 2 and EISC) to produce reinforcing
bar, wire rod and structural sections.
At ES there are three Direct Reduced Iron (DRI) Plants, three Steel Making Plants (SMP) and five Rolling Mills
(RM), in which DRP1/ SMP1/ RM1/ RM2/RM3 are in Phase 1, DRP2/ SMP2/ RM4 are in Phase 2 and DRP3/
SMP3/ RM5 are in EISC.
SMP-1 has one electric arc furnace with the following characteristics:
• EAF Tap Weight – 150 ton
• Hot Heel – 38 ton
• Total Melt Weight – 188 ton
• Average Charge mix yield ( 100% DRI) – 86.4%
• Charge DRI Weight – 176 ton
• Bucket Weight – 42 ton
• Scrap Bucket (0.6 t/m3) – 55 ton
The new i EAF® system (designed by TENOVA - the Supplier) to be installed, will be used to continuously
monitor gas-phase, energy, and bath/slag properties, and provide real-time control of EAF operation by
dynamically adjusting the process parameters.
The objective is to implement closed-loop control of:
• Oxygen injection
• Carbon injection
• DRI feed rate, based on material characteristics (metallization, composition)
• Electrical Power input
• Lime injection (future)
• Fluxes addition prediction/adjustment based on material characteristics and real time information
• Dedusting system operation
To achieve a dynamic mass & energy balance, it is necessary that both the composition of the EAF off-gas and
the mass flow rate of gases leaving the EAF are measured. New, advanced sensors will be used

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to measure the off-gas velocity, to calculate mass flow rate, as well as temperature at a downstream location
in the fume system.
These measurements, along with downstream and upstream composition measurements, make it possible to
calculate the mass flow rate of gases leaving the EAF. The mass flow rate forms the basis for a gas-phase mass
balance in the EAF freeboard. The gas-phase mass balance in the EAF freeboard, along with continuous off-
gas temperature measurements at the fourth hole, allows for the gas-phase energy balance of the EAF
freeboard.
Emirates Steel is proposing to upgrade the Electrical Arc furnace at SMP1 by adding ‘Process Optimization
System’ to increase the Plant metallic yield, consumptions, Power ON time, and productivity.
This tender requires the Contractor to install equipment delivered by TENOVA for the EAF Process
Optimization system for SMP1 EAF.
2. Contractor Deliverables
2.1 Scope of Work for Installation
The scope of work for the Contractor involves receiving material from Supplier, handling within the plant,
unpacking, installation, testing and commissioning, final painting at site and handing over on time, within
budget, but, most importantly, with zero harm to anybody. The Contractor shall strictly follow the Supplier
Installation Procedure, ES Contractor Safety Performance Management Procedure, Safety Regulation and
Work Permit Procedure during installation. The scope of work shall include, but not limited to the
following:
• Upstream Instrumentation & Engineering Services:
A proprietary upstream instrumentation for the i EAF® system will be supplied as follow:
➢ Two (2) water cooled probes (One working plus one spare probe), which are custom
designed to the exact dimensional requirements for EMIRATES STEEL. The probe will be positioned
upstream at the furnace fourth hole, in the primary duct, to measure the off-gas chemistry directly
before the dilution air.
➢ One (1) Heated Lines of customized length to connect the probe to the sampling station.
➢ One (1) Off-gas Laser/Extractive Sampling Station with proprietary cells for CO, CO2, O2, & H2. This
Sampling Station is designed to be positioned directly on the Melt Shop floor near the probe and
without the need for a controlled environment room.
This unit is designed to remove particulate matter from the off-gas sample and to provide for
alternating gas sampling and back purging cycles in tune with the furnace operating cycle. Each

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sampling station also contains TENOVA Goodfellow’s proprietary cells to analyse for CO, CO2, O2, and
H2 in the clean, wet off-gas.
➢ Fiber optic & coax cables connecting the Extractive/Laser Sampling Station to the multipoint
analyser located in the Control Room.
➢ One (1) Multipoint Laser Analyzer Rack Mounted Analyzer system located in the control room and
connected to each Extractive/Laser Sampling Station by fiber optic & coax cables to provide real-time
upstream & downstream off-gas analysis.
➢ Optical Temperature Measurement (OTM) a proprietary optical sensor to measure remotely the
off-gas temperature of upstream location at the furnace gap including installation kit.
• Downstream Instrumentation & Engineering Services:
➢ Two (2) water cooled probes (One working and one spare), which are custom designed to the exact
dimensional requirements for EMIRATES STEEL. The probe will be positioned downstream in the
off-gas duct to measure the off-gas chemistry.
➢ One (1) Heated Line or non-heated line (to be decided during KOM) of customized length to
connect the probe to the sampling station.
➢ One (1) Off-gas Laser/Extractive Sampling Station with proprietary cells for CO, CO2, & O2. This
Sampling Station is designed to be positioned directly on the Melt Shop floor near the probe and
without the need for a controlled environment room. This unit is designed to remove particulate
matter from the off-gas sample and to provide for alternating gas sampling and back purging cycles
in tune with the furnace operating cycle. Each sampling station also contains TENOVA Goodfellow’s
proprietary cells to analyse for CO, CO2, and O2, in the clean, wet off-gas.
➢ Fiber Optic & Coax cables connecting the Extractive/Laser Sampling Station to the multipoint
analyser located in the control room (the multipoint analyser is supplied on the upstream section)
➢ One (1) Off-Gas velocity sensor – OVM - (for off-gas flow calculation): installed at the downstream
off-gas analysis probe location to continuously measure off-gas velocity rate.
➢ Fume duct modification for Probe and OVM installation.
• Installation and integration of auxiliary plant systems. Auxiliary plant system consists of cooling water,
firefighting interconnecting piping, valving, instrumentations and supports. The Contractor shall
design, install, clean and commission the auxiliary plant system. Contractor shall submit hydraulic
calculations to confirm the suitability of the auxiliary plant system.
• Installation of Supplier provided Electrical items (e.g., motors, LV (Control Cables, Ethernet, Lan
Cables, Communication cable, Optic fiber cable, Profibus) and power cables, cable trays, panels,
transformer, earthing, lighting etc.). Power cables routing, cable tray and cable tray support design

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outside battery limit of EAF Process optimization System shall be done by Contractor. Contractor shall
carryout a site survey, select the most suitable route that is applicable from the safety point of view &
submit the cable routing drawing for ES approval.
• Contractor shall supply the required cables those not supplied by the supplier & any other cables those
required for the completeness of the work.
• Contractor shall supply & install the cable trays with suitable supports. The sizing of the cable trays
shall be suitably done with extra space provision for future cables.
• Separate trays shall be provided for Power, Control & signal cables.
• Any civil works (e.g., concrete core cutting, foundation, etc) if required for the electrical works shall be
included in the scope.
• All cable exit / entry points from/to indoor substation shall be sealed with proper sealing compound.
• Installation of Supplier provided Instrumentation items (e.g., PLC, local control boxes for, automation
system, operator interface system, EWR operator workstation, EWR control desk, communication local
area network, control cables, cable trays required to run the new installation. Control cables routing,
cable tray and cable tray support design outside battery limit of EAF optimization System shall be done
by Contractor. Contractor shall submit the cable routing drawing.
• Contractor shall supply the cables (power & control) & any other electrical components (MCB, MCCB,
Fuses, etc) as per ES approved makes.
• All cables shall be suitable for an ambient temperature of 55°C & operating temperature of 90°C. The
voltage grade of power cables shall be 600/1000 volts.
• If any hot work is carried out then fire blanket, valid fire extinguishers shall be provided & other safety
precautions to be taken.
• Modification in the existing installations as per ESI requirement.
• Installation of Supplier provided insulation material.
• All necessary scaffolding/lifting tools/mobile cranes shall be provided by the Contractor and handled
under own responsibility. Contractor shall also provide all the required documents, licenses, and
certifications to use the same.
• For all site activities including crane operation if applicable, the Contractor shall carryout a detailed
Risk Assessment and Risk Mitigation Plan. The Contractor shall prepare a Job Method Statement (JMS)
and lifting plan for all site activities and obtain approval from Emirates Steel HSE department.

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Scope Matrix
Legend: S - Supplier, C - Contractor, NA - Not Applicable
SN Description Supply Supervision Installation

Work
1. Modification & Installation at EAF C S C
Fume exhaust hoods. Matching
Flanges, piping, tapping, valves
other required accessories.
2. EAF Process Optimization System S S C
3. Water, Nitrogen piping, supports C S C
& accessories.
4. Electrical installation of Supplier S S C
packages
5. Instrumentation, Automation S S C
installation and integration with
existing system of Supplier
packages
6. Scaffolding, Lifting, and handling C S C
equipment
7. Laying & Termination of Cables C S C
(Control, optic fibre,
Communication, LV Power etc),
Cable Trays & their supports,
accessories, MCB, Switchgear, JB,
etc other and consumables.
8. Consumables, hardware electrical C S C
& mechanical required to
complete the installation
9. Commissioning NA S C
10. Functional Tests NA S C

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Reference sketch for the installation of the equipment
Sampling Station Multipoint Analyzer panel

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iEAF NextGen System Overview
The NextGen system is a multi-station gas analysis system capable of measuring real-time process gas chemistry (CO,
CO2, H2, O2, and H2O if required) from several points in the process or different processes. Figure 1 shows the major
components and requirements for a 2 point gas sampling system, which includes patented gas probes, heated
sample lines, sample station cabinets, a multigas laser/control cabinet and a computer. Up to 4 sample stations can
be managed by one laser cabinet.
The process gas sample for each sample station is collected under vacuum via the gas probe mounted in the
ductwork. The gas sample is transported via the heated sample line while maintaining sample integrity until it
reaches the sample station cabinet (SSC), where the gas sample is filtered for dust particulates before reaching laser
based detectors that measure the composition of the gas sample. Each SSC receives laser signals from the control
cabinet and sends analog signal back to the laser cabinet where it is translated into gas composition. The data is then
sent to an iEAF computer via Ethernet connection.
The followings are the specifications, requirements and photos for the three main components of the NextGen
system.
1. Gas Probe
2. Sample Station Cabinet (SSC)
3. Control Cabinet (CC)

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Gas Probe Key Specifications

Item Specification Supply
Dimension and Weight • Approximately 5” OD Supplier M/S TGI supplies gas probes.
• Customized length 2 to 6’ •
Each probe weighs 65 to 100 kg Contractor Scope : Supply material and
(140 to 220 lb) filled with water. fabricate mounting flange to support
the sample probe as per Supplier
drawings and modification in the duct
and Installation mounting flange as per
drawings
Dust Filtration • 5 micron metallic mesh Supplier M/S TGI supplies filters and
filter holders for gas probes
Duct Modification • 6” hole (2 water pipes) for probe Contractor Scope : Supply material and
insertion fabricate mounting flange to support
the sample probe as per Supplier TGI
drawings and modification in the duct
Cooling Water • Max 5 barg inlet pressure and Min Contractor Scope : Supply &
2 bar differential pressure Installation of required piping, flanges,
• 75 USGPM valves, tapping and its accessories etc.
• Max 70 Celsius inlet temperature
• Clean and scale free
Mechanical Connections
Cooling water inlet and outlet 2" NPT Contractor Scope Supply: water lines,
valves, switch
N2 purge (from SSC to probe) 1/2” SS tube Contractor Scope Supply: N2 at SSC
Plant supplies purge piping
Sample (from probe to SSC) 1/2" SS tube TGI scope of supply -heated sample
line and hoses as needed
Gas Probe Reference Phots

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Sample Station Cabinet Key Specifications

General Specification Supply
Dimension and Weight • 53in (1350mm) W Contractor Scope : Supply & Installation of
• 32in (800mm) H • frames for standing/mounting the cabinets
21in (530mm) D
• 800 lb. (363 Kg)
N2 supply (for actuator) 7bar/100 psig Contractor Scope : Supply & Installation of
required piping, flanges, valves, tapping and
its accessories etc.
N2 for purging 7bar/100 psig, 0.3 Nm3/min max Contractor Scope : Supply & Modification,
for 5 min during purging Installation of required piping, flanges,
Compressed air for cooling (Vortex) Vortex model 106-2-H valves, tapping, tube, valve, pressure
100 BTU/hr, 2 scfm @ 100psig indicator and regulators and its accessories
Water for water cooler Exair model 4840-240 etc.
2800 BTU/hr, 1 gpm (4 LPM)
Mechanical Connections
Vortex Air INLET 3/8" tube, 1/4” FNPT Contractor Scope : Supply & Modification,
Nitrogen HEADER supply 1 ½” or 40mm pipe Installation of required piping, flanges,
Nitrogen INLETS and VENT 1/2" and 1/4" tube valves, tapping, tube, valve, pressure
1/2" and 1/4” FNPT indicator and regulators and its accessories
SCC off-gas vents (to be evacuated in 3/8" tube, 1/4” FNPT etc.
safe area) Install probe clamp on mounting flange and
gas probe as per TGI drawings.
SCC drains (to be evacuated in safe 3/8" tube
area) 3/8" and 1/4” FNPT
Sample line (from SCC to probe) 1/2" tube, 1/2" FNPT
Purge line (from SCC to probe) 1/2" tube from header
Water supply and return 1/2" tube or hose, 3/8” FNPT
Additional Connections
Communication (from SCC to CC) Ethernet RJ45 Contractor Scope : Supply of cables cable
Temperature measurement for 2 wire 4-20 mA trays, supports & Installation, cable laying,
heated lines terminations etc
Main power electrical cables properly sized
Fiber (from CC to SCC) optical fibers

Coax Cables (from SCC to CC) coax cables

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Sample Station Cabinet
Dimensional drawings and connection scheme: Front and bottom views

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Multi Point Analyser Control Cabinet Key Specifications

General Specification Supply
Dimension and Weight • 32in (813mm) W Contractor Scope : Supply &
• 83in (2108mm) H Installation of frames for
• 25in (635mm) D standing/mounting the cabinets.
• 420 lb. (190Kg) Repeater needed if longer than
Max distance from SCC 350 ft due to optical fiber limitation 200, Supply of cables cable trays,
Additional Connections supports & Installation, cable
Communication (from SCC to CC) Ethernet RJ45, CAT5 or CAT6 laying, terminations, accessories etc
Communication with plant network Ethernet RJ45, CAT5 or CAT6

Main Power Electrical cables properly sized
Optical Fibers (from CC to SCC) Temp range : -40 to 70 OC Bend
radius : 8” or 207 mm
Coax Cables (from SCC to CC) Temp range : -40 to 80 OC Bend
radius : 2” or 50 mm
Multi Point Analyser Control Cabinet

Dimensional drawing:

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Reference Picture for the Installation

Gas Probe
Piping and
Quick
Connections
Gas probe installation and connections

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Heated
Heated
sample
sample line
Purge line
Water supply
& return connection
Mounting Clamp
Furnace Fume Duct

Flow
Gas Probe Installation Photos

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Probe Flex
Hoses
Clamp
Quick
Connections,
piping and
fire retardant
Photo of Heated Sample Line

Note- 0.5 m minimum bending radius

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Gas Probe Installation Schematic
Duct modification and port for the gas probe
The mounting flange and clamp for the gas probe

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Probe
Clamp See drawing
M-602 for
dimensions
details
Probe
Mounting
Flange
Probe clamp
allows
adjustment of
insertion
depth

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The mounting flange and clamp for the gas probe
connects]
Furnace New Port & Water Flow Furnace

Flow Arrangement Flow
Furnace Top View Furnace

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The protection plate and enclosure box
Fire retardant/Pyro jackets for all connections at the gas probe

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2.2 Exclusions
All civil installation works are not part of Contractor’s scope.
2.3 Inspection and Test Plan (ITP)

The Contractor shall submit an ITP for ES review and approval and the Contractor shall carry out inspection
as per agreed ITP.
The Contractor shall issue Notice of Inspection (NOI) for ES inspection.
The Contractor shall prepare necessary inspection reports welding qualification records, NDT reports, test
reports, and with traceability reports for all materials and Submit for ES review progressively and submit
as a dossier at the completion of job.
2.4 Commissioning
The Contractor shall commission the EAF Process Optimization as per Supplier instruction.

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Upon completion of project a snag list shall be prepared for balance activities which need to be attended
by Contractor. Any noncompliance with contract shall be intimated to Contractor through Non-Conformity
Notice (NCN).
2.5 Performance Guarantee and Warranty

After successful commissioning, the Contractor shall support the Supplier for completing functional tests
to demonstrate the performance.
All equipment and component parts within the Contractor’s scope shall be warrantied against faulty
design, defective materials and poor workmanship and failure due to normal operations, for at least 24
months from the date of issuing Provisional Acceptance Certificate (PAC).
2.6 Site Visit

The Contractor shall make a site visit with proper industrial clothing dress code (casual dress not allowed)
prior to offer submission to clearly understand site conditions, the nature of installation equipment and
method to be adapted to perform the scope. Any queries, clarifications and additional information
required shall be requested by Contractor in written in the form of Technical Queries (TQ) prior to offer
submission.
Note: After site visit contractor must send filled HSE QUESTIONNAIRE HSD-GR-FM-150 along with offers
2.7 Spares
All installation and commissioning spares shall be provided by Supplier.
3. Relevant Designs and Specifications

• The Contractor shall follow the Supplier drawings and documents for handling, installation, testing and
commissioning of EAF Process Optimization System.
• The Contractor shall follow the ES engineering standards and guidelines in the installation of project.
• The Contractor shall consider ES H&S procedure and requirements for the project including all permit
related requirements.
• The Contractor shall comply with all applicable UAE local regulations.
• In the absence of required guidelines in ES engineering standards, international standards need to be
followed.

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4. Work Location
• The work location for this project shall be EAF, SMP1 plant, in phase 1 of Emirate Steel. The specific location
of work is the EAF SMP1 plant.
• If any preassembly to be performed at ES premises, then the same to be carried out at an allotted location,
which shall be away from the installation location to continue the plant operation and maintenance
without any hindrance.
• Any service such as water, gas, electricity, office space, telephone is not foreseen in ES scope. If required,
the same shall be arranged by Contractor.
5. Time/Schedule Requirements
• The contractor must attend Pre-mobilization meeting and onsite safety induction prior to the job start.
• The Contractor shall complete a level-2 schedule for the project specifying required time frame for the
installation, testing and commissioning along with bid proposal.
• The Supplier shall deliver the complete EAF Process Optimization system in the 1st Quarter of 2022. The
Contractor shall complete installation, commissioning, cold test, hot test, and performance guarantee test
(PGT) of EAF Process Optimization system in the major shutdown of 14 days duration in January 2022.
• A detailed planning package including work schedule (engineering deliverables, procurement,
construction, and commissioning), work breakdown structure, progress measurement document, work
force and equipment loading etc. to be provided after award of contract.
• The normal working time for Contractors shall be 8.00 AM to 4.00 PM Sunday to Thursday at ES site.
6. Relevant ES Management and Coordination Roles and Responsibilities

A. Renato Junior : SMP1 Operation Manager
B. Islam Gamal : Engineering Manager
C. Manoj Kumar Agrawal : Project Engineer
7. Equipment and Materials Requirements

• The Contractor shall be responsible for supplying any equipment/machinery (e.g., crane, forklift, etc.)
required to perform the loading/unloading/erection/installation/commissioning activities. Any
machinery/any equipment shall be in good working condition (e.g., no leaks, all the rotating parts
covered/protected, etc.) as per statutory requirement as well as for good engineering practice. Lack of
compliance with this requirement may cause equipment removal from site or prevent site deployment.

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• The Contractor shall also be responsible for any scaffolding, mechanical modification, temporary
installation, tool/special tool provision as per requirement.
• The Contractor shall be responsible to deploy to site all the necessary tools/special
tools/equipment/material etc. required to perform the job in a safe manner (e.g., harness for work at
height, spill kits, spill trays, tripods, gas monitors, etc.).
• The Contractor shall provide his own utilities (e.g., power, water, compressed air, etc.) as well as
consumables (e.g., welding rods, etc.)
• The Contractor shall be responsible for waste removal and disposal according to local rules and
regulations.
• All the chemicals utilized shall have a remaining shelf life not less than 6 months and MSD shall be available.
8. Quality Requirements
• The contractor shall develop Inspection and Test Plan (ITP) for the jobs and involve ES for regular
inspections and checks. The Contractor shall submit an ITP for ES review and approval and the Contractor
shall carry out inspection as per agreed ITP.
• The Contractor shall establish a Quality Assurance Plan (QAP) for traceability and confirmation of quality
achievements. The Contractor shall submit an QAP for ES review and approval
• The Contractor shall issue Notice of Inspection (NOI) for ES inspection at shop and site.
• The Contractor shall prepare necessary inspection reports welding qualification records, NDT reports, test
reports, and with traceability reports for all materials and submit for ES review progressively and submit
as a dossier at the completion of job.
9. Security Requirements
• Long-term working gate pass for Contractor shall be provided as per their requirements to complete the
project in the specified period.
• Contractor shall make arrangement for the visa, ticketing, hotel stay and local transportations.
• All the prevailing Government and ES Guidelines on COVID-19 shall be strictly followed by the contractor
personnel including all the visitors.
• Contractor shall apply all kind of gate pass in Emirates Steel web side in visitor management system (VMS).
(Accessibility: VMS can be accessed through Emirates Steel website: www.emiratessteel.com/Our
Business/ Business with us/Visitor Management System OR copy and paste below URL on browser:
https://www.emiratessteel.com/business-with-us/).

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• Contractor shall apply for gate pass with all required documents. ES-Security shall provide temporary gate
pass for the working period on daily basis.
• Contractor shall submit Material-In Delivery permit in Emirates Steel VMS system for delivery of any
materials inside ES plants.
• Contractor shall submit Material Removal permit in Emirates Steel VMS system to security while removing
any material (belonging to Contractor) from ES plant.
• Contractor shall submit the recent Covid-19 test results to the security supervisor prior to entering ES.
• Contractor / Sub Contractors shall apply for gate passes request through their concern department.
• Work order copy issued by ES - SCM for Contractor (Contract copy, PO, LOA, or confirmation email) and
for Sub Contractor internal agreement copy between Contractor and Sub Contractor.
• Passports copies for each Contractor’s applicants with valid visa or copy of valid labour card (Applicant
shall be under contractor direct sponsorship visa).
• If contractor bring Sub Contractor then required NOC certificate from both company with their valid
passport, visa, insurance card and emirates id.
• One photo passport size for each applicant (for permanent gate pass).
• Copy of group insurance policy or individual medical insurance card (coverage in Abu-Dhabi).
• Safety induction certificate from H&S dept. proof that all applicants are safety inducted (Visit gate pass
can be issued to facilitate this purpose).
• NOTE: - Visit Visa is not acceptable – mission visa is acceptable for work in ES.
• Designated area shall be provided by ESI for contractor site work.
• All required tools/tackles/equipment to be taken care by Contractor.
10. Contractor Staffing (Management, Supervisory, Technician and Helper) Requirements

• The nos. and competencies of manpower requirements for the technical supervision and advice on
installation shall be specified by the Contractor.
• The Contractor shall arrange the required manpower (supervisors, technicians, and helpers) to complete
the job, on the given target time.
• The Contractor shall always have a dedicated Health and Safety officer present on the site.
• The Contractor shall provide a qualified H&S officer and must be NEBOSH IGC qualified with at least 5 years
of experience in HSE field, he shall be interviewed and approved by ES H&S department.
• Persons working at height, must have completed work at height training with valid certificates.
• Lifting plans activity produced to be done by a competent person, and approved by ES

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• Competency/Training certificates for all working personnel shall be provided.
11. Reporting and Documentation Requirements

• Detailed Level 2 Gantt chart showing project milestones and document submittal dates.
• Contractor experience with EAF (Electrical Arc Furnace & Steel Melt shop activities.
• Contractor reference projects/installations (to include new build and/or within existing operating plants)
for EAF process optimization.
• End user contact details to request references for the Contractor reference projects/installations.
• Daily Manpower report includes: all people at site, working hours, progress, etc.
• Weekly reports: to include any safety issues or concerns, look back/forward on planned works and
schedule.
• Monthly reports: to summarize the above, safety statistics, planned vs actual progress, technical issues,
and concerns with pictures
• All project management related documents including but not limited to inspection test plan, inspection
notice and inspection reports.
• As-Built documents and drawings at the completion of project.
• Contractor shall submit all documents in PDF format and drawings in native AutoCAD format and in PDF
format.
• Contractor shall submit all documents and drawing in English Language and in metric units.
12. Other Requirements

12.1 Deviation
Any deviation from the scope of work shall be intimated to ES before submission of technical offer. The
Contractor shall also submit proposed scope of matrix and general division of work with list of deviation along
with offer in case of any deviation.
12.2 Evaluation of Bids

ES shall evaluate the bids submitted by potential Contractors based on following as minimum,
Contractor’s experience on similar work in ES plants or Steel industries.
Compliance with SOW and submission of required information/detail/drawings/documents along with Bid
Proposal and further ES Clarification queries.
After analysing the bids submitted by Contractor, ES shall request any additional information required through
a Post Tender Qualification (PTC) form.

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13. HSE Requirements for the Work

• Full and clear declaration of specific risks, hazards, and risk mitigation requirements associated with
execution of the required service to be discussed and declared at the location during site visit.
a. Exposure to biological hazard airborne virus (COVID-19).
b. Exposure to high ambient temperature and humidity during summer, summer stoppage hours
c. Manual Handling or Ergonomics that can lead to WRULD and musculoskeletal disorders.
d. Exposure to nip points and sharp edges that can lead to cut and laceration:
e. Exposure to staircase, ladder and fixed platform while ascending and descending.
f. Exposure to overhead or mobile crane operation and suspended or swinging load .
g. Exposure to hammer.
h. Obstructed work area, uneven or slippery surface.
i. Exposure to unexpected movements or uncontrolled energy sources ( electrical, process water and
hydraulic ).
j. Combustible and flammable materials that can lead to Fire and explosion
k. Exposure to Excessive Noise and dust.
l. Exposure to work on top of scaffolding that can lead falling from height, falling of objects, and
scaffolding collapse.
m. Exposure to flying or splinters from the working material may become projectiles.
n. Exposure to welding fumes.
o. Exposure to hot surface, hot parts, flying particles and UV rays that can cause burns and cataracts
cause personal injury by striking the operator or other persons.
p. Rotating and/ or moving equipment.
q. Exposure to compressed oxygen and acetylene gas cylinders.
r. Exposure to electrically energized welding machine and power cables including extension reels that
can lead to electric shock or fire.
s. Exposure to heavy vehicle manoeuvring at workplace, pickup, forklift etc.
t. Exposure to rotating parts from the grinder abrasive wheel that can lead to cuts, laceration & abrasion.
u. Exposure to work at height while using of the manlift and falling object whenever applicable.
• Contractor to submit the below as supporting docs along with their Offer. These docs may be modified
closer to the work taking place but should be comprehensive enough for review at this stage and to
support the Offer at this stage.

EMIRATES STEEL
Supporting Docs Required Yes No N/A

Safety Officer / Supervisor CV/Certs Yes
HSE Plan Yes

JMS/ JSA (can be modified prior to issue for Yes
PTW)
Work at Height Certs Yes
Safety harness inspection 3rd party certificate Yes

Confined Space Certs N/A
Rigger Certs (if applicable) Yes

Competence record of workforce Yes
Lifting Plan (if applicable) Yes
Rescue Plan Yes

Rescue Equipment Yes
Rescue trained person (minimum 2 person in Yes

each group)
Banksman certs Yes
Fire watcher certs Yes
Basis gas monitor and gas testing training N/A

certs
SCBA (if required and trained person certs) N/A
Manlift operator certs (if applicable) Yes
Mobile Crane operator certs (if applicable) Yes
Manpower list Yes

Mobile equipment valid licence and third- Yes
party certs (if applicable)
Lifting appointed person certs (if applicable) Yes
The ES (Standard) Contractor HSE Requirements
• Below is the list of contractual documents applied to this Contract. The Contractor needs to fully familiarize
themselves with them; fully understand them; and fully comply with them. They include, but not limited to,
the following:
a. COVID 19 AWARENESS –ES GUIDELINES.
b. ES 10 Life Saving Rules and 07 HSE Principles.

EMIRATES STEEL
c. ES CONTRACTOR GUIDELINES.
d. HSD-PR-006 Personal Protective Equipment Procedure.
e. HSD-GR-PR-023 HSE Observations and Inspections.
f. HSD-GR-PR-026 Incident Investigation and Reporting Procedure.
g. HSD-GR-PR-003 PERMIT TO (PTW) WORK PROCEDURE.
h. HSD-PR-011 Scaffolding Safety Procedure.
i. HSD-PR-016 Hot Work Procedure.
j. HSD-PR-020 Work at Height Safety Procedure.
k. Work at Height Activity Assessment Checklist HSD-GR-FM-114.
l. HSD-GR-PR-019 Hazard ID and Risk assessment
• Over and above the ES (Standard) Contractor HSE Requirements, and (in some cases) to reinforce them, below
list includes, but not limited to, the safety performance expectations and behaviours required of Contractors
to be engaged on the work/service:
a. IMS & JSA must be communicated through toolbox talk and documented each time the job is to be carried
out.
b. Ensure all the risk controls mentioned in the JMS & JSA are strictly implemented on the field.
c. Be alert for the changes and monitor the effectiveness of controls whenever the work is undertaken and
revise the document if new hazards are introduced, or a significant task step is missed before commencing
the job. Report it immediately to ES Supervisor.
d. Secure appropriate work permit ( refer to procedure HSD-PR-003)
e. Use only tools and equipment in good condition and appropriate for the task.
f. Check tools and equipment to ensure protective and safety devices, machine guards and alarms are
functional.
g. A Declaration to be provided stating that contractor personnel shall strictly follow ES’ s Safety Rules and
Regulations.
h. Permit to work (PTW) is necessary for all works inside ES premises.
i. Trained and qualified technicians to be deployed for the job.
j. 3rd Party working at height training is necessary for all works inside ES premises.
k. Safety Harness must be used while working at height and these harnesses must be certified by 3rd party.
l. All tools and equipment to be use at ES premises workplace should be in good condition and with safety
standard regulation.
m. All lifting tools, tackles and lifting pad eyes must be third party certified, If applicable.

EMIRATES STEEL
n. Heavy equipment- Mobile Crane, Manlift, Forklift etc. must be

-With Third Party certification
-Licensed Operator
-Competent Riggers
-Certified Fitting Supervisors
o. Technician working alone is not permitted, minimum two technicians to work at site.
p. All tools and equipment are pre inspected before start of the job, damaged, fabricated and makeshift are
not permitted.
q. Fire Extinguisher and Blanket must be use during hot work.
r. Close Supervision is required from the Contractor’s Supervisor or Contractor’s Safety Officer.
s. Necessary (certified) scaffoldings for on or above 2 meters working at height.
t. Ladder should held by another person while in use.
u. All contractor employees must undergo ES detailed safety induction well in advance.
v. Strictly follow the COVID-19 Precautionary measures by UAE govt.
w. Personal executing the job must be fit for duty and no symptoms of COVID-19.
x. JMS should be prepared describing complete detailed of the job including technical contents/methodology
as per Emirates Steel prescribed format, submitted to ES for approval before the execution.
y. JMS and JSA must be reviewed and signed by all concerned parties as per ES Hazard identification and risk
assessment procedure with safety focal person of the area. JMS and JSA must be submitted for safety review
well in advance (At least 48 hours in advance).
z. Competency assessment of contractor employees shall be done by concern ES section heads.
aa. All contractor workers must have valid medical insurance card.
bb. Strictly follow isolation procedure while working in electrical / mechanical and process systems.
cc. Contractors are responsible to adhere ES Life Saving Rules and HSE Principles.
dd. The contractor shall provide their workers with job-specific personal protective equipment PPE (including
but not limited to long-sleeve uniform/coverall, helmets/welding helmets, safety/gum shoes, safety
goggles, hand gloves, face shield, Individual Gas monitors.
ee. Contractor site in-charge for safety shall conduct toolbox talk daily with their team and explain the JMS and
JSA for the task. The hazards and risk specific to the working environment and the precautionary measures
shall be discussed.
ff. Contractor shall follow ES Permit to work procedure and safe system of work. Any non-compliance to the
HSE procedures observed, NC shall be raised against the contractor as per SCM policy.

EMIRATES STEEL
gg. Permit receiver should be attending ES permit to work training for understanding and follow the ES PTW
procedure.
hh. If any hot work activity, fire watcher should be certified and follow the PTW procedure.
ii. As an emirates steel contractor working hours must be adhered to and in line with UAE labour law.
jj. To start a job only after getting required permits from Emirates Steel and to follow safety instructions
specified by Emirates Steel Health and Safety Department and Local Law. To comply with PPE standards
applicable for such type of job.
kk. Strictly compliance with ES No-Smoking Policy.
ll. Contractor to use gas cutting set provided with flashback arrestor, hoses, regulators, and torch should be
in Good condition.
mm. To maintain good housekeeping in the workplace with daily and routine cleaning. Disposal of the
generated waste to the designated area in Emirates Steel shall be contractors’ responsibility. The contractor
shall mobilize the workers at the site daily as per the requirements of the site.
nn. Onsite emergency rescue plan along with trained staff shall provide.
oo. The contractor shall provide a qualified safety representative, and he shall be interviewed and approved by
the ES H&S department.
pp. After site visit contractor must send filled HSE QUESTIONNAIRE HSD-GR-FM-150 along with offers.
qq. Contractors must depute sufficient supervisors (at least one supervisor for every 20 workers) to take care
of daily progress of jobs.
rr. All these supervisors must be qualified and must have relevant job experience and safety knowledge as
certified by ES Supervisor.
• Below list includes, but not limited to, the mitigation processes we expect the Contractor to submit for
review and approval of area requisitioned, Area H&S Officer and other ES concerned department before the
job commencement:
a. Job Method Statement (JMS).
b. Job Safety Analysis (JSA).
c. Equipment third party certificate and inspection checklist.
d. Personnel training certificates specific to the risk and designation.
e. Sample risk assessment for any project activity.
f. Company HSE KPI.
g. Lifting tackles, accessories, and pad eyes third party inspection certificate.
h. Approved lifting plan/drawing and/ or design calculation.

EMIRATES STEEL
• Reinforce the fact that all physical routine and non-routine work/activity to be carried out by all Engineering
Service Contractors engaged by Emirates Steel shall be subject to the work control processes detailed in the
Emirates Steel Permit to Work Procedure.
a. Hot Work Permit.
b. Cold work permit.
c. Live or Energized Equipment Permit
d. Excavation Permit
e. Confined space work permit
• Below includes but not limited to the specific H&S competencies, experience, and skills (as appropriate) are
required from the Contractor personnel to be engaged on the work.
a. Deployment of qualified and experienced certified health & Safety personnel.
WORK EXPERIENCE :
-At least 5 Year experience in HSE field.
-2 Years in Oil and Gas Industries.
-NEBOSH certified.
-3 Years in any HSE Fields.
b. Deployment of qualified and experienced Supervisor.

c. Deployment of competent and skilled personnel (not limited to) :
-Technician
-Welder
-Fabricator
-Banksman
• Below includes but not limited to specific HSE-related training is required for Contractor and Sub-Contractor
Staff to be engaged on the work.
a. Permit to work procedure training requirement.
b. Basic first aid and firefighting training
c. ES Health & Safety induction

EMIRATES STEEL
• Below list includes, but not limited to, the ES HSE performance monitoring, observation, and auditing
processes the Contractor can expect to encounter and participate in whilst engaged on the work:
a. PTW Audit.
b. HSE Inspection.
c. ES health and safety shift inspection.
d. HIRA-JSA Audit.
e. Behavioural Interactions.
f. Sr. Leadership Walkabouts.
g. Environmental Audit.
• Any other job-specific HSE-related requirements:

Full and clear declaration of any Specific risks, hazards, and risk mitigation requirements associated with
execution of the required service at the location(s)
The hazards, risk and control measures are the same as mentioned above.
• Other HSE-related requirements:

a. Contractor shall submit work at height rescue plan for review 07 days in advance prior to starting the work
b. Provision of Standard barricades by nylon rope with flickering tape or hard barriers and sign board is
displayed in designated work area by the Contractor whenever applicable.
c. Provision of water drinking facilities.
d. When waiting for another activity or resting, ensure all contractors must be in the designated resting areas
and not wondering around or sleeping in the operation area.
e. All safety representatives of all contractors must have at least the contact number of the HS plant officer.
This is to ensure there's no delay in communication particularly during an emergency
f. PPE: Safety boots, long overalls with arms covered, gloves, glasses, and hard hat. Additional PPE to be
provided, as required by the JMS.
g. Near Miss Reporting: Hazard Observations and Near Miss Reporting is encouraged by ES and is to be
reported.
h. Safety Audits: ES advises that different teams from ES shall visit the area on a continuous basis.
i. The contractor must wear proper industrial clothing dress code (not allowed in casual dress).

EMIRATES STEEL
Define Risk Level (Circle)
Low
Medium
High
Name Signature Date

Requisitioner: Manoj Agrawal 7.11.2021
Area H&S Officer: Varundev Puthalath 11.11.2021
FCA: Lowell Pagulayan 10.11.2021

SCD-GR-FM-074 - SOW - EAF Process Optimization SMP1 Rev-02

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EMIRATES STEEL

SoW Contracted Engineering Services Requirements SCD-GR-FM-074

End User Focal Point):

3. Relevant Designs and Specifications ....................................................................................................... 22

5. Time/Schedule Requirements ................................................................................................................. 23

6. Relevant ES Management and Coordination Roles and Responsibilities .............................................. 23

7. Equipment and Materials Requirements................................................................................................ 23

8. Quality Requirements ............................................................................................................................. 24

9. Security Requirements ............................................................................................................................ 24

11. Reporting and Documentation Requirements ....................................................................................... 26

12. Other Requirements ................................................................................................................................ 26

13. HSE Requirements for the Work ............................................................................................................. 27

Issue No.: 3 1 Issue Date 15.02.2021

Issue No.: 3 2 Issue Date 15.02.2021

Issue No.: 3 3 Issue Date 15.02.2021

Issue No.: 3 4 Issue Date 15.02.2021

Issue No.: 3 5 Issue Date 15.02.2021

SN Description Supply Supervision Installation

10. Functional Tests NA S C

Issue No.: 3 6 Issue Date 15.02.2021

Reference sketch for the installation of the equipment

Sampling Station Multipoint Analyzer panel

Issue No.: 3 7 Issue Date 15.02.2021

Issue No.: 3 8 Issue Date 15.02.2021

iEAF NextGen System Overview

Issue No.: 3 9 Issue Date 15.02.2021

Gas Probe Key Specifications

Gas Probe Reference Phots

Issue No.: 3 10 Issue Date 15.02.2021

Sample Station Cabinet Key Specifications

Fiber (from CC to SCC) optical fibers

Issue No.: 3 11 Issue Date 15.02.2021

Sample Station Cabinet

Dimensional drawings and connection scheme: Front and bottom views

Issue No.: 3 12 Issue Date 15.02.2021

Multi Point Analyser Control Cabinet Key Specifications

Communication with plant network Ethernet RJ45, CAT5 or CAT6

Multi Point Analyser Control Cabinet

Issue No.: 3 13 Issue Date 15.02.2021

Reference Picture for the Installation

Gas probe installation and connections

Issue No.: 3 14 Issue Date 15.02.2021

Furnace Fume Duct

Gas Probe Installation Photos

Issue No.: 3 15 Issue Date 15.02.2021

Photo of Heated Sample Line

Issue No.: 3 16 Issue Date 15.02.2021

Gas Probe Installation Schematic

Duct modification and port for the gas probe

The mounting flange and clamp for the gas probe

Issue No.: 3 17 Issue Date 15.02.2021

Issue No.: 3 18 Issue Date 15.02.2021

The mounting flange and clamp for the gas probe

Furnace New Port & Water Flow Furnace

Furnace Top View Furnace

Issue No.: 3 19 Issue Date 15.02.2021

The protection plate and enclosure box

Fire retardant/Pyro jackets for all connections at the gas probe

Issue No.: 3 20 Issue Date 15.02.2021