Sop for Motor Changing Job

STANDARD OPERATING PROCEDURE Form No.: EHSMSM/446/4013

Form Rev. No.: 01

Effective date: 01.04.2009

SOP No.

SOP/CGL2/EEI/GEN 18

Revision Date

05/06/2012

SOP DESC DEPARTMENT

Motor Changing

Section Page

CGL# 1 and 2, COLD ROLLING MILL

Step No. 1.

Activity (WHAT) Before the Start of the job

MILLS & UTILITIES-IEM, CRM

Responsibility Associated (WHO) Requirements/Hazards/Impacts SAFETY :  Incident caused due to lack of knowledge about the job.  Incident due to lack of awareness of hazard prevailing in the area..  Injury due to non use of proper and adequate safety appliances.

 Injury due to starting the equipment by others.  Injury due to starting of equipment which is not in healthy condition.

REVISION No

1 of 10 Process / tools / PPEs (HOW)

Contractor  Supervisor or person executing the job

02

Safety induction on specific job to be given to all the concerned contractor employees on site, regarding the hazards and their precautions to be taken at the work place which may occur during the execution of job.



Brief description regarding hazards/safety measure will be given to all workmen, every day before starting the job.



Take clearance from operator control room..



Job is to be executed only by trained persons.



Use safety shoes, safety helmet, safety goggles, dust mask, hand gloves. .

ENVIRONMENT: QUALITY:

PREPARED BY

APPROVED BY

Name and Desig.: Nikhil R Nanda

Name and Desig.:

Signature with Date:


Remarks / Reference


Form Rev. No.: 01


SOP No.

SOP/CGL2/EEI/GEN 18

Revision Date

05/06/2012

SOP DESC DEPARTMENT

Motor Changing

Section Page


Step No. 2

Activity (WHAT) Work permit


Responsibility Associated (WHO) Requirements/Hazards/Impacts SAFETY:  Failure of clearance i.e no communication to operator may lead to accidents due to sudden start up of machine.  ENVIRONMENT: QUALITY: line stoppage

REVISION No


Remarks / Reference

Contractor  Always take clearance in the format: Supervisor EHSMSM/WORKS/446/4007 or  This clearance must be taken for all activity. SS/GEN-25 person executing  Revalidate the clearance every 8 hours if the job continuously working.

Contractor Supervisor

02

Stoppage of critical m/c may lead to line stoppage so prior information is required.

PREPARED BY

APPROVED BY


Name and Desig.:





SOP/CGL2/EEI/GEN 18

Revision Date

05/06/2012

SOP DESC DEPARTMENT

Motor Changing

Section Page


Step No. 3

Form Rev. No.: 01

SOP No.

Activity (WHAT) Power cutting clearance


Responsibility Associated (WHO) Requirements/Hazards/Impacts SAFETY: Contractor  Flash injury/Electrocution due to available Supervisor or electrical energy  Sudden start up machine Person Executing the due to available power. job  : Personnel possessing Electrical Competency certificate are only allowed to carry out this job.

REVISION No


 Take power clearance in format  

02

EHSMSM/WORKS/446/4005 Authorization for taking clearance:permit shall be generated and received by an authorized person Jobs where production is affected or ownership of equipment lies with operation unit,the clearance must be taken from operation unit of the department

 This clearance must be taken for all activities, which requires power disconnection. This is in addition to the common clearance form(work permit)  Power should be put off and isolated only by a competent person.  Discharging and gounding of the m/c ,cables electrical equipment where there is possibility of feedback.  Provide equipment lock and danger tag on the isolator.  Drop the equipment lock in group isolation box  Contractor supervisor /person executing the job should provide his own personal isolation lock on the group isolation  The danger tag/lock must contain a serial no and it is to be filled properly and permit number hould be mentioned while filling power clearance form  Every power cutting must be entered in form no 4011 for tracking purpose.

PREPARED BY

APPROVED BY


Name and Desig.:



Remarks / Reference

 SS/GEN-26 


Form Rev. No.: 01


SOP No.

SOP/CGL2/EEI/GEN 18

Revision Date

05/06/2012

SOP DESC DEPARTMENT

Motor Changing

Section Page


Step No.

Activity (WHAT)


Responsibility Associated (WHO) Requirements/Hazards/Impacts

REVISION No

02


Remarks / Reference

ENVIRONMENT: QUALITY: 4

motor removal

SAFETY: Contractor  Barricade the area with safety Supervisor ribbon  Injury while carrying maintenance job or due to poor quality of tools and tackle Person  Accidents due to improper signaling Executing the job to crane perator  Injury while decoupling the motor  Falling of material due to weak sling and wire rope.  Never use slide wrench while decoupling. Contractor ENVIRONMENT: Burn injury while working in alkali /furnaceSupervisor area or Person Executing the job

QUALITY: possibility of wrong direction Person of rotation Executing the

      

Ensure that power is not available in motor T.B with a test lamp Remove motor power cables ,cooling fan cables from T.B and mark it properly .tape the naked terminals properly. Remove the encoder/tacko connection & mark it properly. Decouple the motor from load/shaft Remove the foundation bolts. Remove the motor from site using cranes. Use slings as per load.

 Use test lamp /power tester to check power in motor t.b.  Never use tester for power testing.  Motor terminals should be properly marked  Only one person should give directions to crane operator Use proper tools and tackles.

 Always use proper PPE’s.  Always use proper PPE’s. Supervisor  Contractor Wear high temperature hand  gloves Weartohigh temperature hand gloves to preven or prevent burn injury.  Do not work in gas prone areas without supe  Person Do not work in gas prone areas  Use proper safety appliances for working in th Executing the job without supervision gloves, gum boots, safety goggles, anti skid s  Use proper safety appliances for working in that area (hand gloves, gum  Use goggles to prevent the chemicalsgoing in boots, safety goggles, anti skid shoes, etc.  Use goggles to prevent the chemicalsgoing into eyes. Never interchange motor leads while carrying .check and note connection maintenance activity and mark them properly before opening the terminals

PREPARED BY

APPROVED BY


Name and Desig.:




Form Rev. No.: 01


SOP No.

SOP/CGL2/EEI/GEN 18

Revision Date

05/06/2012

SOP DESC DEPARTMENT

Motor Changing

Section Page


Step No.

Activity (WHAT)


Responsibility Associated (WHO) Requirements/Hazards/Impacts

REVISION No

02


job

PREPARED BY

APPROVED BY


Name and Desig.:



Remarks / Reference



SOP/CGL2/EEI/GEN 18

Revision Date

05/06/2012

SOP DESC DEPARTMENT

Motor Changing

Section Page


Step No. 5

Form Rev. No.: 01

SOP No.

Activity (WHAT) Motor fixing,coupling and connection.


02

6 of 10

Responsibility Associated (WHO) Requirements/Hazards/Impacts SAFETY: Contractor  Barricate the area with safety Supervisor ribbon  Injury while carrying maintenance job or due to poor quality of tools and tackle Person  Accidents due to improper signaling Executing the job to crane perator  Injury while coupling the motor due to poor ppe’s  Falling of material due to weak slings and wire rope.  Never use slide wrench while coupling and foundation  Electrocution while connecting motor terminal

REVISION No

Process / tools / PPEs (HOW) 

     

 

  

Check the motor for its healthyness i.e winding resistance, IR values,inductance & coolong fan,bearing end covers bolt tightness. Place the motor on it’s foundation using cranes. Do alignment ,foundation and coupling of the motor. Ensure that power is not available in motor terminals while carrying connection with a test lamp Connect the motor & fan terminals as per the polarity marked. Mount & Connect cable of encoder / tacko (if applicable). Always use torque wrench while carrying coupling and motor connection

Check dirction of the motor & cooling fan as given below. Ensure that the motor is not connected with the load. Switch 'ON' the drive by pressing uparrow, down-arrow & mode keys at a time. This will load the default parameters in to the drive. Now enter all the details of the motor nameplate into Menu # 2 of the drive. Put the drive in local mode. Give some speed reference to the drive in P1.00 & press start

PREPARED BY

APPROVED BY


Name and Desig.:


Signature with Date: The motor should start rotating 

Increase the ref & take it to the top speed & check for any mechanical noise or vibration.

Remarks / Reference

 Use test lamp /power tester to check power in motor t.b.  Never use tester for power testing.  Motor terminals should be properly marked and connected  Only one person should give directions to crane operator  Use proper tools and tackles.  Maintain alignment records


Form Rev. No.: 01


SOP No.

SOP/CGL2/EEI/GEN 18

Revision Date

05/06/2012

SOP DESC DEPARTMENT

Motor Changing

Section Page


Step No.

Activity (WHAT)


Contractor Supervisor or Person Executing the job

02

7 of 10

Responsibility Associated (WHO) Requirements/Hazards/Impacts ENVIRONMENT: Burn injury while working in alkali /furnace area

REVISION No

Process / tools / PPEs (HOW)    

Remarks / Reference

Always use proper PPE’s. Wear high temperature hand gloves to prevent burn injury. Do not work in gas prone areas without supervision Use proper safety appliances for working in that area (hand gloves, gum boots, safety goggles, anti skid shoes, etc.  Use goggles to prevent the chemicalsgoing into eyes.

QUALITY: possibility of wrong direction Person of rotation. Executing the job Disconnect motor terminals after id run Person executing for alignment using crane. Otherwise this the job. may damage the motor terminals leading a premature failure.

Do motor connection as per the polarity marked Motor needs to be shifted right place for id run so that it does not lead to reopend the motor terminals for alignment.(ex-TR ,KJ motort etc)

PREPARED BY

APPROVED BY


Name and Desig.:



Follow polarity marking.



SOP/CGL2/EEI/GEN 18

Revision Date

05/06/2012

SOP DESC DEPARTMENT

Motor Changing

Section Page


Step No. 6

Form Rev. No.: 01

SOP No.

Activity (WHAT) Return of work permit and Power getting


Process / tools / PPEs (HOW) 

 



ENVIRONMENT:  Waste materials near and around motor or working area


02

8 of 10

Responsibility Associated (WHO) Requirements/Hazards/Impacts SAFETY :  Ensure men and material are removed Contractor Supervisor to avoid electrocution  Ensure temporary earthing removed or Person from all points. Executing the job

REVISION No

Remarks / Reference

Once the job is over remove men material from site and positive SS/GEN-26 isolation lock fom the group isolation and return the work permit taken in format EHSMSM/WORKS/446/4007. Take power getting clearance in form: EHSMSM/WORKS/446/4006 This clearance must be taken for all activities, which requires power connection. This is required wherever power is disconnected with the form EHSMSM/WORKS/446/4005 Power should be put on by a competent person after ensuring that all the work permit (in form #4007)issued to work on the equipment have been cancelled.

 Remove materials used in motor fixing i.e slings, crowbars ,spare foundation and coupling bolts, alignment tools etc

PREPARED BY

APPROVED BY


Name and Desig.:



Maintain good house keeping while and after completion of job.


Form Rev. No.: 01

SOP/CGL2/EEI/GEN 18

Revision Date

05/06/2012

SOP DESC DEPARTMENT

Motor Changing

Section Page


Step No.

Activity (WHAT)


Six directional hazard analysis

SAFETY: Accidents from moving machinery parts,EOT cranes,chemicals ,alkalies,slippery floors, constrained space for motor handling etc . ENVIRONMENT: moving m/c, chemicals moving EOT ,slippery floor

Person Executing the job Contractor Supervisor or Person Executing the job


REVISION No

02

9 of 10

Responsibility Associated (WHO) Requirements/Hazards/Impacts QUALITY: house keeping

7


SOP No.

Process / tools / PPEs (HOW)

Remarks / Reference

Maintain good house keeping

 

Identify the six directional hazards.

Fill the form No.:EHSMSM/446/4015

Refer to Form No.:EHSMSM/446/4015

Use proper ppe’s

QUALITY:

. .

PREPARED BY

APPROVED BY


Name and Desig.:




Form Rev. No.: 01


SOP No.

SOP/CGL2/EEI/GEN 18

Revision Date

05/06/2012

SOP DESC DEPARTMENT

Motor Changing

Section Page


S. No 1. 2. 3. 4. 5 6 S. No 1. 2. 3. 4. 5.


10 of 10

JOB START UP CHECKLIST SOP available Power Clearance Taken Six direcetional hazard identified and filled up Area of work properly barricaded Proper tools are ready and available for the work Before starting the job, cross check that power is not available at motor end JOB FINISH CHECKLIST TB /JB tightness ensured Work finished and All tools and tackles removed Everybody finished the work and has moved away from the sight Make sure no other agency is working on the same equipment Take the power getting clearance, and switch on the power after all locks from the respective equipment/sections are removed

PREPARED BY

APPROVED BY


Name and Desig.:



REVISION No

02

Sop for Motor Changing Job

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