STANDARD OPERATING PROCEDURE

Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01.04.2009

SOP No. SOP DESC DEPARTMENT Step No.
1.

SOP/CGL2/EEI/GEN 18 Motor Changing
MILLS & UTILITIES-IEM, CRM

Revision Date Section Page

05/06/2012 1 of 10

REVISION No

02

CGL# 1 and 2, COLD ROLLING MILL

Activity (WHAT) Before the Start of the job

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. Contractor  Supervisor or person executing the job 

Process / tools / PPEs (HOW)

Remarks / Reference

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. .

  

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

ENVIRONMENT: QUALITY:

PREPARED BY Name and Desig.: Nikhil R Nanda Signature with Date: Name and Desig.: Signature with Date:

APPROVED BY

STANDARD OPERATING PROCEDURE Form No. COLD ROLLING MILL Activity (WHAT) Work permit Responsibility Associated (WHO) Requirements/Hazards/Impacts SAFETY:  Failure of clearance i.: Nikhil R Nanda Signature with Date: Name and Desig. 2 SOP/CGL2/EEI/GEN 18 Motor Changing MILLS & UTILITIES-IEM. Contractor Supervisor Stoppage of critical m/c may lead to line stoppage so prior information is required. SS/GEN-25 person executing  Revalidate the clearance every 8 hours if the job continuously working.: Signature with Date: APPROVED BY .2009 SOP No. CRM Revision Date Section Page 05/06/2012 2 of 10 REVISION No 02 CGL# 1 and 2.: EHSMSM/446/4013 Form Rev. PREPARED BY Name and Desig. No.04.: 01 Effective date: 01. SOP DESC DEPARTMENT Step No.  ENVIRONMENT: QUALITY: line stoppage Process / tools / PPEs (HOW) Remarks / Reference Contractor  Always take clearance in the format: Supervisor EHSMSM/WORKS/446/4007 or  This clearance must be taken for all activity.e no communication to operator may lead to accidents due to sudden start up of machine.

No.2009 SOP No.  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.cables electrical equipment where there is possibility of feedback.: Signature with Date: APPROVED BY . SOP DESC DEPARTMENT Step No.04. job  : Personnel possessing Electrical Competency certificate are only allowed to carry out this job.STANDARD OPERATING PROCEDURE Form No.the clearance must be taken from operation unit of the department  SS/GEN-26   This clearance must be taken for all activities. This is in addition to the common clearance form(work permit)  Power should be put off and isolated only by a competent person.: Nikhil R Nanda Signature with Date: Name and Desig.: 01 Effective date: 01.  Discharging and gounding of the m/c . 3 SOP/CGL2/EEI/GEN 18 Motor Changing MILLS & UTILITIES-IEM. PREPARED BY Name and Desig.: EHSMSM/446/4013 Form Rev. COLD ROLLING MILL 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. CRM Revision Date Section Page 05/06/2012 3 of 10 REVISION No 02 CGL# 1 and 2.  Provide equipment lock and danger tag on the isolator. which requires power disconnection. Process / tools / PPEs (HOW) Remarks / Reference  Take power clearance in format   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.

2009 SOP No.04.check and note connection maintenance activity and mark them properly before opening the terminals PREPARED BY Name and Desig. gum boots.  Use test lamp /power tester to check power in motor t. anti skid shoes.  Always use proper PPE’s. anti skid s  Use proper safety appliances for working in that area (hand gloves.b. QUALITY: possibility of wrong direction Person of rotation Executing the  Always use proper PPE’s. Use slings as per load.  Never use slide wrench while decoupling.  Use goggles to prevent the chemicalsgoing into eyes. Remove the encoder/tacko connection & mark it properly. Decouple the motor from load/shaft Remove the foundation bolts. COLD ROLLING MILL Responsibility Associated (WHO) Requirements/Hazards/Impacts ENVIRONMENT: QUALITY: Process / tools / PPEs (HOW) Remarks / Reference 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.: 01 Effective date: 01. gum  Use goggles to prevent the chemicalsgoing in boots.  Contractor Supervisor Wear high temperature hand gloves to  Wear high temperature hand gloves to preven or prevent burn injury. Activity (WHAT) SOP/CGL2/EEI/GEN 18 Motor Changing MILLS & UTILITIES-IEM.STANDARD OPERATING PROCEDURE Form No.B with a test lamp Remove motor power cables . Never interchange motor leads while carrying .B and mark it properly .  Never use tester for power testing. SOP DESC DEPARTMENT Step No. Remove the motor from site using cranes.: Nikhil R Nanda Signature with Date: Name and Desig. etc. No.tape the naked terminals properly. Contractor ENVIRONMENT: Supervisor Burn injury while working in alkali /furnace area or Person Executing the job        Ensure that power is not available in motor T. CRM Revision Date Section Page 05/06/2012 4 of 10 REVISION No 02 CGL# 1 and 2.cooling fan cables from T. safety goggles.  Motor terminals should be properly marked  Only one person should give directions to crane operator Use proper tools and tackles.: EHSMSM/446/4013 Form Rev.  Do not work in gas prone areas without supe  Person work in gas prone areas Do not  Use proper safety appliances for working in th Executingsupervision without the job gloves. safety goggles.: Signature with Date: APPROVED BY .

COLD ROLLING MILL Responsibility Associated (WHO) Requirements/Hazards/Impacts job Process / tools / PPEs (HOW) Remarks / Reference PREPARED BY Name and Desig.STANDARD OPERATING PROCEDURE Form No. SOP DESC DEPARTMENT Step No.04. CRM Revision Date Section Page 05/06/2012 5 of 10 REVISION No 02 CGL# 1 and 2. No.: 01 Effective date: 01.: Nikhil R Nanda Signature with Date: Name and Desig.: EHSMSM/446/4013 Form Rev.: Signature with Date: APPROVED BY .2009 SOP No. Activity (WHAT) SOP/CGL2/EEI/GEN 18 Motor Changing MILLS & UTILITIES-IEM.

down-arrow & mode keys at a time. This will load the default parameters in to the drive.STANDARD OPERATING PROCEDURE Form No.  Never use tester for power testing.00 & press start    PREPARED BY Name and Desig. 5 SOP/CGL2/EEI/GEN 18 Motor Changing MILLS & UTILITIES-IEM. Give some speed reference to the drive in P1. Put the drive in local mode. Always use torque wrench while carrying coupling and motor connection Remarks / Reference        Use test lamp /power tester to check power in motor t. COLD ROLLING MILL Activity (WHAT) Motor fixing. Place the motor on it’s foundation using cranes.coupling and connection.: APPROVED BY Signature with Date: motor should start rotating  The  Increase the ref & take it to the top speed & check for any mechanical noise or vibration.foundation and coupling of the motor. IR values.2009 SOP No.e winding resistance. Switch 'ON' the drive by pressing uparrow. . SOP DESC DEPARTMENT Step No. 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.: 01 Effective date: 01.04. 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.inductance & coolong fan.  Maintain alignment records   Check dirction of the motor & cooling fan as given below.  Never use slide wrench while coupling and foundation  Electrocution while connecting motor terminal  Process / tools / PPEs (HOW) Check the motor for its healthyness i. Ensure that the motor is not connected with the load. No. Do alignment .: EHSMSM/446/4013 Form Rev. Mount & Connect cable of encoder / tacko (if applicable).  Motor terminals should be properly marked and connected  Only one person should give directions to crane operator  Use proper tools and tackles. CRM Revision Date Section Page 05/06/2012 6 of 10 REVISION No 02 CGL# 1 and 2.: Nikhil R Nanda Signature with Date: Name and Desig.bearing end covers bolt tightness. Now enter all the details of the motor nameplate into Menu # 2 of the drive.b.

SOP DESC DEPARTMENT Step No. Do not work in gas prone areas without supervision Use proper safety appliances for working in that area (hand gloves.KJ motort etc) Follow polarity marking.: Signature with Date: APPROVED BY . Remarks / Reference QUALITY: possibility of wrong direction Person of rotation.(ex-TR .: Nikhil R Nanda Signature with Date: Name and Desig.: EHSMSM/446/4013 Form Rev.STANDARD OPERATING PROCEDURE Form No. Executing the job Disconnect motor terminals after id run Person executing for alignment using crane. CRM Revision Date Section Page 05/06/2012 7 of 10 REVISION No 02 CGL# 1 and 2. safety goggles. Otherwise this the job. Wear high temperature hand gloves to prevent burn injury. may damage the motor terminals leading a premature failure.2009 SOP No.  Use goggles to prevent the chemicalsgoing into eyes.04. gum boots. anti skid shoes. COLD ROLLING MILL Responsibility Associated (WHO) Requirements/Hazards/Impacts ENVIRONMENT: Burn injury while working in alkali /furnace area Contractor Supervisor or Person Executing the job     Process / tools / PPEs (HOW) Always use proper PPE’s. 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. PREPARED BY Name and Desig. Activity (WHAT) SOP/CGL2/EEI/GEN 18 Motor Changing MILLS & UTILITIES-IEM. etc.: 01 Effective date: 01. No.

2009 SOP No.STANDARD OPERATING PROCEDURE Form No.: Signature with Date: APPROVED BY . crowbars . SOP DESC DEPARTMENT Step No. Maintain good house keeping while and after completion of job.spare foundation and coupling bolts. ENVIRONMENT:  Waste materials near and around motor or working area Contractor Supervisor or Person Executing the job  Remove materials used in motor fixing i. 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.04. COLD ROLLING MILL Activity (WHAT) Return of work permit and Power getting 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. No. alignment tools etc PREPARED BY Name and Desig. CRM Revision Date Section Page 05/06/2012 8 of 10 REVISION No 02 CGL# 1 and 2. 6 SOP/CGL2/EEI/GEN 18 Motor Changing MILLS & UTILITIES-IEM.: EHSMSM/446/4013 Form Rev. Executing the job  Process / tools / PPEs (HOW) 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.: 01 Effective date: 01. Take power getting clearance in form: EHSMSM/WORKS/446/4006 This clearance must be taken for all activities. which requires power connection.: Nikhil R Nanda Signature with Date: Name and Desig.e slings.

EOT cranes.: Nikhil R Nanda Signature with Date: Name and Desig.slippery floor   Identify the six directional hazards.:EHSMSM/446/4015 Contractor Supervisor or Person Executing the job Use proper ppe’s QUALITY: . chemicals moving EOT . COLD ROLLING MILL Responsibility Associated (WHO) Requirements/Hazards/Impacts QUALITY: house keeping Person Executing the job Contractor Supervisor or Person Executing the job Process / tools / PPEs (HOW) Maintain good house keeping Remarks / Reference 7 Six directional hazard analysis SAFETY: Accidents from moving machinery parts. PREPARED BY Name and Desig. CRM Revision Date Section Page 05/06/2012 9 of 10 REVISION No 02 CGL# 1 and 2.slippery floors.: EHSMSM/446/4013 Form Rev.alkalies. . Fill the form No. ENVIRONMENT: moving m/c.:EHSMSM/446/4015 Refer to Form No. constrained space for motor handling etc .2009 SOP No.chemicals .: Signature with Date: APPROVED BY .STANDARD OPERATING PROCEDURE Form No. SOP DESC DEPARTMENT Step No.04. Activity (WHAT) SOP/CGL2/EEI/GEN 18 Motor Changing MILLS & UTILITIES-IEM.: 01 Effective date: 01. No.

No 1.: 01 Effective date: 01. 4.2009 SOP No. 5.: EHSMSM/446/4013 Form Rev. 2. and switch on the power after all locks from the respective equipment/sections are removed PREPARED BY Name and Desig. 5 6 S. 2.: Signature with Date: APPROVED BY . 4. 3.STANDARD OPERATING PROCEDURE Form No. SOP DESC DEPARTMENT SOP/CGL2/EEI/GEN 18 Motor Changing MILLS & UTILITIES-IEM. 3. 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. No 1. COLD ROLLING MILL S. CRM Revision Date Section Page 05/06/2012 10 of 10 REVISION No 02 CGL# 1 and 2.04. 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.: Nikhil R Nanda Signature with Date: Name and Desig. No.