LOCO - SOP - E - 0021 Main Alternator Changing

STANDARD OPERATING PROCEDURE
Form No.: EHSMSM/446/4013 Form Rev. No.:Effective date:

SOP No.: TSK/QMS/CMM/MEL/LOCO/SOP/21
Effective Date 27-03-2018 Revision No. 01
SOP Description: Main Alternator changing Section Loco
Department: Loco & Mobile Equipment Page 1 of 7
Step Activity Associated Requirement/Impacts Responsibility Process / tools / PPEs (HOW) Remarks /
No. (WHAT) (WHO) Reference
Sl No Hazard Mitigation
1. Maintain proper housekeeping at work area.
2. Follow designated pathway and staircase while
going to and from Control Room for work permit issuance.
Slip trip and fall at the work
1
area 3. Always maintain 3 Point contact while using any staircase.
P
4. Remain mindful of the debris accumulated in the staircase.
O
d S
5. Keep all required spares at a designated place at job site and barricade the working area.
1. Use of Dust Mask is Mandatory
2 Dust Hazard
l i
2. Always start after positive isolation and after engine cooling.
a
3 Fire hazard due to hot work V
1. If any hot work is required for the maintenance. Use ceramic cloth for spatter arresting.
2. Fire hydrant hose to be fixed at nearest location. Keep fire extinguisher at hot work area.
O P
d S
Name and Designation: Malay Kumar Si
Signature with Date: l i
Name and Designation : Ravi Shankar (161939)
Signature with Date:
a
Printed By -MALAY KUMAR SI(161298)
Page 1
Print valid till - 10-Dec-2021 V
Printed on - 30-Nov-2021 SOP Valid Till - 31-Jan-2022
Safety Safety Safety FR Jacket Safety Full Body Gas Welding Eye Welding Eye CO detector Dust Mask
Helmet Shoe Goggles Gloves Hardness Glass Shield
List Of PPE’s
O P
d S
During
Pre Start-
a l i × × ×
up Job
activity.
During On
V
Job × × ×
O P
d S
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Page 2
1. Preparing of SAFETY :  Take clearance from operation.

job  Insure that all tool and tackles  Isolate the energy source.
are in good condition.  Put track lock to stop unwanted movement of
 Take  Hand injury LOCO under maintenance and also to ensure
clearance  Head injury Sr. Technician/ other LOCO should not come near to LOCO
Technician/
from  Foot injury which is under maintenance.
Contractor
operation  Falling of engine component  Don’t handle components with oily or grease
 Use all
 Slip & trip hazard.
 Dirty floor & hand railing of
Supervisor
O P 
hands, use hand gloves
Use correct size of tools & tackles.
S
required  Clean the loco floor & hand railing properly.
Loco.
PPEs
 Fall down of filter housing top  Take care during ascending or descending
cover & injury.
 Fall down from loco plate form.
l i d 
from loco.
V a 
Hold compressed air hose pipe firmly while
cleaning.
Proper compressed air line arrangement
PPEs –Must use Safety Shoes, Helmet, Safety

Jacket, Safety Goggles, Hand gloves, Dust Mask, Ear
plug and Isolation lock while executing any activity
of the entire job.
O P
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SAFETY:  Clean workshop area. Any grease or oil or any
2. Placing the  Slippage of tools and tackles other slippery substances.
loco on  Exposure to dust Sr. Technician/  Clean thoroughly the engine before carrying out
servicing  Finger injury Technician/ maintenance job.
Contractor
pit/place and  Lack of knowledge about  Take the loco to workshop and park on level
Inspection Supervisor
standard tools & tackles track
 Apply the parking brake and scotch block.
ENVIRONMENT: Nil  Apply track lock to restrict other LOCO
movement towards LOCO which is under
QUALITY:
 Approachable place ergonomic
work place. Ensure proper size
O P maintenance. Put Key of all the locks in positive
isolation box.
and condition of tools.
d S  Give a round inspection around the loco for

safety purpose.
a l i  Safe & flat place, luminous & well-ventilated

area for doing job. Proper place will help to do
job faster maintaining quality.
3. Main
Alternator
SAFETY: V
 Slippage of tools and tackles


Remove silencer cover bolts anticlockwise
( spanner no18-19mm)
Remove engine cover plate spanner(18-19mm)
Removal  Exposure to dust  Remove intake air filter anticlockwise Spanner()
 Finger injury  Remove intake and exhaust pipe line
TOOLS REQUARED Sr. Technician/


anticlockwise (spanner16-17mm).
Remove belt guard anticlockwise (18mm
spanner).
O P
 Hammer Technician/
Contractor 
S
Loose and remove the compressor pipe line
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 Strode Supervisor uncouple.
 Spanner  Lose the compressor base bolts spanner (18-
 Hand gloves 19mm) both side.
 Sealing  Loose the adjustable nut bolts by using (spanner
 Crane 24mm).
 Socket& torque  Remove the compressor belts.
 Then unload the compressor by crane and secure
in safe place.
 Remove cardan shaft by using (spanner no
O P 
18mm).
Remove the partition part between engine and
d S 
compressor room.
Remove the sensor cable from alternator
a l i  Keep the slot wedge between rotor and starter to

prevent bearing and coils damages.
V  Manually rotate crank shaft by using rod on

alternator front side and lose the stater bolts one
by one by using socket and T handle (socket
no24mm).
 Remove the all bolts of rotor.
 Remove the stater bolts anticlockwise by using
(spanner no 19mm).
O P

S
Open all the foundation bolts and take out the
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Page 5
4. bolts.
 Shift Main alternator out from the frame of Main
engine.
 Put wire siling at the lifting hook of the main
alternator.
 Then with the help EOT crane lift the main
alternator and place it at the concrete surface
(marked area).
O P  Clean all the removed nuts and bolts as well as

all the matching surfaces of engine and main
d S alternator.
5.
Installation of
Main

a l i  Lift the main alternator and place it at the

installation position.
Alternator.
V 

Move the alternator towards the main engine.
Match all the bolts of main engine and main
alternator as well as main alternator foundation
bolt.
 Tighten all the bolts are cross tightening way and

keep engine moving time to time.
After completion of job check for any foreign
O P
S
material in maintenance area. Remove all the
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Page 6
unwanted material from the area.
 Connect cardan shaft. Install all the fan belts.
 Check for the completion of job.
Return work SAFETY Sr. Technician/  Check all tool & tackles items removed from
6. permit and  Check all items removed from Technician/ loco and also manpower removed from loco.
clearance form loco. Contractor  Return Clearance form to operation dept.
Supervisor
O P 

Open all isolations lock if applied.
Return key of loco.
PREPARED BY
d S CHECKED BY APPROVED BY
Name and Designation: NAGENDRA RAJ (TSL))

l i
Name and Designation: Ashish Nandan /MI
a
Name and Designation: Ravi Shankar, Sr
Manager
V Signature with Date: Signature with Date:
O P
d S
a
Page 7

LOCO - SOP - E - 0021 Main Alternator Changing

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STANDARD OPERATING PROCEDURE

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

1. Preparing of SAFETY :  Take clearance from operation.

PPEs –Must use Safety Shoes, Helmet, Safety

d S  Give a round inspection around the loco for

a l i  Safe & flat place, luminous & well-ventilated

TOOLS REQUARED Sr. Technician/

a l i  Keep the slot wedge between rotor and starter to

V  Manually rotate crank shaft by using rod on

O P  Clean all the removed nuts and bolts as well as

a l i  Lift the main alternator and place it at the

Name and Designation: NAGENDRA RAJ (TSL))

V Signature with Date: Signature with Date:

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