1. 1. Iron Ore Controlled Document Picture Work Instruction Change out P119 Pulley 2- SL2 Activity / Task Information: The purpose of this document is to describe the method used to provide a unified and planned approach to carrying out the successful removal and replacement of P119 Pulley2. This procedure is applicable to Shiploader 2. Successful completion of this task resides with the Supervising Responsible Person who is expected to be on the job to check and initial set Hold Points throughout the procedure before work can continue and to complete all requirements of the Hand Back Procedure Raw Risk Rating: High (15) Catastrophic Risks: The following Catastrophic Risks apply. Review them every time you complete this activity. Electrical Systems, Isolations, Lifting Operations, Guarding, Traffic Management, Permits / Special Controls: Exclusive control Barricading Hot Work where applicable Hold points Standard PPE Required! Additional PPE required as follows: Dust mask Hearing protection Solvent safe gloves Goggles Sunscreen Welding mask, gloves and apron Life Jacket (mandatory within 2m of wharf edge) Reference Documents: Intranet/ workshop MSDS sheets SPEC-002-M-00011 Alignment of rotating shafts TRAP-000-G-12007 Designing for Conveyor Pulley removal WIN-PRT-GEN-010 Installation and removal of Conveyor Belt Clamps TMAN-087-M-00006 Conveyor Pulleys CHT-IHS-SAF-010 WAIO module 2 isolation training SPR-IHS-SAF-083 Barricading safety procedure FRM-IHS-SAF-128 Dropped & falling objects checklist REG-IHS-SAF-026 Approved rubber collars DWP-PME-M113-007 Taking a Mobile Crane onto Nelson Point Wharf ISL-PME-G87-118 Isolations 0001938 Use of Temporary Travel Strikers Shiploader 1 and 2 088-M-00357 Drawing: SL2 Conveyor boom general arrangement 002-M-00925 Pulley2 Bend/snub 005-M-01147 Plummer Blocks assembly 088-M-00389 P119 drive Counterweight arrangement 088-M-00693 P119 profile and data sheet Document- 0018010 Version No: X.X Approved: DD/MM/YYYY Page 1 of 14 This document is uncontrolled when printed or downloaded and should be discarded after use.
2. 2. Iron Ore Controlled Document Picture Work Instruction Change out P119 Pulley 2- SL2 People: 2 x Mechanical Trades Personnel 1 x Mechanical Supervisor 1 x Shiploader operator 1 x Electrician to isolate (prior to commencement), 1 x Crane operator 2 x Riggers Competency: Electrical licence, Infrastructure Card, Site inductions, Licence to perform high risk work (for riggers and crane operator) Tools & Materials Required: 1 x Normal toolkit 1 x replacement Pulley part number xxxxxx, Mass = 4280kg 4 x Wire brush Torque wrench (640Nm) 4x M24xxxxx Plummer block mount bolts and nuts Pulley alignment equipment X2 xxx mm grease line Blanking Plugs 2 x handheld radios do not use mobile phones for communication! 4 x Men working above signs 2 x Hot Work sign 1 x Roll of Danger Tape 1 x Roll of Caution Tape 1 x Roll of Exclusive Control Tape Information Tags 1 x Bag of rags 2 x Lead lights and extension cords, (night work) 1 x Scraper 1 x 18 shifting spanner Mobile lighting plant (night work) 1 x CRC 1 x roll fine emery tape drive sockets,(36mm) Flogging spanners,(36mm) 2 x Podger/pinch bars c/w rubber collars 1 x Box of gloves Assorted (Pulley mass=4280kg) chain slings and shackles (tested in date) 2x 10 Ton Chain Lifts 1x 10 Ton Pull/lift 1800 Belt Lifting Beams 1800 Belt Clamps 1 x Roll Denso tape Parts storage containers 1 x Truck with hiab Mass = 4280kg 1 x 100 tonne mobile crane Pre checks / Preparation: Isolation requirements have been identified and checked to develop a specific Isolation list. Parts have been ordered and are on site. Tools & Materials are transported to temporary storage area. Arrange a meeting with all concerned with this maintenance activity to develop a unified approach discuss the task in detail and develop a JHA. Request Production Department hose off the work area. Confirm JHA is still relevant for working conditions. Communication to be either visual or by hand held radio. Examine work area for suitable Lifting eyes for Pulley Support (Consult Engineering if unsure) Document- 0018010 Version No: X.X Approved: DD/MM/YYYY Page 2 of 14 This document is uncontrolled when printed or downloaded and should be discarded after use.
3. 3. Iron Ore Controlled Document Picture Work Instruction Change out P119 Pulley 2- SL2 One person will be in charge of any ship loader movement and they are to ensure other members of the work party are clear prior to issuing instructions to the operator. Keep in contact with operator at all times. Standard safety clothing and PPE, to be worn for the duration of the job. Special protective clothing requirements of tasks such as welding or oxy cutting shall be met. A sign shall be prominently displayed to indicate crane in use. If oxy cutting or welding, follow Hot Work procedure. Ensure crane is positioned over a bent prior to lifting. Ensure the equipment is clean before lifting. Weights given are for clean objects; build-up increases mass. Ensure Lifting equipment is sized correctly for the lift being performed. Men working above signs must be displayed in prominent positions below work area. Only designated lifting points to be used when performing lifts. Check weather conditions in relation to crane use Shiploader 1, when in production, must be kept well clear of Shiploader 2 maintenance activities (either shiploader travel shall be isolated or temporary travel strikers installed and tested In Accordance With- 001938). All vehicles shall park in a single row between the yellow lines, land side of the wharf. Equipment Isolation List: (Reference the Isolation Documents if required for this Activity) Equipment Document Number P119 Conveyor / SL2 ISL-PME-G87-118 SL1 & SL2 Use of Temporary Travel Strikers 0001938 Task Isolation List Developed For This Task Document- 0018010 Version No: X.X Approved: DD/MM/YYYY Page 3 of 14 This document is uncontrolled when printed or downloaded and should be discarded after use.
4. 4. Iron Ore Controlled Document Picture Work Instruction Change out P119 Pulley 2- SL2 Task Steps Instructions 1. Perform Pre-Checks 1.1. P119 Pulley 2) is located under the Conveyor Boom on Shiploader2 Pulley 1 Drive 1.2. Arrange an onsite meeting with the Crane Operator and Supervisors to discuss the change out. 1.3. Confirm Pulley 2, counterweight and surrounding area cleaning requirements. Dirt and build up increases component mass Do not let contamination enter water ways Discharge into the harbour shall be zero during cleaning operation. Use Bunding where possible 1.4. Transport tools, equipment and replacement motor (if applicable) to temporary storage area. Position tooling and equipment clear of walkways, ship loader travel and vehicle parking areas. 1.5. Check operation of all lifting equipment to ensure their inspections are in date to ensure they operate at rated capacity. Pulley mass=4280Kg Check: Test tag Wear Nicks Stretch Cuts Cracks Heat damage Chemical damage Suitable SWL for job Inspect all lifting equipment prior to use. Document- 0018010 Version No: X.X Approved: DD/MM/YYYY Page 4 of 14 This document is uncontrolled when printed or downloaded and should be discarded after use. You are responsible for ensuring that you use the most recent version of this document.
5. 5. Iron Ore Controlled Document Picture Work Instruction Change out P119 Pulley 2- SL2 Task Steps Instructions 2. Equipment Preparation 2.1. Organise Ship loader 2 to travel to Northern end of Wharf away from Ship loader 1. Allow sufficient room for the crane, Truck, and lighting towers (if applicable) to be positioned for the changeout. Position Conveyor boom approximately level for Pulley Change out Position 100 over Bent and where it can access P119 Pulley 2. Position spares within crane reach Production to be contacted for this request Crane to be positioned over a bent in accordance with DWP-PME- M113-007 Once Crane is positioned set up an exclusive control zone around perimeter Areas to be targeted for lighting include, Crane working area, access areas and temporary storage area 3. Perform Isolation 3.1. Isolate as per ISL-PME-G87-118 and Task Isolation List. Exclusive Control to be placed and remain in force until completion. Isolation Procedure and Task Isolation List shall be understood and adhered to by all personnel. 3.2. Install and check Temporary Travel Strikers as per 0001938. Either isolate Shiploader 1 long travel or install and test temporary travel strikers. Responsible person to Check: Isolations carried out correctly; Temporary travel strikers, (if fitted), are correctly fitted and tested before continuing past this point. Hold Point Initial:_________ 3.3. Position lighting P119 Drive Platform to provide extra lighting if night work is required. Areas to be targeted include, working area, access areas and any potential hazards. Note: lighting not positioned correctly creates potential hazards. Document- 0018010 Version No: X.X Approved: DD/MM/YYYY Page 5 of 14 This document is uncontrolled when printed or downloaded and should be discarded after use. You are responsible for ensuring that you use the most recent version of this document.
6. 6. Iron Ore Controlled Document Picture Work Instruction Change out P119 Pulley 2- SL2 Task Steps Instructions 3.4. Barricade. People/Access: Barricade entry/exit points with caution tape and information tags. Set up exclusive control zone directly below work zone using Danger Tape and Men working above signs. SPR-IHS-SAF-083, Barricading Safety Procedure. FRM-IHS-SAF-128, Dropped & Falling objects checklist. 3.5. Maintain Housekeeping to minimise risks. Place drop mats on platform mesh areas Use buckets, trays for parts/tool storage Place all rubbish in bins/buckets Place cables/ hoses away from walkways Falling objects. SPR-IHS-SAF-083, Barricading Safety Procedure. FRM-IHS-SAF-128, Dropped & Falling objects checklist. 4. Pulley removal 4.1. Raise P119 Counterweight In Accordance With- M87-533 (with jack) or M87-535 (air winches) to release belt Tension Counterweight mass=42Ton M87-533 Raising P119 Counterweight with Jack M87-535 Raising P119 Counterweight with Air Winches 4.2. Remove any Guards for Pulley 2 access 4.3. Clamp the belt and pull belt down away clear of the Pulley WIN-PRT-GEN-010 Installation and removal of belt clamps TRAP-000-G-12007 Designing for Conveyor Pulley Removal Caution use only approved Lifting Lugs. Consult Engineering if no suitable points exist. Document- 0018010 Version No: X.X Approved: DD/MM/YYYY Page 6 of 14 This document is uncontrolled when printed or downloaded and should be discarded after use.
7. 7. Iron Ore Controlled Document Picture Work Instruction Change out P119 Pulley 2- SL2 Task Steps Instructions 4.4. Using Lifting Equipment rig to support Pulley for Plummer Block support bolt removal Pulley Mass=4280Kg Rigging Picture here Hold Point Initial:_________ Responsible person to Check Support structure is capable of supporting Pulley weight Pulley is prepared for Bolt removal before continuing past this point 4.5. Remove grease lines to Plummer Blocks Blank lines to prevent dirt contamination 4.6. Using the Crane.Pull/lifts and chains, lift the pulley removal channel section and support stands, to be positioned in a suitable area for pulley removal with crane access When positioned correctly follow Hot Work Permit and weld the support stands to prevent movement Hold Point Initial:_________ Responsible person to Check Support structure is capable of supporting Pulley weight before continuing past this point 4.7. RemovePlummer Block to Support frame m24 bolt x4 Warning Pulley may swing when bolts are removed 4.8. Lower the pulley onto the removal trolley 4.9. Pull the pulley on the trolley to a position it can be accessed by the crane TRAP-000-G-12007 Designing for Conveyor Pulley Removal 4.10. Lift the Pulley from the trolley to the ground. Document- 0018010 Version No: X.X Approved: DD/MM/YYYY Page 7 of 14 This document is uncontrolled when printed or downloaded and should be discarded after use.
8. 8. Iron Ore Controlled Document Picture Work Instruction Change out P119 Pulley 2- SL2 Task Steps Instructions 5. Preparation 5.1. Clean, remove build up, grease and dirt from Pulley mounting faces and Support structure. Do not let contamination enter water ways. DISCHARGE INTO THE HARBOUR SHALL BE ZERO DURING CLEANING OPERATION. Use Bunding where possible. 5.2. Inspect Pulley mount faces, support structure and associated equipment. Repair if required. Use Hot Work Permit procedure where nessessary. 5.3. Compare old Pulley with Replacement. Responsible person to Check: Base is serviceable Shims are serviceable Replacement equipment is the same Old, re-used components are serviceable Hold Point Initial:_________ Ref 002-M-00357 Pulley 2 snub, for additional information. 6. Assemble 6.1. Rig Replacement Pulley as per removal. 6.2. Position Pulley on trolley using crane as per removal. 6.3. Pull into place and Rig from structure as per removal 6.4. Safety Responsible person to Check: Pulley is ready to be lifted into position Hold Point Initial:_________ 6.5. Lift Pulley into place ready for Plummer block bolt installation Rigging picture here Ensure Pulley Data Sheet and Pulley Commissioning, attached in appendix are filled out and adhered to 6.6. Install 4x new m24 Plummer block mount bolts. Ensure correct Alignment and shim where necessary. Torque bolts to 640Nm Responsible person to Check: Pulley is correctly fitted, aligned and bolts torqued Hold Point Initial:_________ 6.7. Purge and check operation, then Install grease lines 6.8. Remove Belt Clamps and Rigging Document- 0018010 Version No: X.X Approved: DD/MM/YYYY Page 8 of 14 This document is uncontrolled when printed or downloaded and should be discarded after use.
9. 9. Iron Ore Controlled Document Picture Work Instruction Change out P119 Pulley 2- SL2 Task Steps Instructions 6.9. .Lower P119 Counterweight In Accordance With- M87-533 (with jack) or M87-535 (air winches) to release belt Tension Counterweight mass=42Ton M87-533 Raising P119 Counterweight with Jack M87-535 Raising P119 Counterweight with Air Winches 6.10. Re-Fit removed guards 6.11. Safety Check. Responsible person to Check: Mount bolts secure Pulley is secure and installed correctly Guards in place and secure; No loose tools Pulley ready to be placed in service Area clean Hold Point Initial:_________ 7. Commissioning and Completion 7.1. Remove all tools, equipment and rubbish from the work area. 7.2. Remove isolations and confirm correct operation and belt alignment on the Pulley. Check: No tools, equipment or rubbish remain. Appendix 2 Pulley2 commissioning carried out Hold Point Initial:_________ 7.3. Additional checks required. Post Checks Advise shift maintenance to monitor periodically when back in production. Advise reliability engineering of the change out Check/rectify cleanliness of work area. Full visual inspection of the work area must be carried out to ensure no materials are left behind. All guards and signage are securely in place. Ensure correct Handover and Hand back procedure carried out. Clean and inspect all tools used in the change out for good overall condition and replace in their correct storage area for future use. Fill out the table below and with any suggestions/updates to the procedure and return it to you Supervisor for improvement purposes. Additional information Document- 0018010 Version No: X.X Approved: DD/MM/YYYY Page 9 of 14 This document is uncontrolled when printed or downloaded and should be discarded after use.
10. 10. Iron Ore Controlled Document Picture Work Instruction Change out P119 Pulley 2- SL2 Document- 0018010 Version No: X.X Approved: DD/MM/YYYY Page 10 of 14 This document is uncontrolled when printed or downloaded and should be discarded after use.
11. 11. Iron Ore Controlled Document Picture Work Instruction Change out P119 Pulley 2- SL2 Appendix 1 Pulley Data Sheet PULLEY DATA SHEET Conveyor No: _______________ Pulley No: _________________ Date Required: ___/___/_______ Work Order No: _______________ Drawing No: _________________ Installation Document: ___________ Requisition No: _______________ Stock Code: _________________ Location: _____________________ Ordered: Yes/No D P Req. No. Bolt size ___________ Stock Code: _______________ Coupling: ___________ Stock Code: _______________ Seals: ___________ Stock Code: _______________ Gasket: ___________ Stock Code: _______________ Grid Members: ___________ Stock Code: _______________ Sole Plate Req. Yes No Dwg . No. 002-M-00357 Document- 0018010 Version No: X.X Approved: DD/MM/YYYY Page 11 of 14 This document is uncontrolled when printed or downloaded and should be discarded after use.
12. 12. Iron Ore Controlled Document Picture Work Instruction Change out P119 Pulley 2- SL2 Appendix 2 P119 #2 Pulley Commissioning Horizontal and Vertical Alignment Confirm both alignment in the horizontal and vertical planes using a spirit level. Record completion in the table below: Vertical Alignment (YES/NO) Bearing Alignment Place a dial gauge on the centre of the pulley shaft. The dial gauge needle should be placed on the machined surface of the bearing housing near the PCD of the end-cover bolts. Adjust the dial gauge to zero and rotate the pulley, recording the dial gauge reading at 90 intervals. Record the values in the table below: Location Left Hand Bearing Right Hand Bearing 1. 2. 3. 4. The maximum difference between any two readings must not exceed 0.012 inches (12 thou) (0.31mm). Record Maximum Difference in the table below: Left Hand Bearing Right Hand Bearing CONTRACTOR BHPIO NAME SIGNATURE POSITION Document- 0018010 Version No: X.X Approved: DD/MM/YYYY Page 12 of 14 This document is uncontrolled when printed or downloaded and should be discarded after use.
13. 13. Iron Ore Controlled Document Picture Work Instruction Change out P119 Pulley 2- SL2 Final Checks Check and mark off the following items before job completion: Item Completion End-cover replaced Plummer block bolts fully tensioned Hand spin pulley - free turning? Guards replaced Purge labyrinth Post Commissioning Checks Check and measure the temperature at 30 minute intervals after start-up until the temperature stabilises. Time Temperature 0 min 30 min 60 min 90 min 120 min Note: Normal running temperature is 15 - 20C above ambient. Slightly warmer running temperature may occur during initial running period. CONTRACTOR BHPIO NAME SIGNATURE POSITION Document- 0018010 Version No: X.X Approved: DD/MM/YYYY Page 13 of 14 This document is uncontrolled when printed or downloaded and should be discarded after use.
14. 14. Iron Ore Controlled Document Picture Work Instruction Change out P119 Pulley 2- SL2 Document- 0018010 Version No: X.X Approved: DD/MM/YYYY Page 14 of 14 This document is uncontrolled when printed or downloaded and should be discarded after use.