MAINTENANCE WORK INSTRUCTION. Mech OFF Replace Head Pulley CVXXX
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1 OPF MAINTENANCE WORK INSTRUCTION PYXIS DOCUMENT CLEAN TEMPLATE SCOPE NOTE: SPECIAL TOOLING REQUIRED PREPARATION AND INFORMATION CVXXX Head Pulley The purpose of this document is to detail the safe replacement of CVXXX Head Pulley. Before commencing this work complete a 5 STEP every time to check that no abnormal conditions exist and complete a JHA if prompted by the 5 STEP. Always wear the correct PPE. Always assume the equipment is LIVE until positively isolated, locked and tagged. A Hot Work Permit will be required for this task. A Working at Heights Permit will be required for this task. Rope access kits; 75mm flogging spanner; ¾ drive electric rattle gun, 30, 32, 36, 55mm ¾ drive impact sockets and flogging spanners; 6 x 1.5t come-alongs; 8 x 3t x 2m soft slings; 8 x 2t x 2m soft slings; 4 x 5t x 5m soft slings; 8 x 3.2t shackles. [Insert Drawing XX OPF Layout] Rev 0 PREPARED BY CHECKED BY APPROVED BY Mick Blower 22/10/2013 Page 1 of 10
2 PREPARATION ACTIVITIES Set up 250t crane on the North East side of the screening building. Deliver the new head pulley to the laydown area on the North East side of screening building. Deliver a genset to the GTU and plug in winch. Lift all tooling required up to the work site. Check with the bearing supplier to confirm if the bearings fitted on the new pulley are sealed or non-sealed bearings. This will determine which grease lines need to be fitted during pulley replacement. The conveyor must be isolated in the maintenance position at the North end of the screening building. Barricade the lift area around the crane. Lift and secure counterweight 1. Preparation: Check isolation is in place, conduct a start stop test of the conveyor and eensure the feed is run off the belt. Sign and lock onto the permit as per standard procedures. Utilise Channel 34 to notify all OPF personnel that work is about to commence on lifting the counterweight. 2. Set up to Lift Counterweight: Ensure winch pawl is in the engaged position. Ensure the rope is inspected over the full length to assess general condition and to identify any damage. Ensure the rope is centred in the sheaves and the sheaves and counterweight locating channels are cleaned of any product build-up. 3. Lift the counterweight: Take the weight of the counterweight with the winch, until the first movement of the counterweight is observed. Ensure spotters are in position on all levels. Communicate the impending counterweight movement to all parties that may be affected. Page 2 of 10
3 4. Secure Counterweight: Place the counterweight locking bars in position, when it has been lifted to the required height. Fit locking pins. This is an isolation point. Ensure locking bars are seated correctly and locking pin inserted. 5. Remove only enough safety guarding as is necessary from both sides on the head end of the belt, to install belt clamps. Belt clamps must be installed on the return side of the belt first to prevent belt moving in the direction of slack in the belt, belt will have slack at takeup pulley. 6. Fit the belt clamps on the top side of the belt. Pull 4 5 metres of slack into the top side of the belt using the come-alongs. 7. Once the belt clamps and counterweight locking bars are in place, they will need to be included in the isolation before maintenance work can commence on the head pulley replacement. 8. Remove personal locks and sign off permits for isolation to be modified to include belt clamps and counterweight pins. 9. Change isolation to include the belt clamps and counterweight pins so that work can commence on head pulley replacement. 10. Sign on to new permit ensuring that your locks and danger tags are on the lockboard. Page 3 of 10
4 Remove Rolling Frame and Deflector NOTE: The following steps detail the removal of the rolling frame and deflector as one unit. Should the deflector need to be removed separately from the rolling frame refer to document XXX Disassemble Deflector & Frame CVXXX. This is a Rope Access task and will require a WAH permit. 11. Barricade areas directly below work site and around the crane lift area to prevent other personnel entering the drop zone. Dropped Object Risk 12. Remove guarding around the maintenance bay to access the head pulley area. 13. Remove split pins from the rolling frame link pins. Use a 75mm flogging spanner to remove the castle nuts. 14. Using the 250t crane, rig the rolling frame and deflector using 2 x 2 leg x 13t lifting chains. Basket 2 chain legs at the North end of the deflector between the 2 structural beams. Shorten the other 2 chain legs on the 19 th link from the lifting ring, double wrap and choke at the South end (pulley end) of the rolling frame. Take the weight of the rolling frame and deflector (9.9t), the frame will pivot on the link pins until the full weight is held by the crane. When the full weight is held by the crane remove the 2 link pins from the rolling frame, use soft drift or a block of wood to protect the thread when knocking out pins. Never work or walk under a suspended load. Page 4 of 10
5 Replace Head Pulley 15. Board out the area below the pulley with scaffold to remove the trip / fall hazard. Fall arrest equipment must be worn and area barricaded until scaffold has been erected. 16. Detach all grease lines from bearings and plug or tape the ends to prevent contamination. 17. Measure the distance between the top of the bearing housing mounting flange and the bottom of the jacking block at each jacking screw. Record the measurements on the jacking block. Back off the top jacking screws to allow room at the bearing housings for the pulley to be removed. Use a 55mm flogging spanner to crack the bearing mounting nuts. DO NOT remove the mounting nuts. 18. Loosen the scraper extension bar clamps. Rig the scrapers with the chains choked on opposite sides of the scrapers. Use the crane to remove from mounting bracket. The scrapers will be top heavy and will want to roll to the bottom when removed from the mounting bracket. 19. Inspect the condition of the skirting rubber. Remove and cut a new rubber skirt if required. Page 5 of 10
6 20. Lift the belt pulling beam in between the head pulley and the first idler frame. Rig the pulling beam back to the rail mounting foot with a 3.2t shackle, 2 x 2t x 2m slings and 1.5t come-along on each side. Pull all the belt slack through to the North side of the pulley. 21. Choke a 5t x 5m sling around the belt. Position the choke on the East side of the belt and hook to the crane. Disconnect the 2 come-alongs. Use the crane to lift the belt and move to the West side of the conveyor structure. Basket the belt with a 5t x 5m sling and rig a 1.5t come-along and 2t x 2m sling to the structure of CVXXX to assist with pulling the belt across to the West side of CVXXX structure. Communicate with other work groups and operations to ensure it is safe to access CVXXX and will not impact on any other work groups. 22. When the access pocket is sufficient to remove the pulley, choke a 2t x 2m sling with 3.2t shackle around the head frame and connect to a 5t x 3m sling choked around the belt to sustain the access pocket when the crane is released. Release the crane. Page 6 of 10
7 23. Using the crane, choke the chains around the pulley shaft. Take the weight of the pulley (7.5t) and remove all mounting nuts on West side bearing first. Remove the bottom mounting nuts and then the top mounting nuts from the East side bearing. Swing the pulley out of the head frame and lower to the ground. Keep hands clear of the bearing housings. The bearing housings will spin when removed from the head frame. 24. Clean the mounting blocks for the new pulley using a wire brush and scraper. Check all the mounting stud threads are in good condition and coat with anti-seize. Rig the new pulley and lift into the head frame. Tighten the mounting nuts enough to seat the bearing housings neatly into the mounting blocks. DO NOT fully tension. Release the crane. 25. Use the crane to lift the belt using the slings previously rigged to create the access pocket. Remove the slings rigged to the belt around the head frame and remove the come-along and slings rigged to CVXXX. Use the crane to relocate the belt central to the head pulley. Release the crane. 26. Measure the distance from the top of the bearing housing mounting flange to the bottom of the jacking block. Adjust the jacking screws until the same measurement is obtained as per the original bearing position (as measured in Step 17 above). Lock the jacking screws into position and fully tighten the mounting nuts using a 55mm flogging spanner. Wrap the mounting studs and nuts with densotape. Page 7 of 10
8 27. Basket a 5t x 5m sling around the belt on the South side of the head frame. Use the crane to lift the slack in the belt. Basket a 5t x 3m sling and 2t x 2m sling around the belt and connect back to a 1.5t come-along and 2t x 2m sling rigged around the conveyor structure, on each side of the belt. Use the come-alongs to pull the belt slack back to the conveyor side of the head pulley to allow access to fit the scrapers and skirt. Release the crane. 28. Fit the skirting rubber. Rig the scrapers with the chains choked on opposite sides of the scrapers. Use the crane to refit scrapers to the mounting bracket. The scrapers will be top heavy and will want to roll to the bottom when lifted. 29. Fit the grease lines to the bearing labyrinths on each side of the pulley. NOTE: The bearings installed at the time this document was written were sealed bearings and did not require further lubrication. Check with the bearing supplier before connecting grease lines to the centre of the bearing housing. Plug and neatly tie off any unused grease lines to prevent grease leakage, damage and contamination to unused lines. 30. Remove the slings and come-alongs. 31. Remove the scaffold below the pulley. 32. Using the 250t crane, rig the rolling frame and deflector using 2 x 2 leg x 13t lifting chains. Basket 2 chain legs at the non-pulley end of the deflector between the 2 structural beams. Shorten the other 2 chain legs on the 19 th link from the lifting ring, double wrap and choke at the pivot end (pulley end) of the rolling frame. Lift the rolling frame up to the head frame and align the link pin lugs. Coat with anti-seize and fit the link pins, castle nuts and split pins. Lower the rolling frame onto to the rail. Release the chains. load. Never work or walk under a suspended 33. Ensure all lifting equipment and tooling is removed from the conveyor and work area. Replace all guarding around the maintenance bay area. Page 8 of 10
9 34. Remove personal locks and sign off permits for isolation to be modified for belt clamps to be removed and counterweight lowered. Change isolation so that all belt clamps and counterweight pins can be removed. 35. Sign on to belt movement permit ensuring that your locks and danger tags are on the lockboard. 36. Remove all belt clamps. Be aware of stored energy in the belt when removing belt clamps. 37. Replace guarding removed for belt clamps. 38. Lower the counterweight: Take the weight of the counterweight with the winch, until the locking bars can be removed and pawl disengaged. Lower the counterweight; ensuring spotters are in position on all levels. Communicate the impending counterweight movement to all parties that may be affected. Ensure approx. 1.5m of slack is left on the counterweight rope to allow for counterweight bounce on conveyor start up. Use Channel 34 to notify all OPF personnel that work is about to commence lowering the counterweight. 39. Remove all locks and sign off permit. De-isolate and test run conveyor without feed on and later with feed on, to ensure it is tracking correctly. Check counterweight has taken up fully on the belt. POST-TASK ACTIVITIES HOUSEKEEPING: Ensure all tools are collected and returned to stores. Remove all waste materials from area and place in the appropriate bins. Report any damaged equipment. Leave aisles clear and area free of hazards. Lift old pulley into the transport stand and deliver to the rotables yard. Page 9 of 10
10 Additional Comments SIGN-OFF WHEN WORK IS COMPLETED Do subsequent Notifications exist for all items requiring attention? Yes No Have the required Notifications been raised? Yes No List Notification Numbers: Inspection conducted by: Name: Sign: Date: Supervisor Name: Sign: Date: Page 10 of 10
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