VEDANTA LIMITED
INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: TMD
TITLE: EOT CRANE
VER.NO: 01 REV.NO : 02 DOC NO:- IPP/WI-TMD/053 DATE:07/10/2015 PAGES 1 of 12
STANDARD MAINTENANCE PROCEDURE
ELECTRIC OVERHEAD TRAVELLING BRIDGE CRANE
(OVERHAUL/BREAKDOWN MAINTENANCE PROCEDURE)
POWER MECH PROJECTS LIMITED
4X600 MW IPP
VL, JHARSUGUDA, ODISHA
Prepared By Reviewed by Approved By
PMPL PMPL VEDANTA PMPL VEDANTA
AMIT KUMAR GAYANA P KAR PK
G.P.REDDY A.K.SHAHI
SHARMA MOHAPATRA
VEDANTA LIMITED
INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: TMD
TITLE: EOT CRANE
VER.NO: 01 REV.NO : 02 DOC NO:- IPP/WI-TMD/053 DATE:07/10/2015 PAGES 2 of 12
Management Standard ISO 9001 ISO 14001 OHSAS 18001
Element Name Resource Operational Operational
management Control Control
Element Number 6 4.4.6 4.4.6
1. PURPOSE: - The purpose of this procedure is to define the step by step
activity involved in 85/20T EOT crane Overhauling & break-
down maintenance.
2. SCOPE: - Scope of this document is limited to maintenance of 85/20t EOT
Overhauling & break-down maintenance.
3. REFERENCE: - OEM operation & maintenance manual/ 42 SK J556
4. ANNEXURE: - Nil
5. DISTRIBUTION: - Head Turbine Maintenance & MR IPP VL, Operation
Shift In charge, Shift Engineer.
6. AMENDMENT HISTORY
Sr. No Amendment Page Curren Current Issue
Description No (s) t revision Date
version No.
No.
1. Logo, 5 01 02 07-10-
company 2015
Name, PM
procedure
Prepared By Reviewed by Approved By
PMPL PMPL VEDANTA PMPL VEDANTA
AMIT KUMAR GAYANA P KAR PK
G.P.REDDY A.K.SHAHI
SHARMA MOHAPATRA
VEDANTA LIMITED
INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: TMD
TITLE: EOT CRANE
VER.NO: 01 REV.NO : 02 DOC NO:- IPP/WI-TMD/053 DATE:07/10/2015 PAGES 3 of 12
7. ACTIVITY CHARACTERISTICS :
INPUTS OUTPUTS REVIEW FREQUENCY
All Safety PPE’s like To maintain the availability of Yearly
Helmet, Leather Gloves, EOT crane
Shoes, ear plug, safety belts.
Tools: Tool Box, Spanners,
Hammer, Screw driver,
Torch Light, Scale, grease
gun
8. RESPONSIBILITY: Skilled Maintenance Engineer & Technician
9. DEFINITION: Function of EOT crane is to lifting of heavy equipment for
maintenance, BTG & CW pump house area.
LOCATION: TG HALL-26m & CW pump House
10.SAFETY TABLE :
Job Safety Safety Ear muff Respirator/ Cotton Safety Safety Safety
description/ Helmet Harness Dust Mask Gloves Goggle uniform/ Shoes
PPE -> Jacket
EOT Crane
Y y Y N Y Y Y Y
Prepared By Reviewed by Approved By
PMPL PMPL VEDANTA PMPL VEDANTA
AMIT KUMAR GAYANA P KAR PK
G.P.REDDY A.K.SHAHI
SHARMA MOHAPATRA
VEDANTA LIMITED
INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: TMD
TITLE: EOT CRANE
VER.NO: 01 REV.NO : 02 DOC NO:- IPP/WI-TMD/053 DATE:07/10/2015 PAGES 4 of 12
11. WORK INSTRUCTIONS :
PRE-OPERATIONAL CHECK:
11.1. Ensure that the persons at the work station are using PPE’s at
the time of carrying out the overhauling & break-down maintenance.
11.2. Proper Safety Tool Box talk & SMP prior to starting the job
11.3. Check availability of all necessary tools available at site.
11.4. Working person should be having height pass.
11.5. Use of hammer: Ensure the spanner is tied to a fixed location. Person
hand should not be in between hammer & spanner while hammering
11.6. Check that all lifting equipment and tools are in good condition &
certified
12. PROCEDURE:
Sl DESCRIPTION HIRADEC REF.
No
1 Take the work permit with isolation certificate & Ensure
isolation on site.
2 Ensure Crane is isolated from power source and lockout
before disassembling the drive. Refer Equipment
Isolation Procedure.
3 Mechanical isolation: Suction & Discharge valve
closed & proper tag.
4 Electrical isolation: Motor breaker rack out & take
Lotto key & proper tag.
Prepared By Reviewed by Approved By
PMPL PMPL VEDANTA PMPL VEDANTA
AMIT KUMAR GAYANA P KAR PK
G.P.REDDY A.K.SHAHI
SHARMA MOHAPATRA
VEDANTA LIMITED
INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: TMD
TITLE: EOT CRANE
VER.NO: 01 REV.NO : 02 DOC NO:- IPP/WI-TMD/053 DATE:07/10/2015 PAGES 5 of 12
13. Maintenance for mechanical devices (IPP/HIR-TMD/ROU/375-377)
13.1 Lubrication: The performance and service life of crane mainly depend
on the lubrication status; make sure that the lubricating nipple is unclogged.
Attentions for lubrication:
• The grease should be clean and without any impurity;
• Do not mix different greases;
• Check the sealing status of lubrication system regularly.
Fill the thin grease into rotary areas through the fill‐in holes regularly to reduce the
Mechanical abrasion and prevent rust‐corrosion.
The lubrication work should be conducted under power‐off status.
Lubrication Lubricant Grease
position and name Lubrication Cycle Materials N o. Input Mode
of parts
Bearings of bridge
(GB491‐87)
wheel an d trolley
wheel; About half a year Calcium base 3 Grease gun
Horizontal wheel grease
( GB491‐87)
bearings
Pulley blocks 3 months A s above 3 Grease gun
Prepared By Reviewed by Approved By
PMPL PMPL VEDANTA PMPL VEDANTA
AMIT KUMAR GAYANA P KAR PK
G.P.REDDY A.K.SHAHI
SHARMA MOHAPATRA
VEDANTA LIMITED
INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: TMD
TITLE: EOT CRANE
VER.NO: 01 REV.NO : 02 DOC NO:- IPP/WI-TMD/053 DATE:07/10/2015 PAGES 6 of 12
Rotary shaft of
contactors,
N 68
controllers and monthly Machine oil Oil can
position limit
Switches.
( SY1412‐75)
Rotor an d rolling 3~6 months Lithium base Oil can
bearing of motor grease ZL‐2
( SY1412‐75)
( GB5903‐95) Oil d rum (total oil volume is 123 L,
At t he early stage, replace the Industrial 47 L per main hoist reducer, 55 L
Hoist reducer and lubricant every month; then, L‐CKC150
running reducer replace the lubricant every closed gear (first‐ per auxiliary hoist reducer, 5 L per
0.5~1 year according to theoil class) running reducer. The oil has not
Actual situation. ( GB5903‐95) bee n filled in the factory)
Hoisting brake and Add the lubricant when it is Transformer Oil drum
hoisting driver oil
not enough.
13.2 Steel rope:
Pr event the hanger set from rotating when operating the hoist, thus the steel
rope Will not loosened and its strength will not be reduced. Lubricate the steel
rope timely And properly. Before adding new lubricant oil, remove the old oil
with a cloth which Has absorbed kerosene oil. It is for bidden to clean the rope
with metal brush or Other sharp tools. Do not adopt acidic lubricant or other
corrosive lubricants. The inspection an d discard f or steel rope should meet the
national standard GB5972‐8 6 Inspection an d Discard Specifications for Crane
Steel Rope.
Prepared By Reviewed by Approved By
PMPL PMPL VEDANTA PMPL VEDANTA
AMIT KUMAR GAYANA P KAR PK
G.P.REDDY A.K.SHAHI
SHARMA MOHAPATRA
VEDANTA LIMITED
INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: TMD
TITLE: EOT CRANE
VER.NO: 01 REV.NO : 02 DOC NO:- IPP/WI-TMD/053 DATE:07/10/2015 PAGES 7 of 12
13.3 Hanger Set:
Hanger is one important part of the crane and should be checked
periodically. If the following situations happen, the hook or its
accessories should be discarded and Replaced. 10.3 Hanger S et: hanger
is one important part of the crane and should be Checked periodically. If
the following situations happen, the hook or its accessories should be
discarded and replaced.
• Cracks exist o n the hook surface (rep air welding is not applicable)
• The abrasion on critical section of hooks reaches 10% of its original size.
• The hook opening degree increases 15% of its original size.
• The torsion deflection of hook exceeds 10°.
• Plastic deformation occurs on the critical section or the neck of hook.
• Crack or deformation exists on the hook nut or cross beam.
13.4 Pulley: check the pulley as follows:
• The pulleys can be flexibly rotated; lateral swing should not exceed D/1 000 (D is
the nominal diameter of pulley).
Prepared By Reviewed by Approved By
PMPL PMPL VEDANTA PMPL VEDANTA
AMIT KUMAR GAYANA P KAR PK
G.P.REDDY A.K.SHAHI
SHARMA MOHAPATRA
VEDANTA LIMITED
INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: TMD
TITLE: EOT CRANE
VER.NO: 01 REV.NO : 02 DOC NO:- IPP/WI-TMD/053 DATE:07/10/2015 PAGES 8 of 12
• If the pulley has crack or the rim is damaged, the pulley should be replaced.
• If the abrasion of pulley groove exceeds 25% of rope diameter or the n on‐uniform
abrasion exceeds 3mm, the pulley should be replaced.
• Check the lubrication of bearings.
13.5 Drum: check the drum as follows:
• Check to see whether the drum has cracks; if cracks exist, the drum should b e
Replaced and repair welding is not applicable.
• Check the abrasion status of drum groove; if the abrasion depth reaches 20% of the
Original drum wall‐thickness, the drum should be replace d (can be measured by
drilling a hole on the groove bottom)
• Check the fixation status of steel rope on the drum; whether the press plates are
firmly connected; whether the bolts are com plate; whether the connections are
loosened.
13.6 Wheel: check the wheel periodically and adopt the following procedures:
• If the abrasion of wheel rim exceeds 50 % of origin rim thickness or the wheel rim is
broken, the wheel should be replaced.
• The mutual deviation between the diameters of two matched drive wheels, which is
caused by non‐uniform abrasion, should not exceed 0.1 ~0.2 % of t heir nominal
Prepared By Reviewed by Approved By
PMPL PMPL VEDANTA PMPL VEDANTA
AMIT KUMAR GAYANA P KAR PK
G.P.REDDY A.K.SHAHI
SHARMA MOHAPATRA
VEDANTA LIMITED
INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: TMD
TITLE: EOT CRANE
VER.NO: 01 REV.NO : 02 DOC NO:- IPP/WI-TMD/053 DATE:07/10/2015 PAGES 9 of 12
diameters; t he rolling surface of wheel should be flat and smooth; the abrasion of
rolling surface should not exceed 15%~20% of original rim thickness, or else it will be
Replaced.
13.7 Breaks: Check the hoist breaks every shift. Check the running breaks every 1~3 days
(Check the running brakes very d ay if they are frequently operate d). Check the brakes
to see whether they can work sensitively and properly. Set the brake torque of main
hoist brake to 580N.m and set the brake torque o f auxiliary hoist brake to 380N.m;
after finishing the above checking items, the operator should lift heavy‐ load 150~20
0mm away from ground and brake. This test can deter mine whether the brake is safe
and reliable. If it is abnormal, further inspection should b e conducted.
14. Maintenance for metal structure (IPP/HIR-TMD/ROU/375-377)
14.1 Frame:
Frame is the main stress part among the mental structure of the cane, so the
maintenance of frame has great influence on the safety and service life of
machine. Du ring the operating process, the operator should pay attention to the
follows:
• Avoid rapid starting, rapid breaking and collision.
• Measure the girder deflection periodically to se e whether t he distortion exceeds
the permitted range.
Check the fastening bolt which is used to connect the girder and end.
Prepared By Reviewed by Approved By
PMPL PMPL VEDANTA PMPL VEDANTA
AMIT KUMAR GAYANA P KAR PK
G.P.REDDY A.K.SHAHI
SHARMA MOHAPATRA
VEDANTA LIMITED
INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: TMD
TITLE: EOT CRANE
VER.NO: 01 REV.NO : 02 DOC NO:- IPP/WI-TMD/053 DATE:07/10/2015 PAGES 10 of 12
Beam. Tighten the bolt if it is loose; replace the bolt if it is broken.
Stop operating if the girder has residual deformation (or web destabilization); find
out the repairing method after investigation and consideration.
After repairing or reinforcing the frame, the heavy‐load test should be conducted. It
can be put into use again only after it is proved to be qualified.
• Protect the metal structures to avoid corrosion. Paint the metal structures timely
according to the actual situations.
14.2 Railway:
Check to see whether the railway is straight and flat, whether the press plate is
firm or loose, whether the railway is abraded for the reason of g new rail.
A bright abrasion trace is on the lateral face of railway; if the abrasion is severing,
there will be burrs on the trace.
• A bright spot or scratch exists on the top face of steel rail.
The railway may be abraded to step‐like if the gnaw‐rail phenomenon is severe. In
t his case, we should rectify the rail way or adjust the wheel. Replace the rails
which are severely damaged.
Prepared By Reviewed by Approved By
PMPL PMPL VEDANTA PMPL VEDANTA
AMIT KUMAR GAYANA P KAR PK
G.P.REDDY A.K.SHAHI
SHARMA MOHAPATRA
VEDANTA LIMITED
INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: TMD
TITLE: EOT CRANE
VER.NO: 01 REV.NO : 02 DOC NO:- IPP/WI-TMD/053 DATE:07/10/2015 PAGES 11 of 12
15. COUPLING AND ALIGNMENT
Sl No DESCRIPTION HIRADeC REF.
1 Fixed the coupling at the position by IPP/HIR-TMD/ROU/375-377
proper way as per instruction.
2 Check the gap between motor coupling & IPP/HIR-TMD/ROU/375-377
gear coupling.
3 Check coupling alignment (axial & radial) IPP/HIR-TMD/ROU/375-377
alignment should be < 0.05 mm with the
help of alignment fixer or laser alignment
equipment.
4 Correction of alignment if required IPP/HIR-TMD/ROU/375-377
5 Couple the gear box with motor. IPP/HIR-TMD/ROU/375-377
6 Fix the coupling cover. IPP/HIR-TMD/ROU/375-377
16. EMS CONSIDERATION
16.1 Accumulated & spilled oil & grease should be removed from site & collect it in
waste drum.
16.2 All oil soaked cloth to be dumped oil dust bin.
17. OHSAS CONSIDERATION:
Prepared By Reviewed by Approved By
PMPL PMPL VEDANTA PMPL VEDANTA
AMIT KUMAR GAYANA P KAR PK
G.P.REDDY A.K.SHAHI
SHARMA MOHAPATRA
VEDANTA LIMITED
INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: TMD
TITLE: EOT CRANE
VER.NO: 01 REV.NO : 02 DOC NO:- IPP/WI-TMD/053 DATE:07/10/2015 PAGES 12 of 12
17.1 All people must wear necessary Safety PPE’s like gloves,
helmet, shoes, ear muff etc.
17.2 All personnel new to work in Turbine and those who have had a
two-week or longer break should be acclimatized before
starting work in Turbine.
17.3 Take careful movements to avoid slip or trip.
17.4 All people should have height pass.
18. RECORDS:
Reference numbers on components should be re-marked as necessary to facilitate
assembling. All dimensions should be recorded for future maintenance.
Prepared By Reviewed by Approved By
PMPL PMPL VEDANTA PMPL VEDANTA
AMIT KUMAR GAYANA P KAR PK
G.P.REDDY A.K.SHAHI
SHARMA MOHAPATRA
