REF NO: CRM/ESL/4984/W

CTCM REV NO: 00

AMD NO: 00
EFF. DATE : 01.06.2011
LOOPER WIRE ROPE CHANGING
Page: 1 of 6

STANDARD OPERATING PROCEDURES FOR LOOPER WINCH WIRE ROPE CHANGING

CONTENTS

SR.N DESCRIPTION PAGE

O NO

1 Introduction 02

2 Description of Facility 03

3 Personal hazards 04

4 Risks to environment and plant 04

5 Safety requirement - Training, isolations, PPE, Special equipment 04

6 Emergency preparedness 04

7 Safety Equipment and Tools required 04

8 Pre-conditions before starting of boiler 04

9 Sequential description of activities 05

10 Completion checks 06

11 Important telephone nos. 06

12 List of documents to be maintained 06

13 Monitoring the data - Frequency and corrective actions to be taken. 06

14 Engineering Change notes 06

15 Training records of the employees 06

16 Calibration records 06

17 Documents would be reviewed and authorization 06

ISSUED BY : APPROVED BY :
ISSUED DATE : 01/06/2011
 REF NO: CRM/ESL/4984/W
CTCM REV NO: 00
AMD NO: 00
EFF. DATE : 01.06.2011
LOOPER WIRE ROPE CHANGING
Page: 2 of 6

1. Introduction:
To pull the accumulator looper car and ensure the tension to the strip.

A. Reference drawings:

1) General Assembly:
1) Looper Winch-L95239

Prepared by: Checked by: Approved by:

In charge Head of the department

Signature Signature Signature

ISSUED BY : APPROVED BY :
ISSUED DATE : 01/06/2011
 REF NO: CRM/ESL/4984/W
CTCM REV NO: 00
AMD NO: 00
EFF. DATE : 01.06.2011
LOOPER WIRE ROPE CHANGING
Page: 3 of 6

2 . Description of Facility:
A. Facilities :
Looper winch consist a rope drum on which Wire rope Ø46 is connected through looper car. It is used to provide strip tension and
forward/backward movement of looper car when drum rotates.

B. Equipment details:
QTY
FOR
EQUIPMENT NO SYSTEM CTCM CAPACITY WEIGHT(Kg) LOCATION
Looper Winch
1165 Rope Drum 1 8712 Kg Looper Winch
1165 Wire Rope 240 Mtrs. 1960 KN 2767 Kg Looper Winch

ISSUED BY : APPROVED BY :
ISSUED DATE : 01/06/2011
 REF NO: CRM/ESL/4984/W
CTCM REV NO: 00
AMD NO: 00
EFF. DATE : 01.06.2011
LOOPER WIRE ROPE CHANGING
Page: 4 of 6

3. Personal hazards - In or around the work:

a) Hit by spanner or hammer.
b) Crush/Hit by weight (Wire Rope)

4. Risks to environment and plant - Associated with the work:

N/A
5. Safety requirement - Training, Isolations, PPE, Special equipment:
a) Training on usage of fire extinguishers.
b) Ensure that all persons are wearing helmet, safety shoes and hand gloves during work.

6. Emergency preparedness:

A. Fire:
a) Inform to fire and safety control room and seek for assistance.
b) Inform the area incharge
c) Inform to CTCM in charge.
d) Inform to operation and maintenance shift in charges.
e) Inform to departmental HOD.
f) Take following actions to control and mitigate the fire:
 Seek assistance from fire and safety department and departmental maintenance personnel. .
 Evacuate all the personal at surrounding areas other than personal attending FIRE.
 Use appropriate fire extinguishers like (CO2 extinguisher) available at site for mitigating the fire.
 Use water (Fire water network) to cool the hot areas caused by fire.
 Ensure that fire is attended and recorded in log book.
 Prepare fire incident report and send it to fire control room for detail investigation to avoid such type of fire in future.
B. Spillage of materials
N/A
7. Safety Equipment and Tools - Required.

A. Safety appliances
a) Helmet.
b) Safety shoes.
c) Hand gloves

8. Pre-conditions before starting:

a) Fill looper up to maximum % if possible because it reduce wire rope rigging work hence reduces time.
b) Looper tension switched off.
c) Jog looper winch forward to eliminate the rope tension completely. (Tension due to strip weight and rope weight.)
d) Work permit to perform the job. (Do not take winch drive lockout as for removing and fixing rope, winch jog is required.) Take
precaution (E-Stop) for dismounting rope locking clamp on rope drum.

ISSUED BY : APPROVED BY :
ISSUED DATE : 01/06/2011
 REF NO: CRM/ESL/4984/W
CTCM REV NO: 00
AMD NO: 00
EFF. DATE : 01.06.2011
LOOPER WIRE ROPE CHANGING
Page: 5 of 6

9. Sequential description of activities:

 Remove security cable from thimble.

 Remove looper car pulley rope guard.
 Remove wire rope from looper car pulley and rope support pulley. Place rope on the floor.
 Remove wire rope thimble by removing locking pin with the help of crane.
 From winch control desk, jog the winch drum to unwind the complete rope and place it in looper.
 After emptying the drum press E-Stop on the control desk. And ensure that there is no drive, by jog it in forward or reverse
direction.
 Remove the wire rope locking clamp (04 Nos.) from the rope drum.
 Take out the remaining part of wire rope by pulling with crane or by hand. (Take precaution as the rope is heavy and can fall
on body parts.)
 Clean the wire rope drum thoroughly to remove the accumulated dust along with lubricant.
 Lift the new wire rope reel from its reel center with crane, and place it in looper pit near winch, by hanging on crane.
 Ensure that the free end should be on top during unwinding.
 Ensure the length of wire rope is 240 Mtrs.written on the reel.
 Pull one free end of rope up to winch drum and fix it on the drum.
 Mount all 04 rope clamp and tight all bolts.
 Remove the E-Stop from the winch control desk.
 Make the looper winch drive ready from HMI.
 Jog looper winch slowly to wind the complete rope on winch drum until reel emptied.
 Remove wire rope reel from the looper pit.
 Lift the thimble with the help of crane and fix it on the cable tenon support.
 Insert the thimble pin and lock it.
 Fix security cable to thimble.
 Jog looper winch drum to unwind wire rope and pull it up to the required length to fix in looper car pulley.
 Place wire rope on looper car pulley and rope support pulley.
 Fix looper car pulley rope guard.
 Check the area completely for any abnormality.
 Jog winch drum to tight the rope and strip.
ISSUED BY : APPROVED BY :
ISSUED DATE : 01/06/2011
 REF NO: CRM/ESL/4984/W
CTCM REV NO: 00
AMD NO: 00
EFF. DATE : 01.06.2011
LOOPER WIRE ROPE CHANGING
Page: 6 of 6

 Remove all tools and cotton rags from the area.

 Return work permit to operation incharge.

10. Completion Checks:

a) Clean the area properly to remove the oil.
b) Ensure that compound, cotton rags removed from the work place.
c) Ensure that all tools and tackles have been removed.
d) Ensure that the area is checked for cleaning.

Job Coordination persons:

1. Maint shift in charge,
2. Operation in charge,

Central job Coordination person:

1. Manager Mechanical.

11. Important Telephone Nos.

a) Head of the department contact no - +919879103214
b) Fire and safety control room -2222/3333
c) Care hospital /Ambulance – 5100/5108
d) Security control room -2300/2323

12. List of documents to be maintained - As a backup.

a) Shift log book.
b) History card of the equipment.

13. Monitoring the data

N/A

14. Engineering Change notes - Records to be maintained with proper approvals and formats.
a) All the engineering changes shall be approved on prescribed format from HOD with proper reasons for changes.
b) After changes being made, rewrite the SOPs and revised documents shall be issued to respective control rooms.

15. Training records of the employees

a) Trainings attended by all executives of the CTCM Mech shall be recorded in monthly & annual dept report.

16. Calibration records – For all the measuring instruments

N/A

17. Documents would be reviewed and authorised person for the change in SOPs.
a) Head of the department / CTCM Mech In charge.
b) SOP Shall be reviewed every 2 years and record shall be maintained.

ISSUED BY : APPROVED BY :
ISSUED DATE : 01/06/2011