SOP of Idler Change

STANDARD OPERATING PROCEDURE
Form No.: EHSMSM/446/4013 Form Rev. No.: 00 Effective date: 01-Nov-2009

SOP No.: WBD/CBN/4.1-01/CB MAINT/ 003 Revision No. 00 Effective Date 22/06/2020
SOP Description: IDLER CHANGE IN CONVEYOR Section WASHERY 3
Department :CB Page Page 1 of 9
Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

No. (WHAT) Requirements (WHO) Reference
Hazards/ Impacts
Common hazards and action to be taken
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.
1 Slip trip and fall at the work area 3. Always maintain 3 Point contact while using any staircase.
4. Remain mindful of the debris accumulated in the staircase.
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. Work to be started only after emptying the belt.
2 Dust Hazard
3 Dos and don’ts at working site Do's Don’t

Enter area with mandatory PPE . Do not start job until Proper isolation if required.
For pulling old or new belt use good quality manila rope. Don’t stand near the belt stand.
Use hand gloves before start jobs. Don’t touch any electric cable.
SOP MADE BY: INDRANIL GHOSH (ASST. MANAGER) SOP CHECKED BY: AK ROUT(Sr. MGR) SOP APPROVED BY: MANISH KUMAR (HEAD W-3)
Date: Date: Date:
Sign. : Sign. : Sign. :


Hazards/ Impacts
1. Safety Induction SAFETY: Safety Supervisor ➢ Briefing of the hazards to regarding the area and Trained people
➢ Requirement: Awareness of & supervisor about the job. should be involved in
safety rules, Job hazards, work ➢ Use of safety appliances during the work such as Job
knowledge, use of safety (Safety shoes, Safety Jacket Hand Gloves, safety
appliance, rules about working at Helmet, safety Goggles, Dust Masks).
height, rules about working at Refer safety standard
dusty area, rules about SS/ENGG-58 for use
firefighting. of PPE
➢ Hazard: Unawareness about the

area, Slip trip & fall hazard,
dusty environment.
➢ Impact: may cause Injury &

accident
ENVIRONMENT:
➢ Flying fine dust.
QUALITY:
➢ Ensure proper Positive Isolation.
Date: Date: Date:


Hazards/ Impacts
Mandatory PPE’s required for this job execution.

List Of PPE’ s
Safety Safety Safety Florescent Safety Ear Plug Co Detector Dust Mask Positive Isolation
Helmet Shoe Goggles Jacket Gloves Lock
During Pre Start- √ √ √ √ √ × × √ √

up
During On Job √ √ √ √ √ × × √ √
Any Other PPE Any Other PPE

List Of PPE’ s
[Please [Please
Mention] Mention]
Full Body Hardness Gas Welding Eye Glass

Welding Eye Shield Fire Protection Jacket
During Pre Start-up Job √ √ √ ×
activity.
During On Job √ √ √ ×
Date: Date: Date:


Hazards/ Impacts
2 Engagement of Requirements: Safety 1. Job should be carried out under the supervision of expert Supervisor. Follow standard:
Manpower ➢ Trained People Supervisor 2. All persons must have Six days training and PME Certificate. EHSMSM/
& supervisor 3. Work Permit should be obtained in prescribed format WORKS/446/4007
4. 6-directional hazard must be identified and fill-up in work permit.
ENVIRONMENT:
➢ NA
QUALITY:
➢ NA
Date: Date: Date:


Hazards/ Impacts
3 Pre Start - Up Job SAFETY: Supervisor 1. Safety induction training by safety supervisor and site in Trained people should
Activities ➢ Injury during the charge must be given to workers before starting the job. be involved in job.
handling of Tools & Follow the SS/GEN –
tackles 58 for personal
ENVIRONMENT: 2. Following tools and tackles which is require to executing protective
➢ Dusty Area the job must be accumulated in the working zone area. equipment’s standard.
QUALITY:
➢ Condition of Tools SL. Tools & Tackles Capacity/ Size Nos.
and Tackles No.
1 Spanner M24-M26 As
requ
ired
2 Hammer and crowbar 1 Kg/2 Kg/0.5 Kg As
(hammer) and 3 ft requ
(crowbar) ired
Date: Date: Date:


Hazards/ Impacts
Step Activity Associated Responsibility Remarks/ Reference

No. (WHAT) Requirements (WHO)
Process/tools/PPEs (HOW)
Hazards/Impacts
4 Shutdown & SAFETY: Contractor Supervisor/ Activity: Refer safety standard

Positive isolation ➢ Ensure positive Dept representative/ 1. Ensure positive isolation by filling up isolation form. SS/Gen-58.
isolation of Contractor employee. 2. Use of personal lock in group isolation box
equipment Refer safety standard
ENVIRONMENT: SS/ENGG 03.
➢ NA.
QUALITY:
➢ NA
5 Removal of SAFETY: Contractor Activity: Trained people

barricading net ➢ Use of hand gloves Supervisor/ Dept 1. Remove the barricading nets from its position in should be involved
ENVIRONMENT: representative/ conveyor structure by properly taking out from its in Job .Refer safety
➢ NA Contractor groove. standard
QUALITY: employee/Rigger. SS/ENGG-58 for
➢ NA use of PPE.
Date: Date: Date:


Hazards/ Impacts
6 Troughing frame SAFETY: Contractor Activity: Refer Safety Standard:

/ return bracket ➢ Use hand gloves, Supervisor/ Dept 1. Open bolt of troughing idler frame / return roller SS/ENGG-20, Version-4.0
removal Properly. representative/ bracket using 21-23mm ring & D spanner. Use hammer
ENVIRONMENT: Contractor and screw driver also. For return idler, tie the idler with
➢ NA employee/Rigger. rope before opening bolt.
QUALITY: 2. Topple the troughing idler frame using 3ft crowbar for
➢ NA taking out idler.
3. In case of return idler, take out roller bracket frame
safely using manila rope and 3ft crowbar.
4. Take out roller / idler from its frame slots
7 Installation of SAFETY: Contractor Activity: Refer Safety Standard:

new roller ➢ NA. Supervisor/ Dept 1. Put new roller / idler in the slots safely. Use 1.5lbs SS/ENGG-20, Version-4.0
ENVIRONMENT: representative/ hammer and crowbar to put in the slots.
➢ NA Contractor employee
QUALITY:
➢ NA
Date: Date: Date:


Hazards/ Impacts
8 Position the SAFETY: Contractor Activity:

Troughing frame ➢ NA Supervisor/ Dept 1. Position the troughing idler frame using 3ft crowbar and
and the bracket ENVIRONMENT: representative/ manila rope and fix bolts of required size in the holes
for return roller. ➢ NA Contractor (21-23 mm).
QUALITY: employee/Rigger 2. Position return roller bracket using manila rope and
➢ NA crowbar and put 21-23 mm bolts in hole.
3. Now tighten the bolts using 21-23 mm ring & D
spanner.
9 Fixing of SAFETY: Activity:

barricading net. ➢ NA Contractor 1. Take barricading nets and put into the slots.
ENVIRONMENT: Supervisor/ Dept 2. Now fix it properly by hammering.
➢ NA representative/
QUALITY: Contractor
➢ NA employee/Rigger
10 Return work SAFETY: Activity:

permit ➢ NA 1. Ensure all the jobs are completed and no man with tools
ENVIRONMENT: Contractor / tackles are near the work area.
➢ NA Supervisor/ Dept 2. Any scrap should be removed and put that in designated
QUALITY: representative/ scrap yard.
Date: Date: Date:


Hazards/ Impacts
11 Apply for power SAFETY: Activity:

normalization ➢ NA 1. Release field stop.
ENVIRONMENT: Contractor 2. Unlock personal lock from group box.
➢ NA Supervisor/ Dept 3. Release the shutdown of the equipment as per SOP,
QUALITY: representative/ WBD / CBN / 4.1-01/CB-MAINT/1006.
Date: Date: Date:

SOP of Idler Change

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SOP of Idler Change

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STANDARD OPERATING PROCEDURE

Form No.: EHSMSM/446/4013 Form Rev. No.: 00 Effective date: 01-Nov-2009

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

Common hazards and action to be taken

3 Dos and don’ts at working site Do's Don’t

Form No.: EHSMSM/446/4013 Form Rev. No.: 00 Effective date: 01-Nov-2009

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

➢ Hazard: Unawareness about the

➢ Impact: may cause Injury &

Form No.: EHSMSM/446/4013 Form Rev. No.: 00 Effective date: 01-Nov-2009

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

Mandatory PPE’s required for this job execution.

During Pre Start- √ √ √ √ √ × × √ √

Any Other PPE Any Other PPE

Full Body Hardness Gas Welding Eye Glass

Form No.: EHSMSM/446/4013 Form Rev. No.: 00 Effective date: 01-Nov-2009

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

Form No.: EHSMSM/446/4013 Form Rev. No.: 00 Effective date: 01-Nov-2009

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

Form No.: EHSMSM/446/4013 Form Rev. No.: 00 Effective date: 01-Nov-2009

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

Step Activity Associated Responsibility Remarks/ Reference

4 Shutdown & SAFETY: Contractor Supervisor/ Activity: Refer safety standard

5 Removal of SAFETY: Contractor Activity: Trained people

Form No.: EHSMSM/446/4013 Form Rev. No.: 00 Effective date: 01-Nov-2009

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

6 Troughing frame SAFETY: Contractor Activity: Refer Safety Standard:

7 Installation of SAFETY: Contractor Activity: Refer Safety Standard:

Form No.: EHSMSM/446/4013 Form Rev. No.: 00 Effective date: 01-Nov-2009

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

8 Position the SAFETY: Contractor Activity:

9 Fixing of SAFETY: Activity:

10 Return work SAFETY: Activity:

Form No.: EHSMSM/446/4013 Form Rev. No.: 00 Effective date: 01-Nov-2009

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

11 Apply for power SAFETY: Activity:

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