Change- out P119 Pulley-2

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.

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
 ¾” 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)

 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

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.
You are responsible for ensuring that you use the most recent version of this document.

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.
You are responsible for ensuring that you use the most recent version of this document.

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.

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.

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

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

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

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

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° - 20°C above ambient. Slightly warmer running temperature may
occur during initial running period.
CONTRACTOR BHPIO
NAME
SIGNATURE
POSITION

Change- out P119 Pulley-2

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