PRO-626-XXXX – Conveyor # 34 Drive Replacement

Asset 626 – Conveyor # 34

Work Order #: 369174 Asset #: 626 Date: 6-Nov-2023

Start Time: End Time:

Trades: Millwrights Electricians

(Print Names)

MODE OF OPERATION
Shutdown Mode
 The Asset must be de-energized and locked out.
 The intent is to replace the complete drive assembly on Conveyor # 34.

SAFETY
Complete Work Order FLRA with Foreman.
If you are unsure of something or a particular task, ask your Foreman.
System must be locked out to complete work as required.

REFERENCE MATERIALS
LOTO Form – Asset 626 Conveyor 34
LOTO Form – Asset 625 Conveyor 33

TOOLS
Torque Wrench Screwdrivers Set, Wrench Set
2T Chain Slings (3EA), Shackles 3/4” to 1-1/8” Thin Wall Socket Set
5T Trolleys (2EA), 2T Come-alongs (2EA) 5T Nylon Slings
Laser Alignment Tool Dunnage
MATERIAL
INV15570 Isolation Pad 12EA - 7/8-9X2 NC GR8 HEX C/S PLTD + Nuts, Wshr, Lck.
INV10928 Bolts Kit Coupling Hydraulic Hoses HPU
INV10858 Drive Assembly
SCOPE
Replacement of Drive Assembly on Conveyor # 34.

PROCEDURE
 Any brief preliminary instructions, if applicable
 If any steps need to be edited, write the proposed changes on the procedure form so it can be revised.
 If any item appears abnormal, contact your Foreman, and explain what you observed.

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1. Drive Assembly Terminology

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2. Job Procedure
Step Required Action Visual Aids / Additional Information

2.1 Note rotation of motor before lockout.

2.2 Lockout Conveyors 33 & 34 to start the dismantling

and uncoupling of old drive assembly.

2.3 Dismantle Old Drive Assy. Disconnect all electrical,

instrumentation and hydraulics in the old drive
assembly. Make sure to protect all wiring,
instruments and hoses so any damage during the
replacement is prevented.

2.4 Remove LS Coupling Guard and uncouple gear

reducer from drive pulley, remove HS Coupling Guard
and uncouple gear reducer from electric motor,
dunnage required.

2.5 Unbolt and release electric motor from the base.

Disconnect and dismantle coupling-brake system;

disconnect hoses from the hydraulic block
underneath the drive assembly using the scaffold
2.6 platform available, barricading the area. Make sure all
elements like calipers, hydraulic blocks and hoses are
secured for the installation of the new unit, dunnage
required to support the coupling-brake assembly.

2.7 Unbolt and release Gear Reducer from the base.

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 PRO-626-XXXX – Conveyor # 34 Drive Replacement

2. Job Procedure
Step Required Action Visual Aids / Additional Information

Release base from the main structure by

2.8 disconnecting the safety link, dunnage required to
support the base.

Crane Positioning. Position the crane in the

designated area (yellow zone). Once the new
2.9 assembly is ready and secured, take it from Shed 3
and relocate in the designated area (blue zone).
Barricade the area.

Crane to be ready to lift the main components of old

2.10 drive assembly located in the position shown in the
picture, Level 7.

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2. Job Procedure
Step Required Action Visual Aids / Additional Information

Removing Old Drive Assembly. Barricade the area.

Prepare pallets required for staging the parts to be
2.11
removed. Install the 2EA – 5 Tons Trolley in the lifting
beam. Follow the procedure in Annex 1.

Attach the 2 Tons Chain Hoists to each trolley. Follow

the procedure in Annex 1. The lifting procedure starts
2.12
with the electric motor; attach each chain hoist to the
lifting eyes of the motor. Motor weight is 5320 lbs.

2.13 Lift the motor up until a secure height is reached to

move the motor all the way out to the end of the
beam so can be picked up by the crane. Once the
motor is safely transferred to the crane release the
chain hoists from the lifting eyes and push back the
trolleys to the initial position for the next movement.
Unload the old motor in the designated area, dunnage
required.

Install shackles and chain slings on each of the lifting

points in the gear reducer. Lift the reducer up until the
2.14 load is secured and safe to move. Gear Reducer
weight is 2866 lbs. Transfer the load to the crane and
once is safely secured release the chain slings.

2.15 Now proceed with the base lifting and finally transfer
the load to the crane following same steps as done
with the motor and reducer. Drive Base weight is
1488 lbs.

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2. Job Procedure
Step Required Action Visual Aids / Additional Information

Installing New Assembly. Bolt up the new isolation

2.16 pad INV15570 using new bolts and hardware - 7/8-
9X2 NC GR8 HEX + Nuts + Washers + Locks.

2.17 Repeat steps 2.3 to 2.6 with the new drive assembly.

2.18 Lifting procedure for the new assembly starts with the
base. Secure the load to the crane and lift it up to the
transfer area. Secure the load to be transferred to the
5 Tons Trolleys by attaching the chain slings to the
new base, release the crane. Move the base to the
final position. Secure the base to the structure,
dunnage required to securely support the base.

2.19 Lift the new gear reducer; safely secure the new
reducer to the crane, and then crane to lift it up to the
transfer area. Receive the load with the 5 Tons
Trolleys by attaching the chain slings to each lifting
point in the reducer and transferring the load from
the crane, when is safe release the crane. Secure the
gear reducer to the base. Start assembling the new
coupling-brake system, dunnage required to support
the coupling-brake assembly.

2.20 Lift the new motor; secure the new motor to the
crane, after this, crane will take the motor to the
transfer area. Secure the motor for the lifting; crane
to lift it up to the transfer area. Once there attach the
motor to 5 Tons Trolleys using the chain slings. Safely
transfer the load to the trolleys and release the crane.
Now move the motor to its final position.

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 PRO-626-XXXX – Conveyor # 34 Drive Replacement

2. Job Procedure
Step Required Action Visual Aids / Additional Information

Secure the motor to the base. Re-attach the safety

2.21 link to the base using the Crosby 2150 Carbon Bolt
Type Chain Shackles.

Re-connect electrical supply and instrumentation to

the motor, install grounding wire to base plate as per
2.22
DS-000-3-168-01, Annex 2. Bump test for motor
rotation.

Re-install hydraulic lines from coupling-brake to the

2.23
hydraulic block.

2.24 Connect the LS coupling using bolt kit INV10928.

Apply the proper torque values using the torque
wrench and thin wall sockets. Refer to bolt tightening
torque in Annex 3. Install coupling guard.

2.25 Connect HS Coupling using bolt kit INV10928, align the

coupling using the laser alignment tool and keep
records for baseline. Apply the recommended torque
values in Annex 4. Install coupling guard.

2.26 Transport the removed drive assembly to the HD Shop

and washdown for temporary storage in preparation
to be shipped out for rebuild.

2.27 Clean up the area and secure the site.

2.28 Remove LOTO from Conveyors # 33 & 34.

Power up the system and observe the startup
2.29
sequence. Listen for abnormal noises, vibrations, or
any signs of stress during startup.

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2. Job Procedure
Step Required Action Visual Aids / Additional Information
2.30 Document the startup process, including any issues
faced and actions taken.

Asset 626 – Conveyor # 34

MOTION CHECK - THIS IS A FINAL PRE-RELEASE CHECK TO ENSURE THAT THE OPERATION OF THE ASSET IS
SATISFACTORY.
Perform a visual inspection check of the system during normal operating conditions:
 Ensure all tools are collected and removed from the equipment.
 Ensure all personnel are clear of equipment and in a safe area to observe the equipment.
 Ensure all locks are removed from the equipment.
 Ensure all equipment is reset to normal operating conditions.

NOTES

Trades Initials:

Foreman Signature: Date:

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Annex 1

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Annex 2

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Annex 3

Annex 4
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