STANDARD OPERATING PROCEDURES

Form No. : EHSMSM/446/4013 Form Rev. No. : 01 Effective date: 01.04.2009

SOP No. : FME/CG2/SOP/02B Rev. No : 3.02 Effective Date : 01.05.2024
SOP DESC : Inspection & Maintenance of Crane(EOT)/ Repair Hoist (RH) / Repair Trolley
Section: Crane Group II
(RT)
DEPARTMENT : Field Maintenance Electrical

Note 1 : Positive isolation requirement : ESI document pertaining to the EOT / RH / RT & pertaining to the job covered in this SOP to be demanded & obtained from the WP
issuing person. Job supervisor must be satisfied with this document before starting the job. DSL to be isolated in case of checking of axle boxes of DSL side
(JCC00000000000123345)
Note 2 : PPE Requirements : Job-specific hazards, PPEs & precautions have been included in this SOP. Six directional hazards shall be mentioned in Work permit form by
customer department. Be careful of power cables, DSL, bare cross bars present in EOT / RH / RT. SOP 01 is an integral part of this SOP. No-one should work on crane without
valid Height pass.
Note 3 : Working at Height Requirements : a) Use full body harness wherever both side supports - hand railings are not available. Manila rope / lifeline (made with 10mm steel
wire rope) may need to be fixed on rigid support for this puspose. Ensure to weld / tie to column these rigid supports safely.
b) Provide ground barrication, use tool bag, tie tools & spares with manila rope (while handling)against hazards associated with falling of material from height. Fasten the tools
,objects using a sling / manila rope while working on EOT / RH / RT or gantry.

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c) There should not be any manual lifting if the weight of material exceeds 25kg. More than 25kg load to be handle with proper tools/tackles/lifting devices. (25 kg weight

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handling by one person does not qualify that 4 persons will handle 100kg weight) .
d) No manual handling to be done if clearance around the object to be handled is less than 6 inches to prevent any hand/finger injury. e) Job site

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safety aspects will need to be considered and additional points as required during that time may be added by site in charge keeping in mind that safety of working personnel is
not compromised.
a
side from mill bay gantry V
f) For WRM guide shop crane , Since there is movement of crane above this crane, rail stopper to be fixed on both side on mill bay track rail and barricading to be done on both

Note 4 : Working at EOT / RH / RT Requirements : 1)Single working on EOT / RH / RT is not permitted and a person feels unwells he must leave area immediately. 2) whenever
possible , EOT / RH / RTs must not be parked in the vicinity of poor atmospheric condition for maintenance purpose. 3) for working on repair hoist / repair trolley- barricade the
area below such that any EOT EOT / RH / RT should not come below the repair hoist / trolley. Sick bay to be isolated as applicable and wheel stoppers put to prevent entry of EOT

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EOT / RH / RT inside the working zone. Both over-hoist limit switch trials to be done. Barricade the area before start of jobs. Hard barrication to be done wherever there is
movement of men. Do not allow any un-authorized person under the crane during maintenance. Power collector cage to be covered after comimg out from the cage without fail.

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Printed By -DEEPAK KUMAR SAH(505409) Print valid till - 03-Jun-2024 Printed on - 24-May-2024 SOP Valid Till - 01-May-2025
Note 5 : Points Specific to Self-Maintained cranes:
1) For Hoist or CT brake adjustment of ERS 30T with CT cross bar power ON, position the Trolley to the extreme opposite end of Parking position, bakelite sheet barricading has
been done to prevent any accidental contact with live DC power rails.
2) For maintenance of Heavy Spares Shed 15T, scaffolding to be erected or ladder to be used for maintainance of Power Collector.
3) For maintenance/attending breakdown of MED Mechanical Hydraulic Section 12T EOT / RH / RT, Every person climbing up the gantry and boarding the EOT / RH / RT must
wear full body harness and clamp the hook in lifeline tied up along gantry pathway. Gantry width is very less so everyone moving should be very attentive and walk slowly.
4) For LT rail and girder inspection of ERS 10T , atleast 3 persons should go, Team Leader should position himself in Operator Cabin and other 2 persons should position
themselves safely to observe LT rail and girder during EOT / RH / RT LT movement. EOT / RH / RT movement to be co-oridnated with Operator and Team leader accompaning the
operator using Walkie-Talkie sets. Focussed LED torch should be used to observe any welding cracks/defects etc.
5) During any maintenance activity, Hook Block greasing is to be done while Operator is available and before power cutting. After lowering the hook block, Operator should
switch Off EOT / RH / RT power and hook block greasing to be done. Once completed, hook block to be raised and EOT / RH / RT should be parked in designated parking position
and then power cutting and positive isolation shall be done.
6) Only TSL approved Cat III/Cat IV electrical measuring instruments are to be used.
7) Whenever working in front of live DC Panels during scheduled maintenance/running inspection/attending breakdowns, person must wear following PPEs - Safety Helmet,
FR/LV Jacket, LV Hand Gloves, Safety Goggles and Arc Face Shield in addition with other applicable PPEs.
8) Whenever doing power rail inspection while standing at Power Collector with DSL power ON, all persons must wear following PPEs - Safety Helmet, FR/LV Jacket, LV Hand
Gloves, Safety Goggles and Arc Face Shield in addition with other applicable PPEs.

should not be done without above action has been action.

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9) Whenever doing meggering of drive operated motors, ensure motor connections at TB side are opened or outgoing connections from Drive to Motor are opened. Meggering

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10) Annexure I along with this SOP has to be mandatorily followed for all EOT / RH / RT maintenance activity.

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Note 6: For any major job / infrequent jobs- a record of major objects (tools , tackles , packings etc. ) that may be carried to the gantry / equipment should be maintained by
working agency and same to be verified by TSL site in charge (Reco. Of incident IN00123155)

building crane 50T & 15T, EQMS new loco 30T crane V
Note 7: Following 9 Cranes contains Drum gear coupling: CDQ567 crane, CDQ10 crane, CDQ11 crane, CSD Bay2 25T, CSD Bay3 20T, CSD Bay3 25T, CDQ40MW power house

Drum side gear coupling to be decoupled/opened only after the discussion and permission of TSL CG2 supervisor / Officer at site. If Drum side gear coupling is opened without
drum locking, this will attract following hazards:
1) Due to potential energy stored in rope drum, rope drum may rotate in uncontrolled manner which may damage the rope.
2)Person working on Hookblock or under the crane may get injured due to falling of rope.
3) Person working on drum coupling may get entangled due to rotation of the drum.
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Note 8: Roof clearance to be ascertained before any running inspection.If it is less than 2 mtr then Follow sop-FME/CG2/SOP/04

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Note 9: Hook maint/greasing to be done only when ,no maint. activity on the crane trolley is going on to avoid any fall of material hazard.(JCC00000000000165920)

(JCC00000000000168119)
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Note 10: Rail stoppers are to be fixed on DSL side ,only when there is minimum distance of >3 feet between track rail and power rail,else fix rail stoppers only NDSL side
Note 11: Proper

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checking of any derailment guards / rail lubricators etc. to be done for its integrity. If any additional attachment (like rubber mat etc.) is provided, it should also be checked.

Printed By -DEEPAK KUMAR SAH(505409) Print valid till - 03-Jun-2024 Printed on - 24-May-2024 SOP Valid Till - 01-May-2025
Note 12: Specific Guidelines for working in Electrical Rooms/LV (>=415V) Panels (JCC00000000000209182)
1: Ensure all Jobs inside Electrical rooms/LV (>=415V) panels is done only when person (OPR/NOPR/Contract) is wearing Cotton Gloves/Electrical Arc flash hand gloves. 2: Ensure
all Jobs inside Electrical rooms/LV (>=415V) panels is done only when person (OPR/NOPR/Contract) is wearing Safety Goggles. 3: Ensure all Jobs inside Electrical rooms/LV
(>=415V) panels is done only when person (OPR/NOPR/Contract) is wearing LV Arc Flash Jacket (LV Kool Coat)/Standard Safety Jackets for Steel/Iron Making area with full
Sleeves on & all Buttons closed. Above to be mentioned as special instructions in SOP.
Note 13: Zero Material Fall from Crane - (JCC00000000000236158 & JCC00000000000209806)
1. Check the integrity of all hand railings on cranes - base fixing and middle rung welding condition.
2. Ensure there is no cantilever type arrangement (fixed at one end and free on the other).
3. Gantry & crane to be checked for loose materials (mech/Strutural nature) and to be safely removed. 4.
Brake drum locking to be checked.
Note 14: Additional Precuations to be taken to prevent Hand/finger injuries -
a. For precision lift/lower chain block to be used with the help R/H, mobile crane etc.. Do not use hoist as it may not work accurately and cause equipment damage/ injury to
working personal.
b. For engaging/ disengaging slings, J hook to be used.
c. Special tools to be encouraged like for lifting of track-rails (lifting tackle), finger saver tool etc.
d. Try to have eye contact with operator of mobile crane/RH/man-lifter/chain-block etc. while working with. If not possible, walky talky/ mobile crane must be used. In case of
any confusion, immediately stop any movement of crane. Only one person should give signal.Working at Height Requirements : 1) Use full body harness wherever both side

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supports (railing / chain / temporary manila rope, etc.) are not available. 2) Provide adequate temporary manila rope, wherever necessary 3) Provide ground barrication, use tool
bag, tie tools & spares with manila rope against hazards associated with falling of material from height.

(E-CAUP ID - ECAU0000000000095353)
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e. Temperature gun to be used during brake inspection to check overheating of brake drum. Bare hands should not be used as it may lead to burn injury.

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Note 15: Using mobile Cranes :1) Provide barrication from all side in the work place. During Working of mobile crane, area must be barricaded. 2) No person should enter in the
barricaded area during job execution 3) Use of proper PPEs 4) use Red & Green flag and whistle for signal . 5)Load must be properly fixed with sling. 6)During lifting and lowering

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of material, no person should present in the radar of crane boom. 7)Guide rope to be used. 8) Don't move under the moving crane.9) ensure that the vehicle is parked correctly
before loading. 10) Do not SIT / STAND in the swing area of the crane and also do not climb on the crane while the crane is moving. 11) Flag man with whistle & flag should be
present with the mobile crane throughout the working duration. 12) Proper base plate to be placed as per guidelines of mobile crane procedure. Whenever working with Mobile
Crane, safe distance/safe boom angle is to be ensured between working location and Operator Cabin of Mobile crane to eliminate any accidental fall of material and damage to
operator or Mobile crane.
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Note 16: Precautions to be taken to beat the heat specially during summer/hot weather. ORS/Salted lemon water etc. to made available at site. Rest at regular interval to be
ensured. Please follow the guide-lines circulated by Occupational Health Services (attached in the last page)
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Printed By -DEEPAK KUMAR SAH(505409) Print valid till - 03-Jun-2024 Printed on - 24-May-2024 SOP Valid Till - 01-May-2025
Step Activity Associated Responsibility Remarks /
Process / tools / PPEs (HOW)
No. (WHAT) Requirements/Hazards/Impacts (WHO) Reference
Preparation in SAFETY : Injury 1) during selecting tools- 1) Discuss regarding job details and its SOP for 5 minutes. 2) Select tools,
the section itself:- tackles/spare if house keeping is not tackles,measuring instruments, test lamp and spares as per job requirement. 3) Take the
maintained. 2)Damaged/ defective tools- maintenance,lubrication, site safety checklists and the SOP book. 4) working party must
tacles/instrument also may lead to an take gas detector and respiratory protecting equipment on the EOT / RH / RT if such risk s
accident.3) gas detector shold be calibrated are identified.5) keep tools-tackles/ spares in its designated place followed by 1-S & 2-S Safety Standard :
and in proper working condition. Crane 2 procedure. 2) Use appropriate PPEs 3) Donot keep damaged/faulty tools- tackles/spares SS/ENGG-06
1 Representativ and safety equipment.
SS/ENGG-07
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ENVIRONMENT: NA NA SS/GEN-29
QUALITY: Defective / worn out tools, 1) Use tested,calibrated only Cat III/Cat IV Fluke Continuity Tester/ Fluke Digital Tong
tackles & spares may affect job quality. Tester and test lamp containing 3-lamps each of 40 Watt and the open cable lead should
not more than 1/8". (PHOTO - 1) 2) Do not use defective hand tools.

Obtain Work SAFETY: Obtain WP from authorised person only in Form : EHSMSM/WORKS/446/4007 . (PHOTO -
Permit (WP) Crane 2 2) Safety Standard :
2 Representativ SS/GEN-25
ENVIRONMENT: NA
e / IEM SS/ENGG-07
QUALITY:NA NA
Running
Inspection
SAFETY : 1) Stumbling hazards due to space
constraints / surrounding equipments,
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Refer Annex.-1 for details for EOT only.
(To be done before maintenance activity) a)
structural, etc. 3) Do not touch moving
parts 4) Keep safe distance from coupling

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Checking of Hoist Brake and its smooth operation
b) Observe for abnormal sound, temperature & looseness c) Check all motions

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and any rotating parts and stand in safe
area 5) Hold hand railing or any firm
structure 6) Sudden movement may injure e
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Crane 2

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Representativ
IEM
While working in Open Electrical panels, following PPEs - Electrical LV jacket, electrical
hand gloves and Arc Face Shield must be wore in addition with other PPE's required for
working in EOT / RH / RT. Insulated and only appoved tools must be used.
personnel
ENVIRONMENT: NA
QUALITY : Check for abnormalities and
rectify during maintenance
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Possitioning of SAFETY : 1) Stumbling hazards due to space 1) Shift the EOT / RH / RT to a safe location through 2) Barricade ground area below EOT /
EOT / RH / RT / constraints / surrounding equipments, RH / RT. 3) Hang red flag on EOT / RH / RT. Size 2 meter x 3 meter 4) Co-ordinate with EOT
Repair Hoist /
Repair Trolley
structural, etc. 2) Falling of material from
EOT / RH / RT may injure ground people . Crane 2
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/ RH / RT operator properly 5)Position the trolley at a place where there is a safe approach Safety Standard :
to climb on trolley. 6) Identify & document 6-directional hazards .7) Position the trolley at SS/ENGG-13
4
e / IEM cutting off power. (may not be appliacble for RT / RH)

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Representativ one extreme end where inspection platform is there. 8)Lower the hook block before SS/ENGG-06
SS/GEN-05

ENVIRONMENT: NA
QUALITY : NA
NA
NA
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Printed By -DEEPAK KUMAR SAH(505409) Print valid till - 03-Jun-2024 Printed on - 24-May-2024 SOP Valid Till - 01-May-2025
Step Activity Associated Responsibility Remarks /
Process / tools / PPEs (HOW)
No. (WHAT) Requirements/Hazards/Impacts (WHO) Reference
Take Power SAFETY : Wrong power clearance may lead 1) Obtain power clearance / positive isolation from authorised persons only
Clearnce to Electrical shock , flash or starting of 2) In case of positive isolation all people in the group must put personal lock (PHOTO - 3)
machinery causing unsafe incident. 3) Obtain power clearance in Form : EHSMSM/WORKS/446/4005
4)Ensure that the jaw of Isolator is open and remove the fuses.. Refer Photo11.
Crane 2
5. In case IEM is equipment owner, please ensure that operation countersigns on the Safety Standard :
5 Representativ
permit. SS/ENGG-13
e / IEM

ENVIRONMENT: NA NA
QUALITY : NA NA
Jamming of track SAFETY : 1) People may fall from EOT / RH 1) If another EOT operates on the same gantry, fix rail clamps on LT rails on both sides Safety Standards :
rails & wheels / RT during fixing rail clamps 2) Rail atleast 6m away from the EOTbuffer. Lock all wheel stopper by positive isolation lock with SS/GEN-05
clamp / scotch block may fail under load gantry and mention to work permit.2) Jam the LT & CT wheels by scotch block. 3)use hand SS/ENGG-03
2) hand injury 4) objects falling from EOT / tool lanyard,toolbag for carrying tools and bolt boxes etc.4) Use full body harness during SS/ELEC-05
RH / RT or EOT / RH / RT gantry. Crane 2 fixing rail clamps. 5) Use hand gloves and other required PPEs. 6) Use rail clamp / scotch
6 Representativ block of adequate quality & strength , & fix those rigidly. PHOTO - 4. 7 ) Fasten the tools
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,objects and rail stopper with the gantry railing using a sling / manila rope

ENVIRONMENT: NA
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NA

Carry out
inspection &
QUALITY : NA
SAFETY:1) Stumbling hazards due to space
constraints 2) Slipping of people by oil /
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activities as detailed in the relevant checklists
Refer checklist no. - FME/CG2/ 49 or FME/CG2/48 and
maintenance,
lubrication
grease deposit on EOT / RH / RT 3) Injury
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from failure of tools & tackles . 4) Falling of
material from EOT / RH / RT may injure
FME/CG2/ 29
Annexure. 1.
Refer

Safety Standard :
ground people 5) falling of people from SS/ELEC-05
Crane 2
EOT / RH / RT 6) Electrocution SS/ENGG-06
7
ENVIRONMENT: Gearbox oil may lead to
soil contamination
Representativ
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Prevent falling of oil out of gearbox, or arrest it in suitable tray / container.

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SS/GEN-05
SS/ENGG-03

QUALITY : 1)Check colour of joints.

1) Use Feeler gauge for correct air gap measurement.
Eg., for 4"-8" brakes: 2<a<3 mm

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2)Maintain air gap between 0.8-5mm for

effective operation.
for 12"-19" brakes: 2.5<a<3.5 mm

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Step Activity Associated Responsibility Remarks /
Process / tools / PPEs (HOW)
No. (WHAT) Requirements/Hazards/Impacts (WHO) Reference
Job winding up : SAFETY : 1) Stumbling hazards due to space 1) Fix back all coupling guards & obstacles removed during inspection and maintenance.
constraints / surrounding equipments, 2) Park the EOT / RH / RT at suitable position & lower heavy tools & tackles from EOT / RH
structural, etc. 2) Hand injury from slings / / RT to ground (If required) using light lifting devices .3) Clean the EOT / RH / RT of all scrap
lifting devices 3) Falling of material from / waste / lubricant generated during course of job execution.
EOT / RH / RT may injure ground people 4) 4) Remember identified 6-directional hazards 5) Use hand gloves 6) Do not use damaged Safety Standard :
falling of people from EOT / RH / RT 5) slings 7) Use tested chain block 8) Use lifting tools / tackles of adequate capacity 9) SS/ELEC-05
Support for lifting device may collapse Crane 2 Ensure to work on strong platform & within rigid & adequate side railings 10) Use full body SS/ENGG-06
8 Representativ harness with double life lines properly during working at unsafe locations 11) Ensure that
SS/GEN-05
e the support of the lifting device is of adequate strength. SS/ENGG-03
SS/ENGG-05
ENVIRONMENT: Waste oil / grease / oil- Dispose waste oil / grease / oil-soaked cotton waste, etc. as per customer's procedure.
soaked cotton waste, etc. may lead to soil
contamination
QUALITY : NA NA
Step Activity Associated Responsibility Remarks /

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Process / tools / PPEs (HOW)
No. (WHAT) Requirements/Hazards/Impacts (WHO) Reference
Trial run of EOT / SAFETY : 1) Stumbling hazards due to
RH / RT : space constraints / surrounding
equipments, structural, etc. 2) Hand injury
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1) Remove materials & men away from rotating parts 2) Remove all scotch blocks & rail

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clamps.3) Remove / return Power Clearance / Positive Isolation 4) Take trial run of the EOT
/ RH / RT 5) Remember identified 6-
from tools, tackles & lifting devices 3)
Falling of material from EOT / RH / RT may
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Crane 2
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directional hazards. 6) Keep all controllers & control
switches in neutral / OFF position before switching ON EOT / RH / RT main power. (PHOTO -
Safety Standard :
SS/GEN-25
9 injure ground people 4) falling of people
from EOT / RH / RT 5) Sudden movement
of EOT / RH / RT may injure people V a
Representativ 7 & 8)
e / IEM EHSMSM/WORKS/446/4006
7) Return power clearance in Form :
SS/GEN-26
SS/GEN-05
SS/ENGG-03
SS/ENGG-13
ENVIRONMENT: NA NA
QUALITY : NA NA

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Release Of EOT / SAFETY : NA
RH / RT
ENVIRONMENT: NA
Crane 2
Representativ
NA
Remove barrication, return WP, and release the EOT / RH / RT.
WP in Form : EHSMSM/WORKS/446/4007

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QUALITY : NA
e / IEM
NA

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PREPARED BY
Name and Desig : Manoj Kumar Singh, Sr. Mgr. CG II
Signature with Date : Digitally signed thru' GDCS
Name and Desig : Abhranil Ghosh, Head, CG II
Signature with Date : Digitally signed thru' GDCS a i
APPROVED BY

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Printed By -DEEPAK KUMAR SAH(505409) Print valid till - 03-Jun-2024 Printed on - 24-May-2024 SOP Valid Till - 01-May-2025
 PHOTO – 1 PHOTO – 4 use full body harness
power

PHOTO -2 use
standard WP form
PHOTO-3 Put
the personal

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PHOTO – 5 Use
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appropriate tools.
PHOTO – 6 Use
appropriate tools.

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Individual panel switch.

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Printed By -DEEPAK KUMAR SAH(505409) Print valid till - 03-Jun-2024 Printed on - 24-May-2024 SOP Valid Till - 01-May-2025
 PHOTO – 10 The oil should be in PHOTO – 11 Pour oil if PHOTO – 12 Ensure jaw is open and then remove the fuses.
PHOTO – 9 Take out between the low and high level as
the Oil Level Gauge required.
indicated.

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PHOTO – 12 Ensure
jaw is open and then
PHOTO – 15 Put match mark if it does
not exist.
PHOTO – 14 Verify tightness
using Match mark..
PHOTO – 16 Use Proper size spanners.

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Printed By -DEEPAK KUMAR SAH(505409) Print valid till - 03-Jun-2024 Printed on - 24-May-2024 SOP Valid Till - 01-May-2025
 PHOTO – 17 BCH DCEM Rotate bolt for inner
Brake Adjustment brake shoe adjustment.
Anticlockwise-->tightens
the shoe.
Rotate nuts for outer Clockwise--> loosens the
brake shoe adjustment shoe.

Air Gap
"a" (0.8-
5mm)

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disturb the torque setting of the

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a l i may disturb the brake operation.

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Printed By -DEEPAK KUMAR SAH(505409) Print valid till - 03-Jun-2024 Printed on - 24-May-2024 SOP Valid Till - 01-May-2025
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Printed By -DEEPAK KUMAR SAH(505409) Print valid till - 03-Jun-2024 Printed on - 24-May-2024 SOP Valid Till - 01-May-2025