AMBUJA – LINE III PROJECT
Method Statement: Bearing / Coupling Heating
Method Statement
Bearing / Coupling Heating
AMBUJA LINE III PROJECT
JULY 2024
Prepared By Reviewed By Approved By
LNVT LNVT ACL Limited
PROJECT: AMBUJA, LINE III PROJECT
Client: - ACL
Method statement Number: MS/CH/11
Drawings Ref No:
SL NO. DATE Description Prepared By Checked By
of Revision ( SINOMA
LNVT )
PURPOSE
The purpose of this guideline is to communicate safe operating procedure for heating of
bearing /coupling during installation /overhauling at plants on as and when required basis
including major shutdown /overhauling
SCOPE
This Guideline applies to all bearing /coupling heating during installation /overhauling at all operational
plants and project sites of Clinker unit under ACL control This procedure provides basic steps, risks
envisaged & mitigation measures for safe execution of the above activity.
PROCEDURE
There are 2 ways of bearing/coupling heating
a) By Induction Heater
b) By Hot Oil Bath
NOTE:
It is recommended to carry out bearing /coupling heating by induction heater only
If induction heater of adequate size and capacity is not available to heat the bearing
/coupling then alternatively hot oil bath arrangement can be used but this arrangement has
to be at a fixed dedicated location with proper lifting arrangement and fume exhaust facility
This oil bath heating cannot be done at any location other than the designated place and if it
has to be done it has to be incorporated in daily high risk/critical activity list and after only
review of risk assessment and FLRA duly validated as per authorization matrix
PROCEDURE FOR INDUCTION HEATING
Activities Hazards Safety Precautions
Positioning the Damage to the The heater needed to be
Induction Heater near to the site electronic placed in a
unit. Hit at the ground closed room.
/workshop where coupling/bearing is to
surface. The subsurface should
be fitted. Damage to the plastic be flat and
(approximate weight of the Heater = housing. capable of supporting loads.
800kgs) Failure of EOT/ Hoist/ There should be no
Farana hook during explosion risk in the
transportation. environment.
No aggressive chemicals
should be
there in the environment.
Use tested lifting tools &
tackles for
transporting/positioning the
induction heater
Do not use wire rope
sling to hold the
heater, always use polyester web
slings to hold the heater and that
to from the bottom part and
guiding it with guide
rope to balance the weight.
Loading & positioning the Injury due to tilting of The bearing/coupling to
Coupling/Bearing for heating. heating device. be always
Foot injury due to positioned flat.
falling of Wear all mandatory & site
coupling/bearing. specific
PPE's.
Always use the sliding
table for rolling
bearings & other heavy work
2
pieces.
Always use a suitable
web/wire rope
sling & a suitable lifting device for
the
vertical edge.
Positioning of the Slip of tools Use mandatory& site
bearing/coupling prior to Cut injury Entrapment specific PPE's.
heating can be done by of fingers/hands Ensure no body parts
Moving the support blocks while lowering the comes in line of
into position so that the outer vertical ledge. action while positioning the
ring of the Failure of web/wire coupling/bearing on the support
bearing/circumference of the rope slings, blocks.
coupling is lying on the EOT/Hoist/Hydra Keep the sliding table
support blocks. while positioning the supported on the heater
Vertical ledge. while holding the coupling
Entrapment of finger as the sliding table is a
while positioning the cantilever type.
bearing/coupling on Ensure all lifting tools &
the support blocks kept tackles used
on the sliding table. are tested & are having SWL as
per the
weights lifted/shifted.
Select the vertical ledge with
the maximum possible cross
section. Change the vertical ledge.
Lift the vertical ledge into the
place and align it with the
ground portion of the heater
(apply grease prior to
positioning of the vertical
ledge). with help of
EOT/Hoist/Farana. Moving the
bearing/coupling by means of sliding table
so that the vertical ledge can be lowered
through the inner ring on to the U-shaped
iron
core.
Then lower the vertical ledge
so that it comes in contact
with another ground surface
of the U-shaped core.
Heating of the Serious burns due to The heater is connected
coupling/bearing. contact with hot to an industrial power
For any heating operation surface. socket point connected
the work piece is first Failure/damage of through adequate rating
positioned & then the pacemakers / metallic MCB and 30 mA RCCB
device is switched on. implant made inside in series or through 30mA
Take HOT permit. body. RCBO. The power cable
3
Suffocation. should be dressed such
Electric Shock & Arc that it does not come in
Flash contact with hot surface
leading to damage of
insulation of cable
During Heating operation
the heater
generates an electromagnetic
field that
is highly dangerous to persons
with
heart pacemakers or implant
made from
ferromagnetic material.
Use suitable accessories
in accordance with the
mass of the work piece&
vertical ledge.
Maintain a distance of at
least 01mtr
between the heating device & the
objects around it.
During heating process,
maintain a
distance of at least 02 mtrs
between
yourself & the device. During
heating
process the ACTIVE LED is lit.
Use the heating device in
well
ventilated rooms.
Never place metallic
objects in the
vicinity of the magnetic field.
Do not inhale smoke or
steam occurring during
the heating process.
Do not move /lift the hot
device directly after
heating process.
Do not feed the power
cable through
the U-shaped core.
Never remove the vertical
ledge during heating
process.
Do not modify the heating
device and do not use
vertical ledges which are
self-produced.
Only switch on the device
when the
vertical ledge is correctly
positioned.
Switch off the heating
device using the main
switch when no longer to
be used.
4
Use heat resistant hand
gloves.
The total heating process
to be done
under hard barrication.
Danger of death by fatal
electric shock due to
melted cable sheathing.
For heating two modes can Burn due to hot Use heat resistant hand
be used objects. gloves. Person those who
1) Time Mode have to check the
2) Temperature Mode. temperature of the object
In temperature mode a heated, by temperature
sensor has to be placed gun need to remove any
inside the inner ring of the metallic part carrying,
bearing/ core of the coupling switching off the mobiles
to provide a feed back to the (if any).
system of its heating.
For removing the hot object after heating Burn due to hot Use heat resistant hand gloves.
& achieved the desired temperature, objects. Use tested lifting tools & tackles.
switch Burn injury due to Check hammer condition.
off the equipment, lift the vertical ledge contact No person should be in line of
from top & then slowly slide the table out with hot object. action of the hammer.
of the core area & lift it with suitable lifting Slip of Tools Use leather/thermal hand gloves
tools & tackles Slip & Fall of Man and maintain safe distance from
for further processing. Fall of coupling. the hot object during lifting
Hit with hammer (Lifting & shifting to be done by
Crush injury. Farana)
After positioning of the coupling
in front of the shaft push the hot
coupling inside the shaft. If
required hammering on the
coupling with wooden plank in
between the hammer & the
coupling.
5
For heating of bearings./Couplings
The maximum mass = 1200 kgs.
The Minimum inside Ø = 215 mm
The Maximum outside Ø = 1500 mm
PROCEDURE FOR OIL BATH
HEATING (IF AT ALL
REQUIRED) RISKS ENVISAGED MITIGATION MEASURES
BASIC STEPS
Fire due to flammable Check for flammable materials
Check the site before starting material near the site. and keep safe distance from
heating activity It has to be at fixed those materials.
dedicated location with proper lifting
arrangement and exhaust facility
Selection of oil tub Oil tub may get Diameter of tub should be 100-
damaged due to 150mm bigger than the
insufficient size, load bearing/coupling diameter.
bearing capacity. Depth / Height oh tub should be
twice the height of
bearing/coupling.
Load bearing capacity should be
checked before filling oil and
placing bearing in it.
Placing of the empty tub Injury due to tilting of Keep your body parts away while
manually or by EOT Crane / tub. Foot injury due to placing Use PPE’s like hand
Hydra (If bigger in size). falling of tub. Failure of golves etc. Use tested and
lifting appliances. sufficient capacity of lifting
appliances.( 1-2 Ton chain block
depending on size of tub)
Filling oil in oil tub. Leakage of oil. Check oil tub before filling oil in
Spillage of oil. tub. Oil level to be maintained so
that it could not overflow during
dipping of bearing/coupling and
due to boiling oil can come out of
tub.
Firing of the wooden materials to Splashing of oil Firing to be done inside a zone
heat the oil. Fire Burn injury. which is fully covered with metal
plates from all sides. Proper fume
exhaust facility should be
available Fire resistant hand
gloves must be used. Call
security fire attender before
starting the job. Take hot work
permit if required.
Fire extinguisher, Fire watcher,
6
Fire bucket should be available at
the spot.
Area should be hard barricaded.
Lifting and placing of Fall of coupling Apply sling at the outer race to
coupling/bearing /bearing. avoid slipping of
Foot injury due to bearing/coupling.
falling of coupling Use wire rope for lifting purpose.
/bearing.
Fitting of Labyrinth ring & Input Burn injury due to Use leather hand gloves and
Coupling.(Coupling to be dipped contact with hot maintain
in hot oil bath - Temp of oil object. Slip of Tools safe distance from the hot oil &
_150ºC) Slip & Fall of person object
on spilled oil Fall of during lifting ( Lifting & shifting to
coupling. /bearing be done
Splashing of hot oil by farana)
during coupling After positioning of the
/ bearing removal from coupling/bearing
oil bath. in front of the shaft push the hot
Spread of fire to coupling/bearing inside the shaft.
nearby area. Inform security dept. for keeping
Splashing /Overflow the foam
of hot oil due to type fire extinguisher near the fire
boiling and availability area.
of water droplets Do not keep any flammable item
Fire in hot oil due to near the
boiling. vicinity of fire.
Heating of the coupling/bearing Fire Fire resistant hand gloves must
with gas cutting torch Burn injury to be used.
workmen. Take hot work permit if required.
Check the condition of the hose
pipe,
pressure gauges and cylinder.
All job specific PPEs must be
used.
Cleaning of area. Slip & Fall of Tools & Use cut resistant hand gloves
Shifting of tools and tackles from Tackles while
site Slip & Fall of person shifting jobs.
Look out for slippery floor and
avoid
travelling over it
Emergency Rescue Plan:
In case of any incident, call to emergency Control Room by calling:
For emergency 24hr ambulance facility & Paramedical staffs will be available nearby First
Aid Centre.
In case of vehicle break down or in any incident contact to our Plant & Machinery In-charge
for rescue the vehicle/Equipment.
All emergency contact number is displayed at site for immediate communication around the clock.
Further Onsite Emergency response plan to be followed if any emergency situation is
occurred.
