Underground 12Wk Pump Stations' Motor OFF SERVICE LUBRICATION (DN:10000399286)

TASK EXECUTION │ PROCEDURE / PROCESS

The purpose of this SWI is to provide sufficient procedure and information for performing planned greasing on the pump stations’ motors every 12 weeks. This procedure applies to the Underground pump stations.
40013922PP3001MOTR, 40013922PP2061MOTR
40013922PP3041MOTR, 40013922PP3002MOTR
40013922PP2062MOTR, 40013922PP3042MOTR
40013922PP3011MOTR, 40013922PP2011MOTR
40013922PP2031MOTR, 40013922PP3012MOTR
40013922PP2012MOTR, 40013922PP2032MOTR
40013922PP3021MOTR, 40013922PP2021MOTR
40013922PP2051MOTR, 40013922PP3022MOTR
40013922PP2052MOTR
Approximately 1 Hour. Document number: 10000399286 Effective date: 09/01/2024 Document owner: UG AM Superintendent Site name: Kennecott Underground Department: Asset Management
Please read above attached the SWI for Underground 6Wk Pump Stations' Motor OFF SERVICE LUBRICATION.
Conducted on
Completed by
Completed by
Work Order number
Location
Qualification: Mechanics - Trained, competent and authorized for the task.

HEALTH, SAFETY & ENVIRONMENTAL CONSIDERATIONS

Contact with Electricity

Contact with Electricity
Please follow below CRM controls
• Flame & Arc Flash-resistant clothing with CAT 2 Rating.
• Identify and control the hazards to complete Critical Control Checklists.
• Avoid contact with live equipment.
• Follow Electrical Safety Procedure.

Slip, trip, and falls

• A high standard of housekeeping shall be always maintained to prevent trip hazards.
• Be wary while walking around the pumps, motors, and other live equipment as the area might be slippery.
Use appropriate PPE

Visibility and lightings

Use a headlamp or flashlight when working at the pump station

Force

• Regular rest
• Use appropriate tools.
• Avoid using brute force.
• Work in a team and ask for help from others
Maintain good communication

Work instructions

1. PRE-START PREPARATIONS & ISOLATION (MUST FOLLOW C1 ISOLATION PROCESS)

1.1 Identify and control the hazards using the TRACK
1.2 Prepare material and tools: Ensure that you have the necessary equipment/tools available at the site: - Required Materials - Required PPE - Maintain good housekeeping Proper Inspection of all tools and equipment

2. LOCK OUT, TAG OUT AND TRY OUT!

“HOLD POINT”
Leader and team members (Subject Matter Expert - SME) must verify the critical control(s) where a critical risk exists
2.1 Follow the lock out, tag out and try out procedures. Inform the DG supervisor or team lead of the scope of work and that work about to start.

3. MOTOR GREASING

3.1 The Following instructions of section 2 and 3 will be applied on all pumps of CAD and SWDG pumps.
3.2 Step Instruction
3.2 Greasing with Handheld Grease Gun. • Wipe grease from the pressure fitting, clean dirt, debris, and paint around the grease relief plug. This prevents foreign objects from entering the grease cavity. • Remove the grease relief plug and insert a brush into the grease relief as far as possible. This will remove any hardened grease. Remove the brush and wipe off any grease. • Slowly add grease to minimize excessive pressure buildup in the grease cavity. • Wait for 10 seconds between pumps to allow the new grease to distribute properly. • Watch for grease coming out the relief port. A small amount of purging is normal, but excessive grease purging is a sign of over greasing. • Allow the asset to operate for approximately 20 minutes before replacing the grease relief plug. This reduces the chance that bearing housing pressure will develop. • If regreasing is performed with the asset out of service, run the motor until bearing temperature increases to operating temperature to allow for thermal expansion of the grease. Ensure the relief valve or drain plug is left out during this process. • Allow the asset to run at this temperature for 20 minutes to expel any excess grease before installing the bottom grease relief valves. • After excessive grease has been purged, reinstall the drain plug and clean excessive grease from the relief port area.
3.3 Step Instruction
3.3 Greasing with Handheld Grease Gun with SDT gun assistance. • Wipe grease from the pressure fitting, clean dirt, debris and paint around the grease relief plug. This prevents foreign objects from entering the grease cavity. • Remove the grease relief plug and insert a brush into the grease relief as far as possible. This will remove any hardened grease. Remove the brush and wipe off any grease. • Ensure you are wearing the LubeXpert headphones and that they are connected to the data collector. • Ensure the LubeXpert ultrasonic sensor is properly connected and place it on the bearing housing. • Turn on the SDT LubeXpert, go to WORK ORDERS, and navigate to the machine and bearing you are going to lubricate, and hit Enter. • Follow the prompts on the LubeXpert screen to take an initial reading. Wait for the reading to be saved. • Hit F2 for “GUIDED MODE” and follow the prompts on the LubeXpert screen to lubricate the bearing with the proper amount of grease. • Slowly add grease to minimize excessive pressure buildup in the grease cavity. • Watch for grease coming out of the relief port. The LubeXpert should complete the greasing operation well before excessive amounts of grease are introduced into the bearing housing. • Regreasing should be performed with the asset in service whenever possible. If the asset is out of service, the ultrasonic sensor can not be used. In this case, follow the “Greasing with Handheld Grease Gun” in section 2. Allow the asset to run for 20 minutes with the purge port open to expel any excess grease. After excessive grease has been purged, reinstall the drain plug and clean excessive grease from the relief port area.

4. TASK COMPLETION

4.1 Clean work area of old or used parts.
4.2 Return all unused parts to the warehouse.
4.3 Clean and return all equipment and supplies to their proper location.
4.4 Clean any used specialty tools and return them to their specified location.
4.5 Is the task fully completed? Notify the DG supervisor that the Pump Stations' motor greasing is complete, and it is back in operation.
4.6 Report any defects to the supervisors and the planning team. Any repair done must also be recorded.
ADDITIONAL COMMENTS:
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