STANDARD OPERATING Ref. No.

: SPCT/Eng/SOP/032
ENGINEERING PROCEDURE Version: 2.0
DEPARTMENT Total Pages: 6
Name: QC HOIST WIRE ROPE
REPLACEMENT
Written by: Reviewed by: Approved by:

Nguyen Thanh Vien Le Truong Long Le Truong Long

I. Purpose
- Provide an effective solution to replace QC hoist wire rope.
- Comply with DPW Engineering Policy and SPCT Engineering Management System
- Guide staff clearly the way to complete the task quickly & safely

II. Scope of procedure

- To be applied to ZPMC PANAMAX QUAY CRANES

III. Guidelines
1. Safety and environment compliance, PPE required

2. Detailed descriptions
Flow chart with responsibility identified.

Responsible person: Page 1 of 6 Effective Date: 05 July- 12011

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Workshop & Equipment Manager Version No.: 1.1 Review Date: 05 July 2013

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 FLOW CHART PERSON IN CHARGE
1
Confirm on rope condition & on Operators / Operation
Hoist wire rope, need history record to decide REPLACE Supervisors / Shift
to replace HOIST WIRE ROPE Engineer

2 WS & Equipment
Call man-power Raise Work Order (WO) & Permit Manager / Planning &
(contractor staffs) to Work Inventory Manager

3
With PPE ready Bringing Check the rope & special tools Shift Engineer/ WS &
hand tools, crowbar, hammer, available. Toolbox meeting Equipment Manager /
rope clamps, nylon rope,
Technicians

4
Move reeving mechanism & Put barricade around QC working Ditto
new wire rope to the site area. Put sign DO NOT ENTER

5
Reeve the new wire rope into Hoist slow down till the spreader Ditto
their drums No.1 & No.2 landed & wire rope slacked

6
Mark on the brake disc of rope Ditto
drum & on the cam limit switch

7
Remove cam switch Ditto
of the main hoist
mechanism.
8
Remove indicating mechanism of Ditto
limit switch double rope on drum

9
Lock & draw the rope end No.1 & Ditto
No.2 by chain hoist to slack them.
Remove these ropes to the
platform of machinery house

10
Place the pulley blocks by their Ditto
hooks. Lower the rope ends via
their pulleys

11
Lock & draw the rope No.3 & No.4 Connect the new wire rope with the Ditto
by chain hoist to slack them. old rope end in orderly
Remove these ropes in drum till
leaving 3 rounds on it. Lower these
rope ends to the ground.

Responsible person: Page 2 of 6 Effective Date: 05 July- 22011

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Workshop & Equipment Manager Version No.: 1.1 Review Date: 05 July 2013

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12
Ditto. Note: Sequence of
Re-arrange the the wire rope No.1 & No.2
Check sequence of
sequence of the need to be parallel.
wire rope connection
rope
on the ground

No Yes

13
On the boom tip, secure and Shift Engineer/ WS &
draw the main hoist wire rope Equipment Manager /
with chain hoist to make it slack Technicians
on the clamp
14
Loose the clamp and remove the
Ditto
bolts, put the wire rope onto the
reeving sheaves, and then remove
the chain hoist

15
At machinery house, changing Ditto
hoist control into EMERGENCY
DRIVE ON at the coupling control
box
16
REEVING THE ROPE: Manual
Ditto
control hoist down at the
electrical control box

17
Slowly control hoist down & Ditto
follow rope reeving.

18
Ditto
Solve the abnormal Take care every time
situation. Lock the wire the rope connection
rope & draw by chain passing through the
hoist before doing sheaves

Abnormal
Normal
19 When the returning of old wire rope goes
to the end of hoist drum (Drum No.2 is Ditto
full with old ropes): STOP REEVING

20
Lock the wire rope, draw by chain hoist Ditto
to slack it then move to outside
grooves. Continue from step 16, till 2
first ends of new rope already came to
drum No.1

Responsible person: Page 3 of 6 Effective Date: 05 July- 32011

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Workshop & Equipment Manager Version No.: 1.1 Review Date: 05 July 2013

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21
Fix 2 first new wire rope ends on Shift Engineer/ WS &
drum No.1 Equipment Manager /
Technicians

22
Connect 2 last ends of new wire rope Continue to reeve the wire rope Ditto
with the old wire ropes by rope clamps till 2 last ends of new wire rope
to maintain alignment of the rope coming to drum No.2
reeving
23 Remove the connection with old
wire ropes. Lower the old ropes Ditto
to the ground.

24
Install 2 last ends of new wire Ditto
rope on drum No.2

25 Lock the wire rope, draw by chain

hoist to slack it then release rope Ditto
in drum 1 & pull it out of drum 1
till having same basic rounds with
drum 2

26
Check & Tighten wire rope Ditto
clamps on both drums

27
Start to wind the ropes into their Ditto
drums

28
Ditto
Solve the unequal Follow the balance of
length. Pull the rope the wire rope
into short part nearly same length
Abnormal
Normal
29
When the hoist wire rope Change hoist control into EMERGENCY Ditto
could lift the spreader, DRIVE OFF at the coupling box. Still
CONTROL ON at the machinery house
control box.
30
Continue winding the rope. Check the Shift Engineer/ WS &
balance of spreader. Check quantity of Equipment Manager /
wire rope on drums, about 13 rounds. Technicians
Record redundancy

Responsible person: Page 4 of 6 Effective Date: 05 July- 42011

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Workshop & Equipment Manager Version No.: 1.1 Review Date: 05 July 2013

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31
Lower the spreader to the ground. On the Ditto
boom tip, secure and draw the main hoist
wire rope with chain hoist to make it slack

32
Pull the wire ropes out of the reeving
Ditto
sheaves. Install them to the rope clamps
and tighten bolts. Then remove the chain
hoist
33
Hoisting to stretch the wire ropes, and Ditto
then lower spreader to the ground. On the
machinery house, re-check quantity of
wire rope on drums, about 13 rounds

34
Ditto
Lower the spreader to
the ground. Pull the Confirm the un-
rope into short part balance & wire rope
redundancy
No
Yes

35
Cut the redundant wire rope with
Ditto
compensation for spreader balancing.
Lock the wire rope & draw by chain hoist
to slack it before doing.

36
Hoist up the spreader out of the ground Ditto
about 0.3m to confirm its balance

37
Lower the spreader then hoisting it several
Ditto
times to check the balance & rope
redundancy. Repeat step 35 if necessary

38
On the machinery house, turn the rope Ditto
drum till last marks on brake disc/ cam
LS as setting on step 5.

39
Re-install indicating mechanism of Re-install the hoist cam Ditto
LS double rope on drum limit switch

40
Change to CONTROL OFF at the Shift Engineer/ WS &
machinery house control box. Equipment Manager /
Technicians

Responsible person: Page 5 of 6 Effective Date: 05 July- 52011

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41
Go to CONTROL ON at Operator Ditto
cabin. Hoist up the spreader

42
Ditto
Solve abnormal at Confirm normal
control system control at operator
(Electrical) cabin & CMS
No
Yes

43
Final check by functional / load Operator to do /
test several times Engineering to check

44
Remove barricades & sign
Shift Engineer/
DO NOT ENTER out of
Technicians
QC working area
45
Hand-over to operator for Ditto
OP. Clear & clean the
worked ground area

46 Operation Supervisors /
Create CM to adjust the Record WO
WS & Equipment
spreader balance if required status into ICAM
Manager / Planning &
Inventory Manager
47
Report WO status to Shift Engineer/ WS &
Engineering Director Equipment Manager /
Technicians

HISTORY OF CHANGE

NO. VERSION MODIFIED OF CONTENT DATE OF ISSUE NOTE

1 1.0 Initial issue 20 September 2010
2 1.1 Revised issue 05 July 2011
3 1.2 Revised issue 05 July 2013
4 2.0 Revised issue 05 July 2015

Responsible person: Page 6 of 6 Effective Date: 05 July- 62011

- of 6
Workshop & Equipment Manager Version No.: 1.1 Review Date: 05 July 2013

Uncontrolled document when printed, check SPCT Eng. Dept. for latest version if available.