WHAT IS SAFETY?

S : Sense the difficulty A : Apply your mind F : Formulate plan E : Examine the situation T : Timely action Y : Yields good result WHY I !"ST#IES A#E $T F$%%$WI & SAFETY:

Management is not aware of safety No environment for safety. No pressure from trade union to management. Management's priority towards safety is low. Location problem. Need for large capital investment. Power supply interruption. Problems of Small Scale Industries. Avoid safety regulation Act. No storage facility. No trained man power/ ualified personnel recruitments. !ime factor involvement i.e. no sufficient time being allotted. No periodic inspection is done for e uipments.

WHY SAFETY

Save "uman Life # avoid accidents Improve uality of wor$ %reate smoot& # &ealt&y atmosp&ere 'educe time involvement (uilt confidence internally # e)ternally. Save production cost # Improve productivity. Prevent national loss. Improve economical growt&. "ealt&y atmosp&ere to society.

In industries various steps are needed for safety monitoring. (ut we will limit ourselves to t&e topic allotted* t&at is*. '!esting and Inspection of lifting !ools and tac$les' !&e conference's ob+ective is 'Safety Management'. ,e would li$e to e)plain in brief t&e different types of testing and inspection met&ods and safety in material &andling. I S'E(TI$ : Inspection briefly can be defined as e)amination and verification. All manufacturing industries needs inspection department. -uty of inspection department is to follow t&e laid down norms for visual* dimensional* material conformity* tec&nical re uirements etc. to satisfy t&e products being designed and its ultimate usage re uirements. ,e are not

discussing in dept& met&odology of various inspection tec&ni ues. "owever we &ave listed below various c&ec$s for safety of material &andling. TESTI &: !esting is also anot&er important area w&ere concentration is emp&asi.ed. Normally it is duty of all material &andling e uipment manufacturers t&at product s&ould be tested internally before put in practical usage. It is duty of manufacturer to develop test set up w&ic& satisfies t&e standard re uirements for product. !esting of e uipments confirms t&e uality of materials being used* performance of product* # builds confidence at all levels. !esting s&ould also to be done as per points given below/0

-eclared parameters of velocity ratio* effort etc. As per code or standard lay down. i.e. IS 1213 for %P(*IS 1412 for 5"(*IS0 1677# IS 287 for cranes. Manually operated &oist s&all be tested for 6.9 times of S,L:i.e. Proof load testing; 5lectric wire rope &oist s&all be tested for 6.39 times of S,L:i.e. Proof load testing ; %rane s&all be tested for 6.39 times of S,L:i.e. Proof load testing ; !ool and tac$le s&all be tested for proof load of 3 times of S,L. Any type test re uirements followed. <igorous situation tests.:Automobile; %ranes are verified for deflection test. Speed re uirements s&all be verified in idle condition. 5lectric performance including bra$e and limit switc& function to be verified. After testing it is advisable t&at all parts to be visually c&ec$ed for any wear and tear* condition of wire rope or c&ain etc.

o) )e shall explain in *rief safety and inspection chec+s to *e follo)ed for ,aterial Handling E-uipments. Material &andling e uipments are mainly divided in t&ree ma+or categories /0 ,anual material handling 10 %ifting Tac+les 20 ,echanical Handling0 ,e s&all now tal$ on eac& topic one by one. /3 ,A "A% ,ATE#IA% HA !%I &

Inspect t&e ob+ect for s&arp edges* protruding corners* nails etc. before touc&ing. ,&ile manually lifting t&e material :Load; $eep legs apart* bend $nees= $eep bac$ straig&t to avoid sprains. >eep load close to t&e body. ,&ile moving wit& load/material ma$es sure your vision is not obstructed. -o not drop drums* gas cylinders* barrels etc. on t&e road and roll t&em. ?se trolley or cart for transporting drums* @as cylinders* barrels and carboys. -rum cylinders* containing flammable

li uids s&ould be $ept away from spar$s* flames* &eat etc. No material s&all be stac$ed against walls or partitions to a &eig&t w&ic& can endanger t&e stability of wall. !&e materials s&ould be stac$ed safely and stac$ &eig&t s&ould not e)ceed more t&an 9 At. above t&e ground. -umping* pilling or stac$ing of material below over&ead electric lines s&ould be totally avoided. No material s&ould be piled / dumped or stac$ed at random but only in areas specified for same. 'oads* passage ways s&ould not be bloc$ed by dumping* piling or stac$ing of materials.

13 %IFTI & TA(4%ES

-o not e)ceed safe wor$ing load at any point of time. Avoid crossing* twisting* $notting of a wire rope/c&ain sling. Lift load smoot&ly* avoid +er$s* impact and swings.

23 ,E(HA I(A% HA !%I & @eneral/

%&ec$ bra$es* lifting mec&anism* limit switc&es* controls* guards* wire rope* &oo$* bloc$s etc. of 5"(* 5B! cranes. %&ec$ bra$es* lifting mec&anism controls* guards* tyres etc. of for$lifts. Never drive crane or a ve&icle wit& wet or greasy &ands. Always drive ve&icle at safe speed* slow down w&en ta$ing turns* and blow &orn at corners. ,&en driving wit&out load $eep for$s minimum 69 cm. above ground. Avoid sudden starts and stops. Avoid carrying oil drums* gas cylinders on for$lift boom. -o not cross over conveyors and roller table.

We shall examine the main mechanical handling e-uipments li+e5 /0 Hand operated chain pulley *loc+ 10 Electric Hoist 6loc+ 20 (rane (A#E 7 SAFE "SE A ! I S'E(TI$ (HE(4S: /3 HA ! $'E#ATE! (HAI '"%%EY 6%$(4:

Never lift a load in e)cess of safe wor$ing load mar$ed on t&e bloc$. !wisting of load c&ain s&ould be avoided in single fall or multiple fall. Load to be applied centrally. No direct binding of load wit& load c&ain* i.e. never use load c&ain as a sling.

No e)treme slant slinging. No over lifting* No over lowering* No roug& &andling. -on't forget to oil t&e load c&ain after use* do not use grease for lubricating load c&ain. If Load c&ain +umps* does not wor$ smoot&ly or mar$s in use* it is probably out of pitc& # s&ould be replaced. -o not allow dirt and &ard grease to gat&er in poc$ets of t&e load or &and c&ain. -o not store or leave t&e pulley bloc$s lying on t&e ground w&ere t&ey can collect dirt. %are s&all be ta$en w&en replacing t&e c&ains t&at same @rade and si.e of c&ain is fitted= @rade of c&ain is mar$ed on pulley bloc$s by manufacturer. @ears s&ould be periodically greased. :"P% lit&on03 is recommended; Never weld t&e load c&ain. "oo$ s&ould be used wit& safety latc&. "oo$ s&ould be periodically e)amined for opening* i.e. for elongation. Never lift load from &oo$ corner. 5)amine t&e &oo$ for swivel movement* t&at is top &oo$ under no load and bottom &oo$ wit& load s&ould be possible to rotate. (ra$e system is t&roug& 'atc&et and Pawl mec&anism* &ence never remove pawl. Ariction was&ers s&ould not be lubricated. !&ey are made of bra$e lining material. Bperator s&ould always wear &elmet during operation and no person s&ould stand under lifted load. Bperator s&ould warn persons around to avoid any accidents. %are s&ould ta$en t&at lifted load s&ould not swing during operation. "andling to be done carefully w&ile bloc$ is operated above furnaces or on any &eating e uipment.. It is always recommended to use Pulley (loc$ as per class -esigned. Pulley (loc$ s&ould be e)amined* inspected # tested by an impartial # competent aut&ority once in a year for its wear and safe wor$ing as certified in Aactories Act 64C2.

#outine examination !&e c&ain pulley bloc$ s&ould be regularly inspected for damage and wear and to ensure t&at it is operating smoot&ly. ,&ere t&e &oist is used infre uently* a visual c&ec$ s&ould be made of t&e c&ain pulley bloc$ eac& time it is used. !&e following is a guide to routine c&ec$s* w&ic& s&ould be carried out* on a c&ain pulley bloc$* w&ic& is used in normal operating conditions. ,&ere a c&ain pulley bloc$ is used or stored outdoors or in corrosive or abrasive conditions* inspection and lubrication must be attended to more fre uently.

5)ternal Inspection :Mont&ly c&ec$s; (omponent 8 Type of chec+ Inspection 8 "p+eep

Function "oo$ Inspect visually 6. !&ere s&ould be no deformation of t&e &oo$. 3. !&ere s&ould be no crac$s* or serious damage. 1. "oo$ s&ould &ang s uare to lifting unit or top yo$e :top &oo$; or to bottom bloc$ side plates. All fasteners s&ould be tig&t. S&ould be properly lubricated :?se D%ylesso !>06C8D oil; and free from rust and dust. Slac$ end pin #%&ain anc&or pin %&ain w&eels Load %&ain @uide 'oller Inspect visually Stripper / "and c&ain @uard Lifting and Lowering Lift # lowe ra lig&t load (ra$ing Lift # lower Safe ,or$ing Load "oist s&ould operate smoot&ly and easily. Pawl s&ould clic$ during lifting. Lifting and lowering operations s&ould be smoot& wit&out any of t&e following defects. 6. Load falls* if &and c&ain is released. 3. Load falls w&ile lowering. 1. Load slips. Inspect visually Inspect visually Inspect visually S&ould not be bent. %&ain poc$ets s&ould not be deformed / worn out. S&ould rotate freely. S&ould rotate freely and $eep c&ain in t&e poc$ets of t&e c&ain w&eel. !&ere s&ould not be any damage and wear.

Inspect visually 'ivets* (olts # Nuts %&ain Inspect visually

Internal (onstruction 9Yearly chec+s3 A competent person* as per statutory regulations and to ensure t&e efficient and safe use of t&e c&ain pulley bloc$ s&ould carry t&e routine inspection and tests given above* toget&er wit& t&e following inspections every year. Internal (onstruction 9Yearly chec+s3 (omponent 8 Function Type of chec+ Inspection 8 "p+eep

'atc&et ,&eel # Pawl

Inspect visually before dismantling bra$e :see below;

,ear on t&e ratc&et w&eel profile and pawl s&ould not be e)cessive 0 pawl must engage fully in t&e ratc&et teet&. !&e pawl s&ould not be rusted. %&ec$ t&at t&e pawl stud is secure and t&at t&e circlip / split pin is retaining t&e pawl. %lean out c&ain w&eels poc$ets and c&ec$ t&at t&ese are not deformed. %lean of all lubricant and c&ec$ t&at gear teet& are not c&ipped* damaged or worn. 'e0lubricate. S&ould not be damaged* worn or deformed and must rotate freely. !ip of stripper s&ould not be seriously flattened or damaged. :If in doubt* consult a competent person or fit new items;.

Load %&ain ,&eels # "and %&ain ,&eel Spur ,&eels and %&ain ,&eels

Inspect visually

Inspect visually

%&ain @uide 'ollers Inspect visually Stripper Inspect visually

(ra$e

5)amine t&e screw sleeve* split bus&* friction was&ers* ratc&et ring and &and c&ain w&eel* pawl* pawl spring and pawl stud. All items must be in good condition. !&e faces of t&e screw sleeve* ratc&et w&eel and &and c&ain w&eel must not be worn or scored. !&e bores of t&e screw sleeve and ratc&et w&eel s&ould not be worn or scored.!&e friction was&ers s&ould be measured wit& a vernier caliper. Minimum permissible t&ic$ness is 6.9 mm. Ariction was&ers must not be split or crac$ed.

T#$"6%E SH$$TI & (HA#T Sr0 o0 6. Trou*le Load Slippage (ause (ure

a. Ariction was&er:s; a. 'eplace friction was&ers. may be worn out. b. Ariction was&er:s; b. %lean friction was&er wit& sandpaper. oily. c. Screw sleeve # &and c&ain w&eel is +ammed. d. %&ec$ was&er is not wor$ing. c. %lean screw sleeve # &and c&ain w&eel s uare t&reads for burr / rust formation and re0assemble. d. %&ec$ serration* if re uired* replace c&ec$ was&er. Ad+ust

Nyloc nut. e. 'atc&et w&eel # e. %&ec$ spring* if found defective* pawl arrangement is replace it. %&ec$ ratc&et w&eel # pawl* if not wor$ing. worn out* replace t&em.'atc&et pawl stuc$. %&ec$ # clean pawl stud. 3. (loc$ not a. %&ec$ for load a. 'emove load c&ain twist. &oisting or c&ain twist. lowering loads. b. "and c&ain or b. %lean c&ain w&eels # replace c&ain. load c&ain may be stuc$ due to foreign particles. (loc$ ma$ing noise. a. Split bus& may be a. 'eplace it. worn out. b. Load c&ain stripper damaged. b. 'eplace it.

1.

c. Load c&ain w&eel c. 'eplace it. poc$ets may be worn out. d. @uide roller damaged. d. 'eplace it.

e. Load c&ain is e. %&ec$ load c&ain dimensions* refer +umping from w&eel table # replace load c&ain. poc$ets. f. "and c&ain is slipping /+umping from w&eel poc$ets C. Load c&ain failure a. "oist is overloaded. b. Load c&ain may be worn out. c. Load c&ain may be twist. 13 E%E(T#I( WI#E #$'E H$IST

f. %&ec$ &and c&ain dimensions* refer table # replace load c&ain. a. %&ec$ load to be lifted # capacity. b. 'eplace load c&ain. c. 'emove load c&ain twist.

Never lift a load in e)cess of t&e safe wor$ing load mar$ed on "oist. Always lift load vertically. Never lift wit& t&e point of &oo$. Never run t&e wire rope out too far. Apply grease to t&e wire rope periodically. (efore use of &oist* e)amine t&e wire rope to ensure t&at t&ere is no twist.

-o not lubricate any point of contactors. Inspect t&e wire rope for wear and tear regularly. ?nder no circumstances s&ould t&e &oist be operated w&en Limit Switc& is not operating properly. 5nsure t&at t&e rope drum is perfectly &ori.ontal w&en "oist is used as a fi)ed suspension unit. 5)amine t&e supply provided and connections are made accordingly. 5)amine bra$e operation periodically and set t&e bra$e ad+ustment. Periodically e)amine t&e bolts and nuts. If re uired tig&ten t&em. Load s&ould not be allowed to swing during operation. Bperator s&ould use &elmet. Never open any electrical contact w&en supply is BN. "oist s&ould be e)amined* inspected # tested by an impartial # competent aut&ority once in a year for its wear and safe wor$ing as certified as Aactories Act 64C2. Always use lubricant for gears as recommended by "oist Manufacturer. Periodically e)amine t&at no foreign particles accumulate on (eam on w&ic& !rolley is moving. %are s&ould ta$en t&at 5lectric &oist bloc$ fitted on (eam s&ould be properly ground if it welded. -o not leave load suspended in t&e air for long time. It is always recommended to use "oist as per class -esigned. 5lectrical parts s&all be protected* if application is out door.

AFTE# A '#$%$ &E! ST$' $# WHE ,A4I & A #$"TI E E:A,I ATI$ 6. %"5%> operation of bra$es. 3. %"5%> operation of limit switc&es. 1. %"5%> for damaged &oo$s* ropes or cables. C. >55P rope clean and well lubricated. 9. %"5%> t&e wire rope for improper seating* twisting* $in$ing* wear or ot&er defects before operating t&e &oist. E. %"5%> t&at suspending cables of t&e %ontrol (o) are not bro$en or loosen. If t&e cable is damaged* c&ange it. WHE I "SE 6 "BL- t&e load in a balanced way* securing it by using appropriate e uipment :slingF;. 3 MA>5 S?'5 t&e load clears vicinity* stoc$ piles* mac&inery* or ot&er obstructions w&en raising* lowering or moving t&e load. 1 %5N!5' &oist directly above t&e load before operating* never pull from t&e side. C MA>5 S?'5 t&at t&e load is &ig& enoug& to see and avoid any obstacle lying on t&e ground. 9 A<BI- swinging t&e load or &oo$ bloc$ w&en traveling.

E MA>5 S?'5 t&at t&e load is correctly &eld in t&e &oo$. 7 %"5%> t&at t&e rope reeving is correctly tig&t :slac$ness not desirable;. 2 >NB, AN- ?S5 t&e &and signals for &oisting and traveling. 23 (#A E %rane is general word .<arious types of cranes are/0

"and operated traveling crane :"B!; 5lectric over&ead !raveling crane :5B!; o Su* di;ided as o @antry crane o %antilever crane o Gib crane ,all/Pillar mounted +ib crane Portal crane Mobile crane Locomotive crane Never lift a load in e)cess of t&e safe wor$ing load mar$ed on crane Always lift load vertically. Never lift wit& t&e point of &oo$. Never run t&e wire rope out too far. Apply grease to t&e wire rope periodically. (efore use of crane* e)amine t&e wire rope to ensure t&at t&ere is no twist. -o not lubricate any point of contactors. Inspect t&e wire rope for wear and tear regularly. ?nder no circumstances s&ould t&e crane be operated w&en Limit Switc& is not operating properly. 5)amine t&e supply provided and t&at connections are made properly. 5)amine bra$e operation periodically and set t&e bra$e ad+ustment. Periodically e)amine t&e bolts and nuts* if re uired tig&ten it. Load s&ould not be swing during operation. Bperator/&elpers s&ould use &elmets. Never open any electrical contact w&en supply is BN. %rane s&ould be e)amined* inspected # tested by an impartial # competent aut&ority once in a year for its wear and safe wor$ing as certified as Aactories Act 64C2. Always use lubricant as recommended by crane Manufacture. Periodically e)amine t&at no foreign particles are accumulated on crane movement pat&* i.e. on beam. -o not leave load suspended in t&e air for long time. It is always recommended to use crane as per class designed. Loc$ t&e movement of crane w&en it is not in use. Switc& off t&e power supply w&en crane is idle. Periodically verify t&e supply wire conditions.