Beruflich Dokumente
Kultur Dokumente
General
Guidelines
Lifting
Equipment
and
Operations
10-‐Mar
-‐ New
00
2015
Document
Mahendra
Chougule
Mahendra
Chougule
Dilip
Modak
General
Manager-‐EHS
General
Manager
-‐EHS
Sr.Vice
President
Manufacturing
Rev.
Reason
for
Date
Prepared
by
Issued
by
Approved
by
No.
Issue
Printouts of this document shall be deemed uncontrolled.
Document No:
INTEGRATED MANAGEMENT SYSTEM CEAT-IMP-EHS-GEN-03
PROCESS Revision No:00
Mahendra
Dilip
New
Mahendra
00
10-‐Mar-‐15
Chougule
Modak
New
document.
Document
Chougule
INDEX
1 Purpose 4
2 Scope 4
3 Definitions / Abbreviations 5
10 References 16
1. Purpose
Hoists
and
Lifts
are
used
for
transporting
people
and
goods
between
floors.
If
they
are
properly
designed
and
maintained,
there
is
relatively
little
risk
to
the
people
using
them.
However,
there
can
be
a
much
greater
risk
to
the
person
who
services
and
repairs
the
lifts.
IS
codes
are
followed
for
necessary
guidance
for
safe
installation,
operation
and
maintenance
of
electric
passenger
and
goods
lifts.
The
purpose
of
the
procedure
is
to
ensure
that
procedures
are
in
place
for
the
provision
and
safe
use
of
lifting
equipment
and
its
operation.
2. Scope
This
Standard
is
applicable
to
all
Manufacturing
Plants,
Project
Sites
of
CEAT.
As
per
the
requirements
of
Section
28
&
Section
29
as
per
The
Factories
Act
1948,
this
procedure
is
applicable
for
lifting
equipment’s,
which
consists
of
:
• Hoist
and
Lifts
• Lifting
Machines
• Lifting
Tackles
Commonly
used
Lifting
Equipment’s
in
CEAT
are
given
below:
Lifting
Equipment
3. Definitions
/
Abbreviations
EHS
-‐
Environment,
Health
&
Safety
GM
-‐
General
Manager
VP
-‐
Vice
President
Lifting
Machines
–
“Lifting
Machines”,
means
a
crane,
crab
winch,
teagle,
pulley
block,
gin
wheel,
transporter
or
runway.
Lifting
Tackle
–
“lifting
tackle”,
means
any
chain
sling,
rope
sling,
hook,
shackle,
clamp,
swivel,
coupling,
socket
,
tray
or
similar
appliances,
whether
fixed
or
movable,
used
in
connection
with
raising
or
lowering
of
persons
or
loads
by
use
of
lifting
machines.
Competent
Person
–
“competent
person”,
in
relation
to
any
provision
of
this
Act,
means
a
person
or
an
institution
recognized
as
such
by
the
Chief
Inspector
for
the
purposes
of
carrying
out
test,
examination
and
inspections
required
to
be
done
in
in
a
factory
under
the
provisions
of
the
Factories
Act
1948.
4. Responsibilities,
Authorities
and
Accountabilities
Sr.No.
Description
Responsibility
&
Accountability
Authority
1.
Prepare
specifications
&
design
of
new
Sr.Manager-‐Engg
/
GM-‐Engineering
lifting
equipment
Sr.Manager-‐EHS
2.
Procurement,
Installation
and
Sr.Manager-‐Engg
GM-‐Engineering
Commissioning
of
Lifting
Equipment
3.
Risk
Assessment
of
all
Lifting
Sr.Manager
–
Engg
GM-‐Production
Equipment’s
and
Lifting
Operations
/
Sr.Manager
–
Production
4.
Training
&
Communication
on
Safe
use
Sr.Manager
-‐
EHS
VP-‐Operations
of
Lifting
Equipment’s
5.
Inspection
of
Lifting
Equipment’s
Sr.Manager-‐EHS
VP-‐Operations
General Manager Sr. Vice President General Manager-EHS 10.03.2015
EHS Manufacturing
PREPARED BY APPROVED BY ISSUED BY ISSUE DATE
Document No:
INTEGRATED MANAGEMENT SYSTEM CEAT-IMP-EHS-GEN-03
PROCESS Revision No:00
• Based
on
the
specifications
and
design
recommended
by
the
competent
authority,
Senior
Manager
–
Plant
Engineering
arranges
for
the
procurement,
installation
and
commissioning
of
lifting
equipment
from
the
approved
vendor.
• The
vendor
supplies
the
lifting
equipment
along
with
a
Testing
and
Examination
Certificate
from
a
competent
person
as
per
State
Factories
Rules.
• In
case,
Testing
and
Examination
Certificate
as
above,
is
not
provided
along
with
the
delivery
of
the
lifting
equipment
or
the
specifications
are
not
as
per
the
requirement,
Manager
–
Plant
Engineering
‘Rejects”
the
lifting
equipment
and
arranges
to
return
the
same
back
to
the
vendor.
• In
case,
the
requirement
of
Testing
and
Examination
Certificate
and
specifications
as
mentioned
are
complied,
Manager
–
Plant
Engineering
inwards
of
the
lifting
equipment.
• Sr.
Manager
–
EHS
maintains
the
Testing
and
Examination
Certificate
Hoist
or
Lift
• In
case,
the
valid
Testing
and
Examination
Certificate
is
available,
Manager
–
Plant
Engineering
arranges
for
installation
of
Hoists
/
Lift
through
the
concerned
vendor.
• Manager
–
Plant
Engineering
refers
and
instruct
the
concerned
vendor
to
comply
with
safety
precautions
mentioned
in
work
permit
at
the
time
of
installation
of
Hoists
/
Lift.
• Upon
the
installation
of
the
Hoists
/
Lift,
Senior
Manager
–
EHS
invites
the
competent
authority
for
inspection
of
Hoists
/
Lift.
• The
competent
authority
inspects
the
Hoists
/
Lift
and
either
approves
or
makes
recommendations
based
on
his
findings
in
writing.
• Manager
–
Plant
Engineering
arranges
to
comply
with
the
recommendations
made
as
above
and
arranges
for
inspection
and
receipt
of
Testing
and
Examination
Certificate
by
the
competent
authority.
• Upon
receipt
of
approvals
and
Testing
and
Examination
Certificate
from
the
competent
authority,
Manager
–
EHS
maintains
the
same
in
register
and
permits
the
vendor
to
start
trials
and
commissioning
of
the
Hoist
/
Lift.
• Concurrently
Senior
Manager
–
Plant
Engineering
submits
an
application
to
Lift
Inspector
seeking
permission
for
use
of
such
Hoists
/
Lifts,
as
prescribed
by
the
respective
State
Factories
Rules
(SFR)
along
with
following
annexures.
a. Equipment
details
and
design
specification,
b. Testing
and
Examination
Certificate
issued
by
competent
person
as
per
SFR
along
with
the
supply
of
Hoist
/
Lift
c. Testing
and
Examination
Certificate
issued
by
competent
authority
as
per
certifying
installation
/
commissioning
of
Hoist
/
Lift.
• Manager
–
Plant
Engineering
maintains
the
communications
sent
to
or
received
from
Lift
Inspector.
• Lift
Inspector
accordingly
inspects
the
Hoist
/
Lifts
and
issues
a
certificate
permitting
the
use
of
Hoist
/
Lift.
• Manager
–
Plant
Engineering
maintains
certificate
received
from
Lift
Inspector.
• Only
upon
receipt
of
Certificate
from
Lift
Inspector,
Senior
Manager
–
Plant
Engineering
permits
the
use
of
Hoist
/
Lift.
• Manager
–
Plant
Engineering
arranges
to
display
the
following
details
on
the
Hoist
/
Lift.
a. Equipment
no
b. Safe
Working
Load
(SWL)
General Manager Sr. Vice President General Manager-EHS 10.03.2015
EHS Manufacturing
PREPARED BY APPROVED BY ISSUED BY ISSUE DATE
Document No:
INTEGRATED MANAGEMENT SYSTEM CEAT-IMP-EHS-GEN-03
PROCESS Revision No:00
• In
case,
the
competent
authority
rejects
the
lifting
machine
and
Lifting
Tackle,
Manager
–
Plant
Engineering
arranges
to
put
a
tag
“Rejected”
and
returns
the
lifting
machine
/Lifting
Tackle
back
to
the
vendor
/
contractor.
• Upon
receipt
of
approvals
and
a
Testing
and
Examination
Certificate
from
the
competent
authority,
Manager
–
Plant
Engineering
permits
to
inward
the
lifting
/
machine
Lifting
Tackle
at
the
Plant
Engineering
Stores.
• Manager
–
Plant
Engineering
maintains
the
list
of
lifting
/
machine
Lifting
Tackles.
• Sr.Manager
–
EHS
maintains
the
Testing
and
Examination
Certificate
of
lifting
machine
/
Lifting
Tackles.
• Manager
–
Plant
Engineering
arranges
for
display,
of
an
aluminum
tag
with
the
following
details
embossed,
on
that
equipment
a. Equipment
No
b. Safe
Working
Load
(SWL)
c. Test
done
on
d. Test
due
on
/
Frequency
6.4 Training
and
Communication
• At
the
beginning
of
each
financial
year,
each
Department
Senior
Manager
identifies
workmen
/
contract
workmen
who
can
be
authorized
to
operate
the
lifting
equipment
and
forwards
the
name
of
such
workmen
to
Senior
Manager
–
EHS
General Manager Sr. Vice President General Manager-EHS 10.03.2015
EHS Manufacturing
PREPARED BY APPROVED BY ISSUED BY ISSUE DATE
Document No:
INTEGRATED MANAGEMENT SYSTEM CEAT-IMP-EHS-GEN-03
PROCESS Revision No:00
• Senior
Manager
–
EHS
arranges
for
conduct
of
training
by
an
expert
faculty
or
by
the
OEM
vendor,
on
safe
operation
of
lifting
equipment.
• Manager
–
HR
arranges
for
maintenance
of
records
of
such
Training
Program
conducted.
• Senior
Manager
–
Production
&
Senior
Manager
–
Plant
Engineering
authorizes
workmen
/
contract
workmen
who
have
successfully
completed
their
training
program
to
operate
lifting
equipment.
• During
inspection,
competent
authority
identifies
lifting
equipment
not
complying
with
the
requirements
and
recommends
necessary
modifications
to
be
carried
out
for
compliance
to
the
same.
o If
part
of
the
lifting
equipment
is
deteriorated,
the
competent
authority
recommends
de-‐rating
of
the
lifting
equipment
or
places
usage
restrictions
in
terms
of
load
to
be
carried,
frequency
of
usage
or
maintenance.
• If
in
his
assessment,
competent
authority
finds
that
modifications
cannot
be
carried
out
to
meet
requirements,
he
accordingly
secures
and
segregates
such
Lifting
Equipment
and
arranges
for
display
of
the
notice
“NOT
IN
USE”
on
the
lifting
equipment.
• Competent
person
submits
his
report
of
assessment
to
the
Senior
Manager
–
EHS
with
necessary
modifications
carried
out.
• Senior
Manager
–
EHS
maintains
the
record
of
inspections
of
Hoist
/
Lift
in
Form
as
per
State
Factories
Rules.
• Manager
–
Plant
Engineering
maintains
the
record
of
inspections
of
lifting
machines
and
Lifting
Tackles
in
Form
as
per
State
Factories
Rules.
• The
competent
person
submits
service
report
of
the
maintenance
activity,
which
is
maintained
by
Plant
Engineering.
Breakdown
Maintenance
• Manager
/
Asst.
Manager
–
Production
inform
to
Plant
Engineering
about
the
breakdown
of
lifting
equipment.
• Manager
–
Plant
Engineering
arranges
for
breakdown
maintenance
after
taking
necessary
steps.
• Senior
Officer
–
Plant
Engineering
evaluates
the
seriousness
of
the
breakdown
and
if
he
finds
it
to
be
repairable
by
technicians,
accordingly
deputes
necessary
personnel
for
repair
of
the
same.
• In
case,
Senior
Officer
finds
the
breakdown
of
below
given
type,
he
informs
Manger
–
Plant
Engineering.
a. Brake
assembly
replacement
b. Rope
replacement
c. Hook
replacement
d. Pulley
replacement
e. Any
modification
which
can
increase
the
weight
of
cage
• Manager
–
Plant
Engineering
arranges
for
visit
of
the
competent
authority
as
mentioned
in
Table
1,
above,
to
carry
out
the
maintenance
job.
• Manager
–
Plant
Engineering
also
informs
Manager
-‐
Safety
about
the
breakdown
type
mentioned
above
in
point
3
and
the
steps
taken
to
rectify
the
same.
• Manager
–
Plant
Engineering
arranges
for
recertification
by
competent
authority
on
the
above
issues
before
reuse
of
the
Hoist
/Lift
and
maintains
records
of
the
same.
• Manager
–
Plant
Engineering
arranges
for
submission
of
Testing
and
Examination
Certificate
from
the
competent
authority
to
the
Lift
Inspector
and
Factories
Inspector,
in
case
of
breakdown
as
mentioned
in
point
3
above.
6.6 Disposal
• During
the
course
of
testing
and
inspection,
the
competent
authority
assesses
the
extent
and
of
repair
and
maintenance
as
follows:
a) If
the
entire
lifting
equipment
is
found
to
be
beyond
repair,
he
recommends
de-‐commissioning
of
the
lifting
equipment.
b) If
a
few
parts
of
the
lifting
equipment’s
are
to
be
replaced,
he
recommends
rectification
and
replacement
of
the
same
and
defacing
of
the
disposed
components.
• Sr.Manager-‐
engineering
accordingly
decides
upon
the
action
plan
and
arranges
for
disposal
of
the
lifting
equipment
components.
6.7
Hired
Cranes
and
other
heavy
lifting
machines
• Manager
–
Plant
Engineering
informs
Manager
–
Safety
about
the
entry
of
a
hired
crane
or
other
heavy
lifting
machine
in
to
the
plant
premises
for
purpose
of
execution
of
certain
projects
involving
lifting
of
heavy
equipment.
• Contractor
reports
at
the
Security
Gate
with
the
crane
or
other
heavy
lifting
machine.
• Security
Personnel
informs
Manager-‐Safety
about
the
same.
• Manager-‐
Safety
checks
the
following
documents
with
the
contractor
of
the
Cranes
/
other
heavy
lifting
machines
a) Testing
and
Examination
Certificate;
b) Load
Test
of
Hook;
c) PUC
Certificate;
d) Vehicle
Fitness
Certificate
of
RTO;
e) Drivers
License
for
‘
Heavy
Transport
Vehicle
–
Crane’
• Manager
–
Safety
checks
the
Testing
and
Examination
Certificate
as
issued
under
State
Factories
Rules
for
the
Crane
or
other
heavy
lifting
machine.
In
case
the
same
is
not
available,
Manager-‐Safety
does
not
permit
the
entry
of
the
Crane
or
other
heavy
lifting
machine
inside
the
plant
premises.
• In
case
the
Testing
and
Examination
Certificate
is
available,
Manager
–
Safety
permits
the
entry
of
crane
or
other
heavy
lifting
machine
inside
the
plant
premises.
• Security
Personnel
maintains
the
record
of
entry
of
Crane
or
other
heavy
lifting
machine
in
the
register
kept
at
gate.
• Senior
Manager
–
Plant
Engineering
and
Senior
Manager
of
the
concerned
department
follows
Lifting
Permit
before
use
of
crane
and
other
heavy
lifting
machine
within
the
plant
premises
as
per
the
Work
Permit
Procedure
of
CEAT.
• They
assess
appropriation
of
usage
of
hired
crane
/
heavy
lifting
machine
vis-‐à-‐vis
the
job
requirement
especially
related
to
operating
parameters
like
safe
working
load,
distance
of
travel,
elevation
and
the
like
7. List
of
Work
Instructions
• Safety
Precautions
for
Storage,
Use
and
Inspection
of
Lifting
Equipment
as
per
Annexure-‐I
8. List
of
Formats
&
Checklist
• Lifting
Permit
–
Format
No.
[SR][OH&S][0102014]
• Checklist
for
Hydra
/
Crane
Entry
and
Inspection
Record
9. List
of
Records
Title
Maintained
by
Retention
Period
Design
Specifications
of
Lifting
Equipment
by
Sr.
Manager
-‐
Engg
3
Years
Competent
Authority
List
of
Lifting
Equipment’s
and
their
Sr.
Manager
-‐
Engg
Ongoing
Locations
Testing
and
Examination
Certificates
of
Sr.
Manager
-‐
EHS
3
Years
Lifting
Equipment’s
List
of
Persons
trained
in
use
of
Lifting
Sr.
Manager
-‐
EHS
3
Years
Equipment.
General Manager Sr. Vice President General Manager-EHS 10.03.2015
EHS Manufacturing
PREPARED BY APPROVED BY ISSUED BY ISSUE DATE
Document No:
INTEGRATED MANAGEMENT SYSTEM CEAT-IMP-EHS-GEN-03
PROCESS Revision No:00
Annexure
–I
Safety
Precautions
for
Storage,
Use
and
Inspection
of
Lifting
Equipment
Monorail
Hoist
A.1. Inspection
of
Monorail
Hoist
• Condition
of
Rope
(Rope
condition,
Rope
lubrication,
Rope
drum,
Clamp
on
drum,
Rope
guide,
Rope
tightener)
• Condition
of
Gear
box
(For
noise
and
oil).
• Condition
of
Brake
hoisting
(Shoe
with
liner,
Actuating
assembly,
Coil,
Brake
drum,
Machined
bolts/
nuts,
Rubber
bushes)
• Condition
of
Limit
switches
(Upper
limit
switches,
Lower
limit
switches
for
their
operation)
• Condition
of
Bottom
hook
assembly
(Pulley,
center
pin,
center
pin
locking,
hook,
saddle
diameter,
throat
width,
swivel
of
hook,
Safety
Latch)
• Condition
of
Mono
rail
trolley
(Driving
and
driven
pinion,
Wheel
bearings,
Pinion,
Axle,
Gear
box)
• Condition
of
Cable
carrying
trolleys
(Wheels,
Wheel
bearing,
Frame,
Pulling
chain,
End
stopper)
• Condition
of
Pendant
push
button
station,
Stop
button
on
pendant
• Emergency
stop
button
in
hoist
well
• Interlocking
system
in
hoist
well
• Electrical
terminal
connection-‐
For
contact
and
relays
• Main
power
cable
• All
slings
or
cables
are
removed
from
the
hooks
of
the
hoist
when
not
in
use.
(Dangling
cables
or
hooks
hung
in
sling
rings
can
inadvertently
snag
other
objects
when
the
hoist
is
moving)
• Operators
do
not
use
limit
switches
to
stop
the
hoist
under
normal
operating
conditions.
(These
are
emergency
devices
and
are
not
to
be
used
as
operating
controls)
• Limit
switches
are
never
blocked,
adjusted
or
disconnected
in
order
to
go
higher
than
the
switch
will
allow.
• Upper
limit
switches
(and
lower
limit
switches,
when
provided)
are
tested
in
stopping
the
Monorail
Hoist
at
the
beginning
of
each
shift.
• The
switches
located
on
pendant,
used
for
operating
the
Monorail
Hoists
are
clearly
marked
for
Up
and
Down
movements.
• Pendant
is
so
designed
that
a
constant
push
on
the
control
button
is
needed
to
raise
or
lower
the
load.
• Minimum
of
two
turns
remain
on
the
drum
when
the
load
block
is
on
the
floor,
except
when
a
geared
lower
limit
switch
is
used.
• Railing
at
the
ground
floor
is
interlocked
with
the
vertical
movement
• While
lifting
the
load,
care
is
taken
that
the
load
line
is
in
line
with
the
swing
• Load
is
not
lifted
with
the
point
of
the
hook.
B. Chain
Pulley
Block
B.1. Inspection
of
Chain
Pulley
Block
• Condition
of
hand
chain
• Condition
of
load
chain
wheel
(Wearing,
elongation)
• Condition
of
friction
washers
(For
dryness,
clearance
between
friction
washer
and
pad
plate
is
minimum)
• Condition
of
guide
roller
• Condition
of
main
gear,
intermediate
gear
• Condition
of
pinion
shaft
• Condition
of
bearings
• Condition
of
hook
and
hook
assembly
• Condition
of
carbon
steel
bush
• Condition
of
brake
disc
wear
• Condition
of
spring
mechanism
and
ratchet
and
pawl
for
efficient
operation
• Load
test
B.2. Safety
Precautions
during
operation
of
Chain
Pulley
Block
• Chains
are
not
twisted
• Sling
loads
from
the
centre
of
the
hooks
• Load
lifted
is
not
beyond
the
marked
safe
working
load
• While
lifting
the
load,
care
is
taken
that
the
load
line
is
in
line
with
the
swing
• Load
is
not
to
be
lifted
with
the
point
of
the
hook
• No
over-‐lifting
or
over-‐lowering
is
done
• While
lifting,
swinging
of
the
load
is
avoided
C. Hoist
C.1. Inspection
of
Cage
Hoists
• Maximum
safe
working
load
is
clearly
marked
on
every
hoist
and
no
load
greater
than
that
is
carried
thereon.
• The
cage
of
every
hoist
or
lift
used
for
carrying
persons
is
fitted
with
a
gate
on
each
side
from
which
access
is
afforded
to
a
landing.
• Every
Gate
is
fitted
with
interlocking
device
to
secure
that
the
gate
cannot
be
opened
unless
that
cage
is
at
the
landing
and
that
the
cage
cannot
be
moved
unless
the
gate
is
closed.
D. Lifts
D.1. Inspection
of
Lifts
• Condition
of
end
clamping
• Condition
of
sheave
pulleys
• Condition
of
car
door
• Condition
of
guide
rails
shoe
• Condition
of
landing
doors
• Condition
of
lift
pit
• Condition
of
buffers
• Condition
of
counter
weight
(Number
of
ropes,
Over
speed
governor,
Guide
rails
fixing,
Enclosures)
• Condition
of
Brake
(Brake
assembly,
brake
drum,
brake
liner)
• Condition
of
gear
box
(Coupling,
oil
level,
noise)
• Condition
of
Machine
room
(Ventilation,
Weather
protection,
Guards,
House
keeping)
D.2. Safety
Precautions
for
Lifts
o Shorten
chains
by
tying
a
knot,
twisting
the
chain,
by
putting
a
bolt
through
two
links
or
by
means
of
a
cloth
or
rope
o Drag
chains
on
the
ground.
o Overload
chains
due
to
− Lifting
loads
above
Safe
Working
Load
− Load
getting
caught
in
some
fixture’
− Sudden
jerks
− Sudden
increase
in
hoisting
speed
− Sudden
decrease
in
lowering
speed
• Chains
is
hooked
on
a
stand
with
a
separate
location
for
each
size
of
chain.
Chain
is
never
kept
on
the
ground.
• Always
use
the
correct
pins
in
shackles
and
fasten
them
securely.
• Rings
and
shackles
must
ride
freely
on
the
crane
hook.
• Never
use
worn
out
and
damaged
shackles.
• Safe
use
of
slings
:
− Inspect
the
sling
before
taking
it
into
use
− Never
overload
a
sling
− Lift
sling
vertically
and
not
at
an
angle
− Avoid
spinning
of
load
− Do
not
pull
the
sling
from
under
the
load
− Use
suitable
padding
to
protect
from
sharp
edges
− Remove
slack
before
hoisting
− Use
guide
ropes
while
lifting
long
objects.
• Natural
fiber
ropes
loaded
to
over
50%
of
its
breaking
load
will
be
permanently
damaged.
Synthetic
fiber
ropes
loaded
to
over
65%
may
be
damaged.
Damage
of
fibers
due
to
this
cause
can
be
detected
by
scratching
the
fibers
with
the
fingernail
-‐fibers
of
poor
strength
will
readily
give
way.
• During
inspection
if
there
is
any
doubt
about
the
strength,
the
rope
is
discarded.
Discarded
ropes
is
cut
with
a
knife
at
various
places
to
prevent
its
accidental
use.
F.3. Description
of
Wire
Ropes
• Wire
ropes
are
composed
of
wires,
strands
and
core.
The
wires
are
drawn
to
a
predetermined
size
and
laid
together
in
various
arrangements
having
a
definite
pitch
or
lay
to
form
a
strand.
Then
the
required
number
of
strands
are
helically
laid
or
formed
around
the
core,
which
may
be
sisal
rope,
a
metallic
strand
or
independent
wire
rope
core.
• The
size,
number
and
arrangement
of
wires,
the
number
of
strands,
the
lay,
and
the
type
of
core
in
a
rope
are
determined
largely
by
the
service
for
which
the
rope
is
to
be
used.
• In
general,
greater
the
number
of
wires
in
a
strand
and
greater
the
number
of
strands,
the
more
the
flexibility
of
the
rope.
Wire
ropes
are
mainly
used
for
its
greater
strength
/
weight
ratio,
its
constant
strength
and
length
when
wet
or
dry,
and
its
greater
durability.
F.4. Safety
Precautions
during
Use
of
Wire
Ropes
• Lay
of
Wire
Ropes:
It
affects
its
flexibility
and
resistance
to
wear.
Wire
Ropes
With
Regular
Lay:
Wires
in
strand
laid
in
one
direction
and
strands
in
the
rope
laid
in
opposite
direction.
This
is
used
for
making
slings.
This
rope
has
good
resistance
to
kinking,
twisting
and
can
withstand
considerable
crushing
and
distortion.
• Safe
Working
Load
of
Wire
Ropes:
General Manager Sr. Vice President General Manager-EHS 10.03.2015
EHS Manufacturing
PREPARED BY APPROVED BY ISSUED BY ISSUE DATE
Document No:
INTEGRATED MANAGEMENT SYSTEM CEAT-IMP-EHS-GEN-03
PROCESS Revision No:00
Strength
of
Wire
Ropes:
Radius
of
bend
has
an
effect
on
the
"""
strength
of
wire
rope.
Refer
table
given
below:
Pulley
Dia
/
Rope
Dia
Strength
Efficiency
of
Wire
Rope
in
%
40
95
30
93
20
91
15
89
10
86
8
83
6
79
4
75
2
65
1
50
Repeated
bending
and
straightening
of
wire
rope
causes
fatigue.
• If
it
is
to
be
stored
for
long
periods
apply
a
fresh
coating
of
rope
dressing.
• Rewrap
the
rope
and
store
the
coil
off
the
ground
in
a
clean,
dry
and
covered
place.
• Examine
rope
periodically
and
apply
dressing
if
necessary.
Manual
Splicing:
• At
least
3
tucks
with
whole
strands
and,
.2
tucks
with
half
the
wires
cut
from
each
strand.
Splicing
is
served
with
spun
yarn
to
cover
the
sharp
ends
of
wires.
F.6. Bull
Dog
Grip:
Number
grips
to
be
used
for
temporary
splicing
are
as
follows:
0
1000
30
1035
60
1154
90
1414
120
2000
150
3864
F.7. Broken
Wires:
A
rope
may
have
to
continue
in
operation
with
broken
wires,
but
an
early
opportunity
is
taken
to
remove
the
wires.
The
broken
wire
is
bent,
backward
and
forward
with
the
fingers
until
it
breaks
leaving
the
end
tucked
inside.
F.8. Inspection
of
Wire
Ropes
• Excessive
corrosion
• Curls
&
Kinks
• Excessive
wear
• Breaking
of
large
number
of
wires
• Bird
caging
• Damaged
splice
• Rope
stretch
• Reduction
in
rope
diameter
Permissible
Broken
Wires:
Tit
Bits:
• Certain
sections
of
wire
rope
often
get
more
worn,
then
others.
• Rope
on
a
drum
with
two
or
more
layers
will
wear
at
the
point
where
the
rope
starts
each
successive
layer,
and
also
at
the
points
where
the
upper
layer
crosses
the
lower.
• Crane
rope
will
fatigue
at
an
equaliser
sheave.
• Hoist
rope
will
often
fail
from
vibration
fatigue
at
the
point
where
they
are
dead-‐
ended.
Because
of
these
wear
points,
it
is
good
practice
to
move
the
rope
at
regular
intervals
in
order
to
distribute
wear.
G. Hooks
G.1. Inspection
of
Hooks
• Wear
on
the
saddle
of
the
hook;
cracks,
severe
corrosion
and
twisting
of
the
hook
body
and
for
throat
opening.
• If
a
hook
is
overloaded
or
it
is
beginning
to
weaken,
the
throat
will
open.
A
hook
is
considered
unsafe
for
use
if
wear
or
distortion
exceeds
the
following
limits
o Wear-‐
10%
o Throat
opening-‐
15%
(over
the
original
throat
opening)
o Twist
along
the
vertical
axis-‐
10
degree
beyond
the
axis.