Lifting Equipments and Procedure

Compiled by Safety Trainees PECL

15 January 2011.

2. Factories Act-Section 28 (1):Hoists and Lifts

(a) In a factory hoists and lifts should be of : (i)-good mechanical construction - sound material - adequate strength
SWL to be distinguishly marked and greater than this be lifted or carried. no load
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Sec 29. LIFTING MACHINES, CHAINS, ROPES AND LIFTING TACKLES

The Factories Act, 1948 Sec:2(ca): Competent Person

Means: A person or an institution recognised as such by CIF for carrying out tests, examination and inspections required to be done in a factory under provisions of this Act regarding: (i) qualifications and experience of person and facilities available at his disposal; (ii) qualifications and experience of persons employed in such institution and facilities a/v therein, with regard to conduct of such tests, examinations and inspections, and more than one person or institution can be recognised as a competent person in relation to a factory.
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The Factories Act, 1948 Sec:2(j): Machinery

Includes prime movers, transmission machinery and other appliances whereby power is generated, transformed, transmitted or applied.

Lifting Equipments:
Hydras CRANES: limit switches Fork lifts Magnetic lift crane Mobile cranes: wheel ,crawler EOT Gantry Chain pully:spur gear,worm wheel Winch machine

Lifting tackle:
Slings Ropes Shackles Swivel Rings Couplers Sockets, Eyebolts. Frames & spreaders Plate lifting clamps

Overview
Terms & definitions Planning the lift The lift Landing the load Dos & Donts Case study Slinging methods Safe slinging practice
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Terms & Definitions

Competent person: A person who has acquired, through a combination of qualifications, training or experience, the knowledge and skill to perform the task required. Grommet: Endless wire rope sling. MBL: Minimum breaking load of the lifting tackle. SWL: Safe working load.
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Definitions
Tag line:
A rope of suitable strength, construction and length attached with an appropriate recognised bend or hitch to the load, used to control the load during lifting or positioning.

Test certificate:
A certificate issued by an authorized person
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SIMPLE CHAIN PULLEY BLOCK

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Planning the lift

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Planning the lift

Absence of planning leads to Short cuts, using unsafe procedure, equipment & It may cause An ACCIDENT OR DELAY

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Planning the lift

The following points must be considered during planning:
Where the load is to be picked up from Where the load is to be placed What areas to be passed over Any obstructions in the way How the load is to be slung How the slings are to be removed and access to them
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Planning the lift

For complex lifts, following points may have to be considered:
Special lifting accessories such as spreader beams to ensure that the load is safely lifted and without damage to the product (large machineries, generators, etc.) Special connectors to connect special built in connecting points. The operations may involve: Turning loads over or standing them upright Using more than one crane to lift a load.

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The lift
After slinging but before lifting, the following must be considered
Are the slings undamaged and properly attached to the load? Is the crane hoist rope vertical? Is the load free i.e not attached to any thing else? Are the legs of multi legged sling equally loaded? Are all spare all spare legs of the sling are hooked up to the master link on the lifting hook?
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The lift
After slinging but before lifting, the following must be considered

Are all personnel clear of the load? Is the landing site prepared to take the load? If required, is hand/tag lines attached to the load?

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Check Before Lifting

Now lift the load a short distance above the ground and check that:
The load is balanced and stable. The legs of the slings are at correct angles. Any packing pieces used, are in place and sound. The load itself is not stressed, especially when lifting packing cases, timber etc, which can fail under the loads applied due to lifting.

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Landing the load

Before landing the load check that:
The landing area will take the weight of the load. There is sufficient space for the load. There are strips of timber or similar on which to land the load such that the slings can be easily removed by hand.

The load should be landed gently to ensure that it is not damaged and that the crane does not receive any shock loading.
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Dos & Donts

Always Ensure that only authorized slingers/signalers attach or detach loads, or signal the crane operator. Discuss operations with the crane operator (special operations). Ensure that the capacity of the crane is sufficient. Seek expert advice when using eye bolts, plate clamp etc. Use tag line always Never Wrap tag line around hand or body. Leave a suspended load unattended. Pass loads over people. Ride or climb on suspended loads. Stand or walk beneath the loads. Use pipes to support for landing the load

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SWL OF SLINGS
SAFE WORKING LOAD OF SLING G = 10 TON at 90 INCLUDED ANGLE SAFE WORKING LOAD WITH ANGLE 10 TON 3.45 TON 6.80 TON 7.07 TON 12.25 TON 14.14 TON

90 160 140 120 60 0

P = G / Cos 45

SWL at angle =P X Cos /2

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SLING ANGLES AND SAFE WORKING LOADS

90 angle at hook corresponds to 45 sling angle

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SLING ANGLES AND SAFE WORKING LOADS

.

When L = S Sling angle is 60

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SLING ANGLES AND SAFE WORKING LOADS

Calculating SWL H is the vertical distance from the saddle of the hook to the top of the load. L is the distance measured along the sling from the saddle of the hook to the top of the load. The ratio H/L will be same as the ratio h/l
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SLING ANGLES AND SAFE WORKING LOADS

Determining capacity of 2-Leg Bridle Hitch SWL = SWL (of single vertical hitch) X H/L X2
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SLING ANGLES AND SAFE WORKING LOADS

When sling legs are not of equal length use smallest H/L ratio.

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SLING ANGLES AND SAFE WORKING LOADS

Determining capacity of 3-Leg Bridle Hitch SWL = SWL (of single vertical hitch) X H/L X 3 When sling legs are not of equal length use smallest H/L ratio.
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SLING ANGLES AND SAFE WORKING LOADS

Determining capacity of 4-Leg Bridle Hitch Load may be carried by only 3 legs while the fourth merely balances it. Therefore the recommended SWL is: SWL = SWL (of single vertical hitch) X H/L X 3 When sling legs are not of equal length use smallest H/L ratio.
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SLING ANGLES AND SAFE WORKING LOADS

Determining capacity of Single Basket Hitch For Vertical legs (fig A): SWL = SWL (of single vertical hitch) X 2
For inclined legs (fig B): SWL = SWL (of single vertical hitch) X H/L X 2
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SLING ANGLES AND SAFE WORKING LOADS Determining capacity of Double Basket Hitch with inclined angles SWL = SWL (of single vertical hitch) X H/L X 4

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SLING ANGLES AND SAFE WORKING LOADS Determining capacity of Double Wrap Basket Hitch Depending on the configuration, SWLs are the same for the Single Basket Hitch or the Double Basket Hitch.

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SLING ANGLES AND SAFE WORKING LOADS Sling angles less than 45 (formed by the choker) are not recommended. If they must be used the formula is: SWL = SWL (of single vertical hitch) X H/L X A/B X 2
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SLING ANGLES AND SAFE WORKING LOADS

Determining capacity of Double Wrap Choker Hitch

Depending on the configuration, SWLs are the same for the Single Choker Hitch or the Double Choker Hitch.
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Endless Sling choker Hitch Configuration

Endless or Grommet Sling in Vertical Hitch

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SLING ANGLES AND SAFE WORKING LOADS

Endless Sling in Double Basket Hitch Configuration

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Endless or Grommet Slings

Standard Eye-to Eye slings

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SLING ANGLES AND SAFE WORKING LOADS

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Effect of sling angle on Webbing

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Twisted Eye Slings

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What can happen, if, adequate safety is not observed?

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A case study 1
The incident:
In June 2003, a tragic incident occurred at one of the oil and gas development site in Algeria, resulting in one fatality and two injuries.
The incident occurred during the assembly of an onshore drilling rig. A large section of the rig was being lifted when a lifting chain failed.
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A case study 1
Actual measurement to hook position was 9.43 m. 7.5 m to centre of crane slew ring correct jib head/hook position

Probably out of alignment in this direction (this would transfer entire load to one sling)

Sketch of out-of-alignment load path during lift, resulting in lifting chain failure

Chain being pulled into angle would increase tendency to jam and prevent chain slipping round to equalize loading
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A case study 1
The causes, as established by an investing team:
Use of an underrated chain sling. Incorrect slinging and lifting techniques. The crane hook was positioned off-centre, resulting in the load path being out of alignment. Combined with a hinged load, this prevented the sling from equalizing on all chain legs when raised. Consequently, the entire load of 23.1 tonnes was placed on one chain leg that had a breaking load of 18.9 tonnes resulting in failure of chain
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Case Study 2
Job : erection of gantry crane beams Description of Accident:
Two beams of 11.5m X 1.5m X 0.75m weighing about 6 tones were lying on concrete sleepers. Out of two beams one beam was lying on sleeper in horizontal position. The other beam was in vertical position and was to be positioned to make alignment with the first beam.
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Case Study 2
Job : erection of gantry crane beams Description of Accident:
Slings were placed around the vertical beam. Mr. XYZ went up the beam to adjust the sling. He adjusted the sling and stood in between the two beams. In the meantime someone gave signal to lift the beam. Crane operator lifted the beam by about 4 mm up its position.
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Case Study 2
Job : erection of gantry crane beams Description of Accident:
During that operation beam swayed towards the first beam and Mr. XYZ was caught between the two beams. On hearing the scream, crane driver placed the beam back on its original position.

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Case Study 2
Job : erection of gantry crane beams Description of Accident:
Mr. XYZ got up and tried to get out of two beams but he stumbled and fell down on sleepers, got injury near left eyebrow. He was taken to hospital, but was declared as dead.

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Case Study 2

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Case Study 2 -

Investigation

1. No hand rope (tag line) was used to avoid swinging of the job. 2 Both the lifting rope used are having N no. of kinks on it., naturally these kinks will have tendency to swing the job. 3. No lifting hole or lugs were made to the beam to rotate it. 4. Crane operator does not know who gave him signal for lifting the job.

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Learning from the incidents

Apart from lifting machine, it is also necessary to take care of lifting tackles and lifting procedure

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Safe Slinging Practice

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Safe Slinging Practice

Crane hook must be on the CG

C.G.

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Safe Slinging Practice

This load is not stable. The hook is over the CG, but the CG is above the lifting hook. This load is top heavy, and could overturn while being lifted

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Safe Slinging Practice

This load is stable The hook is right over the CG.

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Safe Slinging Practice

Unstable

The hook is not over the centre of gravity

The load will shift until the CG is under the hook. This will make landing the load very difficult, and could cause major problems in crainage
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Safe Slinging Practice

500 Kg 500 Kg

1000 Kg 707 Kg 707 Kg

1000 Kg 1932 Kg 1932 Kg

90

90

45

45

30

30

15

15

1000 kg

1000 kg

1000 kg

1000 kg

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How to identify the correct angle?

At 45 degrees, H = L As the angle becomes less than 45 degrees, H will be less than L Therefore ensure that H is always = or > L
L 45 H

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Safe Slinging Practice

Balanced load
off centre 1/2 off centre 3/4 off centre Point loading

Can carry 100% of rated load

Can carry 88% of rated load

Can carry 80% of rated load

Can carry 70% of rated load

Can carry 40% of rated load

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Safety latches omitted

Safe Slinging Practice

Softeners, padding or use of blocking..

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Safe Slinging Practice

Tag line should be attached to the load swinging and to help it landing in the right place.
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Unsafe Slinging

Lift and lower the load smoothly, do not jerk

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Unsafe Slinging

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Unsafe Slinging

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Unsafe Slinging

Is it right method to extend a chain sling?

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Unsafe Slinging

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Sling storage

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Hand Signals
When should the crane operator follow hand signals?
A crane operator should always move loads according to the established code of signals, and use a signaler. Hand signals are preferred and commonly used.

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Hand Signals
Who can give the hand signals?
a person qualified to give crane signals to the operator, there should be only one designated signaler at a time, a crane operator should move loads only on signals from one signaler,

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Responsibility of the signaler

The signaler must:
be in clear view of the crane operator, have a clear view of the load and the equipment, keep persons outside the crane's operating area, never direct a load over a person.

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Standard Hand Signals For Controlling Overhead Cranes

With forearm vertical, forefinger pointing up, move hand in small horizontal circle

HOIST

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Standard Hand Signals For Controlling Overhead Cranes

With arm extended downward, forefinger pointing down, move hand in small horizontal circle. LOWER

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Standard Hand Signals For Controlling Overhead Cranes

Arm extended forward, hand open and slightly raised, make pushing motion in direction of travel.
BRIDGE TRAVEL

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Standard Hand Signals For Controlling Overhead Cranes

TROLLEY TRAVEL. Palm up, fingers closed, thumb pointing in direction of motion, jerk hand horizontally.
TROLLEY TRAVEL

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Standard Hand Signals For Controlling Overhead Cranes

Arm extended, palm down, hold position rigidly.
STOP

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Standard Hand Signals For Controlling Overhead Cranes

Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal. (Hoist Slowly shown as an example.)
MOVE SLOWLY
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Standard Hand Signals For Controlling Overhead Cranes

Crane operator spreads both hands apart palms up.

MAGNET DISCONNECTED

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Finally, we must remember.

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Objective Of Good Slinging

The sling and its method of use should
be suitable for the load.

The method of attachment of the sling

to the load and the sling to the lifting appliance should be secure.

No

part of the sling should be overloaded either by the weight of the load or by the method of slinging.
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Objective Of Good Slinging

The slinging method should ensure
that the load is secure and that the load will not fall from the sling.

The load should be balanced and stable

and should not violently change its attitude when lifted.

The load must not be damaged by, or

cause damage to, the sling.
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If we remember & achieve this Objective..

The probability of accident will be minimum

Sling storage

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