,r{/'

.)' ,/

,' Check first the condition of groove tri ascertain The

groove gauges are used to check loose or tight the
wlre-rope movement on the.Sheeve or Drum.

STORAGE WIRE ROPE SUPPLY METHOD

"I? i-l

e Logrcal precautions to be explained

WIRB ROPE REPLACBMENT CHECK-LIST

Sr. Type of Defect Limit for Review and Replacement

No.
1 Reduction of wire-rope Reduction more than 0"4 mm - upto 8 mm O wire-ropes
diameter due to corrosion Reduction more than 0.8 mm - upto i3 mm @ wire-ropes
or worn out wires. Reduction more than 1.2 mm - upto 19 mm (D wire-ropes
2 Broken outside wires Twelve randomly distributed broken wires in one rope
lay or Four brokg:r wires in one strand in one rope lay.
a
Wom outside wires Wear of one-third of the original diameter of outside
individual wires.
4. Corroded bent or broken Any of these conditions indicates need for replacement.
wires at end connections
5. Severe kinking crushing When such kinking etc. results in distortion of rope
cutting or unstrandine stnrcture

* Any heat damage or wild-splatter on rope are sufficient reasons for questioning safety and
considering the replacement.
r i-.."-
L- -_

ritGGiNG AN$ I{ANCIr,}NC IN FI-ANT oPER.ATroNs

(Lecttrre notes prepaned by Ajit V.pawardhan)

I. WIIAT IS RTGGING AND HANDLING IN PI,ANT AND

MAINTENANCE

How it is different from handling of marerials of various types. It is basically

safe
hqdftns of co]nPgnenl utilised in process plant ,such us R"fir.ry and *f*J
activities, by proper selection and utilisation of material handling
iT*Tce
equrprnent.

) NO HANDLING IS BEST HANDLING

Upto 15% of the cost of components could be due handling transporting,

shifting
and locating in final position. It does not add anything
to value tt o"sh it is inevitable
to handle the material. From business angle time spent and cost incurred
are
important and henc the need for proper attenticin and economy.
Delay in handling is
loss of skilled labour waiting for it.

3. MANY OBJECTIVES OF TMPROVED MATERIAL T{AI{DLING:

+ Reduce time and cost of handli.,g.

r Economise in storage space and warehouse
o Save other labour time by cutting waiting
r Eliminate'danage to material and other assets
+ knprove working condition by reducing labourious work
+ Facilitate use of material and speed up delivery of material to client or processing
plant.

I' AS PER 'ASME' - Material Handling is an art and science involving,

moving packing and storing of substance in any @nvenient form.
U' Another Def. - Material Handling is a preparation placing and positioning
of
materiai to facilitate movement or storage.

o
 IIOW 'TO DIAGNOSIS IIANDI-INC PtrTOBt,E,M [N STORA(;I.,, ['SF.], NNI)
IIOTJSE KT'EPING OF' MAT'E,RIAL
, .-1 -_ -

n 'l"ake an on lookcr "s point ol' view and look around . ]'hird pafly approach draws out
obvious flaws.

. Is your storage area looking shabby or dumped-up. What is not looking good is not
stacked well?

. Is material waiting too long in your area or moved fwice or more in same space?

. Is the material stored kept in classified form and can be identified quickly? (alongwith
weight)

. Is the material kept in package / sub-package unit suitable for firther transportation?

Is the volume over the floor area utilised i.e. ceiling height is exploited for storing?

G fu'e the items requiring frequent handting nearer to exit gates.

' e Is the laying of material in Racks Bins or in Stacking free from Safety Hazard.

. Is there stage handling before final delivery?

' . Is handling doing any damage to Article ?

o Are there any accidents during Handling?

. In case of packed goods, are handling in structions clear

c
 .Di;,r-,r, r:,i' ri11i,'l r; ia Cein:nicn Vlirc Iirrpe Ahirrct.

Ahuse Posslhlo Caurcr

Pefigrrs Wire breakis Chsck for rope bent around too small a radius;
{rrnsvsrse=either straight vibration or whipping;,wobbly iheaves;:rolleis too
across or Z shapo. small, reverso bonds; bent shafts; tight grooves;
Broksn snds will appsar. torrosion, small drums and sheavos; incorrect rope
8ralrry" construction; impropor installation, poor end
attachments. All running rope, if Ieft in service
long enou$1 will svmtualty fail by frtieue.
Tension Wire break reveals Check for overloads; sticky, grabby clutches; jerky
predominantly cup and conditions; loose bearing on drum; fast starts, fast
.cotre fractures with stops; broken sheaves flange; wrong rope size &
some 45 o shear bre*s. grade; poor end aftachmeuts. Check for too groat a
strain on rope after factors of deterioration have
weakened iL
Abrasion Wire b&ts#fraintt Check for change in rope or sheavs size; change in
displays outer wires load; overburden change; frozen or sfuck sheaves,
worn smooth to knifs soft rollers, sheaves, or drums; excessive fleet
edge thinness. Wire angle; misaligument of sheaves; kinks; improperly
broken by ebrasion in aftached fittings; g1t & sand; objects imbedded in
combination with rope; irnpropa grooving
another factor will show
a combindion break
Cut, Wire ends are pinched Check on all the above conditions for mechanical
gouged, or down, mrshed, and/or abuse, or either abnormal or accidental forces
roEhwire cut itr s rough diagonal drrnng installation.
sher-like matrte{.
Torsion or Wire ends show Check on all the above conditions for mechanical
firistitrg evidence of twist and/or abuse, or either abnormal or accidental forces
cork-screvY decl durieg installation
Muhing 'Wires are flattened and Check on all the above coaditions
for mechanical
spread at broken ends. abuse, or either abnormal or rccidental forces
&rine installalioa
Corrosion Wire surfacos are pitted Indicates Irrproper tubrication or storage.
with break showing
evidence eithsr of
fatigue, tensian or
abrasion
Abrasion Reduced cross section is A long term condition nonnal to the operatiog
phrs fatigue broken off squa.re process.
thereby producing &

chisd shpe.
Abrasion Reduced cross section is A long term condition normal to the operating
phts tarsion necked down as in a cup process.
and cone coafiguration.
'ferisiie break produces
a chisd shrye
n

r'r)
!";t:-t

WHAT' ES MA'FEREAL HANSI,ENG

&tHE@$ r+ty$Sry-4r,,.combfnaqrq! ql' llq$g.ds, fa.c:=ltrielr,,,tqrb-.qq.. and.equipment.,,

lor moving packaging and storing of matcrizrls to niect specific oblcctives"

Material Handling and Productivitv Ratios.

:, :;:
. t-

Manufacturing Actual Production Man/Machine Time

voptt@gy ,Total time spent by ManAr4achine in Production/operation
,,
r,
Material Handline . Personnel assigned to material handline
Lahour Ratio Total personnel in Production/Operation

Storage Space Storage Space occupies

Utilisation Ratio Total available storage space

Aisle Space . Space Occupiedrbv Aisles

feree!ilndisatra! Total space available

Material Handline Accidents due to Material Ilandling

Salery Ratio Total Number of Industnal Accident

-1

SOLVING MATERTAL HANDLING PROBLEM

i IDENTIFY AND DEFINE THE PROBLEM

:
iI COLLECT AND ANALYSE THEDATA
!

III. EVALUATE ALTERNATIVE SCLUTIONS

IV. SELECT THE PREFERRED APPROACH

V DEVELOP AND IMPLEMENT T+IE PLAN

 T:;.l;i e 1-L2: (Cont'd)
Abuse Symptome Possible Causes
Abrasion Reduced cross section is A long term,".g"gndition normal to
4!uef1dgg11 ;;$-g!gu4{5a.!Ele;thsre_by_..,,: thqepetati-nHuls_Ceis.-. :_,....._ : _.-_ :

pToducinf cfii-ui sh"p".

"
Abrasion...-. Reduced cross section is A long term condition normal to
plus tensi6-n ., necked down as in a cup the operatingprocess.,
: l':!r .
and cone configuration.
Tensile break produces a
chisel shape. :

A THIS FOPE WAS DAMAGED BY BEING FIOLLED ' llir"1 r' '
OVER SOME SHARP OBJECT. p HERE THE STRAND WIRES WERE SNAGGED

B THIS EFFECTOFDRUMCRUSHING IS EVIDENCE

OF BAD WINDING CONDITIONS

H A) SERIOUS WEAR RESULTING FROM

EXCESSTVE BEND|NG, AND B) LOCALTZED WEAR
BROUGHT ABOUT BY POOR CUT-OFF PRACTICE,

C AN OCCURRENCE THAT IS CALLED A POPPED

CORE. I THIS IS AN ILLUSTRATION OF A SERIOUS
CONDITION WHERE THE ROPE SLIDES OVER OR
AGAINST ITSELF.

J AN ILLUSTRATION OF VALLEY TYPE FATIGUE

D THIS IS A TYPICAL BIBD CAGE CONDITION BHEAKS. FLEXING THE ROPE EXPOSES BROKEN
WIRES HIDDEN IN VALLEYS BETWEEN STRANDS.

I HtS tS THE AppEAftANCE OF A TyptCAL

_ -_
tr IENSION K THESE DAMAGES WEFIE TIIE NESUL-T OF BAD
BN.ENK. A RESULT OF OVERLOADING
DRUM WINDING
I,'ig":l-52: Iixomples of ruire rope abuse.
66

o
 " carrier selected degelds
' need f or moveritent, upgn the.site ground
-;gri_"1!e5_, - rn conditj-ons and
b:-ayS"l.
-:=-. D,"'9}9n ,,- limi!_atjerl&: _of
?!d ,9-g44t=,Erl1j=Ei"+r*pr;l=1o" *L.r=*unf:of-,.c-ranes
'- 'wlth--16.d whiEE-:iG* nornair,
around chosen fixed positlo". '".a permitted except rotation

l;ii:: '!Jfi";ffi*T"
convent j-onal
:1;.=i;H:,li::.
-or
on rheir boom
3"",s:
"ti".tural
adding o'reducing gvp-J."
boom pilJ"i" ;,
boom
""n'ni. :ii3l:" ;;
stopping the workr r" J*=e--o? ^rrvarauric reassembly while
.";;+.r.y-'aro",
achieved by retracliri-""or"' . the same
_ is.
'
hydraulically- when rreivy -ana .*t.-rroi-rrg-
'.high a;; boom length
conventional boom is."i.i"UfJ ri?t" are involvea the
lighter and more set-ups -;;;-;"quired But when the load is
]ifts, the hydrauli" noo* i" *or. for shorter and quick
be operationJt on reaching the suitable . f t can almost
site
Mobile cranee assembly and safety preeautions
A conventional type of Mobile
a disassembled iiate. crane arri_ves at job_site in
necessary before setting certain precauti-onary measures are
for operation.
"p-Jt "-'crane
' 3-ti.;J?;tt"fff- must be checked to make sure
that rhey
' Boom sections must
due to transport and be checked for damages gr di-storsi_on
handling.
'' when boom .
is assembled, it must not be
machine is leveled to avoid raised until the
o The ground should be tippirrg
firm
-;;;ri"ilrJ
and i,eveled and larqe timber
shourd b" ro or
::ff:.*xr." supplemenr the ground
o The correct seguence
of boom a_ssembly procdd.ure and
::*ffi"Ht#ffio"" need to ne rorrowed'ro,
^
sarisracrory
e
:ffi"ffiT:":;:rri5i".n"ro" or Handbook includins road charts
I ' Proper understandi"g
-:nd_
Jno ,i.nterpretation of l0ad_charts is
erri"le,,?
::;";:Hr,i;;;:r" ,,"e or nto* heishr, ansle
 Electrical Hazards

L;l-ecErocucl-ons are
Electrocutions among ,most frequently repeated.
and dangerous adcidentS ir
TIIE. .I,ARGEET SINGLE CAUEE OF
FATAI,II IEg .4SSOCIATED
_
WIIH::CETNES .
:: .r -"i ::"
' .,,:: lt'

f deal solutj-on can' be..:to. ilput off the po$er supply but
lrhen not feasible keep,.,ths1crane as far from line's a5
possible . ' '' '.':1i ',,
Lavs govern the movement of Cranes near powerlines
unless deenergised and uisibl-y grounded at point of
vork

Minimum distance should be 10' for linos upto 50 IflI and

addj-tional 0.4" j-nches per Ifif ove-r 50 lff.

In transit rsith no l-oad and boom lorrrered the clearance

shall be a ruinimum of d r .
A separate signal persin to be emplolre{ to rrarn against
approaching the lirnits. -

t The operator must pay attention to signal-person.

a other personnel to keep away from contacting the .l-oad.

Treat aII lines and r,rj-res as 'hot', until you have

reliable information about the condition
Errect guide-poles or post for guiding Cranes repeatedly
going under the overhead line

f-)
\J
 c The counter weight addition,/reduction or rotation needs to
be done carefully to avoid tipping due to absence of boom
- ----plEees or due t-o-:Iack of out-rigger stretched sett:,ng
e The failure of Mobile Cranes at sites can cause vast
damages, mainly due to human errors related to above
mentioned points-

! -,
..:: r

TCfi{ER CRAT{ES

T-ower crane is,;;:q,-{;common .sight at many gongtruction sj-tes _

The Tower Cranes i are useful for situations. which require
-hiqh:ri;;
operations in congested area rike construcii-""-."i
buildinq's in Metro-cities, where tal1 building are already
existing in the narrow lanes of cities which prohibits use
of any other types of crane. rn addition to this Tower
cranes make it possi-ble to rift moderately heavy l_oads to
great heights while providing an extremery deep reach, they
are very economj-cal when a large amount of lifts over a long
period of time is reguired.
These are number of types of tower Cranes used around the
worl-d wi-th ease because of common design and sharing of
components at various wqrk-sites. Tower cranes wirl be
either fixed type or slewing (rotating) Lower type. The
complete tower unit, in some cases can travel afonq'tracks-
The tower cranes are al-so classifled according to Jib
construction and wo:iking or the type of Tower structure
detai-Is (for e - g. telescopic type ) -
:

Tower Cranes are al-so characterised according tc their

mounting configuration. They are availabre as rail- *orrrteJ
uni-ts, stati_onary unj-ts, climbing units and mobile units
(either truck or crawler mounteci) .
Tower Cranes over a period of tjme have evolved intc a wrde
varrety of lifting devices for e.g. pirlar cranes, postal
Cranes and Hammer heacl
 :iw
'::".ffi
roi*r

' -.,:,. --:-

. Load ratings for aII Cranes are on stationary and tevel application
uith outriggers. There a-re no ratings for pick,#n-a..-'.
carry
operatl-ons. .. ..1

,,. . l .- : -. ,
: .::

r gith load travel procedure should be as per Manufacturer's

instirrctions .ttl the_ ,lo"ag--:d boom shguld aluays be carried
. ',. .,
in U-ne

'4, The swing brake and suing lock shou-Id be set'

a The max load during such travels should neve.r exceed rating given
for over the side on rubber and extreme cauti-on should be exercised
if. load exceeds 503 of rated capacity.
Crane operator should be arrailable in the Cab apart from regular
Vehicle Driver.
Travel speed should be as lon as possible and sudden startlstops
should be avoided

Tag or restrain lines should be provided to control the swinging of

roio if necessary.

.' use the shortest boom length setting and at lowest possible angle to
avoid toppling.
If trarreling with outrigger beam, check the side obstructions- Also
avoid traveling on uneven unstable or uncompacted ground.

o
- ..'. ..,,/

TACKLES
CARE OF PULLEY BLOCKS AND

; Main ieaSonS

. Overloading

. Undue Friction

. Angle of Pull

. Condition of roPe

. Sudden aPPlication of load

o Lack of lubrication.

TNSPECTION FOR DEFECTS

+Checkfor#EXCEsslVEwearonmovingpartssuchaSgrooves,pins,bearings
and end connections'

+ Check the smoothness sheavs groov:

or bent links, eyes' shackles or

+ Look for signs of overloading such as elongated
center Pins.

t Make sure that all cable-keeper are in place'

c Check the clearance between sheaves and check

fl
the gartitio3-ates' it shtiuld be
so that there is no danger of the rope
slipping betrveen the gaps'
small
"nough