SAFETY ALERT / 04
Hoist limit switch stopper of
Crawler crane (P&H) fell down
Incident Details:
Date of Incident: 24.01.2019
Time of Incident: 00.50 Hrs
Location of the incident: SRU (PR-04-63)
While jerking the crane boom for concreting
purpose the limit switch stopper fell down on
ground from 14 meter height which was having
weight of 3.6 KG.
Root Cause:
 By-passing or not adhering to Manufacturer’s
prescribed Preventive/ Periodical Servicing
Schedule
 Inadequate periodic maintenance and lapses in
daily inspection by crane operator/ Supervisor.
 Retaining bolt and nut assembly of anti-two
block were not periodically inspected for correct
tightness and security. Thus over a period of
time got loosened which was not noticed due to
absence of rigid daily inspection
Probable cause:
 The operator may have done boom jerking with
overload.
 Nut and bolt system used to secure stopper
block around the wire rope of crane got slacken
while jerking.
 Wear and tear of the chain link due to friction
with the hoist cable.
 Inadequate periodical maintenance of
equipment.
 Inadequacy or lapses in daily inspection by
equipment operator.
Recommendations:
 Any kind of bypassing of manufacturer’s manual/
instructions should be strictly prohibited.
 Daily visual inspection of whole equipment shall
be carried out before operating the equipment
and should be recorded.
 Defective items / devices should be replaced
immediately.
 Overhead moving parts of crane retained by bolt
& nut shall be retained using self-locking nuts/
check nuts/ split pins.
 Periodical maintenance shall be carried out
without fail.
 Joint inspection shall be carried out fortnightly by
P&M Coordinator, equipment operator and HSE
personnel and should be duly recorded. The
inspection shall include but not limited to
checking of the following accessories like swing
alarm, reverse horn, load chart, SLI visual &
audible alarms, limit switch functioning, anti-two
block condition.
 Unauthorized replacement of equipment parts or
replacement with spurious parts should be
strictly prohibited.
Broken Pieces of
Limit switch stopper
February 2019
 SAFETY ALERT / 04

CORRECTIVE ACTION TAKEN:

1- Joint inspection of all cranes has been carried out for all heavy equipment. The team comprises HSE Advisors,
HSE officers, P&M Engineers and operators.

2- The chain used to hang anti- two block of crane hoist limit switch indicator has been replaced in all cranes by two
wire rope cables.

Before After

February 2019