MAINTENANCE OF CARGO GEAR and _THE BOCK WORKERS REGULATIONS. The Dock Workers (Safety, Health and Welfare) Regulations, 1990 have been formulated pursuant to the Dock Workers (Safety, Health and Welfare) Act, 1986 to safeguard the lives and interests of dockworkers. It applies to all major ports in India, 3 The Act provides for thé appoihtment of a Chief Inspector and other inspectors: who. will exercise the PoWers conferted under them under the Act and the Regulations, to ensure that the provisions ‘of ‘the Act and the Regulations ‘are being complied with in the ports under their jurisdiction. Definitions Authorised person means a person authorised by the employer. master of the ship or a responsible person to undertake a specific task or tasks and who Possesses the necessary technical knowledge and experience to tindertake thartask..:. Competent person means a ‘person belonging to a testing - establishment which’ is: approved by : the: Chief Inspector. for the purpose. of” testing. ~~ €Xamination, afinealing and certification of lifting appliances, loose géar and ~— wire rope and includes persons recognised.under similar regulations abroad. Responsible person means a person appoitited by the employer, master of the' ship, ‘the owner of the géar or Port authority, as the case.may be.ta be “responsible for the performance of a Specific duty’ or duties’ and who. has sufficient knowledge and experience and: the’ requisite authority for the Proper performance of his duties. : Beis Lifting appliance means all stationary or mobile cargo handling appliances Such: as cranes, derricks, Power operated famps, etc including their Permafient attachments and machinery-uséd onboard or ashore ‘for raising, lowering, or moving cargo from one position to another while suspended or ‘Supported. ° 204 > mi a5 ADAIR COL ax ~ - Oro RoRORaRO™ oro moan tl COTO FO" Am &Loose gear includes hook, shackle, swivel, chain, sling, lifting beam, Powers of the Taspector € : © An inspector may, for any port he is appointed, OC i, ° Enter, With or without assistance, any ship, ddck, warehouse or other’ premises Where dock work is being carried out or where he has reason to believe that dock work is being carried out; ii,. Examine the ship, dock, warehouse, lifting ‘appliance, loose gear, lifting, device, staging, transport equipment, or other premises, or equipment used or to be used for dock work; iii. Require. any register, muster roll or other document relating to the employment of dock workers to be produced and’ examine such document; “Take on the spot or otherwise evidence of any person as he may deem necessary’; ‘Take copies of regi records « or other documents or “portions. of them which he may consider are. relevant to the inquiry of any offence which he has.reason to believe has been committed; ore | | PBDI RR PRIA z Take photographs, sketches, samples or. weigh, méastire or record iything he considers necessary for the ‘purpose of examination or_ inquiry; vic vii. Hold. an inquiry into. the cause of any accident or dangerous - occurrence which he has reason to believe was the result of failure of any lifting appliance, loose gear, transport equipment, staging or non- ‘compliance of any provision of the regulations; viii... Direct the port authority or other employers of the dock workers to get them medically examined if necessary; Oo OV Ar ot OY IR ' Provided no person shall be compelled to answer any question or give evidence tending to incriminate himself, 205I ix. Issue show cause notices in respect of any safety, health or welfare Provisions arising under the regulations: £ x7 Pray . : arising under e After every visit, the Inspector shall issue’an improvement: or prohibition s notice to the owner, master, officer-in-charge ‘or agents of the ship. port c authority, owner of lifting appliance or other. gear or employer of the dock ¢ workers pointing out the non-compliance of the Act or regulations, if any. in 9 the form 'specified. ce : 7 : .€ Where. conditions are dangerous to the life, safety or health of the dock workers, dock work may be ‘prohibited until the defects Specified in the prohibition’ notice have been Specified and the Inspector has withdrawn the , Prohibition order. A person responsible for breach of the regulations shall be guilty of an offence and is punishable with imprisonment for upto six months or a fine of Rs.5,000/- or both: B . momonone RoR Tests atid examination‘of Cargo Gear aC ——A record_of thé_particulars ination-of tifting “appliances. ___© loose gear and heat treatment shall béentered and maintained in the Register 1: O ry, Chains, etd-and Wite Ropes (Form II). "Certificates. im the C form specified, shall be ‘obtained from a competent person in respect of the e following and attached to the Register. “.O _ oH Initiat and periodical test and examination of winches, detrickit and their accessory gear - Form III 2. Initial and periodical test ahd examination ‘of cranes or hgists and their ‘accessory gear -FormiV.. 3. Test, examination and fe-examination of: loose gears Form V. c 4. Test and-examination of wire:ropes — Form VI cq, 2065. Heat treatment and examination of loose gears - Form VII 6. Auisial thorough cxuinination of jose gears — Form Vili! The register and certificates shall be kept on board the ship and produced on demand to:an Inspector. They shall be retained for at least five years after the date of the last entry; 7 ‘The register (Form Il) contains the following parts':- Part I = Initial and Periodical load test of lifting appliances and their annual thorough éxaminations : : : Part II-- h itial and periodical load-test of loose gears and-annual thorough » examinations a Part III ~ Annealing of Chains, Rings. Hooks, Shackles and Swivels (other than those exempted) No lifting appliance or loose gear, shall be used for dock work unless the entries required to be made in the register and the’ certificates of test and examination ‘required to be attached are done. _ ‘Procedure for testing derricks and cranes Before, testing derricks or cranes, especially heavy lifts, the competent person must ascertain that the stability of the ship is adequate. A derrick shall be tested with. its boom atthe minimurh angle to the” horizontal for which it is designed (generally 15°) or at.such greater angle as imay be agreed to. This angle shall be mentioned in the test certificate. ‘The test load shall be applied by movable weights. During. the test, the boom. shall be swung, with the test load suspended:as, far as practicable in both directions (P & S). A derrick boom designed to be'raised under power with the load suspended (swinging derrick) shall ‘be raised to its maximum working angle to the * unless required ps rs have been entered in the register in Form 1 207horizontal with the load. suspended and swung to the two outermost positions in addition to the test mentioned above. For derticks used in the Union Purehase system, the SWL in union purchase tig must-be specified by a competent person in Form II and marked on the derrick. boom.’ The two ginfalls. must be coupled together by’ a suitable swivel assembly and the derricks tested at.their approved working positions with a test-load appropriate to the SWL in union purchase, Cranés shall be tested similarly to swinging derricks with movable weights at maximum, minimum-and intermediate radius points as well as such points in the arc of rotation as the competent Person may decide. The test shall consist of hoisting, lowering, braking and swinging through all positions arid operations normally performed. -All limit switches and cut-off will be tested. Additionally, the ‘machinery shall be tested by operating it at maximum - working speed with the SWL suspended. All tests especially for ‘new ships shall be carried ‘out by deadweights, |” Spring or hydraulic balances may only be used for periodical tests. Replacements or renewals.’ In such cases, the balance must be certified mr accuracy to within 2%, by the competent authority, ‘The test lood ie v> be applied with the boom out as far as Practicable in both directions and. the Pointer of the balance ieast 5 minutes. After being tested, every lifting appliance and loose Sear shall be thoroughly xamined to see that no part has been damaged or permanently deformed during the test. a * Maintenance of Cargo Gear “Care and Maintenance of. topes and wires ila, ‘sisal, hemp, coir and cotton, Of these manila ropes are most widely used on board. Synthetic fibres consist of polypropylene, polyester and nylon. : Ropes should be stowed in dry, well-ventilated compartments, They should not be stowed together with paints or chemicals. 208 must remain constant at the test load-for a Period.of at __ eee eae rOcore Je PO MO ROMO ROTON fomtaatas Som CHRopes should not be stowed on. deck or exposed to rain; sun or heat. They should be stowed on gratings so that water may drain and ventilation can take place. They should be dried before stowing. Ropes should be examined externally for wear and tear and damage which will be: evident from:the hairy surface, fusion of compiession of strands, broken strands, etc. They should be examined internally by opening up the strands and viewing the core for. powderiig (in synthetic ropes) or mushiness (in natural. fibres). The deterioration of the ciré results from inadequate drying and ventilation. « Should these signs be present intéranlly of externally, the rope-should not be used. : Eye splices. should have at least four-tucks and the. diameter of the ‘spice should be tapered by halving and quartéring the strands. A smooth taper prevents the ropes from getting snagged in fairleads and other obstructions. c } . © ‘ The eye and other parts which are susceptible to abrasion (such as the parts © which pass over the fairlead lip, around rollers, etc) must be Protected. by a. )--—__..._.-Ganvas'sheathis Se & 7 ¢ + Ropes should be joined to a wire by means of a Tonnesburg shckle or Bordeaux connection. é ) Ropes and wires. should be wound on separate drums. 5 erate : c Ropes or wires which pass around a lead should not be excessively strained 2 as this could damage it. © a : Q Syntheti¢ ropes should not be surged’on drums as the friction generates heat t which could damage the rope. ) : ‘ 2 ‘New coils should be unwound by rotating the coil as the end is drawn: i Care ‘and Maintenance of blocks 209and swi i. Blocks should..be handled wi ith care and not thrown on deck or mishandled They should be Yegiilarly greased through the grease nipples provided. + Only the outer cheeks may be painted. The remaining parts should be oiled as paint hides defects and blocks the &rease nipples. iv. Each block, must be opened up for thorough examination at least-once a year. 7 v. The block ‘is oj locking nut. Peo : at vi The axle. pin’ is removed and. the ‘inner “sheaves separated. from: the housing. A visual examination is to. be carried out ofall the ‘parts for cracks ‘and déformation especially. the. sheaves and axle. pin Which bear the load, oe a fart vii.Dents in’the side cheeks should be Straightened out so that the wire'does ~ hot get stuck in the gap between the cheeks and the sheave. The -weardown.of the bush bearing: or of the-axle pin must not’ be excessive, - ix. The groove of the shi down, » x. The swivel must be free to rotate » xi, After greasing; Pened by removing the split pin and unscrewing the eave should not be unevenly or excessively wom the parts. may be assembled and put together: The shéav: Maintenance of Hatches and Hatch covers. The watertighiness. of hatch avoid large ‘cargo claims. - Teasons ‘ es : fa covers is Imperative to Protect ‘the cargo and Hatch. covers leak dué to one of the following &._ Improper closure arid battening dowh of hatches . % Poor condition of structure, rubber % Loss of watertightness' durin; which may be caused during packing and closirig devices 1g. due to torsional stresses or racking stresses Tough weather or improper loading It often is the case with haicl hes arid holds that the maintenance carried. qui is generally that which is immediately required for the voyage or. , : carried out on parts or areas that are easily accessible or easily, a ‘210 RAIA AD RD ROROTOFO oO Omomosmonoro™ | AR At Ay Oo OOo’ O. Ot ot oO! aos o. OKDEO MARAT A mn Difficult to maintain, inaccessible and unimportant areas are often neglected ots their d: A planned maintenance system will take care of each and every tiny part of the hatch cover system giving it the attention it requires at suitable intervals. A sufficient amount of spares must be maintained on board. Rust_removal from steelwork : The top and’ sides of the hatch covers, coamings and stays must be thoroughly checked for signs of corrosion and reduction in plate: thickness: Chipping and ‘painting is recommended in a planned manner so that all areas are ‘given adequate attention. Areas particularly liable-to corrosion include welded seams on the hatch top. edges of pontoons, drain: channets, circuinference of: lightening holes in stays. edges of flanges. or brackets, shadow areas such as behind eccentric wheels where chipping devices: cannot reach, underside of the trackway, retaining channels for rubber packing, etc. Cleaning : Efficient cleaning of the holds. will prolong the economic lifé of the ship, rétard corrosion and assist in passing hold inspections. A rinse with fresh water: after hosing down quickens drying and retards corrosion. Particular attention must be paid to the underside of covers where a waterjet “does riot reach with adequate pressure and where Cargo residues get lodged ~ in beams and stiffeners leading to contamination of the next cargo when hatch covers are-opened.or closed. Dirt and cargo residues on the trackway and rubber packing will prevent watertightness. Other areas such as bilges must be kept clean and deodorised. Testing : Testing of the hatch covers for weathertightness is mandatory prior every Voyage and also the pumping out of the bilges. These facts must-be entered into the deck log book. Weathertightness' may be’ ascertained by” means of a chalk test or hosé test of both. Damage: A ‘careful watch must be imaintained for damage to hatches and hatch covers and: the stevedores immediately notified. A damage report must be prepared and signature of the foreman obtained and the damage Yepaired: at the: earliest. -Coamings, ladders,-ventilators are areas most susceptible to damage. Grab damage may occur -at the tanktop while bulldozers can damage: the shipsides and hoppers, Bilge covers often get Picked up during bulk discharge. 2ulCompression bars : Compression bars must be of an even height, with a rounded profile and no sharp edgés due to corrosion as this could damage the rubber packing. If uneven, they ‘must be ground-cr built. up by welding Rubber backing : The rubber packing all around the hatch covers and across _ tach panel should be in.a g00d condition, elastic and’not hardened, Rubber packing should be protected from Paint and chemicals, The channels in” which the. Packing sits should be free of corrosion. Rubber packing is to be teplaced if damaged: or compressed to less than’ 80%- of original size. Rubber packing cannot'be tepaired or replaced in bits and pieces as uneven compression will result, The entire Jength must be replaced, The retaining channels must. be chipped and painted Prior to renewal of rubber packing. Eccentric wheels : Eccentric wheels should freely rotate even by hand. They J Should be greased at' least once a month and especially after a long voyage. Every six months depending on their use, they should be opened up, cleaned, greased and the bearings renewed if necessary. Whee! bush and wheel pin . Must be replaced if there is more than I mm Wear down.” ~~ Balanging wheels : Balancing wheels must be maintained in a similar way to "+ “eeeéntric wheels. a ; Towing chains’: Towing chains are Susceptible to elongation as they bear a * Jot of stress when pulling the covers, If elongated a ap will appear between joining panels when closing, A temporary measure may be to twist the chain a half or a full turn." However any elongation means a deformation and Weakening or loss of Strength. If excessive, the Particular length of chain must be replaced £ Quick-acting cleats : Quick-acting cleats and screw-bolt cleats Pull the hatch cover down tight over the coaming, thus oinpressing the rubber packing. The length of the cleat should be adjusted by the nut so as to Produce just the right amount of compression,” Over compressing will Permanently deform the rubber ‘packing’ While under compressing it will’ not produce Weathertightness.’ All cleats should produée a uniform compression of the 212 yon IRORORIAOD A, OAS CA OMOAKC | | PoMrorarar a Sorubber packing. The stem of the Cleat and threads should be protected from corrosion by painting/greasing. Cross joint wedges : The hardened metal pads over which the wedges’ aré driven should be of sufficient height arid not worn down to give adequate“ tightness between the cross panels. Leaf springs in the wedges have a‘ tendency to fall out which hampers closing of the hatch covers. Cross joint wedges often bend or crack under pressure in which case they must be replaced. They.should produce a uniform pressure along the athwartships hatch cover panels. 7 i © . Drain valves : Non-return drain valves at the hatch corners should ‘be* P© checked for ‘clogging: by dust or cargo: residues and tested for efficient _ functioning. Pull.wire : "The ‘pull wire for the covers should be. in good condition. and‘ greased. Blocks through which it is led must also be regularly checked and. maintained. Spares ; A large number of hatch cover spares are. generally carried out,on‘ board but ships’ officers ‘are often unaware of their location or usé due to* being buried under old, mooring ropes, wires, etc. In a planned mainteriance systema proper-record—of-~ the: spares-must-be- maintained. down. to-thé---- ©, smallest grease nipple and pin!. Hydraulic hatch covers ~ Operation and maintenance 1) Start both hydraulic pumps and let them reach normal operating speed: . Hatch covers are not to be operated on one pump only. In extremely cold weather; pumps must be started well in advance or be kept running to circulate the oil and maintain it in low viscosity condition. ) © ¢ ) Opening of hatch covers y C 5 2) Ensure j a) all cleats around hatch cover have been released. UG b) No person or thing is on the hatch top. y c) Wheel runway is clear of obstacles. 7 d) Stoppers have been released. e) Lookout is placed on blind areas. ‘2133) Shift control lever to “OPEN” position.: Forward and aft hatch covers must be opened/closed in the correct sequel nce. 4) Ensure wheel Stoppers are set in position to prevent closing. 5) In case of pump trouble, hydraulic oil Jeak, etc. hatch covers may be opened by emergency wire pull. In such case, it should be also shut by wire pull. .., Flexible hoses i, Flexible hoses should not be twisted, check the line marking on them is Straight. ii, Do not step on them, put heavy things or forcibly bend the hose. iii, Do-not use a pipe wrench but'a correct spanner from thé tool. box to fasten and'unfasten them. Pump uni “i, Check oil level in hy instructions, ii. \Chéck pump unit for abs iil. Check filter for stains necessary. iv. Check functioning of pressure gauge. 'v. Test relief valve for operation at the set pressure. vi. Check stop valve and check valve for malfunction due to internal leaks, . Vii.Check for oil leaks in hydraulic lines, flexible hoses, valve. stand and " hydraulic cylinder. 7 ydraulic tank. Renew oil as Per manufacturers normal noise, vibration or high temperatures, » wash metal ‘filter-and renew paper filter as” 214 POR AIAOD AO an any SON oncnono mone OD SO amo oO aren ome) Oo Ce