Thermax Power O&M 1

SAFETY IN OPERATION OF LIFTING TOOLS

• PURPOSE
– 40% Accidents are due to Material handling
– It accounts 40% production cost
– It does not add value to the product but it cost to the product
– A large cost of product cost is due to Material handing
– Major activities in Cement Industries is Material Handling
– Listing tools and tackles comes under Material handling activity
– It has potential for high risk and accidents

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 Lifting Equipment

Lifting equipment - “work equipment used for lifting or lowering loads and
includes its attachments used for anchoring, fixing or supporting it”

Types of Lifting Equipment

• Cranes
– Tower
– Mobile
• Forklifts
• Hoists/ Chain Block
• Excavators (360)
• Shovels/ Bobcat
• Slinging/ Rigging

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 Lifting Equipment

General Precautions
• All lifting equipment must be marked with Safe Working Load (SWL)
• Lifting equipment should not be used to move loads heavier then the
SWL
• All lifting equipment and rigging must have a current 3rd party
certification
• Lifting equipment should only be operated by people who have been
trained to do so
– Operator must be adequately trained/ licensed
• Never stand or allow anyone to stand under suspended loads
• Ensure all lifting equipment has no obvious defects
– All lifting equipment should be inspected before use

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 Outrigger Use

• Proper outrigger use

– Solid ground
– Level
– Fully extended
– Stable base
• Use cribbing to distribute the load

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 Outrigger Use

Wheels should not be touching

the ground

All outriggers should be

fully extended

Correct outrigger placement

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 Outrigger Use

Improper out rigger placement

lowers the SWL of the crane; will
lead to a tipping accident

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 Outriggers NOT extended

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 Forklifts

• Must be trained to operate

• Never lift more then the SWL
• Travel with load in a lowered
position
• Travel with forks in a lowered
position
• Do not lift personal unless a
certified lifting basket is used
• No passengers while traveling

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 Hoists/ Chain Block

Power hoist
– Usually electric or air
operated
Chain hoist (or "chain
fall"); Chain Block
– Hand operated
Must have SWL marked
on equipment
Never use to lift more
then the SWL

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 Example of 3rd party
certification

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 TIPS FOR CORRECT LIFTING PRACTICE

 Find out the correct weight of the load to be lifted

 Slightly lift the load check for CG , imbalance etc

 While lifting ensure that the load is not obstructing to any

 of the parts of structure

 Loose nuts & bolts must be kept in a box and not on the

 structures.The box to be properly anchored.

 Avoid sudden break or sudden release of the load . Impact

load may result in breaking of the rope/chain

 persons with B.P or epilepsy shall not be allowed to work at

heights

 Barricade the area of loads lifting/ sparks falling

 Full body safety Harness is a must at heights more than 1.8M

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 CLASSIFICATION OF LIFTING APPLIANCES

LIFTING APPLIANCES

Lifting tools Lifting tackles

cranes D-shackles
Hoists Wire ropes
Chain pulley blocks Chains
Jib crane Clamps etc

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 LIFTING TOOLS AND TACKLES

Lifting tool is device which is used to lift load such

 Chain block

 Jacks

 Cranes etc

 Winch

 Mono rail

Lofting tackle is device which is used to facilitates for lifting load

such as

 Rope

 D- shackles

 Hooks

 Eye bolts etc

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 CHAIN BLOCK

PROPER USE OF CHAIN BLOCK

 Never drag the chain block on the floor. It must be caried

 Chin block when not in use must be hanged on hooks and

kept under cover and not left on floor

 It must be inspected before and after use

 Chain block to be lubricated periodically

 Once in year or often dismantle the chain completely and

examine the parts thoroughly and replace worn out parts.

 Maintain proper service record of chain block

 Load capacity never be exceed. It is advisable to lift 10% less

load then specified. Jerks load while lifting to be avoided
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 JACKS

It is a portable tools used for lifting heavy load s through short

distance. There are several types of jacks

 Screw Jacks

 Screw jacks with ratchet handle

 Hydraulic Jack with inbuilt pump

 Hydraulic jack with separate pump etc

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 JACKS

PROPER USE OF JACK

 Chose a jack of at least 25% higher capacity htna the load to

be lifted

 Use wooden block below and above jacks to reduce chance

of slipping

 Use same capacity and same stroke length jacks when lifting
load with two or more jacks simultaneously

 Inspect, clean lubricate jacks before and after use of jacks

 Never drag the jacks on floor

 When not in store jacks properly in racks after applying a thin

layer of grease to prevent rust

 Use jacks according to instruction of manufacturer. All jacks

have a marks on the ram indicating the limits of ram travel
which never be exceeded
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 INSPECTION LIFTING TOOLS

 It is divided into two type

1. Frequent inspection

Daily , Monthly and weekly and monthly

2. Periodic Inspection

Quarterly, Half yearly and yearly

 Frequent Inspection

 All functional operating systems like winch assembly,

control blocks, safety devices, electrical equipments
hydraulic system etc must be inspected daily

 Running ropes shall be inspected on monthly basis and

record to be kept

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 INSPECTION LIFTING TOOLS

Periodic Inspection

 It includes

1. Oil levels and lubrication of all the parts

2. Inspection of rope and rope termination fittings

3. Spillage oil grease, grease and other materials

4. The function of brakes

5. Functioning of limit switches

6. Functioning of electrical switches

7. The cover and safety guards

8. Functioning alarm

9. Functioning of load indicating system

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 INSPECTION LIFTING TOOLS- PERIODIC INSPECTION

Periodic Inspection

1. Deformation cracks, corrosion of jibs, blocks etc

2. Deformation like throat opening and bending of

hooks ( Throat opening 15% with latch and 8% with
out latch). Max bending allowed is 5% either side

3. Loose bolts, rivets and bearings

4. Worn out hooks, pins, bearings, shaft, gears, rollers

locking and clamping device

5. Excessive wearing on break system and lining

6. Improper functioning electrical devices including limit

switches

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 PREACUTION TO BE TAKEN DURING MAINTENANCE

1. The crane must be moved to a location with at least

interface with other carne/equipments or operator

2. All the controller must be off position

3. LOTOTO to be applied

4. Warning sign crane under maintenance

5. Rail stopper to be provided

6. Crane must not take into operation if the guards are

not put properly

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 LIFTING TACKLES

Lofting tackle is device which is used to facilitates for lifting load

such as

 Rope

 D- shackles

 Hooks

 Eye bolts etc

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 ROPE

Lofting tackle is device which is used to facilitates for lifting load

such as

 Rope

1. Fibre rope

2. Wire rope

3. Synthetic rope

4. Chain

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 Types of Rigging/ Slinging

Wire Rope Slings

Chain Slings

Synthetic Web Slings

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 Rigging/ Slinging Inspection

Wire slings should be inspected before each use

Should be marked with SWL

Slings with
Damaged or
broken wire
strands must be
removed form
service

Bird caging

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 FIBRE ROPE

Handling care and Use of Fibre rope

 If the inside the rope is dirty, if the strand have begun to unlay
or if the rope has lost its life elasticity it should not used for
hoisting
Dia of Nylon Manila
the rope rope rope(Kgs)
in inch ( Kgs) FOS(6)
FOS(6)
¼ 170 Nil
½ 560 120
¾ 1290 245
1 2230 410
1¼ 3450 610
1 1/2 4990 840
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 WIRE ROPE

Construction of 6/19 wire

rope
6=no. of strands
19 =no. of wire ropes in each
strand
19( 1/6/12) I.e 12wires over 6
Core of the
wires over one wire.
rope
Type of cores
1. Fiber core: sisal, polypropylene or nylon
2. Wire core : IWRC (Independent wire rope
core), SSC (steel strand core) or Armor core
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 WIRE ROPE COMPONENTS

CORE

WIRE

STRAND

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 PROPER USE OF WIRE ROPE

CORE

WIRE

STRAND

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 PROPER USE OF WIRE ROPE

CORE

WIRE

STRAND

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 PROPER USE OF WIRE ROPE

CORE

WIRE

STRAND

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 THUMB RULES

 STRAND
LOAD CARRING CAPACITY THUMB RULE
FORMULA

W = 8d2
( W in Kgs. ; ‘d’ in mm )
CORE

WIRE

Subject to zero included angles between the Ropes.

Thermax Power O&M N.B : The same formula is valid for D-Shackles also. 32 32
 Banks man/ signal person

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 CAPACITY OF ROPE AT VARIOS ANGLE

CORE

WIRE

STRAND

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 LIFTING TACKLES

Dead End U BOLT

U-Bolt
CORE

WIRE Saddle
SADDLE

CORRECTSTRAND

Installed properly as to number, direction, spacing and torque.

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 LIFTING TACKLES

CORE

INCORRECT INCORRECT
WIRE

STRAND
Do Not Alternate!
Saddle is on Dead End!

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 LIFTING TACKLES

Load Load

CORE

INCORRECT INCORRECT
Result
WIRE

Correct Orientation –STRANDIncorrect Orientation –

Load is in the plane of When the load is applied to the
the eye. eye in this direction it will bend.

Always load an eyebolt in the plane of the eye.

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 HOOKS

CORE

INCORRECT
WIRE

STRAND

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 LIFTING TOOLS AND TACKLES LEGAL PROVISION

Lifting Machines, Chains, Ropes and Lifting Tackles

1. Every chain, rope and lifting tackles for the purpose of raising or lowering
persons goods or materials.

a) All parts including the working gear, whether fixed or moveable of every lifting
machine and every chain, rope or lifting tackle shall be-

(i) of good construction, sound material and adequate strength and free from defects;
(ii) Properly maintained and
(iii) Thoroughly examined by a competent person at least once in every period of
twelve months or at such intervals as the Chief Inspector may specify in writing,
and a register shall be kept containing the prescribed particulars of every
examination.

b) No lifting machine and no chain, rope or lifting tackle shall except for the purpose
of test, be loaded beyond the safe working load which shall be plainly marked
thereon together with an identification mark and duly entered in the prescribed
register; and where this is not practicable, a table showing the safe working loads
of every kind and size of lifting machine or chain, rope or lifting tackle in use shall
be displayed in prominent positions on the premises.

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 LIFTING TOOLS AND TACKLES LEGAL PROVISION

Lifting Machines, Chains, Ropes and Lifting Tackles

c) While any person is employed or working on or near the wheel track of travelling
crane in any place, where he would be liable to be struck by the crane, effective
measures shall be taken to ensure that the crane does not approach within (six
meters) of that place.

2. The State Government may make rules in respect of any lifting machine or any
chain, rope or lifting tackle used in factories.

a) Prescribing further requirement to be complied with in addition to those set our in

this section.
b) Providing for exemption from compliance with all or any of the requirements of this
section, where in its opinion, such compliance is unnecessary or impracticable.

For the purpose of this section a lifting machine or a chain rope or lifting tackle shall
be deemed to have been thoroughly examined if a visual examination supplement,
if necessary, by other means and by the dismantling of parts of the gear, has been
carried out as carefully as the conditions permit in order to arrive at a reliable
conclusion as to the safety of the parts examined.

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 •Thank you

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