SAFETY IN

PLANT & MACHINERY

OPERATION
 P&M BUSINESS UNIT– A GLANCE

• TOTAL ASSET ACQUISITION VALUE – 785 Cr.

• MAJOR ASSET – 3355 NOS
• MINOR ASSET – 8005 NOS
• ISO 9001 CERTIFIED
•RIGHT EQUIPMENT FOR RIGHT JOB
•COMPETENT / TRAINED OPERATOR
& DRIVER.
•PERIODICAL SKILL EVALUATION OF
P&M WORKMEN.
•SAFE OPERATION WITHIN SPECIFIED
LIMITS.
• SAFE WORKING CONDITIONS
(Suitable Ground Condition, Safe
access/egress, Emergency exits,
Interlockings & Guards,)
•TAG-OUTS / LOCK-OUTS.
•REGULAR MAINTENANCE SAFETY
INSPECTION.
 What is Maintenance ?
Any method adopted to keep a system in
good working condition @ economical cost

• Types of Maintenance

– Periodic / Regular
– Preventive
– Predictive
– Breakdown
 SAFETY SYSTEMS RELEVANT TO
P&M.

1. CRANES INSPECTION CHECKLIST &

REPORT.
2. VEHICLE AND EARTH MOVING
EQUIPMENT INSPECTION CHECKLIST AND
REPORT.
3. ALL LIFTING EQUIPMENTS (OWN / HIRED /
S/C) WILL BE TESTED BY A COMPETENT
PERSON BY EVERY YEAR.
4. WINDER INSPECTION CHEKLIST & REPORT
 L A R S E N & T O U B R O L IM IT E D
E C C D IV IS IO N ( E n g in e e r in g , C o n s t r u c t io n & C o n t r a c t s )
P la n t & M a c h in e r y B u s in e s s U n it
Q u a lit y M a n a g e m e n t S y s t e m

D A IL Y C H E C K S & M A IN T E N A N C E S C H E D U L E

N a m e o f O pe r a to r : _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ A s s e t C ode : A s s e t D e s c riptio n : C r a n e

M a r k a c c o r di n g ly : P e r fo r m e d N ot ca rrie d ou t M on th :

D a t e o f In s p e c t io n
S N o . C h e ck P o in ts 1 2 3 4 5 6 7 8 9 10 11 12 13
1 E n g i n e o i l le v e l
2 E n g i n e c o o la n t le v e l
3 F a n be lt t i g h t n e s s
4 A i r c le a n e r c h e c k i n g
5 W a te r te m p g u a g e w o r k i n g
6 R P M m e te r w or k i n g
7 En gi n e oi l pr. g a u g e w ork in g
8 B a tte r y e le c tr o ly te le v e l
9 B o o m c lu tc h & br a k e
10 H o i s t dr u m c lu tc h & br a k e
11 S w in g bra k e c h e c k i n g
12 W i re rope c o n di tion
13 O v e r - H oi s t L i m it S w itc h
14 B oo m L i m i t S w i tc h

S i g n a tu r e o f o pe ra to r / m e c h a n i c

S i g n a tu r e o f s e c ti o n i n -c h a r g e

( P & M - In c h a r g e )
FORM AT No
 L A R S E N & T O U B R O L IM IT E D
E C C D IV IS IO N ( E n g in e e r in g , C o n s tr u c t io n & C o n t r a c t s )
P la n t & M a c h in e r y B u s in e s s U n it
Q u a lit y M a n a g e m e n t S y s t e m

D A IL Y C H E C K S & M A IN T E N A N C E S C H E D U L E

N a m e of O pe ra tor : _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ A s s e t C ode : A s s e t D e s c ri pti o n : V EH IC L ES

M a r k a c c o r di n g ly : P e r fo r m e d N ot ca rrie d ou t M on th :

D a t e o f In s p e c tio n
S N o . C h e ck P o in ts 1 2 3 4 5 6 7 8 9 10 11 12 13
1 E n g i n e o i l le v e l
2 E n g i n e c o o la n t le v e l
3 B r a k e o i l le v e l
4 B a tte r y e le c tr o ly te le v e l
5 F u e l le v e l
6 H y dr a u li c o i l le v e l
7 A i r c le a n e r
8 H a n d bra k e w ork in g
9 A i r p r e s s u r e (br a k e )
10 T yre pre s s u re & w e a r/ da m a ge
11 I n di c a to r s / h e a d li g h ts e tc .
12 U J c r o s s jo i n t bo lt-n u t ti g h tn e s s
13 W h e e l n u t ti g h tn e s s
14 K M R w ork in g
15 W a t e r p u m p ,a lt . B e lt t e n s i o n
16 S te e r i n g s y s te m
17 H o r n ,r e v e r s e h o r n ,w i p e r e t c .
S i g n a tu r e of o pe ra to r / m e c h a n i c
S i g n a tu r e o f s e c ti o n i n -c h a r g e

( P & M - In c h a r g e )
F O R M A T N o .: R
 COMPRESSED AIR
Air receivers:
Hydrostatically tested and approved tanks are used as
air receivers. The Air receivers are tested for a span of
a year regularly by competent authority

SAFETY PRECAUTIONS
• Receivers should be drained frequently to prevent
accumulation of liquid inside the unit.
• Air tanks should not be buried or placed where
they cannot be seen for frequent inspection.
• Each air receiver shall be equipped with at least
one pressure gauge and an safety valve of the
proper design.
• A safety (spring loaded) release valve shall be
installed to prevent the receiver from exceeding the
maximum allowable working pressure.
 Air Distribution Lines:

SAFETY PRECAUTIONS

• Only standard fittings should be used on air

lines.
• Operators should avoid bending or kinking air
hoses.
• Hoses should be checked to make sure they
are properly connected to pipe outlets before
use.
• Air lines should be inspected frequently for
defects, and any defective equipment repaired
or replaced immediately.
• safety valve are used and set to 10 percent
above the operating pressure of the
compressor-
 Operating cranes near
overhead power lines
Indian Electricity Act, 1910(sec.79&80) prescribes minimum clearances
between ground and live conductors and also horizontal distance to be maintained
from building/structures.

Classification of voltage (IE Rule 2(1) (a) ):

1.Low voltage Not exceeding 250v

2.Medium Voltage Not exceeding 650v

3. High Voltage More than 650v & upto 33kv

4.Extra high voltage More than 33kv

 
 

Clearance along /across the road and cross country (IE Rule No.77)

VOLTAGE ACROSS THE ALONG

ROAD THE ROAD
Low and medium voltage 19 ft (5.791m) 18ft.
(5.486m)
High voltage line upto 11KV 20ft (6.096m) 19ft
(5.791m)
For high voltage above 11KV upto 20ft (6.096m) 19ft
33kv (5.791m)
For extra high voltage line (for 20ft (6.096m) Plus 1m for
every additional 33kv OR part every 33kv
thereof
 Components of Steel Wire Rope
Wire are laid helically above a center to form a strand which
is further laid helically over a core to form a rope. The main
component parts of a standard wire rope are
• WIRE
• STRAND
• CORE
Common usage of wire rope
IWRC – Provide good crush resistance and increased
strength
FMC - Provide excellent flexibility
 Storage Of Wire Ropes

Wire ropes must not have suffered corrosion,

rusting, damage or severe contamination with
dirt when they are installed.
 Ropes must therefore be stored in a dry place
and moisture condense prevented from
forming on non galvanized rope.
 Maintenance Of Wire Ropes
• Wire ropes need regular maintenance, with particular care
devoted to the rope drives subject to serve loads
• Ropes must be lubricated at regular intervals, in particular
where they pass round pulleys and drums.
• The actual intervals will depend on local operating
conditions, but subsequent lubrication is normally
recommended at least every two hundred hours of operation.
• In special circumstances – extreme weather, sea air etc
• It may be necessary to reduce the intervals between
lubrication routines.
• The lubricants must be compatible with those already on the
ropes.
• Oils are normally superior to grease because they can
penetrate the interior of the rope, but some greases contain
additives to aid penetration.
 Maintenance Of Wire Ropes
• Rope which move in the operation should be cleaned at
the intervals, since the mixture of dust and residual
lubricant which other wise forms can fresh lubricant from
penetrating the rope.
• Lubrication is also important as a means of preventing
corrosion.
• Fixed ropes should be greased or painted to protect them
against corrosion or rusting.
• If operating circumstances makes it impossible to
lubricate a rope once it has been installed, it’s working
life will be reduced and it should therefore be inspected
at more frequent intervals
WRONG METHOD
CORRECT METHOD
WRONG
METHOD
CORRECT METHOD
VARIETIES OF ROPE
DAMAGES
TYPES OF ROPE DAMAGES
TYPES OF ROPE DAMAGES
Replacement of Wire Ropes
 Structural changes have occurred so that the rope diameter is
15% or more below its original nominal diameter over a fairly
long distance
 Corrosion or rusting has caused the rope diameter to be 10%
or more below the nominal diameter
 The rope diameter is 10% or more below the nominal diameter
on account of wear
 Severe deformation of the rope structure is visible, such as
expanded “baskets”, severe corkscrew deformation, severe
wire strand loops, loose strands on account of corrosion or
wear, loops and twists, mechanical damage, severe kinks or
necking
 How User Departments Can Help
P&M Department
• Spare equipment in time for routine maintenance
• Ensure hired eqpt. are inspected by P&M Dept.
before hiring contracts are concluded.
• Equipment misuse to be avoided.
• Recognize P&M efforts & initiatives at site and
share their problems .
* * * * *
 THANK YOU
FOR YOUR
ACTIVE
PARTICIPATION