Industrial safety of lifting & procedure

Lifting Equipments Lifting Equipments and Procedureand Procedure

15 January 2011.

Compiled by Safety Trainees PECL

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2. Factories Act-Section 28 2. Factories Act-Section 28 (1):Hoists and Lifts(1):Hoists and Lifts

(a) In a factory hoists and lifts should be of :

(i)-good mechanical construction - sound material - adequate strength

© SWL to be distinguishly marked and no load greater than this be lifted or carried.

Sec 29. LIFTING MACHINES, CHAINS, ROPES AND LIFTING TACKLES

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The Factories Act, 1948Sec:2(ca): Competent Person

Means: A person or an institution recognised as such byCIF for carrying out tests, examination and inspections required to be done in a factory under provisions of this Act regarding:(i)qualifications and experience of person and facilities available at his disposal;(ii) qualifications and experience of persons employed in such institution and facilities a/vtherein, with regard to conduct of such tests,examinations and inspections, and more thanone person or institution can be recognisedas a competent person in relation to a factory.

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The Factories Act, 1948Sec:2(j): Machinery

Includes prime movers, transmission machinery and other appliances whereby power is generated, transformed, transmitted or applied.

Lifting Equipments: Hydra’s CRANES: limit switches Fork lifts Magnetic lift crane Mobile cranes: wheel ,crawler EOT Gantry Chain pully:spur gear,worm wheel Winch machine

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Lifting tackle: Slings Ropes Shackles Swivel Rings Couplers Sockets, Eyebolts. Frames & spreaders Plate lifting clamps Tailor-made tackles.

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Overview Terms & definitions Terms & definitions Planning the liftPlanning the lift The liftThe lift Landing the loadLanding the load Do’s & Don’tsDo’s & Don’ts Case studyCase study Slinging methodsSlinging methods Safe slinging practiceSafe slinging practice

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Terms & Definitions Competent person:

A person who has acquired, through a combination of qualifications, training or experience, the knowledge and skill to perform the task required.

Grommet: Endless wire rope sling.

MBL: Minimum breaking load of the lifting tackle.

SWL: Safe working load.

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Definitions Tag line:

A rope of suitable strength, construction and length attached with an appropriate recognised bend or hitch to the load, used to control the load during lifting or positioning.

Test certificate: A certificate issued by an authorized

person

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SIMPLE CHAIN PULLEY BLOCK

Planning the lift Planning the lift

Planning the lifting operation is essential

Planning the lifting operation is essential

to ensure that the lift is carried out

to ensure that the lift is carried out

safely and efficiently safely and efficiently

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Planning the lift Planning the lift

Absence of planning leads to Short cuts, using unsafe procedure, equipment

&It may cause

An ACCIDENT OR DELAY

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Planning the lift Planning the lift The following points must be

considered during planning: Where the load is to be picked up from Where the load is to be placed What areas to be passed over Any obstructions in the way How the load is to be slung How the slings are to be removed and

access to them14

Planning the lift Planning the lift For complex lifts, following points may have

to be considered: Special lifting accessories such as spreader

beams to ensure that the load is safely lifted and without damage to the product (large machineries, generators, etc.)

Special connectors to connect special built in connecting points. The operations may involve: Turning loads over or standing them upright Using more than one crane to lift a load.

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The liftThe lift

Are the slings undamaged and properly attached to the load?

Is the crane hoist rope vertical? Is the load free i.e not attached to any thing

else? Are the legs of multi legged sling equally

loaded? Are all spare all spare legs of the sling are

hooked up to the master link on the lifting hook?

After slinging but before lifting, the following After slinging but before lifting, the following must be consideredmust be considered

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The liftThe lift

Are all personnel clear of the load? Is the landing site prepared to take the

load? If required, is hand/tag lines attached to

the load?

After slinging but before lifting, the following After slinging but before lifting, the following must be consideredmust be considered

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Check Before LiftingCheck Before Lifting Now lift the load a short distance above the

ground and check that: The load is balanced and stable. The legs of the slings are at correct angles. Any packing pieces used, are in place and

sound. The load itself is not stressed, especially when

lifting packing cases, timber etc, which can fail under the loads applied due to lifting.

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Landing the loadLanding the load Before landing the load check that:

The landing area will take the weight of the load. There is sufficient space for the load. There are strips of timber or similar on which to

land the load such that the slings can be easily removed by hand.

The load should be landed gently to ensure that it is not damaged and that the crane does not receive any shock loading.

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Do’s & Don’tsDo’s & Don’ts Ensure that only

authorized slingers/signalers attach or detach loads, or signal the crane operator.

Discuss operations with the crane operator (special operations).

Ensure that the capacity of the crane is sufficient.

Seek expert advice when using eye bolts, plate clamp etc.

Use tag line always

Wrap tag line around hand or body.

Leave a suspended load unattended.

Pass loads over people. Ride or climb on

suspended loads. Stand or walk beneath

the loads. Use pipes to support

for landing the load

Always Never

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SWL OF SLINGSSAFE WORKING LOAD OFSLING

INCLUDED ANGLE θ

SAFE WORKING LOADWITH ANGLEθ

G = 10 TON at 90

90 10 TON

160 3.45 TON140 6.80 TON

120 7.07 TON60 12.25 TON

P = G / Cos 450 14.14 TON

SWL at angle =P X Cosθ /2

SLING ANGLES AND SAFE WORKING LOADS

90˚ angle at hook correspondsto 45˚ sling angle

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SLING ANGLES AND SAFE WORKING LOADS.

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When L = SSling angle is 60˚


Calculating SWLH is the vertical distance from the saddleof the hook to the top of the load.L is the distance measured along thesling from the saddle of the hook to thetop of the load.The ratio H/L will be same as the ratio h/l

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Determining capacity of 2-Leg BridleHitch

SWL= SWL (of single vertical hitch) X H/L X 2

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When sling legs are not of equal lengthuse smallest H/L ratio.

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Determining capacity of 3-Leg BridleHitchSWL= SWL (of single vertical hitch) X H/L X 3When sling legs are not of equal lengthuse smallest H/L ratio.

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Determining capacity of 4-Leg BridleHitchLoad may be carried by only 3 legs whilethe fourth merely balances it. Thereforethe recommended SWL is:SWL= SWL (of single vertical hitch) X H/L X 3When sling legs are not of equal lengthuse smallest H/L ratio.

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Determining capacity of Single BasketHitchFor Vertical legs (fig A):SWL = SWL (of single vertical hitch) X 2

For inclined legs (fig B):SWL= SWL (of single vertical hitch) X H/L X 2

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Determining capacity of Double BasketHitch with inclined angles

SWL= SWL (of single vertical hitch) X H/L X 4

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Determining capacity of Double WrapBasket HitchDepending on the configuration, SWLsare the same for the Single Basket Hitchor the Double Basket Hitch.

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Sling angles less than 45˚ (formed by thechoker) are not recommended. If theymust be used the formula is:

SWL= SWL (of single vertical hitch) X H/L XA/B X 2

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Determining capacity of Double WrapChoker Hitch

Depending on the configuration, SWLsare the same for the Single Choker Hitchor the Double Choker Hitch.

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Endless or Grommet Sling in Vertical Hitch

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Endless Sling choker Hitch Configuration


Endless Sling in Double Basket HitchConfiguration

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Endless or Grommet Slings Standard Eye-to Eye slings

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Effect of sling angle on Webbing

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Twisted Eye Slings

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What can happen, if, adequate safety is not observed?

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A case study 1 The incident:

In June 2003, a tragic incident occurred at one of the oil and gas development site in Algeria, resulting in one fatality and two injuries.

The incident occurred during the assembly of an onshore drilling rig. A large section of the rig was being lifted when a lifting chain failed.

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A case study 1

Actual measurement to hook position was 9.43 m.

7.5 m to centre of crane slew ring correct jib head/hook positionProbably out of

alignment in this direction (this would transfer entire load to one sling)

Chain being pulled into angle would increase tendency to jam and prevent chain slipping round to equalize loadingSketch of out-of-alignment load path

during lift, resulting in lifting chain failure 42

A case study 1 The causes, as established by an investing

team: Use of an underrated chain sling. Incorrect slinging and lifting techniques. The crane hook was positioned off-centre,

resulting in the load path being out of alignment. Combined with a hinged load, this prevented the

sling from equalizing on all chain legs when raised.

Consequently, the entire load of 23.1 tonnes was placed on one chain leg that had a breaking load of 18.9 tonnes resulting in failure of chain

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Case Study 2 Job : erection of gantry crane beams Description of Accident:

Two beams of 11.5m X 1.5m X 0.75m weighing about 6 tones were lying on concrete sleepers.

Out of two beams one beam was lying on sleeper in horizontal position.

The other beam was in vertical position and was to be positioned to make alignment with the first beam.

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Slings were placed around the vertical beam. Mr. XYZ went up the beam to adjust the sling. He adjusted the sling and stood in between the

two beams. In the meantime someone gave signal to lift the

beam. Crane operator lifted the beam by about 4 mm

up its position.

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During that operation beam swayed towards the first beam and Mr. XYZ was caught between the two beams.

On hearing the scream, crane driver placed the beam back on its original position.

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Mr. XYZ got up and tried to get out of two beams but he stumbled and fell down on sleepers, got injury near left eyebrow.

He was taken to hospital, but was declared as dead.

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Case Study 2

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Case Study 2 - Investigation

1. No hand rope (tag line) was used to avoid swinging of the job.

2 Both the lifting rope used are having N no. of kinks on it., naturally these kinks will have tendency to swing the job.

3. No lifting hole or lugs were made to the beam to rotate it.

4. Crane operator does not know who gave him signal for lifting the job.

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Learning from the incidents Apart from lifting machine,

it is also necessary to take care of lifting tackles and lifting procedure

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Safe Slinging Practice

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C.G.

Crane hook mustbe on the CG

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This load is not stable. The hook is over the CG, but the CG is above the liftinghook.This load is top heavy, and could overturn while being lifted

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This load is stableThe hook is right over

the CG.

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The hook is not overthe centre of gravity

The load will shift until theCG is under the hook.

This will make landing the load very difficult, and could cause major problems in crainage

Unstable

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1000kg

1000kg

1000kg

1000kg

4590 90

45 30 30 1515

707 Kg

500 Kg 500

Kg

707 Kg

1000 Kg

1000 Kg

1932 Kg

1932 Kg

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How to identify the correct angle?

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45HL

At 45 degrees, H = L

As the angle becomes less than 45 degrees, H will be less than L

Therefore ensure that H is always = or > L


Can carry88% of

rated load

Can carry100% of

rated load

Can carry80% of

rated load

Can carry70% of

rated load

Can carry40% of

rated load

Balanced load ¼” off

centre1/2” off centre

3/4” off centre

Pointloading

Safety latchesomitted 59

Safe Slinging PracticeSofteners, padding or use of blocking..

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Tag line should be attached to the load swinging and to help it landing in the right place.

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Unsafe Slinging

Lift and lower the load smoothly, do not jerk

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Unsafe Slinging

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Unsafe Slinging

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Unsafe Slinging

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Is it right method to extend a chain sling?

Unsafe Slinging

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Sling storage

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Hand SignalsHand Signals When should the crane operator

follow hand signals? A crane operator should always move

loads according to the established code of signals, and use a signaler.

Hand signals are preferred and commonly used.

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Hand SignalsHand Signals Who can give the hand signals?

a person qualified to give crane signals to the operator,

there should be only one designated signaler at a time,

a crane operator should move loads only on signals from one signaler,

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Responsibility of the signaler The signaler must:

be in clear view of the crane operator, have a clear view of the load and the

equipment, keep persons outside the crane's

operating area, never direct a load over a person.

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Standard Hand Signals For Controlling Overhead Cranes

With forearm vertical, forefinger pointing up, move hand in small horizontal circle

HOIST

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With arm extended downward, forefinger pointing down, move hand in small horizontal circle.

LOWER

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Arm extended forward, hand open and slightly raised, make pushing motion in direction of travel.

BRIDGE TRAVEL

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TROLLEY TRAVEL. Palm up, fingers closed, thumb pointing in direction of motion, jerk hand horizontally.

TROLLEY TRAVEL

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Arm extended, palm down, hold position rigidly.

STOP

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Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal. (Hoist Slowly shown as an example.)

MOVE SLOWLY

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Crane operator spreads both hands apart – palms up.

MAGNET DISCONNECTED

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Finally, we must remember….

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Objective Of Good SlingingObjective Of Good Slinging The sling and its method of use should

be suitable for the load. The method of attachment of the sling

to the load and the sling to the lifting appliance should be secure.

No part of the sling should be overloaded either by the weight of the load or by the method of slinging.

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Objective Of Good SlingingObjective Of Good Slinging The slinging method should ensure

that the load is secure and that the load will not fall from the sling.

The load should be balanced and stable and should not violently change its attitude when lifted.

The load must not be damaged by, or cause damage to, the sling.

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If we remember & achieve this Objective…..

The probability of accident will be

minimum

Sling storage

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