Lifting Equipments and Procedure15 January 2011. Compiled by Safety Trainees PECL

*2. Factories Act-Section 28 (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*

*The Factories Act, 1948 Sec:2(ca): Competent PersonMeans: 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: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.

*The Factories Act, 1948 Sec:2(j): Machinery Includes prime movers, transmission machinery and other appliances whereby power is generated, transformed, transmitted or applied.

Lifting Equipments:HydrasCRANES: limit switchesFork lifts Magnetic lift craneMobile cranes: wheel ,crawlerEOTGantryChain pully:spur gear,worm wheelWinch machine

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Lifting tackle: SlingsRopesShacklesSwivelRingsCouplersSockets, Eyebolts.Frames & spreadersPlate lifting clampsTailor-made tackles.

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OverviewTerms & definitions Planning the liftThe liftLanding the loadDos & DontsCase studySlinging methodsSafe slinging practice*

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*

*SIMPLE CHAIN PULLEY BLOCK

Planning the lift Planning the lifting operation is essential to ensure that the lift is carried out safely and efficiently *

Planning the lift Absence of planning leads to Short cuts, using unsafe procedure, equipment&It may cause An ACCIDENT OR DELAY *

Planning the lift The following points must be considered during planning:Where the load is to be picked up fromWhere the load is to be placedWhat areas to be passed overAny obstructions in the wayHow the load is to be slungHow the slings are to be removed and access to them*

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 uprightUsing more than one crane to lift a load.*

The 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 must be considered*

The liftAre 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 must be considered*

Check Before LiftingNow 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.*

Landing the loadBefore 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.*

Dos & DontsEnsure 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 *

*SWL OF SLINGS

SAFE WORKING LOAD OFSLINGINCLUDED ANGLE SAFE WORKING LOADWITH ANGLE G = 10 TON at 909010 TON

1603.45 TON1406.80 TON

1207.07 TON6012.25 TONP = G / Cos 45014.14 TON

SWL at angle =P X Cos /2

SLING ANGLES AND SAFE WORKING LOADS90 angle at hook correspondsto 45 sling angle*

SLING ANGLES AND SAFE WORKING LOADS.*When L = SSling angle is 60

SLING ANGLES AND SAFE WORKING LOADSCalculating 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*

SLING ANGLES AND SAFE WORKING LOADSDetermining capacity of 2-Leg BridleHitch

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

SLING ANGLES AND SAFE WORKING LOADSWhen sling legs are not of equal lengthuse smallest H/L ratio.*

SLING ANGLES AND SAFE WORKING LOADSDetermining 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.*

SLING ANGLES AND SAFE WORKING LOADSDetermining 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.*

SLING ANGLES AND SAFE WORKING LOADSDetermining 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*

SLING ANGLES AND SAFE WORKING LOADSDetermining capacity of Double BasketHitch with inclined angles

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

SLING ANGLES AND SAFE WORKING LOADSDetermining capacity of Double WrapBasket HitchDepending on the configuration, SWLsare the same for the Single Basket Hitchor the Double Basket Hitch.*

SLING ANGLES AND SAFE WORKING LOADSSling 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*

SLING ANGLES AND SAFE WORKING LOADSDetermining capacity of Double WrapChoker Hitch

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

Endless or Grommet Sling in Vertical Hitch*Endless Sling choker Hitch Configuration

SLING ANGLES AND SAFE WORKING LOADSEndless Sling in Double Basket HitchConfiguration*

Endless or Grommet Slings Standard Eye-to Eye slings*

SLING ANGLES AND SAFE WORKING LOADS*

Effect of sling angle on Webbing*

Twisted Eye Slings*

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

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A case study 1The 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.*

A case study 1Actual 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*

A case study 1The 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*

Case Study 2Job : erection of gantry crane beamsDescription 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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Case Study 2Job : erection of gantry crane beamsDescription of Accident: 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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Case Study 2Job : erection of gantry crane beamsDescription of Accident: 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. *

Case Study 2Job : erection of gantry crane beamsDescription of Accident: 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*

Case Study 2 - Investigation1.No hand rope (tag line) was used to avoid swinging of the job.2Both the lifting rope used are having N no. of kinks on it., naturally these kinks will have tendency to swing the job. No lifting hole or lugs were made to the beam to rotate it.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*

Safe Slinging Practice*

Safe Slinging PracticeC.G.Crane hook mustbe on the CG*

Safe Slinging PracticeThis 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 *

Safe Slinging PracticeThis load is stableThe hook is right over the CG. *

Safe Slinging PracticeThe 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 crainageUnstable *

Safe Slinging Practice1000kg1000kg1000kg1000kg4590904530301515707 Kg500 Kg500 Kg707 Kg1000 Kg1000 Kg1932 Kg1932 Kg*

How to identify the correct angle?*45HLAt 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

Safe Slinging PracticeCan carry88% of rated loadCan carry100% of rated loadCan carry80% of rated loadCan carry70% of rated loadCan carry40% of rated loadBalanced load off centre1/2 off centre3/4 off centrePointloadingSafety latchesomitted*

Safe Slinging PracticeSofteners, padding or use of blocking..

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Safe Slinging PracticeTag line should be attached to the load swinging and to help it landing in the right place.*

Unsafe Slinging Lift and lower the load smoothly, do not jerk*

Unsafe Slinging *

Unsafe Slinging *

Unsafe Slinging *Is it right method to extend a chain sling?

Unsafe Slinging *

Sling storage*

Hand SignalsWhen 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. *

Hand SignalsWho 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,*

Responsibility of the signalerThe 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.*

Standard Hand Signals For Controlling Overhead Cranes With forearm vertical, forefinger pointing up, move hand in small horizontal circleHOIST*

Standard Hand Signals For Controlling Overhead CranesWith arm extended downward, forefinger pointing down, move hand in small horizontal circle.LOWER*

Standard Hand Signals For Controlling Overhead CranesArm extended forward, hand open and slightly raised, make pushing motion in direction of travel.BRIDGE TRAVEL*

Standard Hand Signals For Controlling Overhead CranesTROLLEY TRAVEL. Palm up, fingers closed, thumb pointing in direction of motion, jerk hand horizontally.TROLLEY TRAVEL*

Standard Hand Signals For Controlling Overhead CranesArm extended, palm down, hold position rigidly.STOP*

Standard Hand Signals For Controlling Overhead CranesUse 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*

Standard Hand Signals For Controlling Overhead CranesCrane operator spreads both hands apart palms up.MAGNET DISCONNECTED*

Finally, we must remember. *

Objective Of Good SlingingThe 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.*

Objective Of Good SlingingThe 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.*

If we remember & achieve this Objective.. The probability of accident will be minimum

Sling storage*

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