Machinery safety inspection
-
Upload
mohd-rozalmi-suhaimi -
Category
Education
-
view
5.077 -
download
6
description
Transcript of Machinery safety inspection
![Page 1: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/1.jpg)
BOILER
![Page 2: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/2.jpg)
Definition
"machinery" includes steam boilers, unfired pressure vessels, fired pressure vessels, pipelines, prime movers, gas cylinders, gas holders, hoisting machines and tackle, transmission machinery, driven machinery, materials handling equipment, amusement device or any other similar machinery and any equipment for the casting, cutting, welding or electro-deposition of materials and for the spraying by means of compressed gas or air of materials or other materials, but does not include—
![Page 3: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/3.jpg)
Definition
but does not include—
(a) any machinery used for the propulsion of vehicles other than steam boilers or steam engines;
(b) any machinery driven by manual power other than hoisting machines;
(c) any machinery used solely for private and domestic purposes; or
(d) office machines;
![Page 4: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/4.jpg)
Definition
"steam boiler" means any closed vessel in
which for any purpose steam is generated
under pressure greater than atmospheric
pressure, and includes any economiser
used to heat water being fed to the vessel,
and any superheater used for heating
steam, and any pipes and fittings
![Page 5: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/5.jpg)
EXAMPLES OF STEAM BOILER
• Electric Boiler
• Fire Tube Boiler
• Water Tube Boiler
• Combi Boiler
• Waste Heat Boiler
![Page 6: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/6.jpg)
ELECTRIC BOILER
1.Pressure Vessel Is Built To ASME Code 2. Electrical Control Panel Box 3. Electric Heating Elements 4. Low Water Cut Off Probe 5. Second (Auxiliary) Low Water Cut Off Probe 6. Pump "On" Probe 7. Pump "Off" Probe 8. Sight Glass Assembly 9. Operating Pressure Control 10. High Limit Pressure Control w/ manual reset 11. Steam Outlet 12. Safety Valve 13. Steam Gauge Assembly 14. Steam Pressure Gauge 15. High Temperature Insulation Surrounds The Pressure Vessel 16. Large (3" x 4") Easily Accessible Handholes 17. Feedwater Shut Off Valve
![Page 7: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/7.jpg)
FIRE TUBE BOILER
![Page 8: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/8.jpg)
FIRE TUBE BOILER
![Page 9: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/9.jpg)
WATER TUBE BOILER
![Page 10: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/10.jpg)
![Page 11: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/11.jpg)
COMBI BOILER
![Page 12: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/12.jpg)
WASTE HEAT BOILER (HRSG)
![Page 13: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/13.jpg)
Every steam boiler before being put into
service for the first time, be subjected to
hydrostatic test for at least 20 minutes:-
Two times the ASWP, if the boiler pressure is
< 100 psi
1½ times the ASWP + 50 psi, if the boiler
pressure is > 100 psi
Note: If the boiler has been tested satisfactorily by the
manufacturer or if it is an old boiler, the
required H.T pressure is 1½ times the ASWP
STEAM BOILER
![Page 14: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/14.jpg)
Every steam boiler inspected for the first
time or the ASWP has been altered shall be
tested under steaming condition to the
satisfaction of the Chief Inspector:-
Note: The boiler other than a water tube boiler shall be
tested with the safety valves set at the ASWP firing
for at least 10 minutes with feed water & main stop
valve closed. Where the accumulation of pressure
exceeds 10% of ASWP, the area of the safety
valves are considered insufficient
STEAM BOILER
![Page 15: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/15.jpg)
Person in charge according to boiler heating surface
Note : Each boiler man should not be in charge of more than 2 boilers.
Heating Surface (ft2) Person-in-charge
HS ≤ 500 1st or 2nd grade Boilerman
500<HS≤2,000 1st grade Boilerman
2,000<HS< 5,000 1st grade Boilerman + Visiting Engineer
5,000<HS<10,000 1st or 2nd grade Engineer +1st grade Boilerman
10,000<HS<25,000 1st grade Engineer +1st or 2nd grade Engineer + 1st or 2nd
grade Boilerman/shift
25,000<HS< 50,000 1st grade Engineer + two 1st or 2nd grade Engineer + 1st or
2nd grade Boilerman/shift
HS>50,000 1st grade Engineer + 1st or 2nd grade Engineer /shift + 1st or
2nd grade Boilerman/shift
![Page 16: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/16.jpg)
PACKAGE BOILER
1. Furnace (1st gas pass)
2. Tubes (2nd gas pass)
3. Tubes (3rd gas pass)
4. Combustion chamber
5. Front smoke box
6. Rear outlet box
7. Water gauge glass
8. Safety valve
9. Main stop valve
10. Feed check valve
11. Water level control
12. Manhole
13. Spare connection (steam)
14. Spare connection (water)
15. Feed pump
16. Control panel
17. Burner
18. Forced draft fan
19. Fan inlet silencer
![Page 17: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/17.jpg)
NAME PLATE
REGISTRATION PLATE
SAFETY VALVE
GAUGE GLASS
PRESSURE GAUGE
INSPECTOR‘S TEST PRESSURE GAUGE
ATTACHMENT
MAIN STOP VALVE
LOW WATER ALARM
LOW WATER FUEL CUT-OUT
FUSIBLE PLUG
FEED PUMP
FEED CHECK VALVE
BLOWDOWN VALVE
BOILER ESSENTIAL FITTINGS
![Page 18: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/18.jpg)
NAME PLATE
Function: To provide important information
Every boiler shall be provided with:-
A name plate which bears the following:-
Name and address
Serial number
Design pressure
Design Code
Hydrostatic test pressure
Date of hydrostatic test
BOILER ESSENTIAL FITTINGS
![Page 19: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/19.jpg)
REGISTRATION PLATE
Function: To display the registration number
allocated by the Chief Inspector
(PMD No…………)
Every boiler shall be provided with:-
A registration plate - which bears the registration
number
BOILER ESSENTIAL FITTINGS
![Page 20: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/20.jpg)
SAFETY VALVE
Function: To release the boiler pressure in the
event of high pressure exceeding the
ASWP
Every boiler shall be provided with:-
At least two safety valves - one spring-loaded type
If heating surface area < 100 sq ft - one spring-
loaded type
Able to discharge the steam and maintain pressure not more than 10% of ASWP
BOILER ESSENTIAL FITTINGS
![Page 21: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/21.jpg)
Structure of safety valves
![Page 22: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/22.jpg)
Common defects with safety valves
Broken spring or spring with crack or spring with
pittings.
Worn out seat or steam cut through the seat.
Bent spindle.
![Page 23: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/23.jpg)
GAUGE GLASS
Function: To provide level indication for boiler water
Every boiler shall be provided with:-
Two gauge glasses
If evaporative capacity <300 lb/hr of steam from
and at 212 0F
- one gauge glass with two test cocks
The lowest visible part shall not be lower
than the lowest safe working level
BOILER ESSENTIAL FITTINGS
![Page 24: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/24.jpg)
GAUGE GLASS
![Page 25: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/25.jpg)
Common defects with water gauges
Both ends of the gauge worn out.
Inlet pipe chokes with scales.
![Page 26: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/26.jpg)
WATER COLUMN
![Page 27: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/27.jpg)
PRESSURE GAUGE
Function: To provide pressure indication for a boiler
Every boiler shall be provided with:-
A steam pressure gauge
Fitted above the highest part of the steam side
Provided with a siphon
Dial not less than 6 inches in diameter
Graduation from 0 to not < 11 3 times but
not > 2 times the ASWP
BOILER ESSENTIAL FITTINGS
![Page 28: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/28.jpg)
Pressure gauges • Every steam boiler shall have a pressure gauge.
• Every pressure gauge shall be connected to a boiler above the highest water level with the dial of the gauge in the vertical plane. It can be read from the firing position. A dial shall
– > 6‖ diameter
– scale ranges from 0 PSI to between 1 to 2 times authorized working pressure.
– Red mark to indicate max. authorized working pressure.
• Pressure gauges are connected to the steam space of boiler usually have a ring type siphon tub which fills with condensed steam and protect the dial mechanism from high temperatures.
.
Pressure gauge with ring siphon
![Page 29: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/29.jpg)
INSPECTOR‘S TEST PRESSURE GAUGE
ATTACHMENT
Function: To provide a connection for a reliable
pressure gauge of the Inspector and check the
accuracy and recalibration
Every boiler shall be provided with:-
An Inspector‘s test pressure gauge attachment
Consists of a valve or cock carrying a socket fitted with a plug
Mounted near the pressure gauge
BOILER ESSENTIAL FITTINGS
![Page 30: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/30.jpg)
PRESSURE GAUGE ATTACHMENT
![Page 31: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/31.jpg)
MAIN STOP VALVE
Function: To put boiler into service and stop the
steam supply when the boiler is shut
down
Every boiler shall be provided with:-
A main steam stop valve
Fitted direct to the boiler shell
Bear the manufacturer‘s name, design pressure and direction of flow
BOILER ESSENTIAL FITTINGS
![Page 32: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/32.jpg)
MAIN STOP VALVE
![Page 33: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/33.jpg)
LOW WATER ALARM
Function: To provide an audible sound when the
water level is low
Every boiler shall be provided with:-
A low water alarm - for boilers :-
Fired with solid fuel & press > 250 psi or
Fired with liquid/gaseous fuel not fitted
with low water fuel cut out
BOILER ESSENTIAL FITTINGS
![Page 34: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/34.jpg)
LOW WATER ALARM
![Page 35: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/35.jpg)
LOW WATER FUEL CUT-OUT
Function: To stop the boiler immediately by shutting
off fuel and air supply in the event of very
low water level
Every boiler shall be provided with:-
A low water fuel cut-out - boilers fired with liquid &
gaseous fuel
Connected to burner control system
BOILER ESSENTIAL FITTINGS
![Page 36: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/36.jpg)
LOW WATER FUEL CUT-OUT
![Page 37: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/37.jpg)
Common defects with water alarm
Mobrey float is water logged.
Mobrey float is dented.
Inlet pipe choked with scale.
![Page 38: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/38.jpg)
FUSIBLE PLUG
Function: To give early protection from direct heat in
the event of loss of boiler water
Every boiler shall be provided with:-
A fusible plug - boilers fired with solid fuels only
Fitted 2 to 3 inches above the highest tubes
Fusible alloy shall melt at a temp not
>150 0F greater than saturated steam
temp corresponding to the ASWP
BOILER ESSENTIAL FITTINGS
![Page 39: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/39.jpg)
LOCATION OF A FUSIBLE PLUG
![Page 40: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/40.jpg)
FEED PUMP
Function: Draws water from the feed tank and
delivers it under pressure to the boiler
Every boiler shall be provided with:-
Two feed pumps - heating surface area >150 sq ft
BOILER ESSENTIAL FITTINGS
![Page 41: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/41.jpg)
FEED CHECK VALVE
Function: To control amount of feedwater to the
boiler and prevent back flow of feedwater
from the boiler
Every boiler shall be provided with:-
A feed check valve
Clearly marked with the flow direction
Bear the manufacturer‘s name and design pressure
BOILER ESSENTIAL FITTINGS
![Page 42: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/42.jpg)
FEED CHECK VALVE
![Page 43: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/43.jpg)
Common defects with check valve
Bent spring.
Seat worn out.
![Page 44: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/44.jpg)
BLOWDOWN VALVE
Function: To remove impurities and control water
level
Every boiler shall be provided with:-
A blowdown valve
Attached direct to the shell and at the lowest
point of the boiler
Bore not < 1 inch in diameter
Clear indication of open & close position
BOILER ESSENTIAL FITTINGS
![Page 45: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/45.jpg)
BLOWDOWN VALVE
![Page 46: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/46.jpg)
Common defects with blow down valve
Seat with steam cutting.
90° turn gear worn out.
Seat surface worn out.
Handle broken.
![Page 47: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/47.jpg)
BOILER DEFECTS
Crack of metal part or welding part – nozzle
crack, shell crack, header crack etc.
Tube burst
Buldging or dented at furnace side or tubesheet
Pipe sagging
Pitting and corrosion
Hard scaling
![Page 48: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/48.jpg)
Inspection of Foundation To check the existence of any
cracks in the brick lying,
confirmation shall be done for
the expansion clearance and
condition of heat insulation.
![Page 49: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/49.jpg)
Flue Gas System
![Page 50: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/50.jpg)
Fire Side
![Page 51: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/51.jpg)
![Page 52: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/52.jpg)
ILLEGAL REPAIR
![Page 53: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/53.jpg)
Superheater : 1 - 1.25 ton steam/tube
![Page 54: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/54.jpg)
Violent rupture caused by scaling
This tube is bent almost to a right angle, caused by the severity of the burst
![Page 55: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/55.jpg)
A rupture at a single bulge
The tube had experienced long-term overheating caused by scaling
![Page 56: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/56.jpg)
Rupture Caused by Scaling
![Page 57: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/57.jpg)
![Page 58: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/58.jpg)
Scaling
WATER SIDE
![Page 59: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/59.jpg)
WATER SIDE
![Page 60: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/60.jpg)
Corrosion Pitting
![Page 61: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/61.jpg)
Drums and Internal Parts
![Page 62: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/62.jpg)
PRESSURE VESSEL
![Page 63: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/63.jpg)
Definition
"unfired pressure vessel" means any enclosed vessel under pressure greater than atmospheric pressure by any gas or mixture or combination of gases and includes any vessel under pressure of steam external to the steam boiler and any vessel which is under pressure of a liquid or gas or both, and any vessel subject internally to a pressure less than atmospheric pressure but does not include gas cylinders;
![Page 64: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/64.jpg)
Definition
"fired pressure vessel" means an enclosed
vessel under pressure greater than
atmospheric pressure which is subjected
to direct firing, but does not include a
steam boiler;
![Page 65: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/65.jpg)
Bekas Udara / Tangki LPG
![Page 66: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/66.jpg)
![Page 67: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/67.jpg)
Pengandung Di Loji Petrokimia / Loji Penapisan Minyak
![Page 68: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/68.jpg)
![Page 69: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/69.jpg)
![Page 70: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/70.jpg)
![Page 71: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/71.jpg)
Inspection
External Inspection
Internal Inspection
Hydrostatic Test
Leak Test
Proof Test
![Page 72: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/72.jpg)
Name Plate
Inspection Hole/Door
Pressure Gage
Drain Cock
ESSENTIAL FITTINGS
Steam Receiver
Stop Valve
![Page 73: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/73.jpg)
Name Plate
Drain Cock
Pressure Gage
Inspection Hole
ESSENTIAL FITTINGS
Air Receiver
![Page 74: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/74.jpg)
Safety Valve/ Rupture Disc
Pressure Gage
Name Plate
ESSENTIAL FITTINGS
Other Vessels
![Page 75: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/75.jpg)
SAFETY RELIEF VALVE
![Page 76: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/76.jpg)
Conventional
Metal Rupture Disc
CHOOSE TYPE
![Page 77: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/77.jpg)
Pressure gauge
(i) not be less than three inches in diameter across
the dial: Provided that where the external shell
diameter of the unfired pressure vessel is less
than twelve inches and the pressure in such
vessel is not more than one hundred and fifty
pounds per square inch, such gauge shall not be
less than two inches in diameter;
(ii) be graduated from zero to not less than one and
one-third times and not more than twice the
authorised safe working pressure of the pressure
vessel to which it is fitted;
(iii) have the authorised safe working pressure clearly
marked in red on the dial;
(iv)be provided with a single stop pin at the lowest
pressure reading;
(v) accurately show the pressure within a tolerance
of plus or minus two per centum of the authorised
safe working pressure of the pressure vessel to
which it is attached.
![Page 78: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/78.jpg)
Name plat
![Page 79: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/79.jpg)
Stop Valve
![Page 80: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/80.jpg)
Drain Pits
![Page 81: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/81.jpg)
External Inspection
![Page 82: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/82.jpg)
Evident of Leakage
External Inspection
Any leakage of gas, vapour
or liquid should be
investigated. A leakage
coming from behind
insulation coverings,
supports or settings, or
evidence of a past leakage
should be thoroughly
investigated by removing
any covering necessary to
establish the source.
![Page 83: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/83.jpg)
Structure Attachments
External Inspection
The mountings for an unfired
pressure vessel should be
checked for adequate allowance
for expansion and contraction,
such as that provided by slotted
bolt holes or unobstructed saddle
mountings. Attachments of legs,
saddles, skirts or other supports
should be examined for distortion
or cracks at welds.
![Page 84: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/84.jpg)
Vessel Connections
External Inspection
Manholes, reinforcing plates, nozz1es
or other connections should be
examined for cracks, deformation or
other defects. Bolts and nuts should
be checked for corrosion or defects.
Tell tale holes in reinforcing plates
should remain open to provide visual
evidence of leakage as well as to
prevent pressure built up between the
vessel and reinforcing plate.
Accessible flange faces should be
examined for distortion and to
determine the condition of gasket
seating surfaces
![Page 85: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/85.jpg)
Abrasives
Dents
Distortion
Cuts and Gouges
Surface Inspection
Weld Joints (New Vessel)
External Inspection
![Page 86: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/86.jpg)
COMMON WELDING DEFECT
![Page 87: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/87.jpg)
?? Reduced Inlet Piping
Anything wrong
here?
Reduced
Inlet Piping
![Page 88: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/88.jpg)
?? Discharges Pointing Down Anything wrong
here?
Anything wrong
here?
Discharges
Pointing Down
![Page 89: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/89.jpg)
?? Long Moment Arm
Anything wrong
here?
Long
Moment Arm
![Page 90: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/90.jpg)
?? Will these bolts hold in a relief
event
Anything wrong
here?
Will these
bolts hold
in a
relief event?
![Page 91: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/91.jpg)
Internal Inspection
A general visual inspection is the first
step in making an internal inspection. All
parts of the vessel should be inspected
for corrosion, erosion, hydrogen
blistering, deformation, cracking and
laminations
![Page 92: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/92.jpg)
Internal Inspection
![Page 93: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/93.jpg)
Uniform Corrosion
![Page 94: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/94.jpg)
Pitting
Pitting Corrosion showing wormhole
attack pattern, where pits are
interconnected.
![Page 95: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/95.jpg)
Corrosion Pitting Narrow,deep
Shallow, wide
Elliptical
Undercutting
![Page 96: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/96.jpg)
Galvanic Corrosion
Galvanic ringworm corrosion, often
occurring four to six inches from the upset,
where carbon particles have been
spheroidized.
![Page 97: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/97.jpg)
Heat Affected Zone
Heat-affected zone (HAZ) corrosion is a
type of galvanic corrosion which occurs
along a weld seam.
![Page 98: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/98.jpg)
Grooving Corrosion
Raindrop attack occurs in gas condensate
wells. In areas, water condenses on the
metal surface, causing deep pits with tails
![Page 99: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/99.jpg)
Creep Corrosion
Mesa attack is a form of CO2 corrosion
that occurs in flowing environments, and
occurs where a protective iron carbonate
coating is worn away in areas.
![Page 100: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/100.jpg)
Erosion Corrosion
Erosion Corrosion, or flow-enhanced
corrosion, usually occurs in areas where
the diameter of the pipe or direction of flow
is changing. Severe metal loss can quickly
occur.
![Page 101: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/101.jpg)
Fatigue
Corrosion due to fatigue occurs in areas
of cyclic stresses. Here we see fatigue
corrosion in a drill pipe.
![Page 102: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/102.jpg)
Crack
![Page 103: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/103.jpg)
INSPECTION OF HEAT EXCHANGER
![Page 104: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/104.jpg)
NDT is used to inspect pipelines to prevent leaks that could damage the environment. Visual inspection, radiography and electromagnetic testing are some of the NDT methods used.
Remote visual inspection using a robotic crawler.
Radiography of weld joints.
Magnetic flux leakage inspection. This device, known as a pig, is placed in the pipeline and collects data on the condition of the pipe as it is pushed along by whatever is being transported.
Pipeline Inspection
![Page 105: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/105.jpg)
Non Destructive Testing
![Page 106: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/106.jpg)
The use of noninvasive
techniques to determine
the integrity of a material,
component or structure
or
quantitatively measure
some characteristic of
an object.
i.e. Inspect or measure without doing harm.
Definition of NDT
![Page 107: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/107.jpg)
Six Most Common NDT
Methods • Visual
• Liquid Penetrant
• Magnetic
• Ultrasonic
• Eddy Current
• X-ray
![Page 108: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/108.jpg)
Most basic and common
inspection method.
Tools include fiberscopes,
borescopes, magnifying
glasses and mirrors.
Robotic crawlers permit
observation in hazardous or
tight areas, such as air ducts,
reactors, pipelines.
Portable video inspection
unit with zoom allows
inspection of large tanks
and vessels, railroad tank
cars, sewer lines.
Visual Inspection
![Page 109: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/109.jpg)
SPECIMEN
SPECIMEN
SPECIMEN
STEP 1:
CLEAN THE SPECIMEN WITH
THE CLEANER
STEP 2:
WIPE DRY THE SURFACE AND
SPRAY THE PENETRANT
THOROUGHLY ON THE SURFACE
AND LET IT SETTLES, 15-20
MINUTES. WIPE CLEAN THE
SURFACE.
STEP 3:
APPLY THE DEVELOPER (WHITE)
AND LET IT SETTLES FOR A FEW
MINUTES. RED LINE APPEARS ON
THE SURFACE WITH HAIR LINE
CRACK
HAIRLINE
CRACK
HAIRLINE
CRACK
DEVELOPER HAIRLINE CRACK
APPEAR RED
DYE PENETRANT PROCESS
![Page 110: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/110.jpg)
• A liquid with high surface wetting characteristics is
applied to the surface of the part and allowed time to
seep into surface breaking defects.
• The excess liquid is removed from the surface of
the part.
• A developer (powder) is applied to pull the
trapped penetrant out the defect and spread it on
the surface where it can be seen.
• Visual inspection is the final step in the process.
The penetrant used is often loaded with a
fluorescent dye and the inspection is done under
UV light to increase test sensitivity.
Liquid Penetrant Inspection
![Page 111: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/111.jpg)
Magnetic Particle
Inspection The part is magnetized. Finely milled iron particles coated with a dye
pigment are then applied to the specimen. These particles are
attracted to magnetic flux leakage fields and will cluster to form an
indication directly over the discontinuity. This indication can be
visually detected under proper lighting conditions.
![Page 112: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/112.jpg)
Magnetic Particle Crack
Indications
![Page 113: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/113.jpg)
Radiography The radiation used in radiography testing is a higher energy (shorter wavelength) version of the electromagnetic waves that we see as visible light. The radiation can come from an X-ray generator or a radioactive source.
High Electrical Potential
Electrons
- +
X-ray Generator
or Radioactive
Source Creates
Radiation
Exposure Recording Device
Radiation
Penetrate
the Sample
![Page 114: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/114.jpg)
Film Radiography
Top view of developed film
X-ray film
The part is placed between the radiation
source and a piece of film. The part will
stop some of the radiation. Thicker and
more dense area will stop more of the
radiation.
= more exposure
= less exposure
The film darkness
(density) will vary with
the amount of radiation
reaching the film through
the test object.
![Page 115: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/115.jpg)
Cracks
Transverse
cracks
Welding defect: Transverse crack. A fracture in the weld metal running across the weld.
Welding defect: Longitudinal root crack. A fracture in the weld metal at the edge of the root pass.
Longitudinal
cracks
![Page 116: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/116.jpg)
Cavities Root pass aligned
porosity
Welding defect : Root pass aligned porosity. Rounded and elongated voids in the bottom of the weld aligned along the weld centerline.
Solid inclusion
Tungsten inclusion
Welding defect : Tungsten inclusions. Random bits of tungsten fused, but not melted, into the weld metal.
![Page 117: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/117.jpg)
Lack of fusion and penetration
Lack of sidewall fusion
Welding defect : Lack of sidewall fusion (LOF). Elongated voids between the weld beads and the joint surfaces to be welded.
Lack of inter-run fusion
Welding defect : Inter-pass slag inclusions. Usually nonmetallic impurities that solidified on the weld surface and were not removed between weld passes.
![Page 118: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/118.jpg)
Lack of fusion and penetration
Incomplete root penetration
Welding defect : Incomplete or lack of penetration (LOP). The edges of the pieces have not been welded together, usually at the bottom of single V-groove welds.
Radiographic image : A darker density band, with very straight parallel edges, in the center of the width of the weld image.
![Page 119: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/119.jpg)
Conductive material
Coil Coil's magnetic field
Eddy currents
Eddy current's magnetic field
Eddy Current Testing
![Page 120: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/120.jpg)
Eddy Current Testing Eddy current testing is particularly well suited for detecting surface
cracks but can also be used to make electrical conductivity and
coating thickness measurements. Here a small surface probe is
scanned over the part surface in a attempt to detect a crack
![Page 121: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/121.jpg)
Power Plant Inspection
Prob
e Signals produced
by various
amounts of
corrosion thinning.
Periodically, power plants are
shutdown for inspection.
Inspectors feed eddy current
probes into heat exchanger tubes
to check for corrosion damage.
Pipe with damage
![Page 122: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/122.jpg)
High frequency sound waves are introduced into a material and they are reflected back from surfaces or flaws. Reflected sound energy is displayed versus time, and inspector can visualize a cross section of the specimen showing the depth of features that reflect sound. f
plate
crack
0 2 4 6 8 10
initial
pulse
crack
echo
back surface
echo
Oscilloscope, or
flaw detector
screen
Ultrasonic Inspection (Pulse-
Echo)
![Page 123: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/123.jpg)
Hydrostatic Test
• Every pressurised equipment must be subjected to
hydrostatic test and witnessed by DOSH Inspector
• Review the manufacturing data report
• Carry out the measurement of the pressurised
equipment and must be in accordance with the
approved drawing
• Hard stamp on flange and issue JKJ 127 if the
test is successful
![Page 124: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/124.jpg)
Why Hydrostatic Test
To check the structure integrity of the
vessel
To check against brittle fracture
To check for leak, and
To obtain a more favourable strees
distribution in a high localised stress
region.
![Page 125: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/125.jpg)
Hazard on Hydrostatic Test
![Page 126: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/126.jpg)
Leak/Soap Test
![Page 127: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/127.jpg)
Pemeriksaan kebocoran
dengan menggunakan
buih sabun untuk tangki
gas
Perkeliling Ketua Pengarah Bil 1 Tahun
2000
![Page 128: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/128.jpg)
Leak Test
Oil separator
vaporiser Piping and
valve
Aboveground LPG
Tank Installation
![Page 129: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/129.jpg)
HOSTING MACHINE
![Page 130: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/130.jpg)
Definition
Hoisting Machine
any equipment for lifting, raising or lowering load such as a lift, escalator, hoist, crane, winch, dragline, piling machine, aerial cableway, funicular railway, access platform, dumbwaiter, vertical conveyor lifter and mechanical loading ramp, and includes transporter, walkalator and other similar equipment, but does not include manual hoist and materials handling equipment
![Page 131: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/131.jpg)
Main crane types
![Page 132: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/132.jpg)
Main crane types
![Page 133: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/133.jpg)
Main crane types
![Page 134: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/134.jpg)
Kereta Kabel
![Page 135: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/135.jpg)
Kren Kembara Atas (OTC)
![Page 136: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/136.jpg)
Kren Derik
![Page 137: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/137.jpg)
OPERATOR KREN
(Bergerak dan Menara)
ORANG KOMPETEN LIF
PENGENDALIAN MESIN PERLU ORANG YANG
TERLATIH
FMA Bahagian III : Orang yang bertanggungjawab/ menerima
latihan yang mencukupi. (Peraturan 26)
![Page 138: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/138.jpg)
TOWER CRANE
![Page 139: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/139.jpg)
Page 139
Features of OTC
![Page 140: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/140.jpg)
Gantry Crane
Control box
Hook
Hook block
Girder
Crab Rail
Hoist Drum
SWL
![Page 141: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/141.jpg)
TYPES OF CRANES
![Page 142: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/142.jpg)
Safety Feature
![Page 143: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/143.jpg)
Structure Inspection
![Page 144: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/144.jpg)
Pendant & Remote Controls
Ensure that all controls are clearly marked
for their intended functions
![Page 145: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/145.jpg)
Securing the hoist rope
to the drum
There must be a minimum of 2 wraps of wire on the drum
when ever the hook block is at its lowest point
![Page 146: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/146.jpg)
ANTI COLLISION
![Page 147: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/147.jpg)
Flashing lights/Audible alarms
![Page 148: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/148.jpg)
Wire Rope Inspection Electromagnetic devices and visual inspections are used to find broken wires and other damage to the wire rope that is used in cranes and other lifting devices.
![Page 149: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/149.jpg)
Wire Rope Construction
![Page 150: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/150.jpg)
Wire Rope Construction
![Page 151: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/151.jpg)
Cth : Lang’s lay FSWR
- biasanya digunakan untuk luffing
- bukan untuk mengangkat
Lebih flaksibel dan kukuh berbanding
kaedah pembentangan biasa.
Digunakan untuk excavator , dragline
pile driving rope
![Page 152: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/152.jpg)
Page 152
Wire Rope Construction
![Page 153: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/153.jpg)
KEROSAKAN WIRE ROPE : KINK
Bagaimanakah ianya
terjadi?
![Page 154: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/154.jpg)
Fatigue
Bending fatigue breaks on ropes made out of compacted outer strands. The distribution of bending fatigue wire breaks is typically random.
![Page 155: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/155.jpg)
Fatigue
Heavily worn wire rope with a few fatigue breaks. The wire ends are displaced in different directions because of rope twist.
![Page 156: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/156.jpg)
Fatigue
This six-strand rope displays almost no wear but a great number of fatigue breaks.
![Page 157: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/157.jpg)
Birdcage damage
![Page 158: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/158.jpg)
Bagaimana cara yang betul untuk
mengukur diameter ??..
Diameter
berkurang kepada
85 % atau lebih
![Page 159: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/159.jpg)
159
Wire rope yang rosak
Broken Strands
Wire rope yang rosak perlulah dikeluarkan untuk
diservis/ diganti
Crushed Rope
![Page 160: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/160.jpg)
Page 160
Wire Rope Defect
Three randomly distributed broken
wires in one strand, in one rope lay.
![Page 161: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/161.jpg)
Page 161
Corrosion of the rope or end attachments.
Wire Rope Defect
![Page 162: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/162.jpg)
Fakta menarik
Sumber : Dave Hermanowski,
Manager of technical training for Harnischfeger Institute, US
Lebih 90 % kes melibatkan kemalangan barang angkatan jatuh dari overhead crane telah dilaporkan adalah akibat kegagalan pada wirerope.
![Page 163: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/163.jpg)
Amalan yang baik mengendalikan
wire rope
SALAH BETUL
![Page 164: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/164.jpg)
Amalan yang baik mengendalikan
wire rope
![Page 165: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/165.jpg)
Lifting hook The lifting hook must be stamped or
marked with the SWL
Is is an offence to ride on the lift hook
Only approved lifting cages are allowed to
be use when lifting people
![Page 166: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/166.jpg)
Page 166
Hook Requirement Provided with safety latch
Hook opening
Hook twisting
No cracks
Hook
Opening
Twisting
![Page 167: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/167.jpg)
Hook Requirement
![Page 168: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/168.jpg)
The grooves must be smooth and free from surface defects which could cause rope damage
Sheaves
![Page 169: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/169.jpg)
Three Types of Slings
1. Chain Slings
2. Wire Rope Slings
3. Synthetic Web Slings
![Page 170: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/170.jpg)
Identification Tag
![Page 171: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/171.jpg)
Sling Load Capacity and Sling
Angles The load capacity of the sling is
determined by its weakest component.
Never overload a sling.
Remember, the wider the sling legs are spread apart, the less the sling can
lift!
1000 lbs Lift Capacity
707 lbs Lift Capacity 500 lbs Lift Capacity
![Page 172: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/172.jpg)
Synthetic Slings Sling capacity varies from manufacturer to
manufacturer, no set standard like wire rope has.
User must look at Individual Sling Capacity Tag to
determine Safe Lifting Capacity of that sling.
If the Tag is not readable or is missing,
Do not use it!
Inspect sling before each days use, and as often as
necessary during the day to assure safety of sling!
Sharp edges can slice a sling in two without warning
as the load is tensioned. Use softeners or padding
on corners.
![Page 174: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/174.jpg)
Jangan digunakan jika terdapat
Kesan kerosakan :
1. Asid
2. Terbakar
3. Terpotong
4. Terputus dari regangan
5. Geseran berlebihan
6. Kesan kelaran
7. Kesan tertebuk
8. Regangan berlebihan/ carik
9. Kehilangan tag/ pudar
![Page 175: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/175.jpg)
Chain Slings
![Page 176: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/176.jpg)
Hi Tensile Chain Slings
![Page 177: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/177.jpg)
Chain Grade Identification
Chains are marked on a link at intervals
The word ‗grade‘ means the strength of chain
If there are no marks or stamping, the chain should be considered to be mild steel grade L
![Page 178: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/178.jpg)
Chain Slings Only Grade 8 or better ALLOY Chain can be used for
overhead lifting purposes! All chain is not rated the same!
Chain must have a capacity tag attached to it.
Chains will withstand more rough handling and abuse, but a
chain with the same rated lifting capacity of wire rope will be
much larger in diameter and heavier in weight.
Chains must be inspected daily before use and as often as
necessary during use to assure safety.
It is the riggers responsibility to do the inspections!
![Page 179: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/179.jpg)
Chain Sling Inspection Items Cracks, stretches, severe nicks, gouges, welding
splattered or deformed master links, coupling links, chains or other components.
One leg of a double or triple chain sling is longer than the others.
Hooks have been opened more than 25% of the normal throat opening measured at the narrowest point or twisted more than 10 degrees from the plane of the unbent hook.
Chain size at any point of any link is less than stated in the chart on the next slide, the sling shall be removed.
![Page 180: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/180.jpg)
Chain Slings
Only chain slings purchased from
the manufacturer are allowed.
No homemade slings allowed!!
![Page 181: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/181.jpg)
Wire Rope Sling Capacities
![Page 182: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/182.jpg)
Wire Rope Sling Choker
Adjustments
![Page 183: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/183.jpg)
Types of Wire Wire Rope Slings
![Page 184: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/184.jpg)
Wire Rope Sling Inspection Items
Three randomly distributed broken wires in one strand, in one rope lay.
Wear or scraping of 1/3 the original diameter of outside individual wires.
Kinking, crushing or any damage resulting in distortion of the wire rope.
End attachments that are cracked, worn or deformed.
Corrosion of the rope or end attachments.
![Page 185: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/185.jpg)
185
Rigging Equipment Slings
Types of slings include alloy steel chain, wire rope, metal mesh, natural or
synthetic fiber rope, and synthetic web.
Chain Wire rope Metal mesh Synthetic
![Page 186: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/186.jpg)
Page 186
Wire Rope Socket
![Page 187: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/187.jpg)
Page 187
Wire Rope Clip
![Page 188: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/188.jpg)
Safe Usage Practices
Slings should be stored off of
the floor and hung on racks
whenever possible in a clean,
dry environment.
Never drag slings across the
floor.
Always hook with a “closed
hook” arrangement (hooks
facing out).
![Page 189: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/189.jpg)
Spreader Bar Spreader bars are used when our slings
go outside120° (angle)
![Page 190: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/190.jpg)
Spreader Bar
![Page 191: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/191.jpg)
Storage Store undercover on suitable racks or on hanging
pegs
Clean, inspect and lubricate
![Page 192: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/192.jpg)
Shackles There are two main types of shackle —
―Dee‖ and ―Bow‖
Never use a shackle or pin which is bent
Never allow a shackle to be pulled at an
angle
![Page 193: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/193.jpg)
Eyebolts
![Page 194: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/194.jpg)
Minimum size for: Rope hand held as a tag-line on loads is 16mm.
Load restrains – 12mm
![Page 195: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/195.jpg)
Common Hooks and Shorteners
![Page 196: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/196.jpg)
Plate Clamp
Plate Clamps are used to lift steel plate.
They should be used at all times when
lifting plate steel.
Before using the clamp always read the
Operator‘s Manual supplied with the
clamp. Do not UNDERLOAD the lifting
clamp.
The minimum working load must be at
least 10% of the W.L.L;
![Page 197: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/197.jpg)
Plate Clamp
![Page 198: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/198.jpg)
Plate Clamp
![Page 199: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/199.jpg)
![Page 200: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/200.jpg)
Chain blocks and come along
NEVER use a hoist for
lifting, supporting or
transporting people
![Page 201: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/201.jpg)
![Page 202: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/202.jpg)
1926.550(a)(8) Belts, gears, shafts, pulleys, sprockets, spindles,
drums, fly wheels, chains, or other reciprocating, rotating, or other
moving parts or equipment shall be guarded if such parts are
exposed to contact by employees.
![Page 203: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/203.jpg)
![Page 204: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/204.jpg)
![Page 205: Machinery safety inspection](https://reader034.fdocuments.us/reader034/viewer/2022050801/554a1b9fb4c9058c5d8b53ad/html5/thumbnails/205.jpg)