Material Handling and Rigging Training Module reliacce industrial ltd .pptx

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1. SAFE MATERIAL HANDLING Targeted Audience Riggers

2. Welcome to our Facilities

3. BEFORE WE START 2

4. 3   Introduction Manual Material Handling Mechanical Material handling (a) Definition of crane. (c)Safety Guidelines & Precaution while Operating Mobile cranes (d)Hazards of crane (f)Safety Features in Cranes (g)Basics of Rigging- Four Basic Rules of Rigging, Wire Rope slings, Web slings, Safe Load Angle. 4.Material handling Visuals.  5. Case Studies Contents (e) Safety Guidelines while operating with Gantry and E O T cranes

5. INTRODUCTION 4 40% of accidents in an Industry are due to Unsafe material handling. practices.

6. 5 INTRODUCTION A process of securing the object to be moved by any lifting equipment RIGGING : Lifting Load Centre of Gravity Environment Materials involved Slings Shackles Eyebolts Spreader Beams Trunions , Lugs etc., Vessels Structural Members Pipes Rebars etc., Cranes Chain Pulley Blocks Hook Chuk Winches Rollers Jacks etc., The knowledge about rigging is crucial to incident-free execution of lifts

7. 6 MANUAL MATERIAL HANDLING Manual Handling – Any activity requiring the use of force exerted by a person to lift, push, pull, carry, or otherwise move or restrain any animate or inanimate object. The maximum recommended weight to be lifted : 55 kg

8. 7 MANUAL MATERIAL HANDLING Hazards: Strains, Sprains, Fractures, cut, bruises lumber Pain. Methods: Foot position , Knee bent, back straight, Head. Accessories: Hook , crowbar , jack, hand truck etc.

9. 8 SAFE LIFTING

10. 9 SAFE LIFTING

11. 10 SAFE LIFTING Use Your Head and Save Your Back! Stand close to the load Bend your knees - not your back ! Let your legs do the lifting Get Help with heavy or awkward loads ! Use the right tools! Means using your head!

12. 11 SAFE LIFTING Carrying the load… Hold the load close so you can see over it. Keep the load balanced. Avoid twisting the body Watch out for pinch points -- doorways, etc. Face the way you will be moving.

13. 12 MECHANICAL MATERIAL HANDLING Mechanical Materials Handling Involves various types of Chain Pulley Blocks, Winches, Different type of Cranes (Mobile cranes, Gantry cranes, EOT Cranes, Tower Cranes Etc.) Other Lifting Mechanisms. Mechanical Material Handling Enhances the Load / Shifting capacity several times than that of manual Handling

14. 13 Crane safety Definition of Crane Crane is a machine meant for lifting or lowering a load and moving it horizontally and slewing it to left or right and in which hoisting is an integral part of machine. It may be driven manually or by power and may be a fixed or mobile.

15. 14 Force X Force Y Crane weight Fulcrum Total Load x y Basic principle of Crane A Crane is designed on the Principle of load moment

16. 15 Check slings and hooks for any defects. No man movement under suspended load . No suspended load to be kept unattended . Lower the boom in adverse weather condition. SAFETY PRECAUTIONS DURING THE USE OF CRANE Don’t carry out heavy lift operation in night hours.

17. 16 Don’t perform lifting operation if wind velocity is more than 25 km/ hr. Don’t carry out any lift if visibility is limited by heavy rain, fog, low lighting etc . Don’t allow wheels of hydraulic crane to touch the ground while in use. Check condition of crane Any visual damage or oil leakage. Don’t allow free fall of load. Speed of the crane on the road to be restricted to 10 km / hr. SAFETY PRECAUTIONS DURING THE USE OF CRANE

18. 17 Lift compressed gas cylinders only in cradle . While hoisting equipment is in operation, the operator should not leave his position . When parking crane, always use the brake . Refueling should not be done while the engine is running. Minimum 3 meters is required 'in plan' between any part of the crane/load the lines of the nearest overhead cable. SAFETY PRECAUTIONS DURING THE USE OF CRANE

19. 18 Crane Operator : Display a responsible attitude and be of a minimum age of 25 years. Have a valid state / country driver's license and safe driving permit (SDP)   issued by RIL security. Medical examination. Training. Signal Man : Follow signals from authorized signalman only Emergency stop signal List of authorized signalman to be maintain CRANE OPERATORS & SIGNALMAN

20. 19 Hazards Of Crane Major hazards : Overturning of Cranes Contact with electrical cables O/H pipelines sudden release of load Damage to UGU Structural failure Contact or collision with other plant and structures Falling objects Wind Condition.

21. 20 Improper Crane Setup Over loading Two-Blocking Two-blocking occurs when the hoist block or hook assembly comes in contact with boom tip, causing the hoist line to break and the hook and load fall down. Obstruction of vision Due other object or Environment. Mechanical Failure Due to poor maintenance & improper crane operation. Operator Error Hazards of Crane

22. 21 Supporting Surfaces Soil Conditions must be sufficient. Blocking & Cribbing should be used.

23. 22 Positioning of Outriggers Transmitting the Load; must always be level.

24. 23 Positioning of Outriggers Transmitting the Load; must always be stable and never block under outrigger beams inside the floats. WRONG VIOLATION

25. 24 Effect of a swinging on load radius Always lift load gently & operate crane motions slowly to avoid swinging. (A swinging load will increase the overturning moment of the cranes

26. 25 Purpose of Outriggers Spreads out the load so the supporting surface can support it. Transmits the load without bending or breaking .

27. 26 Positioning of Outriggers Transmitting the Load - Properly placed with no gaps or spaces between pieces. VIOLATION

28. 27 Safety latch for hook blocks Hoist limit switch Anti-two-block switch Load movement indicator Swing lock Hoist wire drum lock Limit switch for boom lowering & raising Individual lock for booms Over load indicator Boom extension limit switch Swing limit switch Safety Features in Crane.

29. 28 Only authorized person can operate Fork truck. Always Secure load kept on fork of fork truck Load should not obstruct operator vision Always kept forklift neat and clean. Before taking reverse give reverse horn and check no person stand behind . Maintain daily inspection record . Guide Lines for Fork Lift Operation

30. 29 Keep all lifting tool tackles in tool box when not in use. Only authorized Person will Operate Always use seatbelt Hydra speed not exceed more then 5km when carrying material and 10km when travelling without any load. Only operator will seat in hydra. Roll over protection provide for operator Maintain daily Inspection record. Guide Line for Operation Of Hydra 8. Minimum 3 Mt.from O/H electrical lines .

31. 30 1.Only Authorize Person will operate crane . 2. Hoist operators must inspect equipment daily before use. 3. Do not carry Load From walkways. 4. No Vehicle park inside the Shop. 5. Maintain daily inspection record. 6 Do not operate a crane or hoist if limit switches, steel ropes, chains or other components are worn or in disrepair. 7. Anti collision tripping mechanism in Place 8. Crash Pad in Place Guide Line For EOT CRANE Operation

32. 31 Do not keep Gas Cylinder , Energized cable , energized machine on travelling path of crane . Do not stand between track path of crane . Lock the crane when not in use. Maintain daily inspection record . Only Authorize Person will Operate. Guideline for GANTRY CRANE

33. 32 Guideline for GANTRY CRANE Cables Lying on Rails of Gantry Crane Travel

34. 33 DEFINITIONS OF LIFT CATEGORIES Lift Category Criteria Requirement Simple Gross load is less than 10 MT Gross load represents less than 85% of the load chart at working radius. Within the normal operating parameters of the crane Lifting over non-sensitive areas Risk Assessment/ Job Safety Analysis Method of Statement Permit To work Repetitive Straight forward repetitive operations Tandem / Multiple involving the use of more than one crane Risk Assessment / Job Safety Analysis Method of Statement Permit To work Lifting Plan

35. 34 DEFINITIONS OF LIFT CATEGORIES Lift Category Criteria Requirement Complex Gross load is greater than 10 MT Gross load represents more than 85% of the load chart at working radius, Over or in sensitive areas – active or energized hydrocarbon-containing process equipment, near overhead electrical power lines Continuation of a lifting operation with different equipment (due to malfunction, inadequacy or unsuitability Tandem lift with two cranes Transferring the load from one lifting appliance to another Load with unknown / difficult to estimate weight and / or centre of gravity Load is special and / or expensive whose loss would have a serious impact on production operations Mobile crane on untested / uneven ground Load lowered into or lifted from a confined space Risk Assessment / Job Safety Analysis Method of Statement Permit To work Lifting Plan

36. 35 LIFTING PLAN Lifting Plan – a documented approved plan meticulously worked for lifting the material (Load) showing : Ground area preparation requirement. Mobile cranes with type and capacity, type of lift with counter weights. Crane hook weight. Weight and dimension of load. Boom length and luffing angle. Maximum and minimum load radius. Slings size, capacity and its weight. Included angle between slings. Mobile cranes positions, marching with load. Clearance from nearest equipment/structures for both load and counter weights. Permissible wind velocity. Percentage loading of crane capacity.

37. DEFINATION OF RIGGING Rigging is the part of the lifting operation which forms the link between the load and the lifting device.

38. 37 RIGGING PRECAUTIONS Before lifting check the sling is properly attached to the rope. Avoid impact / jerk load Never ride on a load Never allow load to be carried over the head of personnel Never work under suspended load. Ensure all personnel stand clear while load is lifting, lowered and the sling is removed. Never leave a load suspended in air when the crane/ hoist is unattended. Attach Tag Lines Prior if Necessary. .

39. 38 Wire Rope Constructed with three components 1.Core 2.Wire 3.Strand. Understanding the numbers for classification The first number is the number of strands The 2nd number is the number of wires in each strand . Center Wire rope Strand Wire Core WIRE ROPE SLINGS 6X17 6X10 most widely used class 6X37

40. Visual inspection indicates excessive damage, Wire rope sling shall be removed from service and destroyed if: Reduction of rope diameter bellow nominal diameter due to loss correct support internal or external corrosion, or wear of outside wires, A number of broken out side wires and the degree of distribution or concentration of such broken wires, the rope shows other signs of excessive wear, corrosion or defect . WIRE ROPE SLING INSPECTION Damage steel ferrule & wear-off SWL marking Unraveling Bird caging Excessive Wear Kinks Broken Wires Reduced Diameter Rope Lay Length

41. 40 DAMAGED LIFTING TOOLS AND TACKLES SHALL NOT BE USED Burn damage

42. 41 REMOVE FROM SERVICE Immediately remove damaged or defective slings from service

43. 42 Cut Damaged Non-standard Red color Coded DAMAGED LIFTING TOOLS AND TACKLES SHALL NOT BE USED

44. 43 WEB SLINGS

45. 44 CLASSIFICATION OF WEB SLING ACCORDING TO MANUFACTURING MATERIAL

46. 45 Diameter of Sling and construction of slings . A general thumb rule to estimate SWL = 8D 2 WIRE ROPE SLING CAPACITY ½ Inch sling = 0.5 X0.5 X8 = 2 Tones

47. SHACKLES Examples of Damages that can occur in Shackles Damaged Threads CRACKS

48. 47 Vertical Vertical Basket Choker RB 39 SLING HITCHES

49. 48 Make sure that the horizontal distance between the points of attachment of the load, does not exceed the length of the slings. This will ensure that the angle between the two legs of the sling does not exceed 60 o The recommended maximum angle between the two legs of a sling is 90 o. The recommended maximum angle between the vertical and any leg of a sling is 45 o Sling Angles .

50. Note: For a Safe rigging practice to keep sling angles 60 degrees 1000 LBS 1000 LBS 1000 LBS 1000 LBS 500 LBS 500 LBS 577 LBS 577 LBS 707 LBS 707 LBS 1000 LBS 1000 LBS 60° 45° 30° HORIZONTAL ANGLE AFFECT SLING CAPACITY

51. 1000 Kg T = 577 Kg 60 T = 577 Kg WIRE ROPE SLING CAPACITY AT DIFFERENT ANGLES

52. 1000 lBS T = 767 Kg 45 T = 767 Kg WIRE ROPE SLING CAPACITY AT DIFFERENT ANGLES

53. 52 T = 1000 Kg T = 1000 Kg 1000 Kgs. WIRE ROPE SLING CAPACITY AT DIFFERENT ANGLES

54. 53 1000 Kg T = 1932 Kg 15 T = 1932 Kg WIRE ROPE SLING CAPACITY AT DIFFERENT ANGLES

55. Loading / unloading of materials from truck / trailer shall be done under the supervision of a competent supervisor. Materials shall be properly secured along with truck so that they do not fall out of truck / trailer . No material should protrude out of truck, which can cause injury or property damage. In case of trucks having tail doors, doors shall be kept closed during transit. Personnel shall not sit in material compartment. They should sit only in the personnel cabin . Ensure the stacking of material in a single stack so far possible . Ensure the use of suitable sleepers dunnage / separators to facilitate safe slinging / deslinging and to prevent hands and finger injuries due to caught under the load. Ensure no body is taking rest / sitting beneath truck ,trailer parked in lay down areas etc. GUIDELINES FOR TRANSPORTATION OF MATERIAL TRUCKS/TRAILERS

56. 55 CASE STUDY 01 A crew was engaged for opening a bundle of 04 nos. of I beams. During the process of opening the bundle , one member toppled on wooden sleeper kept for stacking members and fell on the foot of a crew member causing crush injury.

57. 56 CASE STUDY 02 Fitting of cross bracings activity was carried out for electrical posts. The work was done with the help of man lift (Nifty 170) and two workers were engaged for this work. During the fitting process, bucket of the man lift twisted anti clockwise due to telescopic interlocking failure at around 3mtr height from ground. As a result workers inside the bucket fell down and sustained with minor injuries. Since they were wearing mandatory PPE’s such as helmet, safety shoe & safety harness serious injuries were averted .

58. 57 CASE STUDY 03 At one of the construction site one 75T crawler crane with 150 ft. boom was engaged by an Agency to lift and shift a load of around 12mt. While the crane was slewing the load, it lost balance and started toppling. Seeing the above crane toppling, crane operator of another agency, who was sitting in his cabin, around 40 - 45 m away, got frightened and jumped out of the cabin and tried to run away. Unfortunately he ran in the same direction where the boom was falling and got hit and trapped under the falling boom resulting in severe injuries. It seems the victim did not anticipate the risk as he was quite away from other agency’s crane and could not pay any attention to the working of the other agency’s crane. It was too late; by the time he could realize the risk and react with proper judgment.

59.   Thanks!! 58