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SAFETY IN OPERATION OF

P&M EQUIPMENT

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OBJECTIVE

TO IDENTIFY POTENTIAL

HAZARDS IN PLANT & MACHINERY AND

TAKE APPROPRIATE CORRECTIVE ACTION

TO PREVENT ACCIDENTS

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SAFETY MANAGEMENT

ISafety :- Danger Free Situation / Work Environment

EXITEXITMAIN MENUMAIN MENU>><<

RESPONSIBILITIES OF AN EMPLOYER

* A safe System of Work (Methodology & Removal of U/A)

* Safe Access to & Egress from the place of work

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A HAZARD IS SOMETHING WITH THE POTENTIAL TO CAUSE INJURY.

Ex : A naked cable lying on the ground.

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RISK IS THE LIKELIHOOD THAT THE HAZARD WILL RESULT IN AN ACCIDENT.

RISK ALSO CONSIDERS HOW SERIOUS THE RESULTANT INJURY WOULD BE.

Ex : A person receiving injury due to a naked cable.

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PLANT & MACHINERY PLANT & MACHINERY

LTCG - SAFETY ENGG. DEPT. (S-1)

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BROAD SAFETY FEATURES OF VARIOUS PLANT, MACHINERY & EQUIPMENT.

BROAD SAFETY FEATURES OF VARIOUS PLANT, MACHINERY & EQUIPMENT.

EARTH MOVING & CRANE

MATERIAL HANDLING

PERSONNEL HANDLING

PLANTS (Batching, Crushing, Hotmix etc.)

ELECTRICAL SYSTEMS & M ACHINES

LTCG - SAFETY ENGG. DEPT. (S-2)

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•COMPETENT / TRAINED OPERATOR & SIGNALMAN.

•SAFE OPERATION WITHIN SPECIFIED LIMITS.

•SAFE WORK CONDITIONS (Suitable Ground Condition, Safe access/egress, Emergency exits, Interlocking & Guards,)

• REGULAR SAFETY INSPECTION.

•PREVENTIVE MAINTENANCE

•TAG-OUTS / LOCK-OUTS.

LTCG - SAFETY ENGG. DEPT. (S-3)

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SAFETY SYSTEMS RELEVANT TO P&M.SAFETY SYSTEMS RELEVANT TO P&M.

1. CRANES INSPECTION CHECKLIST & REPORT.

2. VEHICLE AND EARTH MOVING EQUIPMENT INSPECTION CHECKLIST AND

REPORT.

3 ELECTRICAL SAFETY INSPECTIONCHECKLIST & REPORT.

4. WORK PERMIT SYSTEMS.LTCG - SAFETY ENGG. DEPT. (S-4)

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How User Departments Can Help P&M Department

Spare equipment in time for routine maintenance During recruitment of skilled workmen, site P&M Dept. should

be involved Trained manpower (technicians & operators) should be preferred

for daily rated workmen Ensure hired eqpt. are inspected by P&M Dept. before hiring

contracts are concluded. Assist site P&M Dept. to carry out Predespatch repairs Provide manpower, money & time for above Equipment misuse to be avoided. Release equipment when it is not required. Involve P&M in-charges in the site meetings. Recognise P&M efforts & initiatives at site and share their

problems & your achievements.

* * * * *

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CONCLUSION

Let us identify the potential P&M Hazards,

take corrective action in time and

prevent accidents.

EXITEXITMAIN MENUMAIN MENU>><<

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SAFETY IN CRANE

OPERATIONS

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CRANES

MOBILE CRANE

TOWER CRANE

GANTRY CRANE

OVERHEAD TRAVERSE

CRANE

CRANE WITH HEAVY LIFT

ATTACHMENT

CRAWLER MAUNTED

WHEEL MOUNTED

FORK LIFTS

SEMI GANTRY CRANE

CANTILEVER GANTRY CRANE

TYPES OF CRANETYPES OF CRANE

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CRAWLER MOUNTED LATTICE BOOM CRANES - NOMENCLATURE

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CALCULATING THE SIDE CLEARENCE AND HEAD ROOM

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CALCULATING THE SIDE CLEARENCE AND HEAD ROOM

r

R

A

D C

O B

DCOB

ACAB

DC

OB

X AC

AB

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SAFE USAGE OF CRANESAFE USAGE OF CRANE

VARIOUS LOAD TO BE CONSIDERED:

1. VERTICAL FORCES DUE TO LOAD / WEIGHT OF CRANE

2. HORIZONTAL INERTIA

3. SLEWING FORCES

4. WIND FORCES

5. SIESMIC FORCES

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STABILITY OF THE CRANE STABILITY OF THE CRANE

CRANE ACT AS A LEVER

C.W.

wFULCRUM

THE FULCRUM IS NOT A POINT CONTACT. AREA OF CRAWLERS ACTS LIKE THIS

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CRANE ACT AS A LEVER

STABILITY OF THE CRANE STABILITY OF THE CRANE

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FOUR PARAMETERS ARE IMPORTANT1. OPERATING RADIUS

2. HEIGHT

3. BOOM LENGTH

4. WEIGHT OF THE LIFT

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FOUR PARAMETERS ARE IMPORTANT

r

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TIPPING DUE TO IMPROPER GROUND CONDITION

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TIPPING DUE TO OVERLOADING

r

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SAFETY CONSIDERATIONS OF CRANESSTABILITY OF CRANE AGAINST TOPPLING:

STABILITY CONSIDERATION IS THE MAIN CONCEPT CONTROLLING LOAD RATING IN A CRANE. HENCE THE ELEMENTS WHICH CONTRIBUTE TO ACT AGAINST STABILITY SHOULD BE KNOWN :

IT IS GENERAL PRACTICE, THAT BASED ON STABILITY THE CRANE RATING ARE SET AS A PERCENTAGE OF TIPPING LOAD AND IN CASE OF ‘TATA CRANE’ ALL RATINGS INDICATE, 75% OF TIPPING LOADS

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SAFETY CONSIDERATIONS OF CRANESTHE TIPPING STAGE ONCE REACHED, THE CRANE

MAY START TILTING.

WHEN THE CRANE STARTS TILTING, OPERATOR IS

IN A VERY DIFFICULT POSITION TO CONTROL THE

PROBABLE ACCIDENT BECAUSE THE TILTING

MOVEMENT IS FAIRLY RAPID.

THIS FOLLOWS THE LOAD GETTING OUT OF

RADIUS, MORE AND MORE AND ULTIMATELY

LEADING TO THE ACCIDENT.

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OPTIONS OF THE OPERATOR

1. TO DROP THE LOAD WHICH POSES SERIOUS THREAT. THE OPERATOR SHOULD POSTPONE THIS OPTION UNTIL IT APPEARS THAT OVER-TURNING OF THE CRANE IS INEVITABLE

2. BOOMING IN (HOISTING THE BOOM) QUICKLY CAN RECOVER STABILITY BUT THIS REQUIRES VERY FAST ACTION FROM THE OPERATOR.

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CRANE BOOM FAILURE•BOOM SUSPENSION IS REQUIRED WHEN LENGTH OF THE BOOM IS MORE THAN 70 FT.

•WITH MAXIMUM BOOM LENGTH AND GANTRY IN FOLDING POSITION - CRANE SHOULD NOT TRAVEL.

•WITH GANTRY LOW (FOLDING POSITION) NO LOAD SHOULD BE LIFTED

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FROZEN LOAD HANDLING

THE LOAD WHICH IS FROZEN ON THE GROUND SHOULD BE LOOSENED UP BY OTHER MEANS NOT BY USING CRANE POWER.

IN THE TOP MOST PART BUCKLING TENDENCY IS OBSERVED

BOOM SHOULD NOT BE LOADED BY OTHER LOAD OTHER THAN DESIGNATED LOAD

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FROZEN LOAD HANDLING

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CONSEQUENCES OF FROZEN LOAD HANDLING

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BOOM OVER CAB ACCIDENT

BOOM BACK STOP DOES NOT STOP BOOM FROM GOING BACKWARDS, BUT IT HELPS TO :

1. PREVENT THE OPERATOR’S CABIN FROM BEING DAMAGED - WORKING AS A WEDGE

2. WHILE TRAVELLING WITH LOAD ON UNEVEN SURFACE IT PROVIDES CUSHIONING

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BOOM OVER CAB ACCIDENT

REASONS:

1. IMPROPER ADJUSTMENT OF CLUTCH.

2. OPERATOR’S FAILURE TO DISENGAGE THE CLUTCH.

OPERATOR CAN SEE THE BOOM BACK STOP AND ASSESS THE CONDITION TO TAKE ACTION

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BOOM BACKSTOP

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“BOOM - OVER - CAB” ACCIDENT

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PREVENTION OF “BOOM - OVER - CAB” ACCIDENT1. MANY PEOPLE MISTAKENLY FEEL THAT BOOM BACKSTOP PROVIDED ON A CRANE WILL PREVENT BOOM-OVER-CAB OCCURRENCE.

THIS WOULD HAVE BEEN POSSIBLE ONLY IF THE BOOM IS PULLED TOWARDS THE CAB WITH FAIRLY LOW LEVEL PULLS AND A DEVICE PROVIDED IN THE BOOM HOIST CLUTCH, TO SLIP WHEN ENCOUNTERED LOAD RESISTANCE, BEYOND CERTAIN SAFE AMOUNT OF PULLS, WITH SIMULTANIOUS ALERT SIGNAL TO OPERATOR FOR CORRECTIVE CONTROL ACTION.

HENCE ‘TATA’ CRANES ARE FURNUSHED WITH BOOM HOIST KICK-OUT IN ADDITION TO BOOM BACK STOPS. THE BOOM HOIST CUT-OUT STOPS THE LIFTING MOTION WHEN THE BOOM REACHES CERTAIN PREDECIDED ANGLE. A FUNCTIONAL DEVICE OF THIS TYPE WOULD PREVENT OVER LIFTING OCCURRENCE. THE CRANE OPERATOR SHOULD ENSURE THAT THE BOOM HOIST KICK-OUT DEVICE IS IN OPERATIVE CONDITION ON DAILY BASIS.

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PREVENTION OF “BOOM - OVER - CAB” ACCIDENT

HOWEVER THE POSSIBILITY OF BOOM-OVER-CAB ACCIDENT IS STILL NOT COMPLETELY RULED OUT AND REMAINING FACTORS WHICH COULD CAUSE SUCH AN ACCIDENT IS DEPENDENT ON OPERATOR’S JUDGEMENT. THE CONDITION CAUSING SUCH AN ACCIDENT ARE AS UNDER:

1. DROPPING OF A HEAVY LOAD SUDDENLY OR ACCIDENTLY WITH BOOM AT NEAR VERTICAL ANGLE OR SUDDEN FAILURE OF HOIST ROPE.

2. WHEN TRAVELLING ON ROUGH TRAVEL PATHS CAUSING EXCESSIVE BOUNCE

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BOOM KICK OUT- FOR TATA CRANE

HOW IT FUNCTIONS:

WHEN THE HYDRAULIC KICK OUT SWITCH IS DEPRESSED DUE TO BOOM OVER-HOISTING, THE OIL UNDER PRESSURE FROM THE COMPENSATOR, IS RETURNED BACK TO ZERO PRESSURE OF THE RESERVOIR LINE, THEREBY DISENGAGING THE BOOM HOIST CLUTCH.

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THE PURPOSE OF BOOM BACKSTOPS IS THEREFORE LIMITED TO FOLLOWING

1. TO GIVE VISUAL INDICATION TO CRANE OPERATOR THAT HE IS REACHING UNSAFE ANGLE.

2. IN CASE OF BOOM-OVER-CAB ACCIDENT OCCURING, THE DAMAGE TO MACHINE IS LIMITED TO BENDING OF BOOM WHICH WOULD ARCH OVER THE DECK MACHINERY, AVOIDING A DIRECT HIT ON THE MACHINE.

3. TO ABSORB MINOR BOUNCING ON THE BOOM, RAISED CLOSE TO MAXIMUM ANGLE WHEN THE CRANE IS MOVING WITH LOAD.

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SAFETY RULES FOR CRANE OPERATORS

1. NEVER PICK UP A LOAD BEYOND THE RATED LOAD CAPACITY AT THE GIVEN ANGLE AND THE LENGTH OF THE BOOM

2. NEVER MOVE THE LOAD OR THE CRANE UNLESS CLEARED BY THE SIGNALER ON THE JOB. THIS IS EXTREMELY IMPORTANT WHEN THE LOAD IS HANDLED BY MORE THAN ONE CRANE.

3. WHEN THERE ARE SEVERAL PERSONS ON THE JOB OBEY SIGNAL FROM ONLY THE PERSON ASSIGNED AS THE SPOTTER (SIGNALLER). OBEY ON EMERGENCY STOP SIGNAL GIVEN BY ANY ONE.

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4. WHEN RAISING, LOWERING OR SLEWING THE LOAD, PLEASE ENSURE THAT IT WOULD SAFELY CLEAR ADJACENT STOCK PILES OR MACHINERY.

5. NEVER LEAVE THE CRANE, WITH LOAD SUSPENDED.

SAFETY RULES FOR CRANE OPERATORS

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SAFETY RULES FOR THE HOOK ON HELPER

1. BEFORE BEGINNING EACH SHIFT, CHECK SLINGS, CHAIN, HOOKS ETC.

2. WHEN CRANE IS TRAVELLING, WALK AHEAD OF THE LOAD. NEVER PERMIT ANYBODY UNDER THE LOAD.

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SAFETY IN SAFETY IN OPERATIOOPERATION OF N OF WHEEL WHEEL LOADERLOADER

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PRECAUTION DURING MAINTENANCEDO NOT STRART ENGINE IN A CONFINED SPACE

RELEASE PRESSURE BEFORE CARRYING ANY REPAIR IN HYDRAULIC SYSTEM

BE CAREFUL WHILE REMOVING REDIATION CAP

ALWAYS PUT WOODEN BLOCK UNDER RAISED COMPONENTS

ARREST WHEELS BY PUTTING BLOCK WHILE PARKING

PERIODIC CHECKING OF SAFETY COMPONENTS i.e. BRAKE PARTS, STEERING HOSES.ETC.

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WHEEL LOADER

DMAKE : L&T - CASEMODEL : W20OPERATING WEIGHT ; 9995 KGOVERALL OPERATING HEIGHT : 4674 MMHEIGHT UP TO CANOPY TOP : 3102 MMLENGTH (BUCKET IN GROUND) : 6203 MMGROUND CLEARANCE : 401 MM.LIFT CAPACITY (MAX. HEIGHT): 4757 KGLIFT CAPACITY (GROUND) : 8820KGTURNING RADIUS (CARRY) : 10820 MMARTICULATION ANGLE : 40 DEG

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SAFETY DURING OPERATION

KEEP ALL PERSONNEL CLEAR OF LOADER ARMS, ATTACHMENTS, AND ARTICULATED JOINT.

ENSURE THE OPERATERS AREA , HAND RAILS & STEPS ARE FREE OF OIL OR LOOSE OBJECTS

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SAFETY IN SAFETY IN OPERATION OF OPERATION OF VIBRATORY VIBRATORY COMPACTORCOMPACTOR

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VIBRATORY COMPACTORMODEL : 1102 OR 1104 ( L & T - VIBROMAX )OPERATING WT : 11100 Kg. MAX. SERVICE WT : 12600 Kg.AXLE LOAD : 5800 Kg (F) 5300 Kg (R)FREQUENCY : 28 / 36 Hz . AMPLITUDE : 1.6 /0.6 mmWORKING SPEED : 0 TO 6 KmPH . TRAVEL SPEED : 12 Kmph STEERING LOCK ANGLE : 37O

TURNING RADIUS : 3.7 M (Min)GRADEABILITY : 24 0

WIDTH (MAX) : 2.3 MHEIGHT (MAX) : 3.015

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VIBRATORY COMPACTOR

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BEFORE STARTINGKEEP ACCESS FACILITY AND OPERATING AREA CLEAR.

ALLOW ONLY AUTHORISED PERSON TO OPERATE THE M/C.

GIVE BRIEF IDEA TO OPERATOR ABOUT WORK ZONE

DEMARK FIRMLY WORKING ZONE FROM EXISTING LIVE TRAFFIC ZONE KEEPING CONSIDERABLE MARZINE

ENSURE THE ARTICULATION LOCK IS REMOVED

GIVE PROPER TIME FOR CHECKING / MAINTENANCE OF THE M/C BETWEEN TWO CONSECUTIVE SHIFT

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WHILE OPERATINGDON’T ALLOW ANYBODY IN OPERATOR’S CABIN / DANGLING ON FOOTREST

SHOULD BE OPERATED FROM OPERATOR’S SEAT ONLYNEVER VIBRATE WHEN M/C IS IN STAND STILL

SHOULD NOT BE OPERATED IN HIGH SPEED IN DOWNHILL.

CHECK THE EFECT OF M/C OPERATION ON BULDINGS WHILE WORKING IN CLOSE VICINITY

MOVE IN TO LOOSE SOIL WITH THE DRIVEN DRUM

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INCORRECT PRACTICESVIBRATING ON ROCK OR CONCRETE

VIBRATION ON SOILS WITH UNFAVOURABLE GRAIN PROPERTIES AND WATER CONTENT

VIBRATION ON ALREADY COMPACTED SOIL

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PARKINGBEFORE LEAVING OPERATOR’S SEAT ENSURE PRECAUTIONARY MEASURES ARE TAKEN AGAINST ROLLING AWAY OF ITS OWN.

ENGAGE PARKING BRAKEINSERT WEDGE BELOW THE

WHEELAVOID PARKING IN SLOPE

PUT INDICATION LAMP WHILE PARKED IN LIVE TRAFFIC

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SAFETY IN SAFETY IN OPERATIOOPERATION OF N OF MOTOR MOTOR GRADERGRADER

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MOTOR GRADERMODEL : GD605R2 (BEML)

WEIGHT : 12595 KGTRAVEL SPEED : MINMAX

FORWARD 305KM/Hr 43.6KMPH REVERSE 4.1KMPH51.6KMPHTURNING RADIUS : 10.4MOVERTURN ANGLE ; 350

GRADEABILITY : 240

LENGTH : 8270 MMWIDTH : 1970 + 400 MMHEIGHT : 3200 MMBLADE LENGTH : 3710 (4010) MM

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BEFORE STARTING OPERATION

CHECK THE LAY OF ROAD AND SOIL OF WORKING ZONE TO DETER MINE DENGEROUS POINTS AND BEST METHOD

ALL SYSTEMS ARE TO BE CHECKED PROPERLY ie. STEERING,BLADE, BRAKE. ANY OIL LEAKAGE AND LEFT OUT TOOLS AND TACKLES ON M/C.

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BEFORE STARTING OPERATION

ENSURE THE WORKING AREA IS CLEAR AND SOUND HORN BEFORE BACKING THE M/C.

PLEASE CHECK LEFT OUT LEAVES/PAPER/DIESEL SOAKED COTTON ON ENGINE COMPERTMENT

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AFTER STARTING THE ENGINE

•CHECK ALL WARNING DEVICES ND GAUGES

•CHECK THE PLAY AND TRAVEL OF EACH LEVER AND PEDAL

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ENSURE THE SAFETY OF WORKERS NEAR THE MACHINE

ALWAYS SOUND THE HORN TO WARN THE WORKERS WORKING NEAR THE ENGINE.

CHECK THE REAR PARTICULARLY BEFORE BACKING THE MACHINE

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•EXHAUST GAS IS VERY DANGEROUS.

•WHILE RUNNING THE ENGINES FOR LONG PERIOD IN POORLY VENTILATED AREA THERE IS A DANGER OF GAS POISONING

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•READ THE OPERATION AND MAINTENANCE MANUAL CAREFULLY.

•LEARN HOW TO USE THE CONTROL DEVICES, GAUGES AND WARNING DEVICES.

• BE SURE YOU UNDERSTAND THE MEANING OF THE CAUTION PLATES.

• REMEMBER THE CHECK POINTS AND CHECKING METHOD OF COOLING WATER AND HYDRAULIC LEVELS

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BEFORE STARTING THE MACHINE.•EXAMINE THE LAY OF THE LAND

•INSPECT LEAKAGE'S FROM THE FUEL

•USE SEAT BELT

•USE THE RAIL AND STEPS WHILE GETTING ON OR OFF THE MACHINE

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OPERATE THE BLADE TO CONFIRM THAT THEY ARE FUNCTIONING NORMALLY

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MOVE THE MACHINE SLOWLY AND LISTEN CAREFULLY TO THE ENGINE OR GEARS TO CONFIRM THAT THEY ARE NOT MAKING ANY UNUSUAL NOISES.

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•CHOOSE A SAFE PLACE AND TURN THE MACHINE RIGHT AND LEFT TO CONFIRM THAT THE STEERING DEVICES ARE FUNCTIONING NORMALLY

•IF THE TESTS REVEAL ANYTHING WRONG CONTACT THE PERSON IN CHARGE OF THE MACHINE.

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THE MACHINE SHOULD BE

ALWAYS OPERATED AT

SPEED WHERE IT CAN BE

CORRECTLY CONTROLLED.

NEVER DO THE FOLLOWING

SPEEDING

SUDDEN STARTING,

BRAKING, TURNING

SNAKING

COASTING

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•AS FAR AS POSSIBLE AVOID TURNING THE MACHINE ON A SLOPE.

•IT MAY CAUSE THE MACHINE TO ROLL OVER OR SLIP SIDEWAYS

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BEFORE GOING UP OR DOWN A SLOPE, SELECT A TRAVEL SPEED

MOST SUITED TO THE SLOPE.

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•OBSERVE TRAFFIC REGULATIONS AND LEAVE MARGIN FOR EMERGENCIES.

•NEVER ALLOW ANY PERSON THAN THE OPERATOR TO RIDE ON THE MACHINE DURING THE OPERATION

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LAND GRADING

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REPARING OF GRAVEL ROAD

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SNOW REMOVING

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SCARIFYING

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MIXING

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SPREADING

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GENERAL GENERAL PRECAUTIONSPRECAUTIONS

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BE READY TO HANDLE FIRE OR ANY OTHER MISHAP

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SAFETY IN SAFETY IN OPERATION OPERATION OF DOZEROF DOZER

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MAKE SURE THERE IS NO OBSTRUCTION OR DANGER IN THE AREA BEFORE LOWERING THE BLADE

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ALWAYS DRIVE SLOWLY WHEN PUSHING EARTH TOWARDS CLIFF

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APPLY THE BRAKE LOCK WHEN PARKING THE MACHINE

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DO NOT COAST DOWN WITH MAIN CLUTCH DISENGAGED

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MOVE THE MACHINE BACKWARDS AT ONCE WHEN IT BEGINS TO SINK IN TO THE GROUND SLIGHTLY

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ENSURE THAT THERE IS NO OBSTRUCTION WHEN REVERSING YOUR MACHINE

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MAKE SURE THAT THERE IS NO ONE FORWARD BEFORE STARTING THE MACHINE

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•Never jump on or off the running machine

•Never allow anyone to ride on the machine.

•The seat is only for the operator

•Always face in the direction of travel

•Never stand or work around the machine while it is in motion or being worked

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