Plant & Machinery

by
[Link] PRASAD
 Percentage of Fatalities related to
Plant & Machinery (P&M) Operations

% of
Fatalities
Related to
P&M
operations
 Siting
 Bearing Capacity of the Soil.
 If Capacity is poor a minimum three layers
of criss-cross bearing packing shall be
provided.
 The strength of foundation or structure, on
which the machinery may stand.
 The proximity of hazard, such as nearby
structures, overhead electric conductors etc.
 Fencing of Machinery
► Allrotating & Moving parts
of machines should be
guarded

► Guards should not be

removed when the machine
is on.

► Guard removed for

maintenance should be
replaced as soon as
possible.
 Types Guards
► Fixed: A permanent part of the machine, these
guards are typically made of sheet metal, screen, wire,
bars, or plastic.
► Interlocked: They control the action of the machine
by automatically shutting it off if the interlocked
guards are opened or removed.
► Adjustable:
These barriers can be manually adjusted
to accommodate various sizes and shapes of material.
► Self-adjusting: They open just enough to accept
different sizes of stock, and then automatically return
to the reset position.
 Access

Safe and adequate means of access including

handholds and footholds shall be provided to
all parts where a person may have to walk,
climb or work.
 Maintenance
► Work-permit system shall be
implemented
► Maintenance shall be done only
by authorized personnel
► No repair & maintenance works
while the machine in operation
► Electric Power shall be shut off
and relevant fuses removed.
► Lock out / Tag out system shall
be followed.
 Fire Prevention

► One 2kg Stored Pressure type Dry

Chemical Powder fire extinguisher
shall be provided in all the mobile
construction machineries.

► Extinguishers should be inspected

& maintained

► Operator to be trained on use of

fire extinguisher
 Earth Moving, Lifting & Hoisting Machinery
General

 The Operator shall be adequately,

protected from weather by providing a
cabin.
 The windows shall be provided with
toughened safety glass and wipers.
 Arrangement of the controls & Seat
should permit safe operation of the
machinery without undue fatigue and
discomfort.

 Seat Belt for the Operator to be provided,

with guardrails and toe guards.
 Brakes & Controls

 Effective braking devices shall be provided on the wheels of the

machinery.
 Manual parking brake acting on the driving wheels shall also be
provided.
 Each control shall be clearly identified to show the motions and
direction of movement.
 OPERATORS & DRIVERS

The Operators and Driver shall,

 Be Authorized and competent

 Possess License
 Cover loose hair
 Have clear view of the load & operational
area
 Act upon the instructions of the signaler
 Operators & Drivers

The Operators and Driver shall

 Not leave his cabin while the machine is running or

the load is suspended
 Switch off the electric power supply or stop the
engine and apply appropriate brakes and locks
before leaving the machine
 Have good vision and undergo the medical test for
vision once at least in every two years.
 Operators & Drivers

Before starting, the Driver shall

ensure that the gear and clutch are
in neutral, the brakes, where hand
brakes are provided, are “on”.
 Working near Overhead
Electrical Line

► 50m
 Contd….
► Avoid Working Overhead Power Line.

► In unavoidable case the following minimum

clearance shall be maintained between the
machinery and the line.
11kv and below 1.40m
33 kv and below 3.60m
132 kv and below 4.70m
273 kv and below 5.70m
Working near Overhead
Electrical Line
 Contd…

When it becomes necessary to operate the

machinery with clearances less than those
specified, then

 The power lines shall be shut off and

 The residual charges grounded before
commencing to use the machinery.
 Underground Facilities

Work Permit shall be obtained to carry out earthworks

in places, where underground utility is available.
 Earth Moving Equipment

General safety:
Every vehicle or earth moving
equipment shall have the
following fully functional:

 Silencers;
 Tail lights;
 Power and hand brakes;
 Reversing alarm; and

 Excavator
 Work permit in case of
underground utility
 Safe clearance overhead electrical
Line.
 Not to be operated on grades
steeper than those specified by the
manufacturer.
 Safe distance from excavations.
 The height of the benches in over
burden not to be more than the
height of the boom
 Swing Lock to prevent from
accidental swinging during
operation or transport.
 Excavator
Operator shall
► Be experienced and have valid
Licence.
► Use the seat belts.
► Not exceed load capacity of the
excavator.
► Use reverse horn and swing alarm at
the appropriate time.
► Lower the boom to a safe position
with the bucket on the ground and
turn off the machine before stepping
off for any reason.
► Keep the bucket resting on stable
ground, when not in use and bucket
shall not be left hanging.
 Excavator

Site Workmen shall

► Be educated to keep off the

swing area..
► Prohibited to ride in or work
from excavator.
 Dozer

 When running down the hill

the bulldozer shall be in
the lowest gear.
 Blade shall not be used as
brake except in case of
emergency.
 The blade suspension
arrangement shall be
inspected once a week.
 Dozer

 Provided with Reverse

Horn.
 After the close of work, the
bulldozer shall be left on
level ground.
 Before leaving, the Operator
shall
• Apply the brakes
• Lower blade and
• Put the gearshift lever in
‘neutral’ position.
 Road Roller

 Before a Road Roller is used on the ground,

such ground is examined for its bearing
capacity.
 A Roller shall not be moved downhill with
the engine out of gear.
 Passenger Hoist
Legend
1 Limit Switches / Over-run
Devices
2 Landing Gates
3 Hoist Enclosure
4 Hoist anchored to the
building
5 Hoist Arrester Device
6 Hoist Operation from one
position
7 Dead Man handle
8 Gate Interlocks on Cage /
Platform
9 Landing Gate Interlocks
10 SWL on Hoist
 Passenger Hoist
 Manufacturer’s recommendations shall be followed.

 Hoist shall be erected by competent persons under

the supervision of P&M Engineer.

 Hoist shall be anchored to the building


 Hoist shall be protected by a substantial enclosure to
prevent someone from being struck by any moving
part of the hoist or falling down the hoist way.

 Gates shall be provided at all landings, including
ground level with interlocks.
 Passenger Hoist
 The controls shall be arranged so that the
hoist can be operated from one position
only.
 Hoist operator shall be trained and
competent.
 Safe working load of the hoist shall be
clearly marked in the Cage.
 Hoist shall be inspected weekly by P&M
Engineer and thoroughly examined every six
months by a competent person.
 Passenger Hoist
 Upper and Lower Limit switches shall always be kept
operational.
 Emergency Switch, Emergency Alarm and Emergency
Lamp shall be provided on the platform.
 Adequate illumination shall be provided on the platform.
 Load limiting device shall be provided in the hoist.
 Communication system, like telephone shall be provided
which can be used in case of emergencies.
 Emergency brake system, like centrifugal force brake,
shall be incorporated in the hoist. Such a brake system
shall hold the platform from moving down, if the main
brake fails.
Builder Hoist
Builder Hoist
 Builder Hoist

 Erected in accordance with generally

accepted technical standards.
 Secured to the structure
 Extended to such a distance of at least
900 mm for over-travel.
 Enclosed on all sides at the bottom, and
at all floors to a height of at least 2100
mm from the ground or floor level.
 Provided with a door or gate at least
1800 mm high at each landing.
 Builder Hoist
 Factor of Safety of Suspension
rope of the Bucket should be at
least six
 Provided with an efficient brake
capable of holding the conveyance
with its maximum load in any
position when the power fails
 Materials shall not be carried in
such way that they slip or spill
from the bucket.
 Persons shall not be allowed to
ride on a builder's hoist.
 Builder Hoist
 Inspected at least once every week
by a competent person.
 Limit switches and Load Limiters
shall be maintained operational.
 Electrical Switches and panels shall
be protected from rain. Proper
Earthing shall be provided.
 Electrically powered hoists shall be
equipped with an effective magnetic
release brake which will be
automatically applied when the
controlling machine is in 'stop'
position.
 Builder Hoist
► The person who picks up the load
should use safety belt.
► Wire rope way on the ground shall
be barricaded.
► If required, cross over arrangement
shall be provided.
► Adequate number of pulleys shall
be provided so that the wire rope
does not fall on the ground.
► Wire rope shall be lubricated at
least once in week.
 Builder Hoist
 Inspected on weely
basis by the P&M
Engineer.
 The hoist shall be
inspected by competent
person once in 12
months.
 Effective arrangements
to be made for clear
signals
Signals
Builder Hoist
 Use of whistle signals on hoisting work
shall be avoided. Both alarm & light shall
be used.
 The following set of signals of electric
bells / colored lights shall be used:
 Bell & Red Light to stop
 Bell & Green Light to raise
 Bell & Yellow Light to lower
 A rapid series of bells for emergency stop.
 The signal code shall be posted next to
the signal device at each work level and
at operator’s location.
 All words shall be in large size letters,
clearly visible to all concerned.
 Tirfor

 Manufacturer’s recommendations shall be followed.

 Tirfor shall never be released when it is under load.
 Forward and Reverse levers shall not be used at the
same time.
 A secure anchorage point shall be ensured to hold the
load to be handled.
 Operating lever shall not be extended using pipe or
any means.
 Tirfor

 When used with multi sheave block, it shall be ensured

that they are suited to the load applied.
 Only the manufacturer supplied wire rope shall be used.
 If the operation of tirfor is difficult for one man, the
operation shall be stopped and the number of blocks
shall be increased within the rated capacity of the
machine.
 Wire rope shall be lubricated at least once in a week.
 Chain Pulley Block
 Manufacturer’s recommendations shall be
followed.
 Should be used only for vertical lifting within its
capacity. It shall never be used for pulling the
load.
 A secure anchorage point shall be ensured to hold
the load to be lifted.
 Provided with hook latch.
 Lifting hook shall never be removed from the
Chain Pulley Block, as the removal decreases the
lifting the capacity due to the reduction in number
of falls of the lifting chain.
 Chain Pulley Block

 The lifting chain shall not be wound around the

load. Suitable slings shall be used.
 Chain Pulley Block shall be inspected and
maintained by P&M Personnel on weekly
basis.
 Chain Pulley Block shall be inspected by a
government authorized Competent Person at
least once in a year
 Inspection & Testing of lifting
& Hoisting Machinery

Tested and examined by a competent

person for specified ratings and for safe
operation at least once in 12 months, and
shall be re-tested and re-examined after any
substantial alteration or repair.
 Inspection & Testing of lifting & Hoisting
Machinery
Every lifting appliance with its accessory gear, shall be
subjected to a test load, which shall exceed the safe
working load (SWL) as specified in the following table:
Sl. Safe Test Load
No Workin
. g Load
Upto 20 25 per cent in excess of safe
1
tonnes working load
20 to 50 5 tonnes in excess of safe working
2
tonnes load.
Over 50 10 per cent in excess of safe
3
tonnes working load
 Transporting Machinery
General Safety
Max. Speed Limit inside site : 20 kmph
Every vehicle shall have the following, fully functional:
 Silencers;
 Tail lights;
 Power and hand brakes;
 Reversing alarm; and
 Search light for forward
and backward movement
 Transporting Machinery

Brakes and Controls

Motor trucks, tractors and dumpers shall
 Be equipped with brakes that will hold them
under the heaviest load that may be hauled in
any operating conditions and
 Enable the vehicle to be locked when
stationary.
 Transporting Machinery

Draw Gears Motor trucks, hauling trailers and

tractors shall be equipped with draw gear such
that during coupling no workmen can come
between the vehicles being coupled or the
vehicles being coupled cannot run into each
other.

 Vehicles shall not move down the hill with the

engine off or with the engine out of gear.
 Transporting Machinery

Drivers

 Only competent and licensed persons shall drive

motor trucks and tractors.
 Drivers shall be required to leave the cabins and
stand in the clear while the motor trucks are
being loaded.
 Drivers of tripper trucks used for hot mix plants
and batch mix concrete plants and similar
operations shall wear the industrial safety
helmets.
 Transporting
Machinery
Operating Condition
 Motor trucks should be stationed at
such a distance from the Excavator
that there is a clearance of at least
0.6m between the Truck and
Excavator
 Where the driver does not have a clear
field of vision the movement of motor
trucks and tractors shall be controlled
by a code of standard hand signals.
 When uncoupling vehicles, both
vehicles shall be blocked by brakes or
chocks.
 Transporting Machinery

 Vehicles being loaded or

unloaded shall be braked or
blocked.
 Motor trucks shall not be
loaded beyond their
capacity.
 Before a loaded motor truck
starts,
 the load shall be secure,
 evenly distributed
 of safe height, length and
width.
Asphalt Plant
 Asphalt Plant
Rotary Driers
 The primary exhaust fan should be kept running at all
times when the plant is working.
 If it is necessary for personnel to enter the drum e.g.
for clearing jammed material, the drum must be
stationary; the drive motor isolated and locked out;
the drum cooled to a tolerable temperature; and the
exhaust fan kept running. Work Permit System shall
be implemented.
 Asphalt Plant
Batch Heaters
 The exhaust fan shall always be running before lighting
the burner(s).
 With any flame failure the batch heater shall be
thoroughly purged before attempting to re-light.
 Persons shall be aware of hot gases and / or flame
coming from the batch heater ports.
 If Liquefied Petroleum Gas (LPG) is used and the
electrode fails to ignite the gas, the batch heater shall be
purged before attempting to relight.
 Operator shall ensure that no unauthorized persons enter
the mixing section of the plant whilst it is in operation.
 Asphalt Plant

Mixers
Mixer discharge gates that are actuated
pneumatically or hydraulically shall be
made dead and the pressure in the
controller discharged before any
maintenance or repair work is carried out
on the mixer.
 Asphalt tanks

 Clean up all spillages immediately following the occurrences.

 Ensure that the low binder cut-off float switch is operable.
 On oil fired tank, ensure that the fusible plug to the automatic
fuel cut-off is correctly set is in position and functional.
 Ensure that the temperature cut-off is correctly set for the
type of binder in the tank.
 On Hand Charged Asphalt stirrer tank, ensure that the
protective grill is in position when the filling lid is open.
 On electrically heated tanks, ensure that the main contactor
cabinet doors and the heater chambers are locked.
 Asphalt Plant

General
 Operation of asphalt plant shall be under the supervision
of a competent person.
 Workmen handling hot asphalt shall wear gloves, rubber
boots, goggles and protective clothing.
 No naked flame shall be used for ascertaining the level
of asphalt.
 Thinners shall not be heated over an open flame.
 Asphalt Plant

 If burner goes out, the fuel supply shall be cut

off and hot tube shall be thoroughly blown out
by the fan so as to prevent backfire.
 Spilled asphalt shall be promptly cleaned up.
 A chimney or other suitable exhaust
arrangements shall be provided to remove the
combustion gases and dust.
 If the percentage of CO, CO2, etc. in the work
atmosphere is more than the TLV (SCBA) or
suitable Respirator shall be used.
 Batching Plant

Mixer Drum

Silos

Concret e
Loading
Area

Scrapper

Skip Area
 Batching Plant
Operation
 The plant should be operated, only if all safety
devices such as interlocks, guards, emergency
stops, etc. are in place.
 Before starting the plant, it shall be ensured that
nobody is working on the plant.
 Starting and stopping procedures, control devices
/ signals shall be followed according to the
manufacturer’s guidelines.
 No one shall be allowed to enter the danger area
of skip.
 Batching Plant
Maintenance:
 Only authorized technicians shall be allowed.
 On and off procedures as per manufacturer’s
instruction manual.
 Work Permit System for repair and maintenance
works (like, mixer drum cleaning, works on skip
etc.) carried out on the Batching Plant.
 After completion of maintenance:
 The plant is clear of all the men doing the job
 All tools and tackles are removed.
Crusher Plant
 Crusher Plant

 Qualified Operators to be employed

 Methodology for clearing blockages
 All accesses and work platforms with guard
rails.
 There shall be efficient energy isolation
system.
 Stop blocks shall be provided to prevent
vehicles approaching too near the plant.
 Work-permit system shall be implemented for
repair and maintenance of the plant.
 Crusher Plant
Dump Hoppers
 All plant attendants working in the area of
dumping shall be alert to the movement of
vehicles and be aware of the signals.
 Raw materials dumping by tippers, dumpers
etc. shall be permitted when a signal (light
or sound) is given.
 No persons shall be allowed to enter dump
hopper to clear blockages unless the feeder
mechanism is stopped and the dumping
signal is on “STOP”.
 Crusher Plant

Crusher Feeder
 Feeder attendant shall be responsible for
operating dumping signals.
 No person shall climb on to any scalping
screen or feeder unless the machinery is on
stop and the dumping signal is on “STOP”.
 Person shall be employed to prevent dumping
and the main power supply switch is locked in
‘OFF’ position to prevent starting of the
machinery.
 Crusher Plant
Belt Conveyors
 Persons not to travel on the Conveyor & Walking
under conveyor are prohibited.
 If walking under conveyor is unavoidable, safety
nets to be provided.
 Guards to be provided at all pulleys, idlers and
driving and take off drums.
 Pull Chord Switch to be provided along the
conveyor to stop it in case of emergency.
 Conveyor to be provided with overload trip and
sequencing interlocks.
 Spillage shall be cleaned up daily.
 Crusher Plant

Screw Conveyors

 The cover plates of screw conveyor shall

not be used as walkways.
 Cover plates shall not be removed while the
machine in operation
 Crusher Plant

Skip hoists

 Skip hoists shall be fitted with the limit

switches controlling the top and bottom
positions.
 Before any skip hoist is set in motion the
operator should ensure that the guards at
ground level are securely fixed in position.
 Crusher Plant

Bucket elevators

 Open Bucket elevators shall not be used as

ladders.
 Plant operators shall not enter an elevator pit
unless the boot is securely guarded and a safe
means of access is provided.
 Crusher Plant
Crusher - Primary (Jaw/Gyratory)

 A safe System of work for relieving blockages.

 Before relieving blockages in any jaw crusher,
the feeder should be on “STOP” Position and
any surcharge of material shall be barred off.
 No person shall be allowed to enter the gape
of a crusher jaw whilst in motion.
 Crusher Plant

Crusher – Primary Impact (Hammer

Mill)
 Inspection door on impact crusher shall not be
opened whilst it is under motion.
 No one shall enter the stationary crusher unless the
drive motor isolated. Lock out/Tag Out system to be
implemented.
 If any welding is to be carried out inside the crusher,
proper ventilation system shall be provided.
 Crusher Plant

Chutes
 To release blockages in delivery chutes poking bars to
used to avoid trapping fingers.
 Chutes shall not be used as walkways.
 Persons shall not be allowed to work inside unless the
machinery is on “STOP”.
 Change over doors on chutes shall be released only when
the material flow has ceased.
 Any blockage of the material on chutes to be released
only when the material flow has been arrested.
 Crusher Plant

Hopper Gates
 Poking upwards into the hopper not to be
done, as any sudden release of the blocked
material may result. Poking to be carried out
only from a secure platform.

Stone (gravel) washing equipment

 Precautions shall be taken to prevent
walkways, ladders, stairways and plant areas
becoming slippery.
 Crusher Plant

Vibrating Screens

 Operators not to climb on to the ‘live’

side frames or on to the deck of any
vibrating screen whilst in motion.
 Before climbing on to screen or into a
rotary trammel, the motion to be stopped
and the motor to be isolated. Lock out /
Tag out system to be implemented
Air Compressor
 Air Compressor

General

 To be inspected regularly by qualified and trained

employees.
 All pipes, hoses, and fittings are to withstand the
maximum pressure.
 Air supply shutoff valves to be located (as near as
possible) at the point-of-operation.
 Air hoses to be kept free of grease and oil to reduce
the possibility of deterioration.
 Hoses shall not be strung across ground, floors or
aisles. When possible, air supply hoses shall be
suspended overhead.
 Air Compressor
General
 Hose ends to be secured to prevent whipping if an
accidental cut or break occurs.
 Hose couplings to be inspected frequently.
 Before a pneumatic tool is disconnected (unless it has
quick disconnect plugs), the air supply shall be turned
off at the control valve.
 Compressed air shall not be used under any
circumstances to clean dirt and dust from clothing or
of a person’s skin.
 Air Compressor

General
 Goggles/face shields or other eye protection shall
be worn by personnel using compressed air for
cleaning equipment.
 Static electricity can be generated through the
use of pneumatic tools. This type of equipment to
be grounded.
 Rotating & Moving parts, such as compressor
flywheels, pulleys, and belts are to be guarded
 Air Compressor

Air receivers
 The maximum allowable working pressures of air
receivers not to be exceeded except when being
tested.
 Air receivers to be fitted with a drain cock that is
located at the bottom of the receiver.
 Receivers to be drained frequently to prevent
accumulation of liquid inside the unit.
 Air Compressor

Air receivers
 Each air receiver to be equipped with at least one
pressure gauge and safety valve of the proper
design.
 A safety (spring loaded) release valve to be
installed to prevent the receiver from exceeding
the maximum allowable working pressure.
 Air receiver shall be identified with working
pressure, capacity, test details, etc.
 Air Compressor
Pressure regulation Devices
 Onlyqualified personnel to be allowed to repair or
adjust pressure regulating equipment.
 Safetyvalves to be set to a pressure not less than
10 percent above the operating pressure of the
compressor but never higher than the maximum
allowable working pressure of the air receiver.
 Blow-offvalves to be located on the equipment
and shielded so that sudden blow-offs will not
cause personnel injuries or equipment damage.
Never Stand
Never Stand between
between the
the Pump
Pump and
and
Transit Mixer
Transit Mixer
Boom Placer
IfIf the
the pump
pump becomes
becomes energized
energized
everything that
everything that touches
touches the
the pump
pump is
is also
also
energized
energized
 Use aa spotter
Use spotter when
when the
the boom
boom is is in
in aa
confined area
confined area or
or near
near obstructions
obstructions or or
wires. if he is nearing trouble.
•Spotter should warn the wires.
operator
•Two sets of eyes are better than one.
 Never open
Never open aa Pressurized
Pressurized Line
Line
1. A plugged line may have maximum pump pressure
inside.
2. Wait until the operator reverses the pump and tells you
that it safe to open the pipe.
 Watch for
Watch for This
This

The truck can tip over if the soil gives away.

 Cleaning with
Cleaning with Compressed
Compressed Air
Air

Never open a pipe that has been pressurized with air.

Never use compressed air to clear a blockage. Use Ball
Catcher
SAFETY DEVICES IN CRANE
Over Hoist Limit switch

Boom Limit Switch Hook Latch

Angle Plate
Pointer
TOWER CRANE

Soil bearing Strength

Rails – Straight, level & buffer
stop
Limit switches, Aviation lamp,
lightning arrestors
SWL displayed
Communication – Signal man
After work –
hook released from load and
raised to the max.
Crane shifted to end of rail &
anchored to rail.
boom free to swing
 Maintaining wire ropes
Preferred method
since rope opens up Air Blast
over sheave allowing Application
Temporary oil to penetrate
Winding
Drum

Brush
Application

Dip and Swab Application

 MAINTENANCE OF HAND
TOOLS
Handled by stores in coordination with P&M

Check and certify for use by tag

 Weekly Inspection

Repaired ones
 P&M SAFETY SYSTEMS

A B

C D

E F

G PM-20F –PTW PLANT & MACHINERY

 ENVIRONMEN
T

 diesel and other fuels;

 lubricants and hydraulic fluids;
 Solvents/ chemicals;
 hazardous waste;
 contaminated water;
 drums and/or tanks of unknown contents
CONTRACTORS’ EQUIPMENT
Case Studies
 The Point at Upper Portion Upper Portion
which the
casing end
rope got
damaged

CRANE CRANE HEIGHT= 57 8MT

BOOM BOOM LENGTH = 35MT

MAX. BOOM LENGTH =

COLLAPSE 33
mt
boo
35MT @ 2T LOAD

m
2
The victim got m
trapped
between
trolley and
floor

Floor Level -
9
II
m
(Reinforced)

K - 5-408 BAKRA CRANE

 G.L
OFF

Service Engineer trying to ON

switch OFF the starter

“Z” type sheet pile

Temporary
Work Platform driven for shoring

G.L

Co-worker
9 mts

Working Level
9 m below GL
Victim holding the
submersible pump PIT filled
inside the pit with slush &
 HOTMIX PLANT
Dryer

Hot
Storage
Mixing Drum Bin

Operator
Gate Cabin
Victim
Standing
Skip
 CONCLUSION

"One machine can do the work of fifty

ordinary men. No machine can do the
work of one extraordinary man."

-- Elbert Hubbard
Any Questions ?