Safety In Testing of LA & LG
Industrial Accidents in Last 3 Years
140
120
100
80 Handling Goods
Machinery Moved by Mechanical Power
Machinery not Moved by Mechanical
Power
60
40
20
0
2020 2021 2022
Source: DGFASLI
Material Handling
– 40% Accidents are due to Material handling
– It accounts 40% production cost
– It does not add value to the product but it cost to the
product
– A large cost of product cost is due to Material handing
– Major activities in Cement Industries is Material Handling
– Lifting tools and tackles comes under Material handling
activity
– It has potential for high risk and accidents
Competent Person
• A competent person is regarded as competent if he is well
trained and possesses adequate knowledge and practical
experience in handling the similar type of lifting appliances or
lifting gear. He should be able to detect and assess defects
and potential hazards that could limit the safe performance of
the lifting appliances or lifting gear.
Skills Required
• A competent person should be fully familiar with and apply the following
aspects of knowledge and skill:
– the operation or use of the lifting appliance or lifting gear that he has to inspect;
– the location and function of safety devices, master switches, on-off switches;
– the safety rules, precautions, servicing and overhaul requirements and limitations
as defined in the operation and maintenance manual of the lifting appliances or
lifting gear
– the Rules ,Regulations and Standards applicable
– the skill of using hand tools, machine tools, measuring instrument and testing
devices to conduct simple functional checks
– the maintenance record of the lifting appliances or lifting gear
– the safe system of work to take care of himself and of other persons working with
him during inspection.
– Where the competent person making this examination forms the opinion that the
lifting appliance cannot continue to function safely, he shall forthwith give notice in
writing of his opinion to the owner of the lifting appliance
– He must also, as soon as is practicable, make a report in the required format
Skills Required
• Appropriate practical and theoretical knowledge and
experience of the lifting equipment to be tested or
thoroughly examined as will enable them to detect
defects or weaknesses and to assess their importance in
relation to the safety and continued use of the lifting
equipment.
• To be sufficiently independent and impartial to allow
objective decisions to be made.
• To ensure that all parts of lifting equipment exposed to
conditions causing deterioration to such equipment are
properly examined, at the required intervals
Skills Required
All reasonable measures should be taken to ensure that any load cannot:
• strike and injure someone - the simplest way to achieve this is by ensuring no-one is
close enough for this to happen and is prevented by barriers or some other method,
from moving into a position where this could happen.
• drift dangerously or fall freely - drifting of loads can be caused by a variety of reasons
such as weather conditions, lack of control by the persons engaged in the lifting
operation or failure of equipment. lack of control by those responsible can be dealt
with by proper training and instruction and failure of equipment can be prevented
in many cases by proper use and maintenance of equipment.
• release unintentionally - regular checking of lifting and release equipment to ensure
it is operating correctly, and that when in use it is within its safe working load limits,
are two ways free falling of loads might be prevented.
• that personnel are not positioned beneath suspended loads, or moved above them
or that persons are likely to move into the path of a suspended load. - the simplest
way to achieve this is by ensuring no-one is in the danger area and is prevented by
barriers or some other method, from moving into it whilst lifting is in progress.
Safe System of Work
• A safe system of work should be developed to ensure
the safety of personnel engaged in the job in addition
to carrying out of a good quality and accurate
inspection, examination or test.
• He should provide and maintain a safe system of
work that is safe and without risk to health.
Planning Before Start-Up
• Leveling & support
• Know the basic crane capacities, imitations, and job site
restrictions, such as the location of power lines, unstable soil,
or high winds.
• Personnel aware of hoisting activities.
• Barricade areas within swing radius.
• Ensure proper maintenance and inspections.
• Determine safe areas to store materials & place machinery.
OSHA requirements
• For lines rated 50 kV. or below - 10 feet;
• Over 50 kV- 10 feet + 0.4 inch for each 1 kV. or twice the
length of the line insulator
• Person shall be deputed to observe clearance ;
• Cage-type boom guards, insulating links, or proximity warning
devices be used on cranes,
Proximity of Hazards
( IS-13367(part-1): 1992
proximity hazards – not < 900 mm clearance between crane
& obstacle
Consult Electricity Board if working area is within 15 meter of
overhead lines on steel towers and 9meter of overhead lines on
wood, concrete or steel poles
warning or marker at least 6 meter horizontally along the ground
from the outermost conductor at a tower or pole position
Marking of crossing route and erection of “Goal posts”
effect of wind , adequacy of access & sustain of load by grounds)
General consideration for selection for the
operation, IS: 13367- Part I, 1992
• Weight, dimensions and characteristics of loads
• Operational radii, speed of various operations, height of lifts and area of
movement.
• Number, frequency and type of lifting operation
• Anticipated life expectancy for permanent installed crane
• Site, ground and env. Conditions
• Space for crane access, erection traveling, operation and dismantling
• any special operational requirement
SAFETY IS: 13367- Part I, 1992
• Identifiable of crane slinger and signaler by crane driver
( high visibility clothing or other means)
• Safe system of work
documented and no verbal instructions (maintenance, repairs,
inspection etc.,)
• Permit to work
(Issue of designed form/certificate, Upon completion, signature of
the person who carried out the lifting operation to certify that
a) All tools have been removed, All guards replaced, all safety
devices are operating and all persons are advised that it is no
longer safe to do so)
• Personal safety equipment- Appointed person to ensure
Availability of required PPE
Inspection & Maintenance of PPE before and after its use
Maintenance of record of inspection
Awareness of the requirements relating to the personal safety and
its correct use by all personnel working on, visiting or in the
vicinity of crane.
• Access and Emergency escape
Provision and maintenance of safe access
a) For driving positions
b) For inspection, maintenance, repair , erection &
dismantling
c) Provision of suitable rope in case of emergency
• Documentation
Safe working load chart
Instruction manuals
Test certificates
Records
Technical information including maintenance instructions &
performance data provided by manufacturers
Test certificates, records of thorough examination and
inspections including ropes and brakes ( whether statutory or
not)
Record of significant repairs and modifications
Details of occurrences
Incidence or accidents however slight
Shock loads
Statutory requirements of reporting DO/ accidents
The system should include the following :
• site conditions
• weather conditions
• test weights
• procedure and safety precautions ;
• prevention from swinging or wheeling outwards of loads;
• competence of operator engaged in examination or
testing;
• use of information;
• emergency procedure; and
• administration of the safe system of work.
Site Conditions
• Whenever possible, the lifting appliance or lifting gear should be examined and tested in
open area or workshop where no other work activities are carried out concurrently
• The ground or structure for support the lifting appliance should be well consolidated,
structurally stable and capable of withstanding the loads that would be applied to it.
• Ensure that there are no hidden hazards in the vicinity such as cable ducts, drains, pipes,
back-fill areas, cellars or other underground weakness when testing of a lifting appliance
is conducted.
• Lifting appliances should not be examined or tested in the vicinity of overhead power
lines. In general, brick or masonry work, metal or bamboo scaffolding, or temporary
structure or working platforms should not be used as a test site during the proof load
test
• The site where the test is conducted should be of sufficient area and have unrestricted
overhead clearance to allow the unobstructed movement of the lifting appliance and
load throughout all its appropriate test movements.
• It should also keep in mind to ensure all personnel not involved in the test be kept away
from the test area. Particular care should be taken when a mobile crane or a tower crane
is tested near a public area, highway, or occupied buildings. Appropriate time and date
should be arranged with all relevant parties to keep away traffic and pedestrians during
the test.
Weather Conditions
• If the test site is situated in an open area, examinations or
tests should not be carried out in adverse weather condition.
• Gusting wind may introduce an additional adverse effect on
the safe handling of the load and the safe operation of the
lifting appliance.
• Accident may happen to the personnel involved in the
examination or test as rainy weather may increase the
slipperiness of the frame structure of the lifting appliance on
which they may walk.
• Suitable safety precautions should be devised if examinations
and tests in such weather condition could not be avoided.
Test Weights
• Calibrations of weights
• The suspended test weights should be kept as close to the
ground as possible, such as in the range of 100mm to
200mm above ground.
• Safety precautions should be taken to ensure the work safety
of the personnel involved in the proof load test if the test
weights are required to be hoisted or travelling along a path
• Test weights should be made up of concrete/metal
blocks/plates, preferably with markings to show their actual
weights. Under no circumstances, should reinforcement
bars, wooden planks or life load be used as test weights.
Procedure and Safety Precautions
• A proper procedure should be worked out :
– Define the sequence of work
– Responsibility of each personnel engaged in the inspection, examination or test of a
lifting appliance or lifting gear.
– It should set out which tests to be carried out first and what follows a non-destructive
test
– Note down all safety precautions from relevant codes of practice,
national/international standards and the manufacturer's operation and maintenance
manual, and incorporate them into the safe system of work
– Proper procedure and safety precautions for manually handling heavy test weights,
equipment and lifting tackles should be laid down
– When working at height, safety measures to prevent fall of persons should be adopted,
including the provision of safe access and egress, proper working platforms and
personal protective equipment such as independent life lines and safety harnesses, etc.
– Ensure that every personnel is fully familiar with the Safe Procedure.
Prevention from Swinging or Wheeling of Loads
• When a lifting appliance operates with various SWLs at different working radii,
adequate precautions should be exercised during the proof load test to prevent
the load from swinging or wheeling outwards
• In case of a horizontal jib crane with trolley, suitable device should be fitted at
the maximum radius of the jib, e.g. clamps to prevent the trolley from moving
beyond this point.
• The safe system of work should specify the competence of the operator who is
engaged in the functional test or proof load test.
• The operator should be familiar with the characteristics of the lifting appliance,
the safety precautions in handling overloading and the limitation of the lifting
appliance in the brake test, functional test and proof load test.
• He should be able to put the lifting appliance under control at any time during
the examination and testing work
• He should fully understand all signals given by the competent examiner to
operate the lifting appliance smoothly and accurately.
Other Useful Information
• The CP should understand three engineering factors that influence the lifetime of LA:
• deformation
• wear and
• corrosion
• Everything wears, and wear will usually develop significantly on moving parts such as
bearings, gears, pistons, seals and on parts to which there are relative motions with
other components
• Machine members will deform when they are subjected to loading
• Competent persons should assess materials, tolerances, and assembly of moving parts,
gaining an impression as to whether any undesirable conditions exist which will produce
unacceptable wear and deform rates. This is an area where it is necessary to rely heavily
on manufacturer's specifications
• Every lifting appliance comes with a manufacturer's specifications manual. CP should see
them for the specifications of the lifting appliance and the ‘Do’ and ‘Don't’ and the
‘Caution’ statements in the operation and maintenance manual.
• He should also take a look at
– the relevant documents such as standards or codes of practice;
– maintenance records; and
– accident history
Emergency Procedure
• An emergency procedure should be developed and
included in the safe system of work.
• The procedure should specify the equipment for
handling the collapsed lifting appliance, removing of
test weights, assignment of personnel in charge of
the emergency procedure.
• Ensure medical assistance within the shortest
possible time for medical treatment in case of a
mishap.
"A man can succeed at almost anything
for which he has unlimited enthusiasm."
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