SAFETY IN

OPERATION &
MAINTENANCE
OF MACHINES
SCHEDULE OF THE PROGRAM :

SL NO DESCRIPTION DURATION IN MIN

1 Introduction 10

2 Safety in Operation of Piling rig 20

3 Safety in Maintenance of Piling rig 20

4 BREAK 10

5 Safety in Operation of Cranes 15

6 Safety in Maintenance of Cranes 15

7 Experience sharing 15

8 How well You Know Me ? 15

INTRODUCTION :

• “If SAFETY is a Joke then Death is the Punchline”

• “SAFETY FIRST, PROGRESS MUST”. EVERYDAY IS
SAFETY DAY. SAFETY HAS NO HOLIDAY.
Safety :
• “I have learnt that safety is not just reflector, boots
and helmets; Safety is in one's MIND- it is your
conviction in doing right things right way.
 Objectives :
• Understanding Of the Safe
O&M REQUIRMENTS OF
RIGS AND CRANES.
• KNOW ABOUT BEST SAFETY
PRACTICES
• SUCCESSFUL
UNDERSTANDING ON
SAFETY PRINCIPLES.
Outcomes :
• Motivating the operators to use their
experience, knowledge and skills to
perform OUR work in a safe way.
• Be the first one to stop the unsafe and
fallow the safe.
PILING RIG OPERATION AND
MAINTENANCE
DRY PILE
WET PILE
CASED PILE
 Hydraulic Rotary Rig :

Hydraulic rotary drilling is used

to dig down deep into the earth .
Identification of Machine :
Name plate
Drilling tools
OPERATORS CAB + DISPLAY
COMPUTER
WIRE ROPES
INSPECTION AND
MAINTENANCE
.
SAFETY APPLIENCES IN
RIG
MAINTENANCE AND
CHECKS
CLARI

• C - CLEAN
• L - LUBRICATE
• A - ADJUST
• R - REPLACE
• I - INSPECT
IMPORTANCE OF
MAINTENANCE IN SAFETY
• It increases the safety of operators
If a piece of plant or equipment is well maintained, the
risk of accidents occurring due to malfunctioning
machinery is reduced.
• Helps you track who is accountable for a piece of
equipment
• Prevent expensive repair works from happening
Rules at construction works

• Importance of signal man and use.

• Importance of site under standing

CRANE OPERATION AND
MAINTENANCE
 DEFINITIONS

• Crane – Consists of a rotating structure for lifting and lowering horizontally

on rubber tires or crawler treads
• Hoist – Used to lift and lower load
• Boom – An inclined spar, strut, or other long member supporting the
hoisting tackle
• Boom stops – A device used to limit the angle of the boom at its highest
position
• Brake – To slow or stop motion by friction or power
• Block – Sheaves or grooved pulleys in a frame with hook, eye and strap
• Jib – Extension attached to the boom point to provide added boom length
for lifting specified loads

31
 Crane Hazards
• Contact with power lines
• Overturns
• Falls
• Mechanical failures
• Moving parts
• Improper load rating
• Excessive speeds
• No hand signals
• Inadequate inspection and
maintenance
• Unguarded parts
• Unguarded swing radius
• Working too close to power
lines
• Improper exhaust system
• Shattered windows
• No steps/guardrails
walkways
• No boom angle indicator
• Not using outriggers
 OSHA-Identified Crane
Hazards
OSHA's analysis identified the major causes of crane accidents to include:
• Boom or crane contact with energized power lines (nearly 45% of the cases)
• Under the hook lifting device
• Overturned cranes
• Dropped loads
• Boom collapse
• Crushing by the counter weight
• Outrigger use
• Falls
• Rigging failures
Who is at Risk?

• Operators
• ALL Persons at Crane
Site

35
Improper loads or speeds can Guard moving Stay out of the swing
result parts such as gears radius
in the tipping of the crane. or belts.
Broken
Window
Make sure broken
windows or other
obstructions do not
prevent the operator
from seeing.
Guardrails

Runways and
steps need to
have
guardrails,
handholds
and slip
resistant
surfaces.
Suspended Loads

Don’t stand under

suspended loads.

39
 Load Capacity - Speed -
Warnings
• Make sure the crane operator can
see the:
– Rated Load Capacities
– Operating Speeds
– Special Hazard Warning or
Instruction

Load Rating Chart

40
Boom Angle
Indicator

A boom angle
indicator must be
on the crane

41
Know the Weight of
the Load
• Refer to shipping ticket or other documentation
• Ensure lift calculations are correct
• Ensure load is within load chart rating for boom length
and load radius of crane
• Crane is rated by the maximum weight it will lift at a
minimum radius and minimum boom length – the further
from its center point, the less it will lift

42
Load-Limiting Factors

• Not level
• Wind
• Side loads
• On its wheels
• Lifting over the side
• Use of extensions, jibs and other attachments
• Limits of wire rope, slings and lifting devices

43
Mobile Cranes –
Lifting Principles
• Center of gravity
• Leverage
• Stability
• Structural integrity

44
Rigging Safety
Issues
• Imported Shackles that do not • Taglines-Not in good condition, oil
meet the ASME Standards soaked
• Synthetic Slings in use that are • Wire Rope Sling-damaged sockets,
damaged kinked or damaged wire rope
– Oil soaked • Chains-damaged links, damaged
– Cut hooks, Incorrect hook pin
– Missing Information Tag • Knots in Tag lines
– Abrasion Damage • Homemade spreader beams
without proper engineering data.
– Weld Damage
Safety Discussion

• The operator must have the authority to stop and

refuse to handle loads until a qualified person has
determined that safety has been assured.
• This applies to any employee / operator involved in
the lift.
LOAD CHART &
SPECIFICATION SHEET
• Load chart

• ASLI – AUTOMATED SAFE LOAD INDICATOR

• Wrong usage of crane

• Safer material handling

Maintenance, Inspection and Crane Certification
A competent person must begin a visual inspection prior to
each shift the equipment will be used.
• Control mechanisms for adjustments • Electrical apparatus for
interfering with proper operation. malfunctioning,
• Air, hydraulic, and other pressurized
lines for deterioration or leakage, • Ground conditions around the
equipment for proper support,
• Hydraulic system for proper fluid • The equipment for level position
level. within the tolerances
• Hooks and latches for deformation,
cracks, excessive wear, or damage • Operator cab windows for significant
such as from chemicals or heat. cracks, breaks, or other deficiencies
• Wire rope reeving for compliance that would hamper the operator's
with the manufacturer's view
specifications.
• Safety devices and operational aids for
proper operation.
 Monthly Inspections
Each month the equipment is in service it must be
inspected and records must be kept for at least 3 months.

Annual/Comprehensive Inspections
At least every 12 months the equipment must be inspected
by a qualified person.
Express your experience

• 1

• 2

• 3
 Question & Answer
1. Types of piling we use at our site.
a) Dry pile b) Wet pile c) cased pile d) cased wet pile

2 . Safety interlock system in piling rig.

a) Emergency switch b) Over hoist limiter c) Display monitor

3. For Safe Drilling position Ground must be.

a) Level b) firm c) firm and level d) all of the above
Question & Answer

4. Daily inspection safety point is

a) Checking oil level b) Greasing of pins c) wire rope
inspection
5. Regular maintenance will increase
a) Life of machine b) safety in operation c) reduced
repair d) all of above
Question & Answer

6. Safe standing position for crane signalling

a) under the boom b) near the counter weight c) near
the operator cabin d) in front of operator outside the
load radius.
7. Full SWL is available in which configuration

a)5 b)3 c)1 d)2 e)4

Question & Answer

8. Correct D clamping of wire rope

a) 1 b)2 c)3

Load chart reading sample

9. SLW at 14M radius @ 22M height
10. safe radius to lift 22T @ 29M height
THANK YOU