Transcript Plant and machinery operation

SAFETY IN
PLANT & MACHINERY
OPERATION
P&M BUSINESS UNIT– A GLANCE
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•
•
•
TOTAL ASSET ACQUISITION VALUE – 785 Cr.
MAJOR ASSET – 3355 NOS
MINOR ASSET – 8005 NOS
ISO 9001 CERTIFIED
•RIGHT EQUIPMENT FOR RIGHT JOB
•COMPETENT / TRAINED OPERATOR &
DRIVER.
•PERIODICAL SKILL EVALUATION OF
P&M WORKMEN.
•SAFE OPERATION WITHIN SPECIFIED
LIMITS.
• SAFE WORKING CONDITIONS
(Suitable Ground Condition, Safe
access/egress, Emergency exits,
Interlockings & Guards,)
•TAG-OUTS / LOCK-OUTS.
•REGULAR MAINTENANCE SAFETY
INSPECTION.
What is Maintenance ?
Any method adopted to keep a system in
good working condition @ economical cost
• Types of Maintenance
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–
–
–
Periodic / Regular
Preventive
Predictive
Breakdown
SAFETY SYSTEMS RELEVANT TO
P&M.
1. CRANES INSPECTION CHECKLIST &
REPORT.
2. VEHICLE AND EARTH MOVING
EQUIPMENT INSPECTION CHECKLIST AND
REPORT.
3. ALL LIFTING EQUIPMENTS (OWN / HIRED /
S/C) WILL BE TESTED BY A COMPETENT
PERSON BY EVERY YEAR.
4. WINDER INSPECTION CHEKLIST & REPORT
LARSEN & TOUBRO LIMITED
ECC DIVISION (Engineering, Construction & Contracts)
Plant & Machinery Business Unit
Quality Management System
DAILY CHECKS & MAINTENANCE SCHEDULE
Name of Operator : _______________________
Asset Code :
Mark accordingly:
SNo.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Check Points
Engine oil level
Engine coolant level
Fan belt tightness
Air cleaner checking
Water temp guage working
RPM meter working
Engine oil pr. gauge working
Battery electrolyte level
Boom clutch& brake
Hoist drum clutch& brake
Swing brake checking
Wire rope condition
Over - Hoist Limit Switch
Boom Limit Switch
Signature of operator / mechanic
Signature of section in-charge
Asset Description: Crane
Performed
1
2
3
Not carried out
4
5
Date of Inspection
6
7
8
9
10
Month :
11
12
13
(P&M - Incharge)
FORMAT No
LARSEN & TOUBRO LIMITED
ECC DIVISION (Engineering, Construction & Contracts)
Plant & Machinery Business Unit
Quality Management System
DAILY CHECKS & MAINTENANCE SCHEDULE
Name of Operator : _______________________
Asset Code :
Mark accordingly:
SNo.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Check Points
Engine oil level
Engine coolant level
Brake oil level
Battery electrolyte level
Fuel level
Hydraulic oil level
Air cleaner
Hand brake working
Air pressure(brake)
Tyre pressure& wear/damage
Indicators/head lights etc.
UJ cross joint bolt-nut tightness
Wheel nut tightness
KMR working
Water pump,alt. Belt tension
Steering system
Horn,reverse horn,wiper etc.
Signature of operator / mechanic
Signature of section in-charge
Asset Description: VEHICLES
Performed
1
2
3
Not carried out
4
5
Date of Inspection
6
7
8
9
10
Month :
11
12
13
(P&M - Incharge)
FORMAT No.: R
COMPRESSED AIR
Air receivers:
Hydrostatically tested and approved tanks are used as
air receivers. The Air receivers are tested for a span of
a year regularly by competent authority
SAFETY PRECAUTIONS
• Receivers should be drained frequently to prevent
accumulation of liquid inside the unit.
• Air tanks should not be buried or placed where
they cannot be seen for frequent inspection.
• Each air receiver shall be equipped with at least
one pressure gauge and an safety valve of the
proper design.
• A safety (spring loaded) release valve shall be
installed to prevent the receiver from exceeding the
maximum allowable working pressure.
Air Distribution Lines:
SAFETY PRECAUTIONS
• Only standard fittings should be used on air
lines.
• Operators should avoid bending or kinking air
hoses.
• Hoses should be checked to make sure they
are properly connected to pipe outlets before
use.
• Air lines should be inspected frequently for
defects, and any defective equipment repaired
or replaced immediately.
• safety valve are used and set to 10 percent
above the operating pressure of the
compressor-
Operating cranes near
overhead power lines
Indian Electricity Act, 1910(sec.79&80) prescribes minimum clearances
between ground and live conductors and also horizontal distance to be
maintained from building/structures.
Classification of voltage (IE Rule 2(1) (a) ):
1.Low voltage
Not exceeding 250v
2.Medium Voltage
Not exceeding 650v
3. High Voltage
More than 650v & upto 33kv
4.Extra high voltage
More than 33kv
Clearance along /across the road and cross country (IE Rule No.77)
VOLTAGE
ACROSS THE
ROAD
ALONG
THE ROAD
Low and medium voltage
19 ft (5.791m)
18ft.
(5.486m)
High voltage line upto 11KV
20ft (6.096m)
19ft
(5.791m)
For high voltage above 11KV upto
33kv
20ft (6.096m)
19ft
(5.791m)
For extra high voltage line (for
every additional 33kv OR part
thereof
20ft (6.096m)
Plus 1m for
every 33kv
Components of Steel Wire Rope
Wire are laid helically above a center to form a
strand which is further laid helically over a core to
form a rope. The main component parts of a
standard wire rope are
• WIRE
• STRAND
• CORE
Common usage of wire rope
IWRC – Provide good crush resistance and increased
strength
FMC - Provide excellent flexibility
Storage Of Wire Ropes
Wire ropes must not have suffered corrosion,
rusting, damage or severe contamination with
dirt when they are installed.
 Ropes must therefore be stored in a dry place
and moisture condense prevented from
forming on non galvanized rope.
Maintenance Of Wire Ropes
• Wire ropes need regular maintenance, with particular care
devoted to the rope drives subject to serve loads
• Ropes must be lubricated at regular intervals, in particular
where they pass round pulleys and drums.
• The actual intervals will depend on local operating
conditions, but subsequent lubrication is normally
recommended at least every two hundred hours of operation.
• In special circumstances – extreme weather, sea air etc
• It may be necessary to reduce the intervals between
lubrication routines.
• The lubricants must be compatible with those already on the
ropes.
• Oils are normally superior to grease because they can
penetrate the interior of the rope, but some greases contain
additives to aid penetration.
Maintenance Of Wire Ropes
• Rope which move in the operation should be cleaned at
the intervals, since the mixture of dust and residual
lubricant which other wise forms can fresh lubricant from
penetrating the rope.
• Lubrication is also important as a means of preventing
corrosion.
• Fixed ropes should be greased or painted to protect them
against corrosion or rusting.
• If operating circumstances makes it impossible to
lubricate a rope once it has been installed, it’s working
life will be reduced and it should therefore be inspected
at more frequent intervals
WRONG METHOD
CORRECT METHOD
WRONG
METHOD
CORRECT METHOD
VARIETIES OF ROPE
DAMAGES
TYPES OF ROPE DAMAGES
TYPES OF ROPE DAMAGES
Replacement of Wire Ropes
 Structural changes have occurred so that the rope diameter is
15% or more below its original nominal diameter over a fairly
long distance
 Corrosion or rusting has caused the rope diameter to be 10% or
more below the nominal diameter
 The rope diameter is 10% or more below the nominal diameter
on account of wear
 Severe deformation of the rope structure is visible, such as
expanded “baskets”, severe corkscrew deformation, severe
wire strand loops, loose strands on account of corrosion or
wear, loops and twists, mechanical damage, severe kinks or
necking
How User Departments Can Help
P&M Department
• Spare equipment in time for routine maintenance
• Ensure hired eqpt. are inspected by P&M Dept.
before hiring contracts are concluded.
• Equipment misuse to be avoided.
• Recognize P&M efforts & initiatives at site and
share their problems .
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THANK YOU
FOR YOUR
ACTIVE
PARTICIPATION