SAFETY IN MATERIALS HANDLING AND CONTINUAL IMPROVEMENT By Aswath Narayana Rao MP Mgr (M)/SP

HAZARDS IN MATERIALS HANDLING LOSING CONTROL OF LOAD STRUCK BY LOAD PHYSICALLY OVER EXERTING ONE SELF EXCEEDING EQUIPMENT CAPABILITIES SLIPPING OF IMPROPERLY STACKED MATERIAL HIT BY SLING SWING OF LOAD LIFTED MATERIAL HANDLING CAUSES SIZABLE PERCENTAGE OF INDUSTRIAL ACCIDENTS. COMMON TYPE OF INJURIES ARE SPRAINS, FRACTURES, WOUNDS, BACK PAINS, AND EVEN FATAL INJURIES.

HAZARDS CONTROLS FOR PROTECTING INJURY WORK PLANNING MECHANICAL LIFTING DEVICES SAFE LIFTING PRACTICES TRAINING PERSONAL PROTECTIVE EQUIPMENT PRECAUTIONS FOR SAFE LIFTING & HANDLING OF MATERIALS PRE-LIFT INSPECTION AND CONSIDERATIONS TECHNIQUES FOR MOVING & LIFTING MATERIALS

WORK PLANNING ACCIDENTS ARE CAUSED DUE TO NO ASSISTANCE LACK OF TRAINING POOR JUDGEMENT POOR SELECTION IMPROPER USE OR MAINTENANCE OF EQUIPMENT POINTS TO CONSIDER : WEIGHT OF THE OBJECT, LENGTH, WIDTH, HEIGHT CENTRE OF GRAVITY HANDLES, TEXTURE AND GRASP POINTS

MECHANICAL LIFTING DEVICES SAFE WORKING LOAD ACCESSABILITY REQUIREMENTS WORKER EXPERIENCE MAINTENANCE STATUS

SAFE LIFTING PRACTICES PROVIDE HAND HOLDS ON THE OBJECT FIRMLY GRIP THE OBJECT USE CARTS OR HANDLING AIDS TRIED TO MINIMIZE THE DISTANCE THAT AN OBJECT IS MOVED CARRY LOAD CLOSE TO BODY PUSH OR PULL RATHER THAN LIFTING POSITION THE STORAGE OF OBJECT AT CONVINIENT HEIGHTS DO NOT TWIST OR BEND WHILE LIFTING LOAD AVOID STAIR CASE INCASE STAIRE CASE IS TOBE USE KEEP ONE HAND FREE TO HOLD THE RAILING

PRE-LIFT INSPECTION & CONSIDERATIONS INSPECT THE LOAD FOR SHARP EDGES SLIVERS, WET OR GREASY SPOTS WEAR HAND GLOVES INSPECT THE ROUTE

MECHANICAL MATERIALS HANDLING TYPES OF SLINGS : MANILA ROPE NYLON ROPE WIRE ROPE CHAIN SLINGS WIRE ROPE SLINGS : THUMB RULE FOR SAFE WORKING LOAD = 8 D X D Kg. D=Dia of wire rope in mm. CONSTRUCTION OF ROPE VARIES FROM 6X19 TO 6X37 WHERE 6 IS NO. OF STRANDS AND 19 TO 37 ARE NO.OF WIRES IN EACH STRAND. THEY ARE WOUND AROUND STEEL CORE OR FIBRE CORE.

INSPECTION OF WIRE ROPE REPLACE THE WIRE ROPE IF THE FOLLOWING DEFECTS ARE OBSERVED EXCESSIVE WEAR BROKEN WIRES CORROSION HEAT DAMAGE KINKING BIRD CAGING CRUSHING UNSTRANDING

“KINKING” , “ BIRD CAGE”

PRECAUTIONS WHILE USING SLINGS USE PROTECTIVE PADDING AT SHARP CORNERS DONOT TWIST OR KNOT THE SLINGS KEEP HANDS AWAY FROM PINCH POINTS STAND AT A SAFE DISTANCE DO NOT ROLL LOADS OVER THE SLING DO NOT DROP SLINGS FROM HEIGHT

Chain slings Chain slings are your best choice for lifting materials that are very hot. They can be heated to Temperatures of up to 1000oF; however, when alloy chain slings are consistently exposed to service temperatures in excess of 600oF, operators must reduce the working load limits in accordance with the manufacturer's recommendations.

Worn-out, damaged, or overloaded chain slings may fail, causing injury or death! Always inspect chain slings before use. Never use worn-out or damaged slings. Never overload or shock load a sling. Free slings of all kinks, knots and twists. Do not drop or rest a load on a sling. Balance loads.   Avoid tipping loads. Do not immerse in corrosive solutions. Use pads around sharp corners. Do not force or hammer hooks into place. Follow all regulations for inspection and removal of worn-out or damaged slings.*

Load on leg Load Angle Factor = L / H Load On Each Leg of a Sling (L1) =Load (lbs.) x Load Angle Factor Number of Legs*

RULES FOR CRANE OPERATORS PREPERATIONAL CHECKS SIGNAL FROM ONE PERSON ONLY EXCEPT STOP SIGNAL DO NOT MOVE LOAD OVER PEOPLE DO NOT EXCEED SWL CHECK THAT ALL CONTROLS ARE IN OFF POSITION BEFORE CLOSING MAIN. MAKE SMOOTH OPERATIONS TO AVOID JERKS

Continual Improvements ( Modifications )

Conv 501 Take up spare Bend pulleys lifting arrangements

AVAILABILITY HOURS OF S/PLANT Year Availability B/D Hrs Maint Hrs Shut down Hrs 2006 - 07 83.37 % 1274.35 2007 - 08 85.82 % 1098.79 2008 - 09 86.51 % 1091.93 380.15 219 2009 - 10 89.47 % 841.63 361.55 320 2010 - 11 90.57 % 562.05 235.9 272.30