Bio-Data

BACK

Now a day's various new plants and construction sites are in progress at various stages.
Every setup requires material handling equipments. Industries are forgetting to attend to
some of the safety measures that need to be taken care of during use of material handling
equipments. Now a day's awareness for safety has increased. Most management now
considers safety as an essential part of the operation. They have written their safety manuals
but adherence to safety codes and practices is missing.
WHAT IS SAFETY?
S : Sense the difficulty
A : Apply your mind
F : Formulate plan
E : Examine the situation
T : Timely action
Y : Yields good result
WHY INDUSTRIES ARE NOT FOLLOWING SAFETY:
Management is not aware of safety
No environment for safety.
No pressure from trade union to management.
Management's priority towards safety is low.
Location problem.
Need for large capital investment.
Power supply interruption.
Problems of Small Scale Industries.
Avoid safety regulation Act.
No storage facility.
No trained man power/qualified personnel recruitments.
Time factor involvement i.e. no sufficient time being allotted.
No periodic inspection is done for equipments.
WHY SAFETY
Save Human Life & avoid accidents
Improve quality of work
Create smooth & healthy atmosphere
Reduce time involvement
Built confidence internally & externally.
Save production cost & Improve productivity.
Prevent national loss.
Improve economical growth.
Healthy atmosphere to society.

In industries various steps are needed for safety monitoring. But we will limit ourselves to the
topic allotted, that is,. 'Testing and Inspection of lifting Tools and tackles' The conference's
objective is 'Safety Management'. We would like to explain in brief the different types of
testing and inspection methods and safety in material handling.
INSPECTION:
Inspection briefly can be defined as examination and verification. All manufacturing industries
needs inspection department. Duty of inspection department is to follow the laid down norms
for visual, dimensional, material conformity, technical requirements etc. to satisfy the
products being designed and its ultimate usage requirements. We are not discussing in depth
methodology of various inspection techniques. However we have listed below various checks
for safety of material handling.
TESTING:
Testing is also another important area where concentration is emphasized. Normally it is duty
of all material handling equipment manufacturers that product should be tested internally
before put in practical usage. It is duty of manufacturer to develop test set up which satisfies
the standard requirements for product. Testing of equipments confirms the quality of
materials being used, performance of product, & builds confidence at all levels. Testing should
also to be done as per points given below:Declared parameters of velocity ratio, effort etc.
As per code or standard lay down. i.e. IS 3832 for CPB,IS 3938 for EHB,IS-3177& IS 807
for cranes.
Manually operated hoist shall be tested for 1.5 times of SWL(i.e. Proof load testing)
Electric wire rope hoist shall be tested for 1.25 times of SWL(i.e. Proof load testing )
Crane shall be tested for 1.25 times of SWL(i.e. Proof load testing )
Tool and tackle shall be tested for proof load of 2 times of SWL.
Any type test requirements followed.
Vigorous situation tests.(Automobile)
Cranes are verified for deflection test.
Speed requirements shall be verified in idle condition.
Electric performance including brake and limit switch function to be verified.
After testing it is advisable that all parts to be visually checked for any wear and tear,
condition of wire rope or chain etc.
Now we shall explain in brief safety and inspection checks to be followed for Material
Handling Equipments;
Material handling equipments are mainly divided in three major categories
1. Manual material handling
2. Lifting Tackles
3. Mechanical Handling.
We shall now talk on each topic one by one.
1) MANUAL MATERIAL HANDLING
Inspect the object for sharp edges, protruding corners, nails etc. before touching.
While manually lifting the material (Load) keep legs apart, bend knees; keep back
straight to avoid sprains.
Keep load close to the body.
While moving with load/material makes sure your vision is not obstructed.
Do not drop drums, gas cylinders, barrels etc. on the road and roll them.
Use trolley or cart for transporting drums, Gas cylinders, barrels and carboys.
Drum cylinders, containing flammable
liquids should be kept away from sparks, flames, heat etc.
No material shall be stacked against walls or partitions to a height which can endanger
the stability of wall.
The materials should be stacked safely and stack height should not exceed more than 5
Ft. above the ground.
Dumping, pilling or stacking of material below overhead electric lines should be totally
avoided.

No material should be piled / dumped or stacked at random but only in areas specified
for same.
Roads, passage ways should not be blocked by dumping, piling or stacking of materials.
2) LIFTING TACKLES
Do not exceed safe working load at any point of time.
Avoid crossing, twisting, knotting of a wire rope/chain sling.
Lift load smoothly, avoid jerks, impact and swings.
3) MECHANICAL HANDLING
General:
Check brakes, lifting mechanism, limit switches, controls, guards, wire rope, hook, blocks
etc. of EHB, EOT cranes.
Check brakes, lifting mechanism controls, guards, tyres etc. of forklifts.
Never drive crane or a vehicle with wet or greasy hands.
Always drive vehicle at safe speed, slow down when taking turns, and blow horn at
corners.
When driving without load keep forks minimum 15 cm. above ground.
Avoid sudden starts and stops.
Avoid carrying oil drums, gas cylinders on forklift boom.
Do not cross over conveyors and roller table.
We shall examine the main mechanical handling equipments like,
1. Hand operated chain pulley block
2. Electric Hoist Block
3. Crane
CARE & SAFE USE AND INSPECTION CHECKS:
1) HAND OPERATED CHAIN PULLEY BLOCK:
Never lift a load in excess of safe working load marked on the block.
Twisting of load chain should be avoided in single fall or multiple fall.
Load to be applied centrally.
No direct binding of load with load chain, i.e. never use load chain as a sling.
No extreme slant slinging.
No over lifting, No over lowering, No rough handling.
Don't forget to oil the load chain after use, do not use grease for lubricating load chain.
If Load chain jumps, does not work smoothly or marks in use, it is probably out of pitch
& should be replaced.
Do not allow dirt and hard grease to gather in pockets of the load or hand chain.
Do not store or leave the pulley blocks lying on the ground where they can collect dirt.
Care shall be taken when replacing the chains that same Grade and size of chain is
fitted; Grade of chain is marked on pulley blocks by manufacturer.
Gears should be periodically greased. (HPC lithon-2 is recommended)
Never weld the load chain.
Hook should be used with safety latch.
Hook should be periodically examined for opening, i.e. for elongation.
Never lift load from hook corner.
Examine the hook for swivel movement, that is top hook under no load and bottom hook
with load should be possible to rotate.
Brake system is through Ratchet and Pawl mechanism, hence never remove pawl.
Friction washers should not be lubricated. They are made of brake lining material.
Operator should always wear helmet during operation and no person should stand under
lifted load.
Operator should warn persons around to avoid any accidents.
Care should taken that lifted load should not swing during operation.
Handling to be done carefully while block is operated above furnaces or on any heating
equipment..

It is always recommended to use Pulley Block as per class Designed.

Pulley Block should be examined, inspected & tested by an impartial & competent
authority once in a year for its wear and safe working as certified in Factories Act 1948.
Routine examination
The chain pulley block should be regularly inspected for damage and wear and to ensure that
it is operating smoothly. Where the hoist is used infrequently, a visual check should be made
of the chain pulley block each time it is used.
The following is a guide to routine checks, which should be carried out, on a chain pulley
block, which is used in normal operating conditions. Where a chain pulley block is used or
stored outdoors or in corrosive or abrasive conditions, inspection and lubrication must be
attended to more frequently.

External Inspection (Monthly checks)

Component /
Function
Hook

Inspection / Upkeep

Type of check
Inspect visually

1. There should be no deformation of the hook.

2. There should be no cracks, or serious damage.
3. Hook should hang square to lifting unit or top
yoke (top hook) or to bottom block side plates.

Inspect visually

All fasteners should be tight.

Inspect visually

Should be properly lubricated (Use "Cylesso

TK-140" oil) and free from rust and dust.

Rivets, Bolts &

Nuts
Chain

Slack end pin

Inspect visually
&Chain anchor pin

Should not be bent.

Chain wheels

Inspect visually

Chain pockets should not be deformed / worn out.

Should rotate freely.

Load Chain

Inspect visually

Should rotate freely and keep chain in the pockets

Guide Roller

of the chain wheel.

Inspect visually

There should not be any damage and wear.

Stripper / Hand
chain Guard

Lifting and
Lowering

Lift & lowe ra light Hoist should operate smoothly and easily.
load
Pawl should click during lifting.

Braking

Lift & lower Safe

Working Load

Lifting and lowering operations should be smooth

without any of the following defects.
1. Load falls, if hand chain is released.
2. Load falls while lowering.
3. Load slips.

Internal Construction (Yearly checks)

A competent person, as per statutory regulations and to ensure the efficient and safe use of
the chain pulley block should carry the routine inspection and tests given above, together with
the following inspections every year.
Internal Construction (Yearly checks)
Component /
Function

Type of check

Inspection / Upkeep

Ratchet Wheel & Pawl Inspect visually

before dismantling
brake (see below)

Wear on the ratchet wheel profile and pawl

should not be excessive - pawl must engage
fully in the ratchet teeth. The pawl should
not be rusted. Check that the pawl stud is
secure and
that the circlip / split pin is retaining the
pawl.

Load Chain Wheels & Inspect visually

Hand Chain Wheel

Clean out chain wheels pockets and check

that these are not deformed.

Spur Wheels and

Chain Wheels

Inspect visually

Clean of all lubricant and check that gear

teeth are not chipped, damaged or worn. Relubricate.

Chain Guide Rollers

Inspect visually

Should not be damaged, worn or deformed

and must rotate freely.

Stripper

Inspect visually

Tip of stripper should not be seriously

flattened or damaged. (If in doubt, consult a
competent person or fit new items).

Brake

Examine the screw sleeve, split bush, friction washers, ratchet ring
and hand chain wheel, pawl, pawl spring and pawl stud. All items
must be in good condition. The faces of the screw sleeve, ratchet
wheel and hand chain wheel must not be worn or scored. The bores
of the screw sleeve and ratchet wheel should not be worn or
scored.The friction washers should be measured with a vernier
caliper. Minimum permissible thickness is 1.5 mm. Friction
washers
must not be split or cracked.

TROUBLE SHOOTING CHART

Sr.
No.
1.

2.

Trouble
Load Slippage

Block not
hoisting or
lowering loads.

Cure

Cause
a. Friction washer(s)
may
be worn out.

a. Replace friction washers.

b. Friction washer(s)
oily.

b. Clean friction washer with sandpaper.

c. Screw sleeve &

hand chain wheel is
jammed.

c. Clean screw sleeve & hand chain wheel

square threads for burr / rust formation and
re-assemble.

d. Check washer is
not working.

d. Check serration, if required, replace

check washer. Adjust
Nyloc nut.

e. Ratchet wheel &

pawl arrangement is
not working.

e. Check spring, if found defective, replace

it. Check ratchet wheel & pawl, if worn out,
replace them.Ratchet pawl stuck. Check &
clean pawl stud.

a. Check for load

chain twist.

a. Remove load chain twist.

b. Hand chain or load b. Clean chain wheels & replace chain.

chain may be stuck
due to foreign
particles.
3.

Block making

a. Split bush may be

a. Replace it.

noise.

worn out.
b. Load chain stripper b. Replace it.
damaged.
c. Load chain wheel c. Replace it.
pockets may be worn
out.

4.

Load chain
failure

d. Guide roller
damaged.

d. Replace it.

e. Load chain is
jumping from wheel
pockets.

e. Check load chain dimensions, refer table

& replace load chain.

f. Hand chain is
slipping /jumping
from wheel pockets

f. Check hand chain dimensions, refer table

& replace load chain.

a. Hoist is
overloaded.

a. Check load to be lifted & capacity.

b. Load chain may be b. Replace load chain.

worn out.
c. Load chain may be c. Remove load chain twist.
twist.
2) ELECTRIC WIRE ROPE HOIST
Never lift a load in excess of the safe working load marked on Hoist.
Always lift load vertically.
Never lift with the point of hook.
Never run the wire rope out too far.
Apply grease to the wire rope periodically.
Before use of hoist, examine the wire rope to ensure that there is no twist.
Do not lubricate any point of contactors.
Inspect the wire rope for wear and tear regularly.
Under no circumstances should the hoist be operated when Limit Switch is not
operating properly.
Ensure that the rope drum is perfectly horizontal when Hoist is used as a fixed
suspension unit.
Examine the supply provided and connections are made accordingly.
Examine brake operation periodically and set the brake adjustment.
Periodically examine the bolts and nuts. If required tighten them.
Load should not be allowed to swing during operation.
Operator should use helmet.
Never open any electrical contact when supply is ON.
Hoist should be examined, inspected & tested by an impartial & competent authority
once in a year for its wear and safe working as certified as Factories Act 1948.
Always use lubricant for gears as recommended by Hoist Manufacturer.
Periodically examine that no foreign particles accumulate on Beam on which Trolley is
moving.
Care should taken that Electric hoist block fitted on Beam should be properly ground if it
welded.
Do not leave load suspended in the air for long time.
It is always recommended to use Hoist as per class Designed.
Electrical parts shall be protected, if application is out door.
AFTER A PROLONGED STOP OR WHEN MAKING A ROUTINE EXAMINATION
1. CHECK operation of brakes.
2. CHECK operation of limit switches.
3. CHECK for damaged hooks, ropes or cables.
4. KEEP rope clean and well lubricated.

5. CHECK the wire rope for improper seating, twisting, kinking, wear or other
defects before operating the hoist.
6. CHECK that suspending cables of the Control Box are not broken or loosen. If
the cable is damaged, change it.
WHEN IN USE
1 HOLD the load in a balanced way, securing it by using appropriate equipment
(sling).
2 MAKE SURE the load clears vicinity, stock piles, machinery, or other obstructions
when raising, lowering or moving the load.
3 CENTER hoist directly above the load before operating, never pull from the side.
4 MAKE SURE that the load is high enough to see and avoid any obstacle lying on
the ground.
5 AVOID swinging the load or hook block when traveling.
6 MAKE SURE that the load is correctly held in the hook.
7 CHECK that the rope reeving is correctly tight (slackness not desirable).
8 KNOW AND USE the hand signals for hoisting and traveling.
3) CRANE
Crane is general word .Various types of cranes are:Hand operated traveling crane (HOT)
Electric overhead Traveling crane (EOT)
Sub divided as
Gantry crane
Cantilever crane
Jib crane
Wall/Pillar mounted jib crane
Portal crane
Mobile crane
Locomotive crane
Never lift a load in excess of the safe working load marked on crane
Always lift load vertically.
Never lift with the point of hook.
Never run the wire rope out too far.
Apply grease to the wire rope periodically.
Before use of crane, examine the wire rope to ensure that there is no twist.
Do not lubricate any point of contactors.
Inspect the wire rope for wear and tear regularly.
Under no circumstances should the crane be operated when Limit Switch is not
operating properly.
Examine the supply provided and that connections are made properly.
Examine brake operation periodically and set the brake adjustment.
Periodically examine the bolts and nuts, if required tighten it.
Load should not be swing during operation.
Operator/helpers should use helmets.
Never open any electrical contact when supply is ON.
Crane should be examined, inspected & tested by an impartial & competent authority
once in a year for its wear and safe working as certified as Factories Act 1948.
Always use lubricant as recommended by crane Manufacture.
Periodically examine that no foreign particles are accumulated on crane movement path,
i.e. on beam.
Do not leave load suspended in the air for long time.
It is always recommended to use crane as per class designed.
Lock the movement of crane when it is not in use.
Switch off the power supply when crane is idle.
Periodically verify the supply wire conditions.
______________________________________________________________________________________________________________

Bio-Data

Shri J.B. Bhatt is a Mechanical Engineer having PG Diploma in Business Administration and Chartered Engineer.
He has worked as Production Engineer with M/s Elecon Engineering Company, VV Nagar from 1979 to 1994. There after he also worked
at Kalama Pumps for a year. Since 1995 he is working as a Manager (Q.A.) with M/s Brady & Morris Engg. Co. Ltd., Ahmedabad.
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