Lifting Gear and Lift Inspection Procedure

Lifting Gear and Lift Inspection Procedure

by | Sep 8, 2019 | Power & Energy

Lifting Gear

  • Lifting Gear – To meet statutory requirements and ensure that lifting equipment can be used in safety by minimizing risk of failure.All lifting gear brought onto the project shall be clearly identified by means of a tag/name plate supplied by the manufacturer, as to safe working load…
  • All lifting equipment in use or in storage must be inspected every three months against the standards LG . Any Lifting Gear and Lift Inspection that is not produced by a recognized and competent manufacturer and lifting gear fabricated from rebar is not permitted.
  • Each equipment/gear to be marked with the serial number and Safe working load in Kg. on the Hook and pulley block or other conspicuous places. If spreader beams or lift beams do not have certification or are of special fabrication then calculations shall be submitted for Client review, prior to the receipt of the required certification.
  • All  lifting machinery and Tackles to be identified-classified to the type eg., Slings, Shackles, Hooks, Chain Pulley Blocks, Traverse Rails & Cradle, etc-numbered and listed by giving a suitable serial number.  SMI shall inspect all lifting gear prior to its arrival at the work site, and thereafter on quarterly basis. It shall be color coded with a durable tag.
  • The color coding (DT, COLOR CODING PROCEDURE) will be set and shall be changed on quarterly basis, in order to identify whether the item in question has been checked during the first one week on every quarter.
  • Crane operators and /or Traverse rail & cradle operator to be trained, where applicable to be trained on hand signals, internal licensed so that handling of loads are ensured. SMI shall maintain all records and inventories as detailed in the HSE and security regulation, to ensure a system of controlling and monitoring the condition of all lifting gear, utilizing the Lifting Gear Register.

Lifting Equipment

Certification :Valid third party certification as to testing and certification shall accompany all Lifting Gear and Lift Inspection equipment brought onto the Project. Such certification shall have been issued within the last 12months and in addition, shall fulfill all relevant legislative requirements.

Initial Testing: Prior to entry on to the work site, all lifting equipment shall be inspected as to integrity and condition. Records shall be maintained of all inspections and fests.

Notwithstanding, SMI shall be fully responsible for the safety of all such equipment and shall, where necessary, implement additional systems of control to those identified in this Project Procedure.

The testing shall be executed by the SMI Competent Lifting Supervisor ay the base of origin prior to being transported / Moved to the construction site, this shall be undertaken at the discretion of Client.

Upon lifting equipment arrival at the work site all cranes can be inspected by the Client at their own discretion and be fitted with all necessary items, these requirements shall include but not be limited to:-

  • Inspector to be appointed to check at regular interval as specified in standard for individual items of Lifting Gear and record findings in register. Records of inspection of Lifting Gear and Lift Inspection appliances
  • Slings must be stamped with maximum permissible load. Test records for load radius indicator and automatic safe load indicator.
  • Slings must be identified by a number. Annual inspection record
  • Examination results after substantial alterations /repair
  • 4 year test certificate and thorough inspection
  • Mandatory inspection certificate of all Lifting Gear and Lift Inspection equipment associated with the crane
  • Checks on lights and warning devices, electrical wiring, battery terminals to be clean, tyre pressure, excessive wear, exhaust
  • Crane driver certificate
  • Condition of Fly Jib
  • Maximum permissible working load to be indicated on the block.
  • Satisfactory working condition of braking system on load.
  • Inspect for wear on sheaves.
  • Inspect for wear and deformation on lifting chain.
  • Ensure sufficient lubrication.
  • Inspect attachment eye for wear and deformation.
  • Serviceability /non serviceability to be recorded.
  • Quarterly check sheet must be signed by Inspector Lifting Gears.
  • Ensure traverse rails are properly secured.
  • Check for wear and corrosion.
  • Check free movement of roller wheels on rails.
  • Ensure proper lubrication.
  • Check for wear and corrosion on roller wheels and pulleys.
  • Serviceability /non serviceability to be recorded.
  • Quarterly check sheet must be signed by Inspector Lifting Gears.
  • A load radius indicator
  • An automatic safe load indicator
  • Crane hooks with a safety catch to prevent displacement of the sling or load from hook.
  • A load radius table to be available in the crane of every variable radius crane.
  • Slings are not to be fatigued ( no breakage of wire strands). Operation manual
  • Fire extinguisher in cab.
  • All controls identified – (levers marked-up)
  • Warning horn & reverse alarm.
  • Proof of load test
  • Anti-two-block devices (operational)
  • Boom angle indicator
  • Slings must be free of kinks. Load indicator
  • Slings must not be worn or corroded. Overload alarm
  • All out riggers shall be marked to show full extension.
  • Cranes shall not be fitted with obstructions to driver view, e. g. sun shades
  • Proper spooling on drum – all systems
  • No indication of mechanical damage. Proper counter weights
  • Condition of Boom section i.e. bent lacings /cords.
  • Proper reweaving – all systems
  • Load blocks – headache ball – hook with latches.
  • Condition of hydraulic rams (telescopic booms).
  • Outrigger beams – rams –floats- mats – pins – locks
  • Boom pendants – gantry bails- pins.
  • Boom hoist wire rope- sheaves – brake – clutch.
  • Main / aux hoist wire rope – sheaves – brakes- clutch.
  • Only when the Client Equipjment Inspector is satisfied that all the above  requirements are met in full will the crane be issued with: –
  • Unserviceable slings to be condemned and replaced.   The completed crane sticker
  • Quarterly check sheet must be signed by Inspector Lifting Gears.  The completed crane inspection form
  • Note: SMI shall  ensure that crane load tables (legible) and maintenance logs shall always be available in the cab of the crane.

Routine Testing

  • Regular checks shall be carried out on a three monthly basis and also where an item of
  • lifting equipment leaves the Project, and thereafter returns to continue work.
  • Thorough inspection & load testing will be conducted if the crane is modified or after    maintenance service.
  • SMI shall be responsible for scheduling inspection to be carried out.
  • All lifting equipment utilized on the work site shall be required to visually display  evidence of such inspection through the use of a Project specific sticker. This sticker shall record details of all inspection carried out and also the due date for next inspection.
  • All testing/inspection shall take place outside the work site perimeter fencing, but the three monthly (but not pre-mobilization) testing/inspection can be take place on site.
  • This discretion shall only be exercised with permission from the relevant Client Area Construction Manager.

Rejection of Lifting Equipment

  • Client will be notified of any rejected item of equipment that fails to meet internationally recognized standards of maintenance and  integrity, or    possessing any defect or damage that may impact upon its safe operation.  unless adequately repaired and re-tested.
  • A Crane Inspection Checklist is available to in Attachment 1. SMI shall arrange testing / inspection so as to minimize impact upon construction schedules.

Operator Competency

  •  All operators, employed on the Project shall be competent to operate the item(s) of equipment for which they have been engaged.
  •  All such operators, in addition to possessing a relevant national drivers /operators license, shall be assessed prior to engagement on the Project.
  •  They shall be assessed in relation to every item of equipment, which they are engaged to operate
  • This assessment shall comprise a verbal test and also a practical
  • demonstration of competence in relation to controls, and in the case of crane age, the rigging and de-rigging of the fly jib and their ability to control and support a team as required.
  •  If successful, the operator shall be awarded a work site license, which shall clearly identify the category of equipment for which the operator is authorized.
  •  This license shall be carried by the operator at all times on the work site, and shall be subject to inspection by the Client.
  •  Failure to carry the license may result in the operator being instructed to stop work until records of the operator’s competence have been established.
  •  The license shall also be subject to endorsement in the event of a breach of safety rules, regulations or recognized good practice.
  •  Such endorsement shall be clearly entered onto the license.
  •  On receipt of three such endorsements, the operator shall be suspended or expelled from the Project.
  •  Not with standing any of the above. SMI shall be fully responsible for ensuring that all operators are competent to carry out all designated tasks.

Heavy Equipment

  • All procedure will be followed by above whatever applicable.
  • Only trained and authorized operation shall be permitted to operate and inspect For pre-start/walk around inspection
  • Check for loose or worn parts and repair or replace immediately
  • Check all fluid/coolant levels
  • Open the radiator cap only when the engine is cooled
  • Inspect hydraulic connectors and hoses for leaks before applying pressure to the system
  • Use paper or cardboard, not hands, to search for leaks
  • Hydraulic fluid escaping under pressure can penetrate skin and cause serious bodily harm
  • Check tires for cuts, bulges, irregularities, abnormal wear and proper inflation
  • A fire extinguisher and first aid kit shall be mounted in the cab
  • Maintain a 3-point contact with the steps and hand rails while getting on/into the machine – do not use the controls or steering wheel as a handhold
  • Do not operate the machine with wet, greasy, or muddy hands or shoes

Machine Maintenance

  • When servicing equipment, fasten a “Do not operate” tag on the steering wheel
  • Slings-rope, wire, chain
  • not worn/corroded
  • free of kinks, no breakage of wires
  • chain kinks not worn
  • attachments U bolts proper
  • Shackle
  • not worn corroded or distorted
  • wear on pin
  • SWL stamped and readable
  • threads free and good condition
  • Hooks
  • Spread in throat opening measure
  • eye not damaged
  • swivel not damaged
  • load pin not damaged
  • SWL stamped and readable
  • braking system on load
  • sheaves wear
  • every chain link good condition
  • eye not damaged
  • swivel not damaged
  • SWL indicated and readable
  • Traverse Rails & Cradle
  • rails properly fitted
  • no wear or corrosion
  • rollers on rail freely moves
  • lubrication
  • roller / pulley wear
  • SWL indicated and readable
  • Remarks on Item Number
  • Remedial Action Item Number
  • Date of Inspection
  • Ensure the cab area is clean and free of debris and tools
  • Clean windshield, mirror and lights
  • Remove all oil, grease or mud and snow from grab irons, hand rails, steps, Pedals and floor to prevent slips and fails
  • Remove or secure any loose items such as tools, chains, bottles from the cab

Starting and Testing

  • Exhaust fumes are dangerous-always has a running machine in a well ventilated area of Lifting Gear and Lift Inspection
  • Controls should be in neutral and the parking brakes set before starting engine
  • Warn personnel in the area that starting the engine
  • Check all gauges, light, instruments and warning devices to assure that they are functioning property and the readings are within normal ranges
  • Test steering and brakes against ground speed to be certain there is no malfunction
  • Ensure all implement controls are operating properly

Refueling Lifting Gear and Lift Inspection

  • Shut off and cool the engine and any electrical equipment before fueling
  • Ensure the fueling area is well ventilated
  • Do not smoke while refueling. Keep open flames and sparks away from area
  • Ground the funnel or fuel nozzle against the filler neck to avoid sparks
  • Do not use gasoline or diesel fuel for cleaning parts
  • Check the battery and electrolyte levels according to manufacturer’s instructions
  • Keep close the fire extinguisher during refueling Lifting Gear and Lift Inspection
Fan Coil System Check List

Fan Coil System Check List

by | Sep 7, 2019 | Power & Energy

Fan Coil System

  • Fan Coil System = Proper earthing condition
  • Inspection for damage of Electric contact point
  • Check proper functioning of all the switch
  • Check any water leakage
  • Clean the drain line to protect Fan Coil System
  • Any damage of the condensed collection tray
  • Check the insulation wet or dry
  • Any damage of the insulation
  • Check the function of solenoid valve
  • Any water leakage
  • Check Fire Extinguisher
  • Inspection for damage of Electric contact point
  • Check the condition of the fins
  • Check any block
  • Clean properly
  • Check the function of the sensor
  • Pipeline for Fan Coil System
  • Outer surfaces of the equipments
  • Painted the rusted surfaces area

Critique and Discussion

Immediately following the drills, key supervisory personnel should prepare a written critique and discuss their conclusions to analyses the success of the drill in achieving the planned objectives. The discussion session can take place at the scene of the drill or in a central gathering location . The discussion session can take place at the scene of the drill or in a central gathering location such as the coffee shop or mess room. The critique discussion should The discussion session can take place at the scene of the drill or in a central gathering location such as the coffee shop or mess room. The critique discussion should

• Review the emphasis of the drill.
• Discuss the problems which occurred during the drill.
• Assess whether the drill was conducted realistically.
• Discuss other possible situations that could have developed.
• Establish the aspects that in most critical need of practice in further drill.Reporting : Every safety drill shall be reported and filed in the Construction site/platform/vessel safety drill
register. The report shall include the following topics:
• Aim of the drill.
• Participants.
• Equipment used.
• Log of the drill completion
• Weak and positive points.
• Conclusions for improvement.

High Pressure Water Pump Check List. Conducting drills

High Pressure Water Pump Check List. Conducting drills

by | Sep 7, 2019 | Power & Energy

High Pressure Water Pump

High Pressure Water Pump – Auto  always ready to abide by the Environmental rules and regulations and belief in sustainable development wholeheartedly. We have functional ETP plant is running 24/7 to discharge neutral water in environment. We are using   Electro Coagulation System.

We have in-house traditional parameter test equipment facility. We fulfill DoE legal requirement in every three months.

We are following Solid waste management facility to dispose the solid wastage in environment friendly method.

We are doing environment friendly wastage management following our own guideline considering the Environmental rules & regulation of local & international.

  • Check the electrical connection of the motor
  • Proper earthing condition of high pressure water pump
  • Inspection for damage of Electric contact point
  • Check the current at each phase at running condition
  • Check the MCB and Overload
  • Is there correct indication at the pressure gauge
  • External cleaning
  • Any leakage at the connecting point
  • Check the insulation
  • Check any leakage of high pressure water pump
  • Check the water leakage
  • Check any abnormal sound
  • Check the motor hot or cool at running condition
  • Any leakage at the valve
  • Is the valve operated easily
  • Pipeline
  • Outer surfaces of the pump and motor
  • Painted the rusted surfaces area

Conducting drills

  • Offshore fire / Gas release Drill Procedure
  • The following steps should be included in every fire / gas release drill:
  • Location of the fire / gas release
  • Sound the alarm
  • Person in Charge assumes control
  • Muster
  • Search
  • Rescue of injured persons
  • Investigate scene of incident
  • Restrict of fire
  • deploy fire Teams
  • Extinguish fire
  • Offshore Abandon Drill Procedure
  • The following steps should be included in every offshore drill:
  • Sound the alarm
  • Contact rescuers
  • Muster
  • Search
  • Rescue injured or trapped person
  • If decision to abandon is taken, board the suitable lifeboats or vessels.
  • Instruction on when and how to deploy
  • Operate all equipment (with the minimum crew on board lifeboats)
  • Deploy Fir Teams
  • Experience Alternate abandonment means
  • Review steps after launch
  • The steps that should be taken after clearing the platform vessel or module are discussed.
  • These steps include:
  • ending circumstances rescuing survivors from the sea:
  • Motoring away from site,
  • Maintain position,
  • stablish radio contact with land or ships in the area,
  • Give treatment to injured,
  • Safe conduct when rescued by large craft or when proceeding to and,
  • Demonstrate good seamanship.
  • A record of all emergency drills, exercises and alarm tests must be kept by the Fire
  • Marshal, HSE Supervisor and HSE Officer on barge/onshore locations in a book or similar to be used specifically for that purpose.
  • The record must include:
  • Date and Times.
  • Type of drill, muster or alarm test.
  • No. of personnel involved.
  • Names of personnel involved (For drills only).
  • Details of recommendations and completed actions.
Cooling Tower Fins Maintenance Check List

Cooling Tower Fins Maintenance Check List

by | Sep 6, 2019 | Power & Energy

Cooling Tower Fins

Cooling Tower Fins

  • Check the electric connection of fan motor 
  • Proper earthing condition
  • Inspection for damage of Electric contact  point
  • Test the PH Value of the cooling water
  • Check the water clean or cloudy
  • Is there any leakage at the float valve for Cooling Tower Fins
  • Check the function of the float valve
  • Check the water level maintain at accepted limit
  • The water distribution at the fin is uniform or not
  • Check scale formation
  • Any type of damage
  • Check electrical connection
  • Check any abnormal sound
  • Check the current and voltage
  • Check the motor hot or cool at running condition
  • Check the leakage at the pipe line and  chamber
  • Pipeline for Cooling Tower Fins
  • Outer surfaces of the equipments 
  • Painted the rusted surfaces area

Conducting Effective Drills

The following three steps are required for drills to be effective:

Plan the drill-effective drills should always be carefully planned to focus the training on a particular need. Planning the drills maximizes the benefits of conducting the drills and minimizes the amount of time wasted during the drill

Conduct the fire drill realistically – The drill should stimulate an actual condition and make the crew performing as though the actual emergency condition existed.

Conclude with a critique and discussion session immediately following the drill will identify the problem  areas   and  point  out   mistakes  while  they  are   fresh  in  the  minds  of  the   crew.

Each drill should be designed to  emphasize a single  aspect of  responding to  an emergency, even though every drill should contain all the steps necessary in a real emergency. A single drill should not attempt to teach crewmembers everything at once. Focusing  the  drill on a single aspect simplifies the drill, can increase the chances of that aspect being remembered during an emergency if necessary, and keeps the  time required  for the drill within an acceptable limit.

Select a suitable location: The location for the drill should be appropriate for the aspect being emphasized. For example a drill that focuses on life raft deployment should beheld at a life raft station. The location for a fire or another emergency situation should vary from time to time.

Avoid undue risk: Drills should avoid exposing the crew installations to situations that may place them in jeopardy. For example toxic fumes should  not be used when training crew members in the use of self- contained breathing apparatus or fires started to test fire fighting system.

The Person in Charge should avoid placing his crew in high risk situation,avoiding all risk should mild seaway can entail some risk, this risk can be reduced to  an acceptable  level with    proper maintenance and training. The benefits  of  operating  this  equipment to increase the chance of successful deployment in a  real  emergency  are  high  and  therefore worthwhile. This  type  of drill  should  be conducted   preferably in sheltered  waters  or in good weather  condition  with the minimum crew on board (3 men).The steps that should be taken after clearing the platform vessel or module are discussed.These steps include:

Electric Resistance Heaters Replace By Infra-Red Heaters

by | Aug 29, 2019 | Power & Energy

Electric Resistance Heaters

Electric resistance heaters are used for heating the glue applied over the print blankets, which holds the fabric in place. When the belt finishes its movement on the upper side and when it moves down, the glue gets dried, which has to be heated again to retain its properties before it is exposed to the fabric again. In place of electric heaters if infra-red heaters are used, the efficiency would be better and energy consumption will be reduced.
Reduced electricity consumption of about 4 kWh/hour per infra-red heater.
Better work environment.

This option of Electric Resistance Heaters is a technology modification option for heating of the print blankets on continuous printing machines. This is a measure applicable to all printing machines that use print blankets (endless), which are coated with adhesives for holding the cloth in place while printing.
Investment cost per infra-red heater is Circuit Maintenance Process . Thus, annual savings are calculated to be INR 86 400 (USD 1 920) for operation of one infra-red heater, replacing three electric resistance heaters. Payback period is less than a month.

Pentachlorophenol by di-chlorophenol

Di-chlorophenol is less toxic than pentachlorophenol and can serve the purpose of a print paste preservative (used also as size preservative) and hence could be used in place of penta-chlorophenol. The measure would result in toxicity reduction.

Next to the working time of the employees involved in the project and installation of the instructions, no extra costs are associated with this measure.

Experience demonstrates a fast pay-back, due to adequate chemical handling by employees, accident prevention and appropriate waste management.
Reduced toxicity. Reduced fire hazards. Microbial growth in effluent treatment plant is not disturbed due avoidance of toxicity.
Applicable in the print paste preparation section of the textile printing industries.
Investment is same (because, it is just replacement of input material). Annual savings in monetary terms is negligible, but there are great environmental benefits along with the operational ease of the effluent treatment plant.

Automatic Self Closing Valve Installation in the Chimney

by | Aug 28, 2019 | Power & Energy

Automatic Self Closing Valve

  • Automatic Self Closing Valve – The moment a burner turns off, a natural draft can develop through the boiler and the chimney. A valve on the chimney that automatically closes when the burner is turned off, keeps the hot air within the boiler.
  • In case this measure is implemented, the boiler better maintains its temperature and pressure. Boiler pressure is maintained during the night and therefore the boiler can quickly be started in the morning.
  • This option is profitable in case the boiler is turned off or on stand-by overnight.
  • The investment costs for an automatic valve range between INR 30 000 and INR 60 000. When the boiler is turned off at night or left on stand-by, this option can have a payback period of two years.
  • There is a tremendous amount of information on the Internet about boiler efficiency. For instance, have a look at the boiler efficiency database. It may be Gas cylinder valve

Measuring the wastewater generation

This option supports you in getting an overview of the amount and quality of the wastewater generated in your company.

Wastewater treatment is an important cost-driver in textile processing and a major source of environmental pollution. Collecting and generating data about wastewater generation are thus key steps to improve your efficiency in textile processing. The reasoning behind it is quite simple: “if you don’t measure it, you can’t manage it”. Using the generated data will help you to draw a trend line of your performance over different time-periods (benchmark), to identify improvement options and to set targets. With a benchmarking process you can compare your performance internally as well as externally, with industry averages or competitors.

In order to determine the generated wastewater streams you can use the following table. Please determine the processes where the largest amount of wastewater occurs. In the case of wastewater, it is not only the amount but also the quality, which count. Where possible, state the generated amount and specify key characteristics1 of your effluent to get information on its quality. If available, use data from the last fiscal year or the last quarter and state the chosen time-period in the table. Otherwise collect the necessary information. Also try to fill out the total wastewater generated, which should not simply add up rows above, but summarise wastewater generated by all processes.

For comparability reasons make sure to use the same time-period (e.g. one fiscal year) for all processes. In case you do not have the information and/or cannot collect it, try to fill out the table based on estimates. In this case, mention in the comments line that the figures are estimates. 

To benchmark your performance and see your improvements, use a “wastewater generated per unit” ratio. The “unit” should be the unit of production that is most useful for you. Examples could be “m2 of product” or “1 000 units of product” (e.g. my company generates X m3 of wastewater for every 1 000 m2 of fabrics produced). You can also use a ratio based on wastewater treatment costs per unit. The management option Measure your water use efficiency is also an interesting option to help you improving your wastewater generation. While this option targets your water output, Measure your water use efficiency helps you to control and reduce the water you put in your processes, contributing directly to reduce your wastewater generation.