1. SAFETY IN MATERIALS HANDLING AND CONTINUAL IMPROVEMENTBy
Aswath Narayana Rao MP
Mgr (M)/SP

2. 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.

3. 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

4. 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

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

6. 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

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

8. 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.

9. 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

10. “KINKING” , “ BIRD CAGE”

11. 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

12. 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.

13. 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.*

14. 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*

15. 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

16. Continual Improvements
( Modifications )

18. Conv 501 Take up spare Bend pulleys lifting arrangements

24. AVAILABILITY HOURS OF S/PLANT
Year
Availability
B/D Hrs
Maint Hrs
Shut down Hrs
83.37 %
85.82 %
86.51 %
380.15
219
89.47 %
841.63
361.55
320
90.57 %
562.05
235.9
272.30