Machinery safety inspection

BOILER

Definition

"machinery" includes steam boilers, unfired pressure vessels, fired pressure vessels, pipelines, prime movers, gas cylinders, gas holders, hoisting machines and tackle, transmission machinery, driven machinery, materials handling equipment, amusement device or any other similar machinery and any equipment for the casting, cutting, welding or electro-deposition of materials and for the spraying by means of compressed gas or air of materials or other materials, but does not include—

Definition

but does not include—

(a) any machinery used for the propulsion of vehicles other than steam boilers or steam engines;

(b) any machinery driven by manual power other than hoisting machines;

(c) any machinery used solely for private and domestic purposes; or

(d) office machines;

Definition

"steam boiler" means any closed vessel in

which for any purpose steam is generated

under pressure greater than atmospheric

pressure, and includes any economiser

used to heat water being fed to the vessel,

and any superheater used for heating

steam, and any pipes and fittings

EXAMPLES OF STEAM BOILER

• Electric Boiler

• Fire Tube Boiler

• Water Tube Boiler

• Combi Boiler

• Waste Heat Boiler

ELECTRIC BOILER

1.Pressure Vessel Is Built To ASME Code 2. Electrical Control Panel Box 3. Electric Heating Elements 4. Low Water Cut Off Probe 5. Second (Auxiliary) Low Water Cut Off Probe 6. Pump "On" Probe 7. Pump "Off" Probe 8. Sight Glass Assembly 9. Operating Pressure Control 10. High Limit Pressure Control w/ manual reset 11. Steam Outlet 12. Safety Valve 13. Steam Gauge Assembly 14. Steam Pressure Gauge 15. High Temperature Insulation Surrounds The Pressure Vessel 16. Large (3" x 4") Easily Accessible Handholes 17. Feedwater Shut Off Valve

FIRE TUBE BOILER

FIRE TUBE BOILER

WATER TUBE BOILER

COMBI BOILER

WASTE HEAT BOILER (HRSG)

Every steam boiler before being put into

service for the first time, be subjected to

hydrostatic test for at least 20 minutes:-

Two times the ASWP, if the boiler pressure is

< 100 psi

1½ times the ASWP + 50 psi, if the boiler

pressure is > 100 psi

Note: If the boiler has been tested satisfactorily by the

manufacturer or if it is an old boiler, the

required H.T pressure is 1½ times the ASWP

STEAM BOILER

Every steam boiler inspected for the first

time or the ASWP has been altered shall be

tested under steaming condition to the

satisfaction of the Chief Inspector:-

Note: The boiler other than a water tube boiler shall be

tested with the safety valves set at the ASWP firing

for at least 10 minutes with feed water & main stop

valve closed. Where the accumulation of pressure

exceeds 10% of ASWP, the area of the safety

valves are considered insufficient

STEAM BOILER

Person in charge according to boiler heating surface

Note : Each boiler man should not be in charge of more than 2 boilers.

Heating Surface (ft2) Person-in-charge

HS ≤ 500 1st or 2nd grade Boilerman

500<HS≤2,000 1st grade Boilerman

2,000<HS< 5,000 1st grade Boilerman + Visiting Engineer

5,000<HS<10,000 1st or 2nd grade Engineer +1st grade Boilerman

10,000<HS<25,000 1st grade Engineer +1st or 2nd grade Engineer + 1st or 2nd

grade Boilerman/shift

25,000<HS< 50,000 1st grade Engineer + two 1st or 2nd grade Engineer + 1st or

2nd grade Boilerman/shift

HS>50,000 1st grade Engineer + 1st or 2nd grade Engineer /shift + 1st or

2nd grade Boilerman/shift

PACKAGE BOILER

1. Furnace (1st gas pass)

2. Tubes (2nd gas pass)

3. Tubes (3rd gas pass)

4. Combustion chamber

5. Front smoke box

6. Rear outlet box

7. Water gauge glass

8. Safety valve

9. Main stop valve

10. Feed check valve

11. Water level control

12. Manhole

13. Spare connection (steam)

14. Spare connection (water)

15. Feed pump

16. Control panel

17. Burner

18. Forced draft fan

19. Fan inlet silencer

NAME PLATE

REGISTRATION PLATE

SAFETY VALVE

GAUGE GLASS

PRESSURE GAUGE

INSPECTOR‘S TEST PRESSURE GAUGE

ATTACHMENT

MAIN STOP VALVE

LOW WATER ALARM

LOW WATER FUEL CUT-OUT

FUSIBLE PLUG

FEED PUMP

FEED CHECK VALVE

BLOWDOWN VALVE

BOILER ESSENTIAL FITTINGS

NAME PLATE

Function: To provide important information

Every boiler shall be provided with:-

A name plate which bears the following:-

Name and address

Serial number

Design pressure

Design Code

Hydrostatic test pressure

Date of hydrostatic test


REGISTRATION PLATE

Function: To display the registration number

allocated by the Chief Inspector

(PMD No…………)


A registration plate - which bears the registration

number


SAFETY VALVE

Function: To release the boiler pressure in the

event of high pressure exceeding the

ASWP


At least two safety valves - one spring-loaded type

If heating surface area < 100 sq ft - one spring-

loaded type

Able to discharge the steam and maintain pressure not more than 10% of ASWP


Structure of safety valves

Common defects with safety valves

Broken spring or spring with crack or spring with

pittings.

Worn out seat or steam cut through the seat.

Bent spindle.

GAUGE GLASS

Function: To provide level indication for boiler water


Two gauge glasses

If evaporative capacity <300 lb/hr of steam from

and at 212 0F

- one gauge glass with two test cocks

The lowest visible part shall not be lower

than the lowest safe working level


GAUGE GLASS

Common defects with water gauges

Both ends of the gauge worn out.

Inlet pipe chokes with scales.

WATER COLUMN

PRESSURE GAUGE

Function: To provide pressure indication for a boiler


A steam pressure gauge

Fitted above the highest part of the steam side

Provided with a siphon

Dial not less than 6 inches in diameter

Graduation from 0 to not < 11 3 times but

not > 2 times the ASWP


Pressure gauges • Every steam boiler shall have a pressure gauge.

• Every pressure gauge shall be connected to a boiler above the highest water level with the dial of the gauge in the vertical plane. It can be read from the firing position. A dial shall

– > 6‖ diameter

– scale ranges from 0 PSI to between 1 to 2 times authorized working pressure.

– Red mark to indicate max. authorized working pressure.

• Pressure gauges are connected to the steam space of boiler usually have a ring type siphon tub which fills with condensed steam and protect the dial mechanism from high temperatures.

.

Pressure gauge with ring siphon

INSPECTOR‘S TEST PRESSURE GAUGE

ATTACHMENT

Function: To provide a connection for a reliable

pressure gauge of the Inspector and check the

accuracy and recalibration


An Inspector‘s test pressure gauge attachment

Consists of a valve or cock carrying a socket fitted with a plug

Mounted near the pressure gauge


PRESSURE GAUGE ATTACHMENT

MAIN STOP VALVE

Function: To put boiler into service and stop the

steam supply when the boiler is shut

down


A main steam stop valve

Fitted direct to the boiler shell

Bear the manufacturer‘s name, design pressure and direction of flow


MAIN STOP VALVE

LOW WATER ALARM

Function: To provide an audible sound when the

water level is low


A low water alarm - for boilers :-

Fired with solid fuel & press > 250 psi or

Fired with liquid/gaseous fuel not fitted

with low water fuel cut out


LOW WATER ALARM


Function: To stop the boiler immediately by shutting

off fuel and air supply in the event of very

low water level


A low water fuel cut-out - boilers fired with liquid &

gaseous fuel

Connected to burner control system



Common defects with water alarm

Mobrey float is water logged.

Mobrey float is dented.

Inlet pipe choked with scale.

FUSIBLE PLUG

Function: To give early protection from direct heat in

the event of loss of boiler water


A fusible plug - boilers fired with solid fuels only

Fitted 2 to 3 inches above the highest tubes

Fusible alloy shall melt at a temp not

>150 0F greater than saturated steam

temp corresponding to the ASWP


LOCATION OF A FUSIBLE PLUG

FEED PUMP

Function: Draws water from the feed tank and

delivers it under pressure to the boiler


Two feed pumps - heating surface area >150 sq ft


FEED CHECK VALVE

Function: To control amount of feedwater to the

boiler and prevent back flow of feedwater

from the boiler


A feed check valve

Clearly marked with the flow direction

Bear the manufacturer‘s name and design pressure


FEED CHECK VALVE

Common defects with check valve

Bent spring.

Seat worn out.

BLOWDOWN VALVE

Function: To remove impurities and control water

level


A blowdown valve

Attached direct to the shell and at the lowest

point of the boiler

Bore not < 1 inch in diameter

Clear indication of open & close position


BLOWDOWN VALVE

Common defects with blow down valve

Seat with steam cutting.

90° turn gear worn out.

Seat surface worn out.

Handle broken.

BOILER DEFECTS

Crack of metal part or welding part – nozzle

crack, shell crack, header crack etc.

Tube burst

Buldging or dented at furnace side or tubesheet

Pipe sagging

Pitting and corrosion

Hard scaling

Inspection of Foundation To check the existence of any

cracks in the brick lying,

confirmation shall be done for

the expansion clearance and

condition of heat insulation.

Flue Gas System

Fire Side

ILLEGAL REPAIR

Superheater : 1 - 1.25 ton steam/tube

Violent rupture caused by scaling

This tube is bent almost to a right angle, caused by the severity of the burst

A rupture at a single bulge

The tube had experienced long-term overheating caused by scaling

Rupture Caused by Scaling

Scaling

WATER SIDE

WATER SIDE

Corrosion Pitting

Drums and Internal Parts

PRESSURE VESSEL

Definition

"unfired pressure vessel" means any enclosed vessel under pressure greater than atmospheric pressure by any gas or mixture or combination of gases and includes any vessel under pressure of steam external to the steam boiler and any vessel which is under pressure of a liquid or gas or both, and any vessel subject internally to a pressure less than atmospheric pressure but does not include gas cylinders;

Definition

"fired pressure vessel" means an enclosed

vessel under pressure greater than

atmospheric pressure which is subjected

to direct firing, but does not include a

steam boiler;

Bekas Udara / Tangki LPG

Pengandung Di Loji Petrokimia / Loji Penapisan Minyak

Inspection

External Inspection

Internal Inspection

Hydrostatic Test

Leak Test

Proof Test

Name Plate

Inspection Hole/Door

Pressure Gage

Drain Cock

ESSENTIAL FITTINGS

Steam Receiver

Stop Valve

Name Plate

Drain Cock

Pressure Gage

Inspection Hole

ESSENTIAL FITTINGS

Air Receiver

Safety Valve/ Rupture Disc

Pressure Gage

Name Plate

ESSENTIAL FITTINGS

Other Vessels

SAFETY RELIEF VALVE

http://www.kunklevalve.com/model6252.asp



http://www.kunklevalve.com/airgasuvmodel30.asp

Conventional

Metal Rupture Disc

CHOOSE TYPE

Pressure gauge

(i) not be less than three inches in diameter across

the dial: Provided that where the external shell

diameter of the unfired pressure vessel is less

than twelve inches and the pressure in such

vessel is not more than one hundred and fifty

pounds per square inch, such gauge shall not be

less than two inches in diameter;

(ii) be graduated from zero to not less than one and

one-third times and not more than twice the

authorised safe working pressure of the pressure

vessel to which it is fitted;

(iii) have the authorised safe working pressure clearly

marked in red on the dial;

(iv)be provided with a single stop pin at the lowest

pressure reading;

(v) accurately show the pressure within a tolerance

of plus or minus two per centum of the authorised

safe working pressure of the pressure vessel to

which it is attached.

Name plat

Stop Valve

Drain Pits

External Inspection

Evident of Leakage

External Inspection

Any leakage of gas, vapour

or liquid should be

investigated. A leakage

coming from behind

insulation coverings,

supports or settings, or

evidence of a past leakage

should be thoroughly

investigated by removing

any covering necessary to

establish the source.

Structure Attachments

External Inspection

The mountings for an unfired

pressure vessel should be

checked for adequate allowance

for expansion and contraction,

such as that provided by slotted

bolt holes or unobstructed saddle

mountings. Attachments of legs,

saddles, skirts or other supports

should be examined for distortion

or cracks at welds.

Vessel Connections

External Inspection

Manholes, reinforcing plates, nozz1es

or other connections should be

examined for cracks, deformation or

other defects. Bolts and nuts should

be checked for corrosion or defects.

Tell tale holes in reinforcing plates

should remain open to provide visual

evidence of leakage as well as to

prevent pressure built up between the

vessel and reinforcing plate.

Accessible flange faces should be

examined for distortion and to

determine the condition of gasket

seating surfaces

Abrasives

Dents

Distortion

Cuts and Gouges

Surface Inspection

Weld Joints (New Vessel)

External Inspection

COMMON WELDING DEFECT

?? Reduced Inlet Piping

Anything wrong

here?

Reduced

Inlet Piping

?? Discharges Pointing Down Anything wrong

here?

Anything wrong

here?

Discharges

Pointing Down

?? Long Moment Arm

Anything wrong

here?

Long

Moment Arm

?? Will these bolts hold in a relief

event

Anything wrong

here?

Will these

bolts hold

in a

relief event?

Internal Inspection

A general visual inspection is the first

step in making an internal inspection. All

parts of the vessel should be inspected

for corrosion, erosion, hydrogen

blistering, deformation, cracking and

laminations

Internal Inspection

Uniform Corrosion

Pitting

Pitting Corrosion showing wormhole

attack pattern, where pits are

interconnected.

Corrosion Pitting Narrow,deep

Shallow, wide

Elliptical

Undercutting

Galvanic Corrosion

Galvanic ringworm corrosion, often

occurring four to six inches from the upset,

where carbon particles have been

spheroidized.

Heat Affected Zone

Heat-affected zone (HAZ) corrosion is a

type of galvanic corrosion which occurs

along a weld seam.

Grooving Corrosion

Raindrop attack occurs in gas condensate

wells. In areas, water condenses on the

metal surface, causing deep pits with tails

Creep Corrosion

Mesa attack is a form of CO2 corrosion

that occurs in flowing environments, and

occurs where a protective iron carbonate

coating is worn away in areas.

Erosion Corrosion

Erosion Corrosion, or flow-enhanced

corrosion, usually occurs in areas where

the diameter of the pipe or direction of flow

is changing. Severe metal loss can quickly

occur.

Fatigue

Corrosion due to fatigue occurs in areas

of cyclic stresses. Here we see fatigue

corrosion in a drill pipe.

Crack

INSPECTION OF HEAT EXCHANGER

NDT is used to inspect pipelines to prevent leaks that could damage the environment. Visual inspection, radiography and electromagnetic testing are some of the NDT methods used.

Remote visual inspection using a robotic crawler.

Radiography of weld joints.

Magnetic flux leakage inspection. This device, known as a pig, is placed in the pipeline and collects data on the condition of the pipe as it is pushed along by whatever is being transported.

Pipeline Inspection

Non Destructive Testing

The use of noninvasive

techniques to determine

the integrity of a material,

component or structure

or

quantitatively measure

some characteristic of

an object.

i.e. Inspect or measure without doing harm.

Definition of NDT

Six Most Common NDT

Methods • Visual

• Liquid Penetrant

• Magnetic

• Ultrasonic

• Eddy Current

• X-ray

Most basic and common

inspection method.

Tools include fiberscopes,

borescopes, magnifying

glasses and mirrors.

Robotic crawlers permit

observation in hazardous or

tight areas, such as air ducts,

reactors, pipelines.

Portable video inspection

unit with zoom allows

inspection of large tanks

and vessels, railroad tank

cars, sewer lines.

Visual Inspection

SPECIMEN

SPECIMEN

SPECIMEN

STEP 1:

CLEAN THE SPECIMEN WITH

THE CLEANER

STEP 2:

WIPE DRY THE SURFACE AND

SPRAY THE PENETRANT

THOROUGHLY ON THE SURFACE

AND LET IT SETTLES, 15-20

MINUTES. WIPE CLEAN THE

SURFACE.

STEP 3:

APPLY THE DEVELOPER (WHITE)

AND LET IT SETTLES FOR A FEW

MINUTES. RED LINE APPEARS ON

THE SURFACE WITH HAIR LINE

CRACK

HAIRLINE

CRACK

HAIRLINE

CRACK

DEVELOPER HAIRLINE CRACK

APPEAR RED

DYE PENETRANT PROCESS

• A liquid with high surface wetting characteristics is

applied to the surface of the part and allowed time to

seep into surface breaking defects.

• The excess liquid is removed from the surface of

the part.

• A developer (powder) is applied to pull the

trapped penetrant out the defect and spread it on

the surface where it can be seen.

• Visual inspection is the final step in the process.

The penetrant used is often loaded with a

fluorescent dye and the inspection is done under

UV light to increase test sensitivity.

Liquid Penetrant Inspection

Magnetic Particle

Inspection The part is magnetized. Finely milled iron particles coated with a dye

pigment are then applied to the specimen. These particles are

attracted to magnetic flux leakage fields and will cluster to form an

indication directly over the discontinuity. This indication can be

visually detected under proper lighting conditions.

Magnetic Particle Crack

Indications

Radiography The radiation used in radiography testing is a higher energy (shorter wavelength) version of the electromagnetic waves that we see as visible light. The radiation can come from an X-ray generator or a radioactive source.

High Electrical Potential

Electrons

- +

X-ray Generator

or Radioactive

Source Creates

Radiation

Exposure Recording Device

Radiation

Penetrate

the Sample

Film Radiography

Top view of developed film

X-ray film

The part is placed between the radiation

source and a piece of film. The part will

stop some of the radiation. Thicker and

more dense area will stop more of the

radiation.

= more exposure

= less exposure

The film darkness

(density) will vary with

the amount of radiation

reaching the film through

the test object.

Cracks

Transverse

cracks

Welding defect: Transverse crack. A fracture in the weld metal running across the weld.

Welding defect: Longitudinal root crack. A fracture in the weld metal at the edge of the root pass.

Longitudinal

cracks

Cavities Root pass aligned

porosity

Welding defect : Root pass aligned porosity. Rounded and elongated voids in the bottom of the weld aligned along the weld centerline.

Solid inclusion

Tungsten inclusion

Welding defect : Tungsten inclusions. Random bits of tungsten fused, but not melted, into the weld metal.

Lack of fusion and penetration

Lack of sidewall fusion

Welding defect : Lack of sidewall fusion (LOF). Elongated voids between the weld beads and the joint surfaces to be welded.

Lack of inter-run fusion

Welding defect : Inter-pass slag inclusions. Usually nonmetallic impurities that solidified on the weld surface and were not removed between weld passes.

Lack of fusion and penetration

Incomplete root penetration

Welding defect : Incomplete or lack of penetration (LOP). The edges of the pieces have not been welded together, usually at the bottom of single V-groove welds.

Radiographic image : A darker density band, with very straight parallel edges, in the center of the width of the weld image.

Conductive material

Coil Coil's magnetic field

Eddy currents

Eddy current's magnetic field

Eddy Current Testing

Eddy Current Testing Eddy current testing is particularly well suited for detecting surface

cracks but can also be used to make electrical conductivity and

coating thickness measurements. Here a small surface probe is

scanned over the part surface in a attempt to detect a crack

Power Plant Inspection

Prob

e Signals produced

by various

amounts of

corrosion thinning.

Periodically, power plants are

shutdown for inspection.

Inspectors feed eddy current

probes into heat exchanger tubes

to check for corrosion damage.

Pipe with damage

High frequency sound waves are introduced into a material and they are reflected back from surfaces or flaws. Reflected sound energy is displayed versus time, and inspector can visualize a cross section of the specimen showing the depth of features that reflect sound. f

plate

crack

0 2 4 6 8 10

initial

pulse

crack

echo

back surface

echo

Oscilloscope, or

flaw detector

screen

Ultrasonic Inspection (Pulse-

Echo)

Hydrostatic Test

• Every pressurised equipment must be subjected to

hydrostatic test and witnessed by DOSH Inspector

• Review the manufacturing data report

• Carry out the measurement of the pressurised

equipment and must be in accordance with the

approved drawing

• Hard stamp on flange and issue JKJ 127 if the

test is successful

Why Hydrostatic Test

To check the structure integrity of the

vessel

To check against brittle fracture

To check for leak, and

To obtain a more favourable strees

distribution in a high localised stress

region.

Hazard on Hydrostatic Test

Leak/Soap Test

Pemeriksaan kebocoran

dengan menggunakan

buih sabun untuk tangki

gas

Perkeliling Ketua Pengarah Bil 1 Tahun

2000

Leak Test

Oil separator

vaporiser Piping and

valve

Aboveground LPG

Tank Installation

HOSTING MACHINE

Definition

Hoisting Machine

any equipment for lifting, raising or lowering load such as a lift, escalator, hoist, crane, winch, dragline, piling machine, aerial cableway, funicular railway, access platform, dumbwaiter, vertical conveyor lifter and mechanical loading ramp, and includes transporter, walkalator and other similar equipment, but does not include manual hoist and materials handling equipment

Main crane types

Main crane types

Main crane types

Kereta Kabel

Kren Kembara Atas (OTC)

Kren Derik

OPERATOR KREN

(Bergerak dan Menara)

ORANG KOMPETEN LIF

PENGENDALIAN MESIN PERLU ORANG YANG

TERLATIH

FMA Bahagian III : Orang yang bertanggungjawab/ menerima

latihan yang mencukupi. (Peraturan 26)

TOWER CRANE

Page 139

Features of OTC

Gantry Crane

Control box

Hook

Hook block

Girder

Crab Rail

Hoist Drum

SWL

TYPES OF CRANES

Safety Feature

Structure Inspection

Pendant & Remote Controls

Ensure that all controls are clearly marked

for their intended functions

Securing the hoist rope

to the drum

There must be a minimum of 2 wraps of wire on the drum

when ever the hook block is at its lowest point

ANTI COLLISION

Flashing lights/Audible alarms

Wire Rope Inspection Electromagnetic devices and visual inspections are used to find broken wires and other damage to the wire rope that is used in cranes and other lifting devices.

Wire Rope Construction


Cth : Lang’s lay FSWR

- biasanya digunakan untuk luffing

- bukan untuk mengangkat

Lebih flaksibel dan kukuh berbanding

kaedah pembentangan biasa.

Digunakan untuk excavator , dragline

pile driving rope

Page 152


KEROSAKAN WIRE ROPE : KINK

Bagaimanakah ianya

terjadi?

Fatigue

Bending fatigue breaks on ropes made out of compacted outer strands. The distribution of bending fatigue wire breaks is typically random.

Fatigue

Heavily worn wire rope with a few fatigue breaks. The wire ends are displaced in different directions because of rope twist.

Fatigue

This six-strand rope displays almost no wear but a great number of fatigue breaks.

Birdcage damage

Bagaimana cara yang betul untuk

mengukur diameter ??..

Diameter

berkurang kepada

85 % atau lebih

159

Wire rope yang rosak

Broken Strands

Wire rope yang rosak perlulah dikeluarkan untuk

diservis/ diganti

Crushed Rope

Page 160

Wire Rope Defect

Three randomly distributed broken

wires in one strand, in one rope lay.

Page 161

Corrosion of the rope or end attachments.

Wire Rope Defect

Fakta menarik

Sumber : Dave Hermanowski,

Manager of technical training for Harnischfeger Institute, US

Lebih 90 % kes melibatkan kemalangan barang angkatan jatuh dari overhead crane telah dilaporkan adalah akibat kegagalan pada wirerope.

Amalan yang baik mengendalikan

wire rope

SALAH BETUL

Amalan yang baik mengendalikan

wire rope

Lifting hook The lifting hook must be stamped or

marked with the SWL

Is is an offence to ride on the lift hook

Only approved lifting cages are allowed to

be use when lifting people

Page 166

Hook Requirement Provided with safety latch

Hook opening

Hook twisting

No cracks

Hook

Opening

Twisting

Hook Requirement

The grooves must be smooth and free from surface defects which could cause rope damage

Sheaves

Three Types of Slings

1. Chain Slings

2. Wire Rope Slings

3. Synthetic Web Slings

Identification Tag

Sling Load Capacity and Sling

Angles The load capacity of the sling is

determined by its weakest component.

Never overload a sling.

Remember, the wider the sling legs are spread apart, the less the sling can

lift!

1000 lbs Lift Capacity

707 lbs Lift Capacity 500 lbs Lift Capacity

Synthetic Slings Sling capacity varies from manufacturer to

manufacturer, no set standard like wire rope has.

User must look at Individual Sling Capacity Tag to

determine Safe Lifting Capacity of that sling.

If the Tag is not readable or is missing,

Do not use it!

Inspect sling before each days use, and as often as

necessary during the day to assure safety of sling!

Sharp edges can slice a sling in two without warning

as the load is tensioned. Use softeners or padding

on corners.

Synthetic Slings

http://www.westernsling.com/images/ee2-9802x4.jpg

Jangan digunakan jika terdapat

Kesan kerosakan :

1. Asid

2. Terbakar

3. Terpotong

4. Terputus dari regangan

5. Geseran berlebihan

6. Kesan kelaran

7. Kesan tertebuk

8. Regangan berlebihan/ carik

9. Kehilangan tag/ pudar

Chain Slings

Hi Tensile Chain Slings

Chain Grade Identification

Chains are marked on a link at intervals

The word ‗grade‘ means the strength of chain

If there are no marks or stamping, the chain should be considered to be mild steel grade L

Chain Slings Only Grade 8 or better ALLOY Chain can be used for

overhead lifting purposes! All chain is not rated the same!

Chain must have a capacity tag attached to it.

Chains will withstand more rough handling and abuse, but a

chain with the same rated lifting capacity of wire rope will be

much larger in diameter and heavier in weight.

Chains must be inspected daily before use and as often as

necessary during use to assure safety.

It is the riggers responsibility to do the inspections!

Chain Sling Inspection Items Cracks, stretches, severe nicks, gouges, welding

splattered or deformed master links, coupling links, chains or other components.

One leg of a double or triple chain sling is longer than the others.

Hooks have been opened more than 25% of the normal throat opening measured at the narrowest point or twisted more than 10 degrees from the plane of the unbent hook.

Chain size at any point of any link is less than stated in the chart on the next slide, the sling shall be removed.

Chain Slings

Only chain slings purchased from

the manufacturer are allowed.

No homemade slings allowed!!

Wire Rope Sling Capacities

Wire Rope Sling Choker

Adjustments

Types of Wire Wire Rope Slings

Wire Rope Sling Inspection Items

Three randomly distributed broken wires in one strand, in one rope lay.

Wear or scraping of 1/3 the original diameter of outside individual wires.

Kinking, crushing or any damage resulting in distortion of the wire rope.

End attachments that are cracked, worn or deformed.

Corrosion of the rope or end attachments.

185

Rigging Equipment Slings

Types of slings include alloy steel chain, wire rope, metal mesh, natural or

synthetic fiber rope, and synthetic web.

Chain Wire rope Metal mesh Synthetic

Page 186

Wire Rope Socket

Page 187

Wire Rope Clip

Safe Usage Practices

Slings should be stored off of

the floor and hung on racks

whenever possible in a clean,

dry environment.

Never drag slings across the

floor.

Always hook with a “closed

hook” arrangement (hooks

facing out).

Spreader Bar Spreader bars are used when our slings

go outside120° (angle)

Spreader Bar

Storage Store undercover on suitable racks or on hanging

pegs

Clean, inspect and lubricate

Shackles There are two main types of shackle —

―Dee‖ and ―Bow‖

Never use a shackle or pin which is bent

Never allow a shackle to be pulled at an

angle

Eyebolts

Minimum size for: Rope hand held as a tag-line on loads is 16mm.

Load restrains – 12mm

Common Hooks and Shorteners

Plate Clamp

Plate Clamps are used to lift steel plate.

They should be used at all times when

lifting plate steel.

Before using the clamp always read the

Operator‘s Manual supplied with the

clamp. Do not UNDERLOAD the lifting

clamp.

The minimum working load must be at

least 10% of the W.L.L;

Plate Clamp

Plate Clamp

Chain blocks and come along

NEVER use a hoist for

lifting, supporting or

transporting people

1926.550(a)(8) Belts, gears, shafts, pulleys, sprockets, spindles,

drums, fly wheels, chains, or other reciprocating, rotating, or other

moving parts or equipment shall be guarded if such parts are

exposed to contact by employees.

Date post:	06-May-2015
Category:	Education
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Machinery safety inspection

Education