Machinery safety inspection

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

 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
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

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

Common defects with water gauges
 Both ends of the gauge worn out.
 Inlet pipe chokes with scales.

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

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

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 FUEL CUT-OUT
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

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
 Every boiler shall be provided with:-
 A feed check valve
 Clearly marked with the flow direction
 Bear the manufacturer‘s name and
design pressure

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

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 FoundationTo check the existence of any
cracks in the brick lying,
confirmation shall be done for
the expansion clearance and
condition of heat insulation.

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

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;

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

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.

 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

?? Reduced Inlet Piping
Anything wrong
here?
Reduced
Inlet Piping

?? Discharges Pointing DownAnything 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

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.

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

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
DEVELOPERHAIRLINE 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
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.

Pemeriksaan kebocoran
dengan menggunakan
buih sabun untuk tangki
gas
Perkeliling Ketua Pengarah Bil 1 Tahun
2000

Leak Test
Oil separator
vaporiser Piping and
Aboveground LPG
Tank Installation

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

 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)

Gantry Crane
Control box
Hook
Hook block
Girder
Crab Rail
Hoist Drum
SWL

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

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.

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

Wire Rope Construction

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.

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

Wire Rope Defect
Three randomly distributed broken
wires in one strand, in one rope lay.

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

Hook Requirement
 Provided with safety latch
 Hook opening
 Hook twisting
 No cracks
Hook
Opening
Twisting

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

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.

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 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 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

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)

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

Minimum size for:
Rope hand held as a tag-line on loads is 16mm.
Load restrains – 12mm

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;

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.

Machinery safety inspection

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