1) The document summarizes the minutes from a machinery safety analysis meeting held by SEPCO HSE's mechanical department in November 2015. 2) Key topics discussed include machinery management procedures, inspection requirements and schedules, violations and best practices observed, and new implementation requirements. 3) Procedures for entry, documentation, and inspections of machinery on-site are defined to ensure safety compliance. Regular inspections will be carried out to check machinery condition, safety devices, and compliance with on-site requirements.

1. Machinery Safety Analysis Meeting
Month of November-2015
O4th December- 2015
SEPCO HSE (Mechanical Dept.)

2. Agenda of the Meeting:
• Machinery management
• Monthly inspection procedure
• Violation /good practices photographs
• Inspection photographs
• Lifting/Hoisting requirements.
• Machineries situation in site.
• Machinery working condition
• New implementation and requirements.

3. MACHINERY MANAGEMENT:
Documents procedure:
• If any new machine comes to site then first inform to Mechanical
Dept. and submit the document in systematic manner given as
below:
1.INSURANCE PAPER
2.REGISTRATION CERTIFICATE
3.DRIVING LICENCE
4. Photocopy of third party certificate under C.G Government (for
Hydra ,Crane , Winch machine and lifting tools and tackles)
Gate-pass Procedure:
• When machine departure from our KMPCL site requested to all
subcontractors to take the photo copy of entry pass in KSK gate
before processing the gate pass procedure, and also that machine
will be registered in SEPCO Mechanical Department.
• First signature the execution department and then processing as
per gate pass format.

4. Cont.………
Circular bill signature Procedure:
• First take the signature of execution department and take the
approval form before come to signature the bill.
Machinery erection or dismantle procedure:
• Submit the erection and dismantle procedure of crawler, tower
and elevator before erection and dismantle.
Entry inspection Procedure:
• When new machine comes to our site ,check all the safety
devices,machinery condition ,documents as per inspection format
and fill the form then submit it to Mechanical Dept. ,after then
SEPCO issued admittance card which was six month validity.

5. Cont.………
On- site documentation Procedure:
• Must attach the valid TPI certificate on winch, Hydra, and all
types of crane.
• Operator must having driving license while operating
machine/vehicle in site.
• Attach the operating procedure of winch machine /crane etc.
on every machine.
• Attach the admittance card in front of machine / vehicles.
• Those machine are not in use attach the not in use tag
issued by Mechanical department.

6. TPI CERTIFICATE
ADMITTANCE CARD
NOT-IN-USE TAG
ON-SITE DOCUMENTATION:

7. Cont.………
OPERATING PROCEDURE DRIVING LICENSE

8. Inspection Procedure:
• Last week of every month SEPCO HSE and
Mechanical Department will check the machinery
safety device ,technical condition ,location etc.
• Every week on Tuesday/Wednesday check the lifting
tools tackles and color coding on different location.
• Special inspection will be organized as per
requirements.
• Chimney inspection together with HSE and Civil
Department.
• On every Saturday organize the tower crane foundation
inspection.

9. Violation /good practices
photographs

10. SIMPLEX: Winch M/C: all the required documents
must be attached on the front side of the machine

11. S.K.Const. : Limit switch broken, no tag line given while lifting
the load, and no color coding of wire ropes and d-shackles

12. SIMPLEX : Hydra : Limit switch broken.

14. TOWER CRANE VERTICALITYAND FOUNDATION
LEVEL CHECKED WITH CIVIL DEPT

15. FOUNDATION LEVEL OF TOWER CRANE CHECKED
FOUND SATISFACTORY
TOWER CRANE B#1 TOWER CRANE B#2

16. TOWER CRANE VERTICALITY CHECKED FOUND
SATISFACTORY
TOWER CRANE B#1 TOWER CRANE B#2 TOWER CRANE ESP

17. SEPCO MACHINERY INSPECTION

18. Lifting/Hoisting requirements

19. • It is requested to all the Sub-contractor’s submit the updated TPI certificate
for entire lifting/rigging equipment's to SEPCO Mechanical dept. as an
earliest. The color coding should be done accordingly which tools has valid
TPI certificate. From the month of December’-10th, It will be check by SEPCO
Mechanical and HSE dept.
Name of the months Types of color
JAN,FEB,MARCH
BLUE
APR,MAY,JUN
GREEN
JULY,AUG,SEPT
YELLOW
OCT.NOV,DEC
PINK

21. Pre-operational site activity and
inspection
• Review the site for possible hazards:
– Overhead lines
– Unstable soil
– High wind
conditions
– Other work
activities in
the area
1a

22. Pre-operational site activity and
inspection
• Characteristics of the load:
– Hazardous or toxic materials
– Weight
– Dimensions
– Center of gravity
• Rigging sketches and information:
– Lift points
– Methods of attachment
– Sling angles
– Load vectors
1b

23. Pre-operational site activity and
inspection
• Rigging sketches and information:
– Boom and swing angles
– Crane orientations
– Rated capacities
– Other factors affecting equipment operation
• Operating procedures:
– Step-by-step instructions
– Applicable rigging precautions
– Safety measures
– Emergency procedures
1d

24. Pre-operational site activity and
inspection
• Additions and modifications to
equipment:
– Tags, instruction plates, decals reflect to
modifications
– Ensure safety factor has not been
reduced by additions/modifications
1f

25. Types of inspections and
checks
• Frequent inspections
occur every day
• Periodic
inspections
occur monthly
• Depend upon
regulation and
equipment involved
2a

26. Frequent inspections
• Daily pre-operational walk-around or pre-startup check
• Exposed moving parts should be guarded/isolated
• High voltage warning signs are displayed
• Crane components
• Wire ropes
• Freedom of rotation of all swivels
• Tires
• Batteries
• Proper lubrication
• Fluid leaks
• Sheaves, drums, rigging, hardware, attachments
• Operating mechanisms
• Guardrails, handholds, steps
• Platforms/walkways
• Turntable connections
3a

27. Continued…..
• Boom and jib
– Look for straightness/damage
– Corrosion
– Cracking/peeling paint
– Bent lacing
• Outriggers
– Distortion/cracking
– Welds
– Extension/retraction of beams
– Floats
• Cab
– Cleanliness of cab
– Control labeling
– Function of gauges, lights, signals
– Service/parking brake
– Seat and cab door operation
– Inspection and maintenance records
3e

28. Pre-startup
• Field of vision
– Broken/cracked windows
– Adjustment/operation of brakes/clutches
– Operation/calibration of boom hoist lockout
– Gauges and warning lights
– Controls
• Inspection records must include the:
– date of the inspection
– signature of the inspector
– serial number of critical component
• Structural damage
• Cracks in welded connections
• Damage or defects of sheaves
• Main hoist and auxiliary drum damage/defects
• Even distribution of the wire rope on hoist drum
• Proper wire rope integrity 3i

29. Periodic inspections
• Performed monthly and/or annually
• Inspection varies depending on
crane use and site conditions
• Maintain records on:
– brakes
– crane hooks
– hoist chains
– ropes
4a

30. Periodic inspections - check
for:
• Excessive wear of brake and clutch
parts
• Worn, cracked, distorted parts
• Defects/damage to the main boom,
jib, boom extensions
4f

31. Hazard of overhead lines
• Maintain appropriate line clearance
• Direct contact
• Indirect contact
• Voltages 50 kv or less, the clearance
distance is 10 feet
• Voltages greater than 50kv, the
clearance is 10 feet plus 4 inches for
every 10 kv over 50 kv
• Use signalmen to assist in maintaining
proper clearances where vision is
obstructed
– Hand signals
– Chart of hand signals
6a

32. Prohibited actions
• Do not exceed load ratings
• Do not change the recommended counterweights
• Do not lift an unsecured/unbalanced load
• Do not lift two separately rigged loads at the same
time
• Do not wrap tag lines around one’s body
9a

33. Rigging And Lifting Safety
• The sling should be protected from the edges once the sling being
used for lifting.
• All the lifting machines, lifting tools and tackles should be with third
party inspection certificate.
• The overload of the lifting machines & tools and tackles is not
allowed.
• Hydra is only permitted for loading and unloading, it is prohibited for
transporting.
• No one is allowed to stay under the lifting objects. A full time person
should be arranged to supervise the lifting work.
• Limit switches, brakes and similar safety facilities in lifting
machineries should be effective.

34. 1. Only qualified operators will be permitted to operate cranes. Operators
are responsible for the exercise of caution necessary for the safe
operation of their equipment.
2. Operators shall immediately report unsafe conditions, including defects
in the machine, to their supervisor.
3. Operators shall not permit anyone to ride the hook or load.
4. When the operator leaves his machine or repairs or being made, it is his
responsibility to set the brakes, secure the boom, take the machine out
of gear and turn off the engine.
5. When making a lift, the operator will take operational signals only from
the man authorized to give them. An emergency stop signal given by
anyone, will be acted upon by the operator.
6. It is the joint responsibility of the operator and the riggers to see that all
hitches are secure and that all loose material is removed before the
loads are lifted. Material should not be hoisted until it is ready to be
used/put into place.
7. Safety hooks, shall be used on all operations where loads are being
handled. Suspended loads shall be controlled by tag lines whenever
necessary.
CRANE TOOLBOX TALK:

35. 8. Booms shall be equipped with a boom angle indicator and a device
designed and constructed to prevent the boom from falling over
backward. Boom heads, load blocks and hooks shall be painted with
high visibility paint.
9. Where necessary to increase stability, cranes, except crawler cranes
and boom type excavators, shall be equipped with outriggers of a
design and strength suitable for the work being performed.
10. Hooks, wire rope, bearings, gears, friction clutches, chain drives and
other parts subject to wear must be inspected at regular intervals and
repaired or replaced as required. Records of such inspections and
resultant action taken shall be maintained by the contractor.
11. Crawler, truck and locomotive cranes must be inspected monthly. A
certification of performance of these inspections is required.
12. When loads are being hoisted, avoid walking under the lift or
permitting an employee to be exposed to the swing of the lift.

36. Daily before operating:
– Check battery
– Check all controls
– Visually inspect
– Wire rope for kinks or
damage
– Sheaves, drums for
damage
– Upper and lower limit
switches.
Inspection and Maintenance

37. • Loads should be well secured.
• Slings should be adequate to the task.
• Slings should be unlinked and load balanced and
secured.
• No sudden stops.
• No obstructions while lifting or traveling.
• No loose items on load or crane before lift.
• Bumping into runway stops is prohibited.
• Hoist line must be vertical prior to the lift (remove
slack in the hoist slowly).
• No crane load should pass overhead of personnel,
clear the area before making the lift.
• No one is to ride the crane without permission.
RIGGING:

38. Crane and Rigging Safety Rules:
• Check limit switches before rigging the load.
• Make sure the load does not exceed rated capacity.
• Know the center of gravity of the load.
• Attach load above the center of gravity for stability.
• Select hitch that will control the load.
• Know the rated capacities of rigging and slinging.
• Inspect all rigging before use.
• Protect the sling from sharp corners.
• Allow for increased tension due to sling angle.
• Equalize loading on multiple leg slings.
• Allow for load reductions when using choker hitches.
• Attach tag line prior to lift.

39. Continued…….
• Keep personnel clear of lift area.
• Wear hard hats when making overhead lifts.
• Lift load a few inches and verify rigging.
• Check for any loose items.
• Know limitations of hoisting device.
• Start and stop SLOWLY! Watch for obstructions (not
only hook and load but outboard end of the bridge).
• Check pathway is clear before making a lift (use a
spotter for blind spots).
• Verify hook completely closes.
• Use appropriate hand signals.
• Maintain load control at all times.
• Never leave load unattended.

40. Machineries situation in site.
 Establishing a high effective machinery management network。
 At present total 18 subcontractors have confirmed a special
mechanical engineer to attend mechanical meeting and all kinds of
inspection organized by Mechanical Dept. ，these mechanical
engineers are responsible for regularly submitting and updating
machinery accounts and documents to SEPCO Mechanical
Department.
 Machinery resource situation：till the end of November 2015，
there are 149 set big—middle—sized machines 、 149 set
machines submitted the documents 、149 set machines gotten
《machinery admittance card》 issued by SEPCO

41. *New implementation and
requirements.
 Requested to each subcontractor must organize a especial inspection of machine once in a week.
 Use firmer ,large steel plate to distribute the load and reduce the weight on the soil.
 Keeping a safe distance from a power line is the key to preventing power line accidents.
 All agencies who are responsible for operation & maintenance of tower crane must remove water
from tower crane foundation after each raining continuously .
 Provide suitable earthling for lightning protection of silo of batching plant and tower crane where
the earthling resistance is less than 10 ohm.
 Provide proper rain protection covers to all electric equipment’s like electric motors, electric
cables, electric panel’s etc.
 At no work condition, take both hooks (small & big) up to hoist limit switch position.
 Hydra shall be prohibited to transport equipment and material for long distance.
 For work completion Do not force on operator for wrong operation.
 Tandem lifting by using hydra is strictly prohibited in our site.

42. HIGHLIGHTS:
SEPCO will organize the ANNUAL meeting
in the first week of January 2016.Request to
all subcontractors concerned engineer
and Project managers kind attend the meeting.

43. THANK YOU