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Write a safe work procedure on maintain sheaves

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Safe Work Procedure: Maintaining Sheaves

Document Number: [SWP-NUMBER] Revision Date: [DATE] Next Review Date: [NEXT REVIEW DATE] Department: [DEPARTMENT NAME]

1. Scope

This Safe Work Procedure (SWP) outlines the necessary safety precautions and procedures to follow when maintaining sheaves. This includes inspection, lubrication, repair, and replacement of sheaves used in hoisting equipment, cranes, and derricks. The procedure applies to all personnel involved in the maintenance of sheaves to ensure their safe and reliable operation. This SWP aims to prevent injuries, equipment damage, and operational disruptions by providing clear guidelines for performing these tasks safely.

2. Definitions

Sheave: A grooved wheel or pulley used with a rope or cable to change direction and transmit force [1].

Running Sheave: A sheave that rotates during operation [2].

Competent Person: An individual who is qualified because of knowledge, training, and experience to perform the specific task and is familiar with the regulatory requirements 5, 9.

3. Responsibilities

3.1 Supervisors

  • Ensure that all workers are properly trained and competent to perform sheave maintenance [1].
  • Provide the necessary tools, equipment, and PPE for workers to safely complete the task.
  • Conduct pre-job briefings to discuss potential hazards and control measures.
  • Monitor work activities to ensure compliance with this SWP and other relevant safety procedures.

3.2 Workers

  • Follow all instructions and procedures outlined in this SWP [3].
  • Inspect tools, equipment, and PPE before use and report any defects to the supervisor.
  • Participate in pre-job briefings and ask questions if unsure about any aspect of the task.
  • Report any hazards, incidents, or near-misses to the supervisor immediately.

3.3 Health and Safety Representative

  • Assist in the development and review of this SWP.
  • Conduct periodic audits to ensure compliance with this SWP and other relevant safety procedures.
  • Investigate incidents and near-misses related to sheave maintenance and recommend corrective actions.

4. Potential Hazards and Risks

HazardRiskControl Measures
Fall from heightSerious injury or deathUse fall protection equipment (e.g., safety harness, lanyard) when working at heights. Ensure proper anchorage points are used.
Struck by falling objectsHead injury, lacerations, fracturesSecure tools and materials to prevent them from falling. Use tool lanyards. Barricade the area below the work zone to prevent unauthorized entry.
Contact with moving partsAmputation, lacerations, fracturesEnsure equipment is de-energized and locked out/tagged out before starting maintenance. Use machine guarding to prevent contact with moving parts.
Electrical shockElectrocution, burnsDe-energize and lockout/tagout electrical equipment before starting maintenance. Use insulated tools and PPE.
Musculoskeletal injuriesStrains, sprains, back injuriesUse proper lifting techniques. Get assistance when lifting heavy objects. Take frequent breaks and stretch.
Pinch pointsCrushing injuries, amputationsBe aware of pinch points and keep hands and fingers clear. Use appropriate tools to manipulate sheaves and ropes.
Sharp edgesLacerations, puncturesWear gloves when handling sheaves and ropes. Use caution when working with sharp edges.
Improper lubricationEquipment failure, increased wearUse the correct type and amount of lubricant. Follow manufacturer's recommendations.

5. Personal Protective Equipment (PPE)

Always use the proper PPE for the job to minimize the risk of injury.

  • Hard hat - Protects the head from falling objects and impacts.
  • Safety glasses - Protects the eyes from dust, debris, and chemical splashes.
  • Gloves - Protects the hands from cuts, abrasions, and chemical exposure.
  • Safety boots - Protects the feet from impacts, punctures, and slips.
  • High-visibility clothing - Increases visibility to prevent struck-by accidents.
  • Fall protection harness - Required when working at heights [4].

Inspect all PPE before use for any signs of damage or wear. Replace damaged PPE immediately.

6. Equipment and Tools

Always use the proper equipment and tools for the job to ensure safety and efficiency.

  • Lockout/Tagout devices - Used to de-energize and isolate equipment before maintenance.
  • Wrenches and sockets - Used to tighten and loosen bolts and nuts.
  • Grease gun - Used to lubricate sheaves and bearings [2].
  • Measuring tools - Used to measure sheave dimensions and rope diameter.
  • Lifting equipment (e.g., chain hoist, come-along) - Used to lift and position heavy sheaves.
  • Fall protection equipment (e.g., ladder, scaffold, aerial lift) - Used to access sheaves at height.

Inspect all equipment and tools before use for any signs of damage or wear. Remove damaged equipment from service.

7. Pre-Job Requirements

7.1 Training and Competency

  • Workers must be trained and competent in sheave maintenance procedures.
  • Training must include hazard identification, control measures, and proper use of PPE and equipment [1].
  • Workers must be familiar with the manufacturer's recommendations for sheave maintenance.

7.2 Pre-Job Briefing

  • Conduct a pre-job briefing with all workers involved in the task.
  • Discuss the scope of work, potential hazards, and control measures.
  • Review the SWP and answer any questions.
  • Ensure that all workers understand their roles and responsibilities.

7.3 Work Area Preparation

  • Inspect the work area for hazards (e.g., slip, trip, and fall hazards).
  • Barricade the work area to prevent unauthorized entry.
  • Ensure adequate lighting is available.
  • Provide a stable and level work surface.

8. Safe Work Procedure Steps

Step 1: Preparation

  • Sub-step 1.1: Notify all affected personnel that sheave maintenance will be performed.
  • Sub-step 1.2: De-energize and lockout/tagout the equipment according to the company's lockout/tagout procedure [5].
  • Sub-step 1.3: Gather the necessary tools, equipment, and PPE.

Safety considerations for this step: Ensure that the equipment is properly de-energized and locked out/tagged out to prevent accidental start-up.

Step 2: Inspection

  • Sub-step 2.1: Visually inspect the sheave for any signs of damage or wear, such as cracks, corrosion, or deformation [6].
  • Sub-step 2.2: Check the sheave groove for smoothness and any surface defects that could damage the rope [2].
  • Sub-step 2.3: Inspect the bearings for proper lubrication and any signs of wear or damage [2].

Safety considerations for this step: Use caution when inspecting sheaves at height. Use fall protection equipment as required.

Step 3: Maintenance

  • Sub-step 3.1: Clean the sheave and remove any dirt, debris, or corrosion.
  • Sub-step 3.2: Lubricate the sheave bearings according to the manufacturer's recommendations [2].
  • Sub-step 3.3: If necessary, repair or replace the sheave. Ensure that the replacement sheave is the correct size and type [7].

Safety considerations for this step: Use caution when handling sheaves. Wear gloves to protect your hands from sharp edges.

Step 4: Reassembly and Testing

  • Sub-step 4.1: Reassemble the equipment and remove the lockout/tagout devices.
  • Sub-step 4.2: Test the equipment to ensure that the sheave is functioning properly.
  • Sub-step 4.3: Document the maintenance performed and any findings.

Safety considerations for this step: Ensure that all guards and safety devices are in place before testing the equipment.

9. Precautions and Safety Measures

  • Lockout/Tagout: Always follow proper lockout/tagout procedures before starting any maintenance work to prevent accidental start-up of equipment [5].
  • Fall Protection: Use fall protection equipment when working at heights to prevent falls [4].
  • Housekeeping: Keep the work area clean and free of hazards to prevent slips, trips, and falls.
  • Communication: Maintain clear communication with other workers in the area to prevent accidents.
  • Equipment Inspection: Inspect all equipment and tools before use to ensure they are in good working condition.

10. Emergency Procedures

10.1 General Emergency Response

  • In the event of an emergency, immediately stop work and assess the situation.
  • Evacuate the area if necessary.
  • Call for emergency assistance (e.g., first aid, fire department) [8].
  • Provide first aid to injured personnel.

10.2 Specific Emergency Scenarios

  • Fall from height: Immediately call for medical assistance. Do not move the injured person unless there is a risk of further injury.
  • Electrical shock: De-energize the circuit if possible. Use a non-conductive object to separate the person from the electrical source. Call for medical assistance.
  • Struck by falling object: Assess the injury and provide first aid. Call for medical assistance if necessary.

10.3 Emergency Contact Information

  • First Aid: [PHONE NUMBER]
  • Security: [PHONE NUMBER]
  • Emergency Services: 911

11. Incident Reporting and Investigation

  • All incidents, near-misses, and hazards must be reported to the supervisor immediately.
  • An investigation will be conducted to determine the root cause of the incident and implement corrective actions to prevent recurrence.

12. References and Related Documents

  • Company Safety Policy
  • Lockout/Tagout Procedure
  • Fall Protection Program
  • [MANUFACTURER'S MANUALS]

Approved by: [NAME AND POSITION] Date: [APPROVAL DATE]

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8 source record(s)

Sources used for this answer

[1] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

Page 26

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\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ - (b) You must ensure that on cab-operated cranes a switch or circuit breaker of the enclosed type, with provision for locking in the open position is provided in the leads from the runway conductors. A means of opening this switch or circuit breaker must be located within easy reach of the operator. - (c) You must ensure that on floor-operated cranes, a switch or circuit breaker of the enclosed type, with provision for locking in the open position, is provided in the leads from the runway conductors. This disconnect must be mounted on the bridge or footwalk near the runway collectors. You must provide one of the following types of floor operated disconnects: - (i) Nonconductive rope attached to the main disconnect switch. - (ii) An undervoltage trip for the main circuit breaker operated by an emergency stop button in the pendant pushbutton station. - (iii) A main line contactor operated by a switch or pushbutton in the pendant pushbutton station. - (d) You must ensure that the hoisting motion of all electric traveling cranes is provided with an overtravel limit switch in the hoisting direction. - (e) You must ensure that all cranes using a lifting magnet must have a magnet circuit switch of the enclosed type with provision for locking in the open position. You must provide means for discharging the inductive load of the magnet. - Runway conductors . You must ensure that conductors of the open type mounted on the crane runway beams or overhead (sometimes known as 'runway conductors') are located or guarded so that persons entering or leaving the cab or crane footwalk normally could not come into contact with them. - Extension lamps . If a service receptacle is provided in the cab or on the bridge of caboperated cranes, it must be a grounded three-prong…

[2] Occupational Health and Safety Regulations, 2020 (Sask. Reg. 10/2020)

Page 128

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S-15.1 REG 10 ## OCCUPATIONAL HEALTH AND SAFETY, 2020 - (8) An operator of pile-driving equipment shall ensure that: - (a) the pile hammer is securely chocked while the hammer is suspended and the equipment is not operating; and - (b) no pile is hoisted in the leads while a worker who is not directly involved in the operation is on the superstructure of the equipment or within range of a falling pile. 31 Dec 2020 c S-15.1 Reg 10 s13-28. ## PART 14 Rigging ## Definitions for Part 14-1 In this Part: 'pendant' means a fixed-length rope that forms part of a boom-suspension system; 'rigging' means any combination of rope, wire rope, cable, chain, sling, sheave, hook and associated fittings used in a hoisting operation. 31 Dec 2020 c S-15.1 Reg 10 s14-1. ## General requirements 14-2 An employer or contractor shall ensure that: - (a) all rigging is assembled, used, maintained and dismantled under the supervision of a competent worker and in accordance with the manufacturer's specifications and instructions; and - (b) any worker who is required or permitted to assemble, use, maintain or dismantle rigging is trained in safe rigging practices. 31 Dec 2020 c S-15.1 Reg 10 s14-2. ## Inspection 14-3 An employer or contractor shall ensure that all rigging and components of rigging are inspected thoroughly at appropriate intervals and visually inspected before use to ensure that the rigging and rigging components will safely perform the intended function of the rigging and rigging components. 31 Dec 2020 c S-15.1 Reg 10 s14-3. ## Maximum loads 14-4 (1) An employer or contractor shall ensure that no load is imposed on any rigging that is in excess of: - (a) 10% of the breaking strength of the weakest part of the rigging, in the case of rigging used to raise or lower workers; and - (b) 20% of the breaking strength of the weakest part of the rigging, in the case of any other rigging.

[3] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 1180

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Oregon Occupational Safety and Health Division Division 2 - (b) Carriages shall have approved mesh guards for the operating sheaves and hand grips throughout the full length of the carriage. Footwalk and toeboards, for ready access to maintenance riggers and for inspection of the operating ropes, sheaves, beckets, and structural parts of the carriage; - (c) Sheaves carrying operating ropes should be as recommended by the rope manufacturer. In no case shall the pitch diameter of sheaves be less than 42 times rope diameter for 6 x 7 rope, 30 times rope diameter for 6 x 19 rope, 18 times rope diameter for 6 x 37 rope, and 21 times rope diameter for 8 x 19 rope. The sheaves shall have 'V' grooves and the radius of the groove shall be 55 percent of the rope diameter. - (23) Operating Ropes. Operating ropes shall be of wire rope construction suitable for the requirements of the cableway. End fastenings shall develop at least 89 percent of the ultimate strength of the rope. Rope ends shall be arranged for complete and easy inspection. - (24) Track Cable Systems. If the design requires that track cables be carried over saddles, care must be taken to see that the saddle radius, rope lubrication and inspection provisions conform to rope manufacturer's recommendations. Track cable connections shall be properly applied sockets using only pure zinc. Clamped ends develop only about 75 percent of the strength of the rope and therefore are not recommended. Supporting members carrying track cable tensions shall be forged steel or rolled steel carrying stress in the direction of rolling. These members shall be arranged so that loads are carried concentrically and so that no eccentric load can be applied to them or to the track cable connections by virtue of failure or non-operation of any joint bearing in the track system. - (25) Backstay. Backstay carrying track cable tensions shall be designed to support the entire load disregarding any load carrying help from side guys. - (26) S…

[4] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

Page 29

Open source document

Source excerpt

\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ - (d) Hoist or load attachment chains, including end connections, for excessive wear, twist, distorted links interfering with proper function, or stretch beyond manufacturer's recommendations. Visual inspection daily; monthly inspection with signed report. - (e) Rope slings, including end connections, for excessive wear, broken wires, stretch, kinking, or twisting. Visual inspection daily; monthly inspection with signed report. - (f) All functional operating mechanisms for excessive wear of components. - (g) Rope reeving for noncompliance with manufacturer's recommendations. - Periodic inspection . You must complete inspections of the crane at intervals as generally defined in (l)(b)(ii) of this section, depending upon its activity, severity of service, and environment, or as specifically indicated below. These inspections must include the requirements of (2) of this section and in addition, the following items. Any deficiencies such as listed must be carefully examined and determination made as to whether they constitute a safety hazard: - (a) Deformed, cracked, or corroded members. - (b) Loose bolts or rivets. - (c) Cracked or worn sheaves and drums. - (d) Worn, cracked or distorted parts such as pins, bearings, shafts, gears, rollers, locking and clamping devices. - (e) Excessive wear on brake system parts, linings, pawls, and ratchets. - (f) Load, wind, and other indicators over their full range, for any significant inaccuracies. - (g) Gasoline, diesel, electric, or other powerplants for improper performance or noncompliance with applicable safety requirements. - (h) Excessive wear of chain drive sprockets and excessive chain stretch. - (i) Crane hooks. Magnetic particle or other suitable crack detecting inspection should be performed at least once…

[5] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

Page 27

Open source document

Source excerpt

\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ - (a) You must ensure that sheave grooves are smooth and free from surface defects which could cause rope damage. - (b) You must provide sheaves carrying ropes which can be momentarily unloaded with close-fitting guards or other suitable devices to guide the rope back into the groove when the load is applied again. - (c) You must ensure that the sheaves in the bottom block are equipped with close-fitting guards that will prevent ropes from becoming fouled when the block is laying on the ground with ropes loose. - (d) You must ensure that pockets and flanges of sheaves used with hoist chains are of such dimensions that the chain does not catch or bind during operation. - (e) You must ensure that all running sheaves are equipped with means for lubrication. Permanently lubricated, sealed and/or shielded bearings meet this requirement. ## Ropes . - (a) In using hoisting ropes, you must follow the crane manufacturer's recommendation. The rated load divided by the number of parts of rope must not exceed 20  of the nominal breaking strength of the rope. - (b) You must ensure that socketing is done in the manner specified by the manufacturer of the assembly. - (c) You must secure rope to the drum as follows: - (i) No less than two wraps of rope must remain on the drum when the hook is in its extreme low position. - (ii) Rope end must be anchored by a clamp securely attached to the drum, or by a socket arrangement approved by the crane or rope manufacturer. - (d) You must ensure that rope clips attached with U-bolts have the U-bolts on the dead or short end of the rope. Spacing and number of all types of clips must be in accordance with (2)(e) of this section. Clips must be drop-forged steel in all sizes manufactured commercially. When a newly installed rope ha…

[6] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 1606

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Source excerpt

Oregon Occupational Safety and Health Division - (G) A sheave guard shall be provided beneath the head sheave of the boom. - (H) Grapples, tongs, and buckets shall not be left suspended when not in use. - (j) Traffic warning signs or signals. - (A) A flagger shall direct the movement of cranes or locomotives being moved across railroad tracks or roads, and at any points where the vision of the operator is restricted. The flagger must always remain in sight of the operator when the crane or locomotive is in motion. The blue flag policy shall be used to mark stationary cars day and night. This policy shall include marking the track in advance of the spotted cars (flag for daytime, light for darkness). - (B) After cars are spotted for loading or unloading, warning flags or signs shall be placed in the center of the track at least 50 feet away from the cars and a derail set to protect workers in or on the car. - (k) Rail car operations and railroad warning devices. - (A) On a dead end spur, a blue signal may be displayed adjacent to the switch opening while cars are being loaded or unloaded. When such warning devices are displayed, the equipment shall not be coupled to or moved. - (B) Equipment which would obscure the blue signal shall not be placed on the track. - (C) Each maintenance crew shall display and remove its own set of blue signals. - (D) A flashing warning light or other device shall be installed near any opening which leads to a passageway crossing railroad tracks adjacent to the building. Such light or device shall be activated prior to any switching or movement of railroad equipment to warn workers of the dangerous condition in the area. - (E) Workers shall not crawl under or pass between coupled rail cars to cross tracks. - (F) An audible whistle, horn, or bell shall be sounded by the locomotive engineer to give adequate warning prior to switching across any road crossing.

[7] Occupational Health and Safety Regulations, 2020 (Sask. Reg. 10/2020)

Page 130

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Source excerpt

S-15.1 REG 10 ## OCCUPATIONAL HEALTH AND SAFETY, 2020 ## Sheaves, spools and drums - 14-7 (1) An employer or contractor shall ensure that: - (a) the diameter of a sheave, spool or drum for wire rope is not less than the diameter specified by the manufacturer of the rope and the rope is the correct size for the sheave, spool or drum over which the rope passes; - (b) the grooving of a sheave is the correct size for the diameter of rope; and - (c) a block or sheave is constructed or installed so that the rope cannot leave the block or sheave groove. - (2) An employer or contractor shall ensure that: - (a) rope fastened to a winding drum is fastened securely; - (b) the number of full wraps of rope that remain on a winding drum corresponds to the manufacturer's recommendations; and - (c) if there are no manufacturer's recommendations, at least 5 full wraps of rope remain on a winding drum at all times. - 31 Dec 2020 c S-15.1 Reg 10 s14-7. ## Knots, wire rope clips - 14-8 (1) An employer or contractor shall ensure that: - (a) no knot or wire rope clip is used as a stopper on a rope or rope end that passes through a winding drum; and - (b) no knot is used to connect rigging hardware to a wire rope. - (2) An employer or contractor shall ensure that all wire rope clips are: - (a) made of drop-forged steel; - (b) installed according to the manufacturer's instructions; and - (c) inspected at frequent intervals to ensure the nuts are tight. - (3) If U-bolt clips are used to fasten wire rope, an employer or contractor shall ensure that: - (a) the U-bolt is installed so that the U section bears on the short or dead end of the rope and the saddle bears on the long or live end of the rope; - (b) the nuts are correctly torqued; and - (c) the number of clips and the amount of rope turn-back conform to the manufacturer's specifications and instructions. - (4) If double saddle or fist clips are used to fasten wire rope, an employer or contractor shall ens…

[8] Kobelco SK235SR-2, SK235SRLC-2 Operation Manual

Page 17

Open source document

Source excerpt

## 1.1 GENERAL SAFETY INFORMATION <!-- image --> ## AVOID INJURY OR DEATH Do not operate or perform any maintenance on this machine until all instructions found in this manual have been thoroughly read and understood. Improper operation or maintenance of this machine may cause accidents and could result in serious injury or death. Always keep this manual in storage stored in the place provided on the machine. If it is missing or damaged, place an order with an authorized dealer/distributor for a replacement. If you have any questions, please consult an authorized dealer/distributor. - 1. Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of personnel. Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in this manual and on the machine should be read and understood by all personnel before starting any work with or on the machine. - 2. Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority. Safety messages are indicated using the following safety alert symbols and signal words. The safety information contained in this manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations. - 3. It is very difficult to forecast every danger that may occur during operation. However, safety can be ensured by fully understanding proper operating procedures for this machine according to methods recommended in this manual. - 4. While operating the machine, be sure to perform work with great care to avoid damage to the machine, and accidents from occurring. - 5. Continue studying this manual until all Safety, Operation and Maintenance procedures are completely understood by all persons working with the machine. - 6. Symb…

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