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

Hazard	Risk	Control Measures
Fall from height	Serious injury or death	Use fall protection equipment (e.g., safety harness, lanyard) when working at heights. Ensure proper anchorage points are used.
Struck by falling objects	Head injury, lacerations, fractures	Secure 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 parts	Amputation, lacerations, fractures	Ensure equipment is de-energized and locked out/tagged out before starting maintenance. Use machine guarding to prevent contact with moving parts.
Electrical shock	Electrocution, burns	De-energize and lockout/tagout electrical equipment before starting maintenance. Use insulated tools and PPE.
Musculoskeletal injuries	Strains, sprains, back injuries	Use proper lifting techniques. Get assistance when lifting heavy objects. Take frequent breaks and stretch.
Pinch points	Crushing injuries, amputations	Be aware of pinch points and keep hands and fingers clear. Use appropriate tools to manipulate sheaves and ropes.
Sharp edges	Lacerations, punctures	Wear gloves when handling sheaves and ropes. Use caution when working with sharp edges.
Improper lubrication	Equipment failure, increased wear	Use 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]

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

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