Safe Work Procedure: Installing Sheaves on an Elevator

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 be followed when installing sheaves on an elevator. It applies to all personnel involved in the installation process, including elevator mechanics, technicians, and supervisors. This procedure covers the safe handling, installation, and inspection of sheaves to ensure proper elevator operation and prevent potential hazards.

This procedure applies to all work environments where elevator sheaves are being installed, including elevator shafts, machine rooms, and construction sites. It is applicable for both new installations and replacements of existing sheaves.

This SWP should be used in conjunction with the manufacturer's installation guidelines, relevant elevator codes and standards (e.g., ASME A17.1), and any other applicable safety procedures.

2. Definitions

Sheave: A grooved wheel used to support and guide a hoisting rope or cable in an elevator system [1].

Elevator Mechanic: A qualified and trained individual responsible for the installation, maintenance, and repair of elevators.

Competent Person: An individual who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them [2].

3. Responsibilities

3.1 Supervisors

Ensure that all workers involved in the sheave installation are properly trained and competent to perform the task.
Conduct pre-job briefings to discuss the SWP, potential hazards, and control measures.
Provide all necessary tools, equipment, and personal protective equipment (PPE) in good working condition.
Monitor the work to ensure that it is performed safely and in accordance with this SWP.

3.2 Workers

Participate in pre-job briefings and understand the requirements of this SWP.
Inspect all tools, equipment, and PPE before use and report any defects to the supervisor.
Follow the safe work procedures outlined in this SWP and any other relevant instructions.
Report any hazards or unsafe conditions to the supervisor immediately.

3.3 Health and Safety Representative

Assist in the development and review of this SWP.
Conduct periodic inspections of the work area to ensure compliance with safety regulations.
Investigate incidents and near-misses related to sheave installation 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, cuts, bruises	Wear a hard hat. Secure tools and materials to prevent them from falling. Establish a drop zone and barricade the area below.
Electrical shock	Electrocution, burns	De-energize and lockout/tagout the elevator power supply before starting work. Use insulated tools and equipment.
Musculoskeletal injuries	Strains, sprains	Use proper lifting techniques. Get assistance when lifting heavy sheaves. Take frequent breaks.
Rope damage	Equipment malfunction, potential for dropped load	Ensure sheave grooves are smooth and free from surface defects which could cause rope damage [1].
Crane or hoist failure	Dropped load, serious injury or death	Inspect crane or hoist before use. Do not exceed the rated load. Ensure proper rigging and load securement.

5. Personal Protective Equipment (PPE)

It is mandatory to use appropriate PPE at all times during sheave installation 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 other projectiles.
Safety shoes - Protects the feet from impacts, punctures, and crushing hazards.
Work gloves - Provides grip and protects hands from cuts, abrasions, and burns.
Fall protection harness and lanyard - Prevents falls from heights when working in the elevator shaft or machine room.

Inspect all PPE before each use for damage or defects. Replace any damaged or defective PPE immediately. Ensure that the fall protection harness fits properly and is adjusted according to the manufacturer's instructions.

6. Equipment and Tools

It is mandatory to use appropriate equipment and tools at all times during sheave installation to minimize the risk of injury.

Hoist or crane - Used to lift and position heavy sheaves. Ensure the hoist or crane is in good working condition and has a current inspection certificate.
Slings and rigging hardware - Used to attach the sheave to the hoist or crane. Ensure slings and rigging hardware are of appropriate size and capacity and are inspected before use.
Hand tools - Wrenches, screwdrivers, pliers, etc. Use the right tool for the job and ensure tools are in good working condition.
Lockout/tagout devices - Used to de-energize and isolate the elevator power supply.
Measuring tools - Tape measure, level, etc. Used to ensure proper alignment and positioning of the sheave.

Inspect all equipment and tools before each use for damage or defects. Remove any damaged or defective equipment from service. Follow the manufacturer's instructions for the safe use and maintenance of all equipment and tools.

7. Pre-Job Requirements

7.1 Training and Competency

All workers involved in sheave installation must be trained and competent in the following areas:
- Safe work procedures
- Hazard identification and control
- Use of PPE
- Proper lifting techniques
- Lockout/tagout procedures
- Use of hoists and rigging equipment
Elevator mechanics must have a valid license or certification.

7.2 Pre-Job Briefing

Conduct a pre-job briefing with all workers involved in the sheave installation.
Discuss the following topics:
- Scope of work
- Potential hazards and risks
- Control measures
- Safe work procedures
- Emergency procedures
- Roles and responsibilities
Ensure that all workers understand the information presented and have an opportunity to ask questions.

7.3 Work Area Preparation

Inspect the work area for hazards, such as slip, trip, and fall hazards, and correct them before starting work.
Ensure adequate lighting is provided in the work area.
Barricade the area below the work area to prevent unauthorized access and protect people from falling objects.
Ensure that the elevator shaft is properly ventilated.
Verify that the elevator car is properly secured and cannot move during the sheave installation.

8. Safe Work Procedure Steps

8.1 Preparation

Step 1: De-energize and lockout/tagout the elevator power supply according to established procedures.
- Verify that the power is off by testing the electrical circuits with a voltage tester.
- Place lockout/tagout devices on the elevator disconnect switch to prevent accidental re-energization.
Step 2: Prepare the work area.
- Clear the area of any obstructions.
- Ensure adequate lighting and ventilation.
- Barricade the area below to prevent unauthorized access.
Step 3: Gather all necessary tools, equipment, and PPE.
- Inspect all tools and equipment for damage or defects.
- Ensure that all PPE is in good condition and fits properly.

[Safety considerations for this step: Ensure proper lockout/tagout procedures are followed to prevent electrical hazards. Verify that the work area is safe and free of hazards.]

8.2 Sheave Removal (if replacing an existing sheave)

Step 1: Secure the elevator car to prevent movement.
- Use appropriate blocking or locking devices to secure the car in place.
Step 2: Disconnect the existing sheave from the hoisting ropes or cables.
- Use appropriate tools and techniques to disconnect the ropes or cables without damaging them.
- Support the ropes or cables to prevent them from falling.
Step 3: Remove the old sheave from its mounting.
- Use a hoist or crane to lift the sheave if it is too heavy to lift manually.
- Take care not to damage the sheave mounting or surrounding equipment.

[Safety considerations for this step: Ensure the elevator car is properly secured before disconnecting the sheave. Use proper lifting techniques or a hoist to remove heavy sheaves.]

8.3 Sheave Installation

Step 1: Inspect the new sheave for damage or defects.
- Ensure that the sheave groove is smooth and free from surface defects [1].
- Verify that the sheave is the correct size and type for the elevator system.
Step 2: Position the new sheave on its mounting.
- Use a hoist or crane to lift the sheave into position.
- Ensure that the sheave is properly aligned and centered on its mounting.
Step 3: Secure the sheave to its mounting.
- Use appropriate fasteners (e.g., bolts, screws) to secure the sheave in place.
- Tighten the fasteners to the manufacturer's specifications.
Step 4: Reconnect the hoisting ropes or cables to the sheave.
- Use appropriate tools and techniques to reconnect the ropes or cables.
- Ensure that the ropes or cables are properly seated in the sheave groove.
Step 5: Remove the elevator car blocking or locking devices.

[Safety considerations for this step: Use proper lifting techniques or a hoist to position the sheave. Ensure that the sheave is properly aligned and securely fastened. Verify that the hoisting ropes or cables are correctly reconnected.]

8.4 Post-Installation Inspection and Testing

Step 1: Inspect the sheave installation.
- Verify that the sheave is properly aligned and securely fastened.
- Ensure that the hoisting ropes or cables are correctly seated in the sheave groove.
- Check for any signs of damage or wear.
Step 2: Test the elevator operation.
- Run the elevator car through its full range of travel.
- Observe the sheave operation for any signs of problems (e.g., excessive noise, vibration).
Step 3: Make any necessary adjustments or corrections.

[Safety considerations for this step: Ensure that the sheave installation is thoroughly inspected before testing the elevator operation. Be alert for any signs of problems during the elevator testing.]

9. Precautions and Safety Measures

Lockout/Tagout: Always follow proper lockout/tagout procedures before working on the elevator system to prevent accidental energization.
Fall Protection: Use fall protection equipment when working at heights to prevent falls.
Lifting Techniques: Use proper lifting techniques to prevent musculoskeletal injuries.
Housekeeping: Keep the work area clean and free of clutter to prevent slip, trip, and fall hazards.
Communication: Maintain clear communication between workers to ensure everyone is aware of the task and potential hazards.

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.
Provide first aid to any injured persons.
Contact emergency services (e.g., fire department, ambulance) if needed.

10.2 Specific Emergency Scenarios

Electrical Shock:
- De-energize the power supply if it is safe to do so.
- Use a non-conductive object to separate the victim from the electrical source.
- Administer CPR if the victim is not breathing.
Fall from Height:
- Do not move the victim unless it is necessary to protect them from further injury.
- Provide first aid for any injuries.
- Call for emergency medical assistance.
Dropped Object:
- Warn people in the area to avoid the falling object.
- Inspect the area for any damage or injuries.

10.3 Emergency Contact Information

Emergency Services: 911
[Company Safety Officer]: [PHONE NUMBER]
[Project Supervisor]: [PHONE NUMBER]

11. Incident Reporting and Investigation

Report all incidents, near-misses, and hazards to the supervisor immediately. All reported incidents will be investigated to determine the root cause and prevent recurrence. Implement corrective actions as recommended by the investigation team.

12. References and Related Documents

ASME A17.1, Safety Code for Elevators and Escalators
[Company Safety Manual]
[Lockout/Tagout Procedure]

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