Safe Work Procedure: Sheave and Alignment

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 steps and safety precautions for performing sheave and alignment tasks. It applies to all workers involved in the installation, maintenance, and inspection of sheaves and their alignment in [SPECIFIC WORK ENVIRONMENT]. This procedure aims to minimize the risks associated with sheave and alignment activities, ensuring a safe working environment.

2. Definitions

Sheave: A wheel or pulley with a grooved rim, used to guide a rope or cable.

Alignment: The process of ensuring that two or more components are positioned correctly in relation to each other.

Runout: The amount of deviation or wobble in a rotating sheave.

3. Responsibilities

3.1 Supervisors

Ensure that all workers are properly trained and competent to perform sheave and alignment tasks.
Conduct pre-job briefings to discuss potential hazards and control measures.
Provide necessary tools, equipment, and PPE in good working condition.
Monitor work activities to ensure compliance with this SWP.

3.2 Workers

Participate in required training and demonstrate competency in sheave and alignment procedures.
Inspect tools, equipment, and PPE before use and report any defects.
Follow the steps outlined in this SWP and adhere to all safety precautions.
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 regular inspections of work areas to identify potential hazards.
Provide guidance and support to supervisors and workers on health and safety matters.

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Moving machinery	Entanglement, crushing injuries	Ensure machinery is properly guarded and locked out during maintenance.
Fall from height	Serious injury or death	Use appropriate fall protection equipment (e.g., safety harness, lanyard) when working at heights.
Musculoskeletal strain	Back injury, sprains	Use proper lifting techniques and mechanical aids to reduce strain.
Sharp edges	Cuts, lacerations	Wear appropriate gloves and use caution when handling sheaves. [1]
Dust inhalation	Respiratory irritation	Use respiratory protection where dust is present. 7, 12
Eye irritation	Eye damage	Wear safety glasses with side shields. 5, 10, 12

5. Personal Protective Equipment (PPE)

Always use the proper PPE for the job. [1]

Safety glasses with side shields - Protects eyes from dust and debris. 5, 10, 12
Gloves - Protects hands from cuts, abrasions, and chemical exposure. 5, 10
Safety shoes - Protects feet from impact and compression hazards.
Hard hat - Protects head from falling objects.
Respiratory protection - Protects against dust inhalation in dusty environments. 7, 12

Inspect all PPE before use for any damage or defects. Replace damaged PPE immediately.

6. Equipment and Tools

Always use the proper equipment and tools for the job.

Laser alignment tool - Used for precise alignment of sheaves.
Straight edge - Used for checking sheave alignment.
Tension gauge - Used for measuring belt tension.
Wrenches and sockets - Used for tightening and loosening bolts.
Lockout/tagout devices - Used for isolating energy sources.

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

7. Pre-Job Requirements

7.1 Training and Competency

Workers must be trained and competent in sheave and alignment procedures, including the use of laser alignment tools and other equipment.

7.2 Pre-Job Briefing

A pre-job briefing must be conducted to discuss the scope of work, potential hazards, and control measures. All workers involved must attend the briefing.

7.3 Work Area Preparation

Ensure the work area is clean, well-lit, and free of obstructions. Barricade the area to prevent unauthorized access.

8. Safe Work Procedure Steps

Step 1: Preparation

Prepare the work area by ensuring it is clean, well-lit, and free of obstructions. Barricade the area to prevent unauthorized access.

Gather all necessary tools, equipment, and PPE.
Inspect tools and equipment for any damage or defects.
Ensure proper ventilation in the work area.

Safety considerations: Ensure the work area is safe and organized to prevent slips, trips, and falls.

Step 2: Lockout/Tagout

De-energize and lockout/tagout the machinery before starting any work.

Identify all energy sources and disconnect them.
Apply lockout/tagout devices to prevent accidental re-energization.
Verify that the machinery is de-energized before proceeding.

Safety considerations: Follow proper lockout/tagout procedures to prevent accidental start-up of machinery.

Step 3: Sheave Inspection

Inspect the sheaves for wear, damage, and proper lubrication.

Check for cracks, chips, and excessive wear on the sheave grooves.
Ensure that the sheaves are properly lubricated.
Replace any damaged or worn sheaves.

Safety considerations: Use caution when handling sheaves to avoid cuts and abrasions. [1]

Step 4: Alignment

Align the sheaves using a laser alignment tool or straight edge.

Use a laser alignment tool to precisely align the sheaves.
Adjust the position of the sheaves as needed to achieve proper alignment.
Verify the alignment using a straight edge.

Safety considerations: Ensure the machinery is locked out during alignment to prevent accidental movement.

Step 5: Tensioning

Tension the belts according to the manufacturer's specifications.

Use a tension gauge to measure belt tension.
Adjust the tension as needed to achieve the correct value.
Ensure that the belts are properly aligned and seated in the sheave grooves.

Safety considerations: Avoid over-tensioning the belts, as this can cause premature wear and failure.

Step 6: Post-Alignment Check

Perform a final check to ensure proper alignment and tension.

Verify that the sheaves are properly aligned and the belts are correctly tensioned.
Remove lockout/tagout devices and re-energize the machinery.
Observe the machinery during operation to ensure smooth and vibration-free performance.

Safety considerations: Keep a safe distance from moving machinery during operation.

9. Precautions and Safety Measures

Lockout/Tagout - Always follow proper lockout/tagout procedures before starting any work on machinery.
Fall Protection - Use appropriate fall protection equipment when working at heights.
Proper Lifting Techniques - Use proper lifting techniques to avoid musculoskeletal strain.
Guarding - Ensure that all machinery is properly guarded to prevent entanglement.
Housekeeping - Keep the work area clean and free of obstructions.

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 and contact emergency services.

10.2 Specific Emergency Scenarios

Injury - Provide first aid and seek medical attention if necessary. 8, 10, 15, 20
Fire - Activate the fire alarm and evacuate the area. 5, 8, 10, 12, 15, 20
Chemical Spill - Contain the spill and follow the appropriate spill response procedures. 5, 8, 10, 12, 15, 20

10.3 Emergency Contact Information

Emergency Services: 911
[Company Medical]: [PHONE NUMBER]
[Safety Department]: [PHONE NUMBER]

11. Incident Reporting and Investigation

Report all incidents, near-misses, and hazards to the supervisor immediately. An investigation will be conducted to determine the root cause and prevent recurrence.

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