锁具管理规定_Lifting_tools_management_.docx

Document nameDocument ID/REV吊具报废标准SLING SCRAP STANDARD DateAuthorApprover18.11.2014Gavin ZhangMartin FencakLifting tools management吊具的管理1 DEMANDS 目的1.1 Define the requirement for purchasing, goods receiving, use, maintenance, inspection and scrap of lifting tools 对公司所使用吊索具的采购、领用、使用、维护、点检、报废过程的管理。 2 DEFINE 定义Lifting tools include webbing sling, chain sling, wire rope sling, hook, shackle, and eye bolt etc. 吊索具是以使用挠性元件不同如钢丝绳吊索、合成纤维吊带和吊链的总称，是起重作业中最基本和使用最广泛的工具本规程所涉及的吊具，具体包括：吊带，吊链，钢丝绳，吊钩，卸扣，吊环等。3 SAFETY USE AND SCRAPT 安全使用和报废3.1 Webbing/round Sling吊带 3.1.1 Safety Use for Webbing/Round Sling吊带的安全使用 Do not drag from beneath load吊带在工作时，不准拖拉，以防损坏吊带； Do not knot when use; Do not twist the webbing /round sling by wheeling the load吊带不准打结使用，承载时不准转动货物使吊带打拧； Use the webbing/round sling with protective cover when the load with sharp/burring edge不要使用没有护套的吊带吊装有尖角、棱边或有毛刺的货物，以防损伤吊带； Do not lifting load in the air for long time. 不允许长时间悬吊货物； Do not put webbing/round sling near the fire and other heat source. Store far away from sunlight. 不要把吊带存放在有明火或其它热源附近，也应注意避光保存； Do not put webbing/round sling in the chemical. 不要把吊带放置在化学品内 Put webbing/round sling on the special shelf when not use. 不使用时，应将吊带放置在专用的架子上。Dragging From Beneath Load在负荷之下拖动Knotted To Shorten打结用来缩短Knotted To Form Eye打结形成 鱼眼状Improper Joining不正确连接Water or Rusty Steel水或生锈钢铁AshesChemical化学品3.1.2 The webbing/round sling should be scraped if吊装带在使用过程中，有下列情况之一时，应予以报废。Working load markings are illegible 工作负荷标识难以辨认 There is a knot in the webbing/round sling. 带状吊带/圆吊带打结The sling stitching is ripped吊带编织有裂口More than 10% of the warp is cut. 超过10%的经线被切断More than 5% of the weft is cut. 超过5%的纬线被切断The cut or friction damage exceeds 10% of the sling width. 切断或摩擦破损超过吊带宽度的10%The webbing sling/round sling was worn and dirty or shows chemical damage. 吊带磨损、变脏、或显示化学性损伤Core of the round sling is exposed. 圆吊带核心暴露The surface of the webbing sling/round sling has melted due to heat. 带状吊带/圆吊带表面受热融化3.2 Chain Sling吊索3.2.1 Safety Use for Chain Sling吊索的安全使用： Do not overload 起重链条决不允许起吊超过其额定载荷的物体。 For one leg chain sling, the lifting point should be vertical and located on the above of load cg. 单腿索具，起吊点应该垂直位于起重物件重心正上方。 For two leg chain sling, the lifting point should be located on two side of the load.双腿索具，吊挂点应该位于起重物件两边，起吊点在重心上方。 For multiple leg chain, the unused chain should be hung on the main chain 如果多腿链条索具某腿未被使用时，未使用的链条应该挂在主环上。 Wear gloves when use chain sling使用链条索具应该带保护手套 索具只许用调节器缩短Only use adjustment to short chain sling 悬挂吊环必须能在起重机吊钩中自由移动 Slowly to lift load, and rest firmly to the new location when land load起吊货物时应缓慢，落下时应平稳。 Put the lifting tools on the special shelves when not use不使用时，应放置在专用的吊具架上。要缩短吊索时使用后备的链钩不要打结在提升重物时确认链条是直的 一般铁链不得用于起重 不得超出荷载使用 不得打结使用 不得使用锤子加工变形的铁环后适用 购买时选择“A”级铁链3.2.2 Chain sling should be scraped if 吊索在使用过程中，有下列情况之一时，应予以报废。 Cracks/bending/twisting of chain链环有裂纹，弯曲或扭曲现象。 Wear of chain diameter is more than10% 链环直径磨损量达原直径的10%。 The length of the chain sling is more than 5% compared with the original length. 链条永久性伸长超过原长5%。 3.3 Wire Rope Sling钢丝绳3.3.1 Safety Use of Wire Rope Sling钢丝绳的安全使用 Take effective action to prevent wire rope sling bending or collide with other articles.应采取有效措施避免钢丝绳在锐角处发生弯折或与其他物体碰撞。 Store in dry and ventilation area, and prevent sunshine directly; Keep away from hot source and corrosive materials. 应存放在通风干燥处，防止阳光直射、热气烘烤和接触酸碱等具有腐蚀性的物质。3.3.2 The wire rope sling shall be disposed if they are钢丝绳如出现下列任何一种情况，应报废处理 The tag or label indicating the maximum load is missing. 显示最大承载的标识不见了 Broken wire, bird cages, and kinks断裂、鸟巢、纽结 Surface wires are worn by 1/3 or more 外部钢丝磨损超过1/3 diameter of wire rope sling is reduced by more than 10% 钢丝绳直径减小值大于10%； The wire rope sling has defects, distortion, bending 钢丝绳的某处被压烂或压扁； The damaged wire meet the following number under some meter _米长度内可见断丝的数量达到下表所示时；3d6d10d普通钢丝绳 General wire rope sling4614钢缆钢丝绳 Steel wire rope sling101540（d为钢丝绳直径） 断裂鸟巢扭结钢丝绳直径发生变化外部钢丝磨损超过1/33.4 吊钩 Hook3.4.1 吊钩的安全使用Safety Use for Hook Use proper hook选择合适大小的吊钩使用 Do not remove or bind the safety latch of hook安全闸片不得拆除或捆绑 Use hook under vertical direction吊钩必须垂直使用 The actual carry capacity will be declined if under lean 如果倾斜使用，荷重会下降 Safety latch should be installed except special hook. 除特殊吊钩外，所有吊钩必须装有安全闸片能负载约100%能负载约86%能负载约80%能负载约70%能负载约40%3.4.2 吊钩的报废标准 Hook Scrap Criterion：54321检查有无磨损和变形检查有无断裂和扭曲检查有无磨损和断裂检查开口是否增加了10%安全闸片是否完好 1) Check the safety latch whether in good condition;2) Check the opening up whether increasing more than 10%;3) Check for wear and cracks;4) Check for wear and deformation;5) Check for cracks and twisting; 3.5 Safety Use and disposal of shackle卸扣的安全使用和报废 Forbid of overload use严禁超负荷使用 Do not use screw to replace shackles pin不得用螺丝替代卸扣的销子 Fully seat the pin 销子要完全锁住 Do not put shackle to aside when lifting吊装时，卸扣不得倾斜到一边使用 Use washer to fix hook 不得使用有套丝的销子；使用套片固定吊钩 Discard it if any cracks, distortion, pin not fixed, or wear achieved 3-5% of original size for any parts当卸扣任何部位产生裂纹、塑性变形、螺纹脱扣、销轴和扣体断面磨损达原尺寸35%时应报废。如果起吊，吊绳会将销子松开垫片吊钩3.6 Eye bolt环眼吊环：3.6.1 Safety Use of Eye Bolt吊环的安全使用：1吊环螺丝必须全部旋入孔内，吊环的肩与起吊物表面紧密接触。如果孔洞不够深，可以加垫片使吊环与起吊物表面紧密接触未与起吊物紧密接触的吊环易变形，折断只能垂直起吊，斜吊会折断2安全点：1、吊钩不能直接吊在环眼吊扣；2、普通的环眼吊扣只适用于垂直吊装；3、环眼吊扣侧翼的吊装角度不少于45度4、不要使用绳索穿过一双环眼吊扣。垫片1) The bolt should totally drill on the load; the bolt hole shall fit into the bolt; Washer may be used to ensure that the shoulder is firmly in contact with the surface. 2) (1) The hook shall not be directly fixed on the eye bolt; (2) Pain eye bolts only apply to the vertical lifting;(3) The angle of lifting of shoulder eye bolts shall not be less than 45 degree.(4) Never use a sling through a pair of eye bolts. 3.6.2 Scrap of the eye bolt吊环的报废： Cracks有开裂； Bending 吊环螺母跟螺丝间发生弯曲；4 INSPECTION 检查4.1 Daily Inspection of Lifting Tools吊具的日常检查：Users conduct visual check before/after use lifting tools; Once find defect, they should stop using and send defect lifting tools to maintenance. 吊具的日常检查，由吊具的使用者在使用前后对吊具的目视检查，一旦发现明显异常，应停止使用。并将问题吊具送至维修部。4.2 Routine Check of Lifting Tools吊具的定期检查：4.2.1 Maintenance conducts routine general check for lifting tools. And record the check result. During the last time check of every month, paint different colour on lifting tools or aluminium tag if check result is ok. 吊具的定期检查由维修人员进行，定期的对吊具进行全面检查，并对检查结果作出记录。每月的最后一次检查时，在检查合格的吊索具或铝牌标识上刷上不同的油漆以显示合格。4.2.2 In order to implement visual management in better way, we define the paint colour of every month.为了更好的执行可视化管理，现定义了每个月刷在合格的吊索具或铝牌标识上的油漆的颜色。MonthRAL 月份 颜色代码Jan一月39#BLACK黑色Feb二月22#GRAY灰色March三月77#GREEN1墨绿April四月21# BLUE蓝色May五月13#GREEN 2葱绿June六月40#WHITE白色July七月39#BLACK黑色Aug八月22#GRAY灰色Sep九月77#GREEN1墨绿Oct十月21# BLUE蓝色Nov十一月13#GREEN 2葱绿Dec十二月40#WHITE白色4.3 Non-routine check of lifting tools吊具的不定期检查：Non-routine check is conducted by EHS. 吊具的不定期检查由EHS人员进行。4.4 Routine check frequency吊具的定期检查频率：Weekly周检Monthly月检Quarterly季度检Remark备注Webbing sling/round sling吊带Chain sling ( include hook)吊链（含吊钩）Year check: crack detection for key position; length measure; diameter measure关键部位探伤；长度的测量，直径的测量Wire rope sling钢丝绳Quarterly check: diameter measure of 季度检：钢丝绳直径的测量Shackle卸扣Eye bolt吊环 Remark: Quarterly check is just for the chain sling and wire rope sling with more than 4 tons rated load 备注：对钢丝绳和吊链（含吊钩）的季度检限于承载量在4吨以上的 5 RESPONSIBILITY 职责5.1 User of Lifting Tools吊具的使用者5.1.1 Conduct daily check for lifting tools before/after use; 在使用前后负责对吊索具进行日常检查； 5.1.2 Immediately stop use and report to line leader once found defect lifting tools; 一旦发现问题吊索具，应停止使用并报告给线长；5.1.3 Correctly use lifting tools 正确使用吊索具；5.1.4 Return the lifting tools to appointed area after use; 使用完后应将吊索具放至专用的吊具架上；5.1.5 Return it in time after use if borrow from other areas. 从其他区域借的吊索具使用完后，应及时归还；5.2 Line Leader 生产部线长：5.2.1 Responsible for store keeping 负责对本区域的吊索具的现场保管；5.2.2 Weekly account their areas lifting tools, and record it. If found missing, they should seek it. 每周对本区域的吊索具进行清点，并作记录；发现缺少，应及时寻找。5.2.3 Responsible for sending defect lifting tools to maintenance.负责将问题吊索具交至维修部；5.2.4 Supervise employees to safely use lifting tools; Once found risk behavior, they should immediately stop employees. 对员工安全使用吊索具进行监管，发现冒险作业，应及时阻止；5.2.5 Responsible for feedback some information to maintenance, such as lifting tools enough or not, any need to purchase new lifting tools, use situation负责跟维修部反馈，吊索具是否足够，或需购买新的，使用状态等等。5.3 Maintenance维修部：5.3.1 Purchase the new lifting tools base on need; Check lifting tools condition & documents when goods receiving, such as clear working load marking, quality certification; Keep the original documents of lifting tools, such as quality certification根据需要购买新的符合安全使用的吊索具；收货时，检查吊具的状态及文件，如清晰地承重标记，产品合