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7/25/2019 Instruction- Transport, Assembly and Disassembly of Terex Demag 400 Ton Crane Cc 2400-1
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Referance Code received date : 27/10/2014 Reviewer
PWI EQ 008 send date : 27/10/2014 Victor G.
Referance Article POSCO E&C Comments SEIL Reply Remarks
8. Instrucciones de Trabajo
8.1
1) El traslado se realiza al interior del proyecto Cochrane
2) Especificar el uso de placas de acero para el traslado hasta su posicion final
3) Recordar que el traslado se realizara con luffing jib de 48+72 metro de pluma
principal.
8.1.
1) Corrected
2) Included in point 8.5.8.
3) Included in point 8.5.8.
8.2.9
Como sabran "si es necesario" el chequeo de las condiciones del terreno
(compactacion y nivelacion) . Especificar
Included in point 8.5.4.
8.2.12. Figura 1
Agregar el uso de placas metalicas durante el traslado de grua dentro del
proyecto.
Included in point 8.5.8.
* Adjuntar Plan de como realizaran el trabajo de colocacion de las placas durante
el movimiento de la grua ( cuantas placas?, como?, donde?, etc)Included in point 8.5.8.
- BLANK -
Traslado, Armado y Desarme Grua Terex 400 ton CC 2400-1
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Work Instructions
TRANSPORT, ASSEMBLY AND DISASSEMBLY OF TEREX
DEMAG 400 Ton CRANE CC 2400-1
Doc. No. : PWI-EQ-008
Rev. : F
Page: 2 of 26
CONTENTS TABLE
Section Description
1 Purpose
2 Scope
3
4
5
6
Responsibilities
Risk classification
Personal protective equipment required
Equipment, materials and tools to be used
7 References
8 Work instructions
9
10
Safety and prevention
Annex
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Work Instructions
TRANSPORT, ASSEMBLY AND DISASSEMBLY OF TEREX
DEMAG 400 Ton CRANE CC 2400-1
Doc. No. : PWI-EQ-008
Rev. : F
Page: 3 of 26
1. PURPOSE
The purpose of this instruction is to define the transport, assembly, disassembly,reparations and change of configuration of the Terex Demag CC2400-1 Crane
inside the facilities of the project for the execution of Cochrane Thermoelectric
Plant construction activities for a consistent and safe performance of the works.
2. SCOPE
This instruction can be applied to the execution of the transport and assembly
works of Terex Demag CC2400-1 Crane for the execution of Cochrane
Thermoelectric Plant construction activities for a consistent and safe
performance of the works.
3. RESPONSIBILITIES
3.1. Site Manager
The Site Manager is completely responsible for the execution of all the works
executed at work. He is also responsible for verifying that all the works develop
according to this construction plan, as well as developing such construction
works. He is responsible of assigning all the necessary supplies to develop the
activities in a safe way.
3.2. Project Construction Manager
The Cochrane Project Construction Manager is responsible for observing and
supervising the works according to the construction plan (CP).
3.3. Project Quality Manager
The Project Quality Manager is responsible for checking and supervising
according to the agreement in this construction plan.
3.4. Construction Department
It is responsible for obtaining the approval of this procedure, communicate,
make it known and applied by every worker involved in the related task.
Provide the necessary supplies to fulfill this procedure in an accurate way.
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Work Instructions
TRANSPORT, ASSEMBLY AND DISASSEMBLY OF TEREX
DEMAG 400 Ton CRANE CC 2400-1
Doc. No. : PWI-EQ-008
Rev. : F
Page: 4 of 26
Provide support to all the crew members in order to know individually and
collectively their development, complying with the expected behavioralstandards and goals related to zero damage.
3.5. 3.5 HSE Department
Advise the operations of the managers and the line of supervision regarding
the safety described on this procedure so it can be implemented and executed
properly.
Advise and inform that the standards indicated on this document are properly
implemented.
Assist in the training of the personnel that will be using tools that comply with
the standards of this procedure.
Inform the workers about the results regarding accidents and incidents.
Inform POSCO in advance by phone about all the incidents in the work area
and provide basic information on the investigation of these incidents within the
first two hours.
3.6. Mobile Equipment Supervisor
Responsible for the fulfillment of this procedure and the instructions that might
be produced. Render it to the personnel directly involved, controlling its
compliance.
Maintain a copy of this work instruction in site.
Keep an auditable register of the awareness of this procedure.
Look after the health and physical integrity of the personnel present in the
tasks, preserving and promoting the mandatory use of the safety elements.
Instruct the personnel under his command in a clear and precise way about
the subjects considered on this procedure.
Control the compliance of the personal protective elements and the correct
execution of the works of his personnel.
Keep and ensure the basic health conditions in the work areas (water,
restrooms) at all times.
Check and perform JSA along with the workers involved in the activity.
Consult with the HSE personnel in case of any doubt about the field conditions.
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Work Instructions
TRANSPORT, ASSEMBLY AND DISASSEMBLY OF TEREX
DEMAG 400 Ton CRANE CC 2400-1
Doc. No. : PWI-EQ-008
Rev. : F
Page: 5 of 26
3.7. Workers
Take notice and comply with the established on this procedure. Keep an auditable register of the awareness on this procedure.
Inform immediately to your direct supervisor about any situation that could
prevent your performance in the entrusted tasks.
All workers must receive a basic training on protective equipment against falls.
Check that all the tools are in good condition and with the corresponding
monthly codification.
Use the personal protective implements properly.
Use the right tools and equipment to perform your works.
Comply at all times with the personal safety measures and those regarding the
surroundings, executing the works properly, according to instructions of their
direct supervisor, especially for the effective implementation of this procedure.
Every time a task related to this procedure is executed, the Supervisor along
with his workers will prepare a Risks Control Sheet (RCS and/or JSA) which
must be signed.
It is very important that the workers take care of themselves as well as their
coworkers.
3.8. HSE Supervisor
Advise about the proper execution of these works.
Keep an auditable register of this procedure awareness.
Assist the line of command on the identification of dangers, risks evaluation
and establishment of control measures.
Make known this procedure with regard to safety aspects and make sure that
the personnel involved in the works are aware of it.
Check that the conditions under these tasks are developed are the safest and
most appropriate.
Control and check daily the Job Safety Analysis (JSA).
In case of identifying a risk factor, any worker, regardless his position, has the
right and the duty to stop the works.
Inform POSCO E&C immediately about all the incidents occurred at site and
submit the background information related to the investigation within the 2
first hours.
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Work Instructions
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DEMAG 400 Ton CRANE CC 2400-1
Doc. No. : PWI-EQ-008
Rev. : F
Page: 6 of 26
3.9. Drivers and/or Operators (Trailer, Forklift, etc.)
Become aware and comply with the established on this procedure. Inform immediately to their direct supervisor about any situation that could
impede their performance in the entrusted tasks.
Use the personal protective implements properly.
Perform a check list of the equipment before operating them to execute their
works.
Always carry the driver license. If the driver has an inappropriate license, he
will not be able to operate the vehicle.
Comply with the maximum speed of 15 Km/h.
Be aware of the transit conditions, complying the signposts established in the
project at all times.
3.10. Riggers.
The Rigger must have an updated certification.
The rigger must enforce the compliance of all the information given in the
lifting plan of the maneuver.
The rigger must possess technical and practical knowledge related to the works
with maneuvers, handle and load lifting using cranes. Support the crane
operator with the directions in the maneuvers by using regulatory signals,
whistle and radio communicator.
The rigger must have formal training and qualification by an authorized
organism.
The rigger must count with all the basic protective elements and wear a
reflective green and yellow jacket, geologist type, with the Rigger stamped
on the back and the company logo in the front.
The rigger must carry his whistle at all times to warn the personnel before and
during the transit of a suspended load.
The rigger has to make sure that the load has been hooked correctly, as well
as all the capacities of the lifting elements used match (diameter, volume, etc.)
Verify that the lifting accessories are in good condition and with the proper
monthly color, following the instructions from the supervisor or foreman in
charge.
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Rev. : F
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The slings must be certified.
Perform the anchorage of the shackles to secure the slings that will be used toperform the load or unload of materials, structures or containers.
The rigger must carry his certification credential at all times.
For maneuvers, an exclusive radio channel must be used when using the radio.
The rigger must forbid the intervention of eternal workers in the maneuvers,
as well as their intervention in the coordination with the operator.
The rigger has to make sure that suspended loads are controlled from a safe
distance by using ropes. An approximately distance of 10m from the falling
materials area.
The steel wire cable must be made of Perlon or another suitable material.
The rigger must not manipulate the ropes at any time.
The rigger has to make sure that the elements and accessories used are the
ones mentioned in the Work Procedure.
The rigger has to make sure and be certain that the radio for the maneuvers
is closed and signalized prior the lifting.
The suspended load will never move over the personnel.
The rigger has to warn the operator immediately if any unusual or dangerous
situation that due to its characteristics might cause damage or injuries to the
personnel.
During his walks through the working points, the rigger must have special
caution with openings, slopes, equipment or any other condition that might
cause an accident.
Direct the download, lifting, transport and positioning maneuvers of the load,
as secure as possible for the personnel, equipment, materials and the
installations involved.
For all the lifting works over 10ton, a special work permit must be emitted
(green permit), which must be written and submitted 48 hours ahead to
POSCO company. The latter will check the work area.
This special permit (green permit), will be written by SEIL E&C CO., LTD.
Authorized and trained personnel (Rigger) will check and calculate all the load
and the crane endurance points.
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DEMAG 400 Ton CRANE CC 2400-1
Doc. No. : PWI-EQ-008
Rev. : F
Page: 8 of 26
In case of Korean Riggers, they must be informed of all these activities, include
bilingual RCS.
4. RISK CLASIFICATION
General Considerations:
4.1. Types of associated risks: During the development of the tasks, there are the
following potential incidents risks:
Fall of the personnel at same level
Fall of the personnel at different level
Hit by
UV Radiation
Overstrain
Cuts
Crushing
Electrocution
Fall of particles
Hit against
Noise exposure
Risk of fire, explosion
Fall of materials
Rollover
Impalement
Entrapment
5. PERSONAL PROTECTIVE EQUIPMENT REQUIRED
All personnel involved in the work must wear the following personal protective
equipment which will be certified:
Safety helmet
Safety harness
Security glasses with lateral UV protection
Leather gloves
Security shoes
Reflective vest
Ear protections
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TRANSPORT, ASSEMBLY AND DISASSEMBLY OF TEREX
DEMAG 400 Ton CRANE CC 2400-1
Doc. No. : PWI-EQ-008
Rev. : F
Page: 9 of 26
Specific PPE
6. EQUIPMENT, MATERIALS AND TOOLS TO BE USED
Materials, tools and machines:
Steel wire rope
Slings
Chain Slings
Shackles
Crane
Signage
90 Ton Crane
7. REFERENCES
7.1. SISP-010 General Lifting Procedure.
7.2. PWI-EQ-007 Tandem Works.
7.3. 5PG-0101-023 Assembly and Disassembly of 600/800 ton Crane.(For
reference only)
7.4. 5PGP-0101-020 Trucks Loading and unloading.
7.5. CCR-SEC-POC-E-SE-0078 Cross Street. (Heavy vehicles)
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Rev. : F
Page: 10 of 26
8. WORK INSTRUCTIONS
8.1. General descriptionThe present instruction is applied to the transportation maneuvers and the
Terex Demag 2400-1 Crane main boom assembly, from its location at the
international yard to the north side of Boiler 2. This transport will be executed
by moving the equipment by its own means. At the final layout, the crane will
be assembled to achieve a configuration with the 72 meters Main Boom. A 90Ton
mobile Crane will be used. The main boom sections will be loaded at their
location and transported to the assembly area.
8.2. Prior Activities
8.2.1. For the transport activities, a special consideration must be taken on the weight
of the equipment (120 Ton) and its main dimensions for its transport,
considering the height and width to prevent interferences (equipment width
8400mm).
8.2.2. Perform the coordination and necessary information regarding the
transportation. Communication with other subcontracts.
8.2.3. To cross the Sptima Industrial N/N Avenue Street with the equipment,
closing it must be considered. Install signage. (According to the CCR-SEC-POC-
E-SE-0078 procedure for crossing the street with heavy vehicles).
8.2.4. 2 signalmen must be there for support, keeping a distance of 10 meters from
the equipment during the cross, on both sides (North-South). Besides signaling
the entrance area.
8.2.5. Install a protection system (made by wood) to prevent the continuous track
system from damaging the asphalt pavement at the main street (see figure
1: 1200 mm broad track system)
8.2.6. For the safe transport of the equipment, 2 signalmen must be included to guide
the crane from the international yard to the north coast from Boiler 2. (See
figure 7: Layout transportation)
8.2.7. Include the areas where all the equipment transporting the elements for the
crane will circulate to its final position on the movement layout. It is necessary
to make known this information.
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8.2.8. Check for possible interferences with the course, prior to authorize the
movement of the Terex Demag AC 2400-1 400 Ton Crane.8.2.9. If necessary, execute refilling or leveling of terrain to enable a safe transport
of the equipment.
8.2.10. Enable the area for the final location, considering the area the boom will
project during the assembly operation. Execute closing of the perimeter to be
used.
8.2.11. Provide an auxiliary mobile Crane for the erection of the main boom of
the Terex Demag 400 Ton Crane.
8.2.12. Perform the assembly of the main boom according to the directions on
the Terex Demag AC2400 Crane manual. (Attachment 2)
Protection of continuous track crossing the street
Figure 1. Asphalt pavement protection system (Wooden plates)
8.3. Safety Considerations
8.3.1. Before starting any maneuver, make sure that the crane as well as the boom
are on a leveled and compacted surface. Working on uneven ground can
cause accidents.
8.3.2. After leveling and compaction, there must be a record of the values
obtained in the compaction of the ground where the crane will operate.
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Rev. : F
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8.3.3. The boom must be placed over the ground, supported by brackets. In the
Crane operation area, steel plates with 50mm of thickness will be installedfor the correct support of the crawlers of the crane.
8.3.4. If there are other equipment close to the crane operation area, the RCS
information must be exchanged with close equipment.
8.3.5. Before erecting the boom, it is necessary to check all the structural
elements of the boom, verifying that no damage exist. These damages are
often produce due to transportation, load and unload.
8.3.6. Check all the cables, cable connections and joints. Verify that they are not
bent and do not have deformations. These deformations are considered as
severe damage.
8.3.7. For the load and unload, use lifting elements in good conditions. Slings,
wire-rope slings and shackles must be checked by a competent personnel.
8.3.8. For the boom assembly process, its sections must be correctly placed on
supports.
8.3.9. Verify the correct installation of bolts, pins and locks, according to the
manual and owners indications for the equipment.
8.3.10. When executing positioning maneuvers of the boom sections, it must be
considered that the wind speed do not exceed 30 Km/h.
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8.4. Assembly activity development, Main Boom Crane Terex Demag CC
2400-1 Test.8.4.1. All safety considerations must be known and implemented prior starting the
activity. Delimit the crane assembly area.
Figure 2.Terex Demag AC 2400-1 400 Ton crane assembly area. (Northern sector,
boiler 2)
8.4.2. The transportation must be executed in a transport properly authorized
(Trailer). Place the pieces in the area designated for the assembly.
8.4.3. Set out a 90Ton crane to load and unload the main boom sections from the
transport.
8.4.4. By using the crane, lay out the elements in the area in order to make expedite
the posterior erection of the equipment, according to the manufacturer
manual.
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8.4.5. The tail and the head of the main boom must be installed by using a 90Ton
crane.
Figure 3. Installation of the head and tail of the main boom. (For reference only)
8.4.6. Install the intermediate sections to accomplish a 72 meters configuration. To
allow easier connections of the upper pins, install the slings with a slight
inclination so the connection of the pins of the upper part can be easier.
Figure 4. Installation of the main boom with a supporting 90Ton crane. (For
reference only)
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Figure 5.Boom Terex Demag AC2400-1 crane.
8.4.7. Check that all pins, clamps and cotter pins are properly installed, according
to the information given by the manufacturer and executed by competent
personnel.
Figure 6. Elements to be examined during the boom assembly stage
8.4.8. Once the superior pins are connected, slightly loose the supporting crane
to allow the perforations on the lower pins get aligned and finally, proceed
to connect the lower pins.
8.4.9. Support the edge on the brackets. Repeat the installation sequence by using
an auxiliary tail crane.
8.4.10. Connect the steel wire between the guide pulley and the top of the boom.
8.4.11. Before lifting the boom, check the safety recommendations.
8.4.12. Lift the main boom.
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8.4.13. For all the lifting maneuvers of the elements that constitute the boom, a
particular lifting plan must be executed.8.4.14. When the boom installation is completed according to the indications of the
manual attached, the following task will be to execute the equipment load
test.
8.4.15. The crane load test will be performed with a 72mt. (67) boom length and
a 28m working radius. The weight of the test will be 40ton. This will be
achieved by using two 20Ton counterweights.
8.4.16. 1 Steel wire ropes with a load capacity of 89.6 ton and 1 shackles
with a load capacity of 68 ton. will be used. These elements must be
checked by competent personnel and they must have their corresponding
certifications.
8.4.17. The load test will last 20 minutes where the 40 ton. weight is lifted and
maintained one minute.
Figure 7 Load Test Configuration.
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8.4.18. Change of hook 400 ton Crane
Hook Hook Block Type 300-200, 300 ton (165.45 kip)capacity.
8.4.19. Define the area where the change will take place, making sure that the area
where the crane will be located is leveled and compacted in order to ensure
the stability of the equipment.
8.4.20. Lower the main boom of the crane in line with the engine room, until it is
horizontally to the ground (0).
Figure 8.
8.4.21. The cable has to be completely retracted to the head of the crane.
8.4.22. Release the lock of the cable and remove the cable from the pulley block
installed.
8.4.23. Remove the existing hook. The hook that will be replaced must be located
in a zone close to the projection of the boom by maneuvers, supported by
crane or boom truck.
8.4.24. Place the new hook, reeve the cable in the pulley block in accordance with
the wanted configuration by using 3 sheaves.
8.4.25. Lift the main boom again and tensioning the cable.
8.4.26. Change of configuration to SWSL (Superlift Mast assembly, 72m
Main boom and 48m Luffing Fly jib).
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Figure 9. SWSL configuration.
8.4.26.1. Lower the 72 m main boom until reaching a horizontal position.
8.4.26.2. Main boom disconnection by using a 130ton or 90ton tail crane, when
appropriate. The pins connecting the boom with the carbody of the
crane will be disconnected by maneuvers.
8.4.26.3. Place the main boom on one side of the crane. Position it on supports
that secure its stability. This maneuver will be executed by using a
130ton or 90ton tail crane.
8.4.26.4. Locate the mast of the superlift in front of the crane.
8.4.26.5. Locate and connect the mast of the superlift by pins to the carbody by
using a tail crane.
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Figure 10. Superlift mast assembly.
8.4.26.6. Make hydraulic and electric connections of the superlift mast.
8.4.26.7. Connect pendants to the mast of the superlit.
8.4.26.8. Check the status of all connections.
8.4.26.9. Once all the connections are checked, rise the mast of the superlift by
using the equipment of the 400ton crane.
8.4.26.10. Locate and connect the main boom to the carbody by pins by using a
tail crane. (See instructions on 8.4.5. and 8.4.6.).
8.4.26.11. With the help of the tail crane, the traversa will be connected to thependants of the main boom.
8.4.26.12. Connect the head of the main boom by pins to the tail of the Luffing Fly
Jib.
Figure 11.
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8.4.26.13. Install the sections necessary to achieve the configuration of the 48m
Luffing Fly Jib.8.4.26.14. Connect by pins with the tail crane the WO and WU type supports.
8.4.26.15. The WO support will be connected to the pendants of the Luffing Fly Jib
extension.
8.4.26.16. The WU support will be connected to the pendants of the main boom.
Figure 12. WU/WO support to the side.
8.4.26.17. With the H1/H2 winch the main lifting cable will pass through the
sheaves.
8.4.26.18. With the W1 winch of the superlift mast, the cable will pass through the
upper sheaves of the WO and WU supports.
8.4.26.19. Locate the WU support to connect by pins with the backstop cylinder.
8.4.26.20. With the E winch of the machine, position the superlift mast backwards
to achieve a 15m radius.
8.4.26.21. Connect the cylinder of the mast of the superlift to the counterweight
weight by pins.
8.4.26.22. Connect the base electrically to the base of the counterweight.
8.4.26.23. Install the 80ton counterweight configuration.
8.4.26.24. With the W2 winch, the main boom have to be lifted until reaching a
67 with the extension.
8.4.26.25. The displacement of the Luffing Fly Jib will be executed on ground level
by using the transportation system (runner).
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8.4.27. Once verified the 67 on the computer of the machine, verifications have
to be made to later take the boom to its working degree.
8.5. General Considerations
8.5.1. All the changes on the configurations made on the crane must be done
in compliance with the indications of the manual of the crane.
8.5.2. In order to have access to the connection point, scaffoldings or ladders
have to be installed if needed, in accordance with scaffolding assembly and
disassembly procedure.
8.5.3. Different equipment for the transport, load and unload of the elements
of the crane will be used, as well as tail cranes for the changes of
configuration of the crane.
8.5.4. Load-bearing capacity of the ground. The permitted load on the ground
is determined by the type and condition of the ground. Information on
permitted ground pressures can be found, for example, in the standard DIN
1054 on permitted ground loads contained in the following table:
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Work Instructions
TRANSPORT, ASSEMBLY AND DISASSEMBLY OF TEREX
DEMAG 400 Ton CRANE CC 2400-1
Doc. No. : PWI-EQ-008
Rev. : F
Page: 22 of 26
Table (extracted from DIN 1054). In our case is D.
If doubts exist with regard to the load-bearing capacity of the ground, an examinationof the ground must be carried out.
Safety clearance from slopes or ditches (Z 41 655, Z 59 255)
A sufficient safety clearance must be maintained from slopes or ditches. This depends
on the type of ground.
Type of groundPermitted ground
pressures (N/cm2)
1. Organic ground in general:
Peat, sapropel, marshy ground
2. Unsealed loose ground: rubble, etc.
3. Non-cohesive ground:
Sand, gravel, stones and mixtures of the same
4. Cohesive ground:
a) Coarse clay, mixed with for example native soil
b) Clay, consisting of weathered and hanging loamc) Fertile clay comprising clay and filling
Rigid
Semi-hard
Hard
d) Mixed grain soil: clay to sand,
gravel and stones areas
Rigid
Semi-hardHard
5. Rock, evenly firm:
Brittle, with weather traces
Not brittle
0
0 10
20
12
13
9
14
20
1522
33
150
400
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Work Instructions
TRANSPORT, ASSEMBLY AND DISASSEMBLY OF TEREX
DEMAG 400 Ton CRANE CC 2400-1
Doc. No. : PWI-EQ-008
Rev. : F
Page: 23 of 26
This clearance can be defined precisely in accordance with DIN 4124. As a general
rule: The clearance a" from the outside edge of the outrigger pad (or support) to the
edge of the embankment must never be less than 2 m.
8.5.5. Option for controlling the Driving Speed. (See annex 3)
8.5.6. Driving without load on the horizontal and angled. (See Annex 3)
8.5.7. Driving without load on a horizontal and graded road surface. (See Annex 3).
8.5.8. Transportation inside the project facilities. In order to execute
movements of the assembled crane, the instructions from the vendors manual
attached regarding the allowed transportation angles must be considered
(Annex 4 Part 6: Transportation of crane on crawlers). It is not recommended
the use of steel plates for the transportation of the crane since when the crane
makes turns, the crawlers might get outside the surface of the plates,
provoking sudden movements in the crane. (Recommendation from the
specialist vendor)
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Work Instructions
TRANSPORT, ASSEMBLY AND DISASSEMBLY OF TEREX
DEMAG 400 Ton CRANE CC 2400-1
Doc. No. : PWI-EQ-008
Rev. : F
Page: 25 of 26
9. SAFETY AND PREVENTION
a) The supervisor and/or foreman will notify all the personnel involved. Keeprecords.
b) Count with the JSA documentation, special permits, etc. required according
to the project standards.
c) Coordinate and inform the activity to prevent interferences in the activity.
d) Check that all the elements are available in the site.
e) Isolate the areas that will be used for the activity.
f) All translations must be guided by signalmen properly instructed and
certified for the activity.
g) Identify if there are any cables or pipes that might be damaged due to the
activity.
h) Maintain quick contact with the work areas.
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Work Instructions
TRANSPORT, ASSEMBLY AND DISASSEMBLY OF TEREX
DEMAG 400 Ton CRANE CC 2400-1
Doc. No. : PWI-EQ-008
Rev. : F
Page: 26 of 26
10. ANNEX
Annex 1: Training Record.Annex 2: Manual: Terex Demag AC-2400-1 Crane.
Annex 3: Driving Conditions (Manual Instructions)
Annex 4: Transportation Conditions (Manual Instructions)
Annex 5: Risk Matrix.
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Training record for PWI(Project Work Instruction)
Cd. : PWI-EQ-008Rev. : FPage: 1 o f 1
Procedure Name (PWI Title): Transport and Assembly of Terex DEMAG 400 Ton. Crane CC 2400-1
Procedure No. (PWI No.): PWI-EQ-008
The employee agrees to:
- Receive safe work instructions, training and coaching by the foreman or supervisor.
- Be reported timely and properly about the risks associated with the task, the correct work methods
and preventive measures by the foreman or supervisor.
- Be reported by the foreman or supervisor of the area about items, products and substances to be
used at work, besides the identification, permissible exposure limits, the health hazards and the
measures of prevention that should be adopted in order to avoid risks.
No. NAME C.I. (ID NUMBER) SIGNATURE DATE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
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ANNEX #2 Manual: TEREX DEMAG CC 2400-1 Crane
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ANNEX #3 Driving Conditions (Manual Instructions)
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5
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Z 58 905
3
12
2
1
95
97
110
98
ANNEX #4 Transportation Conditions (Manual Indications)
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Motor y accionamiento 5
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5.2.8 Observaciones para el funcionamiento
Evitar periodos de tiempo prolongados en marcha al vaco.Estos son dainos para el motor.
Preste atencin al indicador de reserva de combustible. Notrabaje nunca hasta vaciar el depsito.
Con el motor diesel en marcha tiene que estar conectadosiempre el generador a las bateras. Por este motivo no estpermitido aflojar las conexiones de cables durante el servi-cio.
5.2.9 Parada
(Z 58 905)
1. Colocar botn giratorio (110) y pedal acelerador (12) en posi-cin marcha al ralent.
Despus del funcionamiento del motor a plena potencia o atemperaturas del agua refrigerante muy altas debe dejar fun-cionar el motor durante 12 minutos a revoluciones en vacosin carga.
2. Pulse la tecla (95) hasta que se queda parado el motor.
3. Gire la llave de contacto (98a) en sentido contrario al reloj (aposicin 0) y extraiga la llave de contacto.
Al salir de la cabina de la gra debe quitar la llave de con-tacto y cerrar la cabina con llave.
5.3 Desplazamiento automatizado
(Z 58 905)
Accionando el interruptor (97) se cambia el equipo de mando dela regulacin de carga mxima a desplazamiento automati-zado.
As se garantiza un trabaja confortable, ya que no tiene que aju-star de manera adicional las revoluciones del motor.
Una vez accionada la tecla (97) se ajustan las revoluciones mxi-mas del motor deseadas mediante el botn giratorio (110). El pe-dal (12) se encuentra fuera de servicio. Las revoluciones del mo-tor diesel se ajustan sin escalonamiento accionando para ello lapalanca de mandos correspondiente (1,2,3,).
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6
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Z 53 139
n
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Desplazamientos de la gra sobre orugas 6
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6 Desplazamiento de la gra sobre orugas
6.1 Informacin general
Accionamiento:
Cada oruga es accionada por un motor hidrulico a travs de uncuerpo de planetarios. Cada lado se puede accionar sin escalo-namiento por separado y en direccin contraria.
Frenar:Para refrenar el movimiento se utiliza un freno de trabajo hidru-lico, libre de desgaste.
Cada cuerpo de planetarios viene equipado con un freno de ven-tilacin hidrulica cerrado por fuerza de muelle.
Vehculo de contrapeso (a peticin del cliente):La gra sobre orugas puede utilizarse con o sin vehculo de con-trapesos. Para la descripcin del vehculo de contrapesos, ascomo para el ajuste de los distintos parmetros necesarios al re-alizar desplazamientos con el vehculo de contrapeso, consultecaptulo 16.
6.1.1 Direccin principal de desplazamiento
Las palancas de mando (1 + 2 o 3) para el manejo del meca-nismo de traslacin sobre orugas inician nicamente movi-mientos adecuados, cuando la superestructura se encuen-tra en posicin de direccin principal de desplazamientocon respecto aal chasis.
La direccin de desplazamiento hacia adelante en posicin desuperestructura de 0,0 (N, Z 53139) hacia el chasis o la ruedamotriz es la direccin principal de desplazamiento.
No existe ninguna relacin entre la capacidad de carga de la gray la direccin principal de desplazamiento.
ANNEX #4 Transportation Conditions (Manual Instructions)
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Desplazamientos de la gra sobre orugas 6
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6.1.2 Caractersticas necesarias de la carretera
La carretera debe ser plana y de una capacidad de carga sufi-cientemente alta. Al realizar desplazamientos en distintos esta-dos de montaje exsiten ngulos mximos de subida y bajada endireccin de desplazamiento, as como valores lmite de inclina-
cin transversal de la carretera. Hondonadas y cimas en la carre-tera deben ser eliminadas con medidas adecuadas, por lo me-nos en el rea del carril de circulacin. (mediante colocacin dearena o grava; quitando suelo y aplanndolo a continuacin)
6.1.3 Normas para desplazamientos
Preste atencin a una altura de paso suficientemente alta,as como a cables elctricos en el aire, en caso necesario co-loque una persona indicadora fuera de la gra.
Al realizar desplazamientos en terreno desigualado cerca decables elctricos en el aire, debe asegurarse, que en caso deoscilacin del sistema de plumas se sigue manteniendo la di-stancia de seguridad necesaria de 10 m.
El cambio a la dierccin contraria de desplazamiento debe
realizarse siempre con la gra completamente parada.
Controle contnuamente la temperatura del aceite hidrulico,de los reductores de traslacin y de las poleas de rodadura.
Debe mover la gra si es posible con el accionamiento tra-sero, con respecto a la direccin de desplazamiento (espe-cialmente durante desplazamientos sobre terreno en pen-diente).
Antes de pasar un puente, asegrese que tiene la capacidadde carga suficiente para el peso de la gra.
Mantenga una distancia de seguridad de taludes y hoyos!
Para evitar daos en los mecanismos de traslacin sobreorugas debe evitar en todo caso girar encima de zanjas yhondonadas.
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6
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Z 40 520 Z 40 521
Z 40 522 Z 40 523
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Z 00 025
Z 39 428
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Desplazamientos de la gra sobre orugas 6
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6.2 Manejo del vehculo de orugas
6.2.1 Movimientos de direccionamiento
(Z 00 025)
Con las palancas de mando (1 y 2) pueden realizarse los movimientos de
direccionamiento reflejados en la imgen Z 00 025.En las distintas posiciones pueden iniciarse los moivimientos de desplaza-miento siguientes:
Pos. Desviacin de laspalancas de mando (1
+ 2)
Movimiento delos mecanis-
mos de trasla-cin
Movimiento del vehculode orugas
izquierda(1)
derecha(2)
iz-quierd
a
dere-cha
1 haciaadelante
hacia ade-lante
ade-lante
ade-lante
Hacia adelante
2 atrs atrs atrs atrs Hacia atrs
3 atrs hacia ade-lante
atrs ade-lante
Giro a izquierda en elmismo lugar
4 hacia
adelante
atrs ade-
lante
atrs Giro a derecha en el mismo
lugar5 hacia ade-
lante ade-
lanteCurva izquierdahacia adelante
6 haciaadelante
ade-lante
Curva derechahacia adelante
7 atrs atrs Curva derechahacia atrs
8 atrs atrs Curva izquierdahacia atrs
6.2.2 Movimientos de direccionamiento en funcionamiento Tailing
(Z 39 428)
Conectar el interruptor (74). Con la palanca de mandos (3) pueden reali-zarse los movimientos de mando reflejados en la imgen Z 39 428.En funcionamiento Tailing pueden realizarse nicamente desplazamientosen lnea recta.
Pos. Desviacin de lapalanca
de mandos (3)
Movimiento delos mecanis-
mos de trasla-cin
Movimiento del vehculo deorugas
iz-quierd
a
dere-cha
1 hacia adelante ade-lante
ade-lante
Hacia adelante
2 atrs atrs atrs Hacia atrs
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6
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Z 58 906
3 1 2
11 5 9
A A
B B
A
B
CD
53
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Desplazamientos de la gra sobre orugas 6
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6.2.3 Opciones de regulacin de la velocidad de desplaza-miento
(Z 58 906)
El mecanismo de traslacin dispone de dos niveles de velocidad.
El cambio se realiza mediante las teclas (5, 9, 11) en las palancasde mando (1, 2, 3).El ajuste sin escalonamiento de la velocidad final mediante la te-cla basculante (18) funciona tanto en marcha normal como enmarcha rpida.
Conexin de los distintos niveles de velocidad:
Marcha normal:
Tecla (5, 9, 11) no accionada.En el indicador de supervisin del motor y de trabajo de grano aparece ningn smbolo en la pos. 53
Marcha rpida:
Tecla (5, 9, 11) pulsada.En el indicador de supervisin del motor y de trabajo de graaparece en la pos. 53 el smbolo de marcha rpida.
Antes de iniciar el movimiento de traslacin tenga en cuentalo siguiente:
El mecanismo de traslacin se puede utilizar a cada nivel de ve-locidad de 0 hasta la velocidad de desplazamiento mxima. Paradireccionar la mquina, desplazamientos en terreno difcil, ensubidas y bajo carga debe seleccionar siempre la marcha nor-mal. La seleccin del nivel de velocidad debe realizarse siemprecon la gra completamente detenida.
Frenar:
Durante un desplazamiento normal se realiza la tarea de refre-nado por cierre parcial del paso del aceite que vuelve de los mo-tores. El efecto de frenado en marcha normal es ms grande queen marcha rpida.
Con el vehculo parado se refrena el mecanismo de desplaza-miento mediante bloqueo hidrulico de los motores y freno dediscos montados en cada accionamiento.
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Desplazamientos de la gra sobre orugas 6
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6.3 Desplazamiento sin carga sobre carretera horizontale inclinada
6.3.1 Informacin general
Mediante las posiciones de pluma reflejadas en las tablas que si-guen se alcanzan puntos de gravedad ptimos, que garantizanun reparto uniforme de la presin sobre el suelo.
El ngulo de pluma se mide mediante el sensor de ngulo mon-tado firmemente y se puede consultar en el indicador (20) mon-tado dentro de la cabina.
En este indicador de la cabina se visualiza siempre el ngulo ha-cia la horizontal. De esta manera se pueden realizar tanto des-plazamientos hacia arriba como hacia abajo con la misma posi-cin angular de la pluma.
A parte de la inclinacin del suelo indicada debe tener en cuentatambin la inclinacin transversal de la carretera.
Tambin debe tener en cuenta hondaduras y cimas en el suelo,an cuando realiza desplazamientos sin carga.
Modificaciones repentinas del punto de gravedad por inclinacinde la mquina deben evitarse, para evitar la oscilacin del gan-cho y su golpeado contra la pluma. gt.Este peligro es especialmente grande con la pluma en posicinempinada!
Sobre carretera plana puede desplazar la gra en marcharpida, independientemente de la opcin de pluma utilizada.
En caso de una pluma principal a niveles (opciones SH/LH ySSL/LSL) debe tener en cuenta siempre la longitud base pesada(SGL) de la pluma principal.
Unicamente al realizar desplazamientos en lnea recta es posibleun movimiento simultneo (Tailing).
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Desplazamientos de la gra sobre orugas 6
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6.3.2 Desplazamiento sin carga
Pluma en eje longitudinal de orugas
Equipo Ha HiA Inclinacin per-mitida
Condiciones / Limitacio-nes
HA + HiA72 m(236,23 ft)
85 65 10total* 3transversal
Pluma en lado de mon-taa
HA + HiA 72 m(236,23 ft)
85 65 5total* 2transversal
de pista de desplaza-
miento
Ausleger 360
Equipo Ha HiA Inclinacinpermitida
Condiciones / Li-mitaciones
HA + HiA72 m (236,23 ft) 85 65 3total*
HA + HiA72 m (236,23 ft) 85 65 2 total*
Leyenda:
HA = Pluma principal
HiA = Plumn auxiliar
= Angulo
= igual o inferior a = superior a
*total= Suma de inclinacin longitudinal y transversal, p.ej. inc-linacin
permitida 10en total = mx. 7inclinacin longitudi-nal y
mx. 3inclinacin transversal
La pluma tiene que ajustarse al ngulo indicado en la tabla, utili-zando para ello el mecanismo de retraccin o del mecanismo debasculacin 2.En la pantalla (28) se visualiza siempre el ngulo de pluma princi-pal hacia la horizontal.
El plumn auxiliar tiene que ajustarse mediante el mecanismo debasculacin W1 al valor reflejado en la tabla.En la pantalla (28) se visualiza el ngulo del plumn auxiliar hacia
la horizontal.Al cumplir el ngulo reflejado en la tabla resultan puntos de gra-vedad ptimos al realizar desplazamientos sobre carretera hori-zontal.Al desplazarse por subidas y bajadas pueden mantenerse losngulos reflejados en la tabla.
Al realizar un desplazamiento por una subida con la gra,tiene que colocar el sistema de plumas siempre en el ladode la montaa!
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Desplazamientos de la gra sobre orugas 6
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6.4 Desplazamiento con carga sobre carretera horizontale inclinada
6.4.1 Informacin general
Pueden realizarse desplazamientos con gra con todas lascombinaciones de pluma con carga.
A los desplazamientos con carga se aplican las tablas de ca-pacidades de carga y las observaciones a las tablas mencio-nadas.
Siempre debe mantener la carga a un radio ms pequeo po-sible y cerca del suelo al realizar el desplazamiento.
Desplazamientos con carga deben realizarse siempre enmarcha normal. Modificaciones de la direccin de desplaza-miento deben realizarse tan lentamente como sea posible.
Debe evitar en todo caso la oscilacin de la carga (si fuesenecesario amarre la carga).
El suelo tiene que ser plano y con una capacidad de cargasuficientemente grande (compare valores de presin sobreel suelo).
Desplazamientos con carga estn permitidos hasta una velo-cidad anemomtrica mxima de 9,8 m/sec (32,15 ft/s2).
Valores anemomtricos ms pequeos, reflejados en las tablasde carga correspondientes, deben tenerse siempre en cuenta.
Al realizar desplazamientos con la gra con equipo superliftmontado, debe prestar atencin que se ha levantado el con-trapeso de superlift.
Los interruptores de final de carrera del bastidor base delcontrapeso de superlift funcionan nicamente al trabajarcon la gra y no tienen ningn efecto sobre el mecanismo detraslacin. Por esta razn debe controlar contnuamente la
distancia del bastidor base a la carretera al realizar un des-plazamiento!Distancia mnima: 100 mm (3,9 inch)Distancia mxima: 400 mm (15,6 inchEn caso de posibles situaciones de estorbo durante el des-plazamiento tiene que ser posible bajar el contrapeso de su-perlift de manera uniforme y sin ms peligro! En caso nece-sario tiene que aplancar el suelo de la manera correspon-diente.
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7
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Z 53 143
A
Z 53 141
CC
18
3
Z 61 151
73
59
62
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Maniobras de giro y frenado de la superestructura 7
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7 Movimientos de giro y frenado de la superestructura
El accionamiento de cada mecanismo de giro se realiza me-diante un motor hidrulico con cuerpo de planetarios cerrado,con bao de aceite.
Freno de sujecin
En cada engranaje de giro se encuentra montado un freno dediscos bloqueable mecnicamente en posicin abierta, cerradopor fuerza de muelle y con ventilacin hidrulica, para el giro librede la superestrucutra. Este freno de discos es un freno de suje-cin que puede ser utilizado igualmente como freno de trabajodinmico.
El refrenado del movimiento de giro se realiza nicamente me-diante accionameinto de la palanca de mandos (3, Z 53 141)
7.1 Regulacin de la velocidad
La gra puede girar a dos niveles de velocidad.Marcha normal o marcha rpida.
Pulsando sobre la la superficie botn (73, Z 61 151) puedeconectarse la marcha rpida para el mecanismo de giro.
La velocidad de giro debe reducirse a condiciones determinadasde trabajo (dependiendo de la altura del equipo de la gra y delmomento de carga).
La velocidad de giro mxima en marcha normal puede ajustarsemediante el interruptor de basculacin (18, Z 53 141) . Lapalanca de mandos (3, Z 53 141) ajusta siempre la velocidad degiro desde cero hasta la velocidad mxima de giro preajustada.Cuanto ms reducida la velocidad mxima de giro ms exacto sepuede regular la velocidad de giro.En el indicador (59, Z 61 151) se visualiza el valor mximoajustado mediante una flecha roja.La velocidad de giro mxima posible en marcha rpida de la
superestructura corresponde a 1,4 min
1
(1,4 rpm) en caso demotor diesel funcionando a revoluciones nominales.
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7
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Z 54 334
L R
Z 58 035
18
3
19
2
8
Z 61 151
73
59
62
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Maniobras de giro y frenado de la superestructura 7
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7.2 Girar
Funcionamiento normal
Pulsando la superficie botn (62, Z 61 151) se selecciona elmecanismo de giro. El freno de sujecin abre al desviar la pa-lanca (3. Z 58 035).
Girar hacia la izquierda (L, Z 54 334): Basclese la palanca(3) hacia la izquierda.
Girar hacia la derecha (R, Z 54 334): Basclese la palanca(3) hacia la derecha.
Marcha rpida
Pulsando la superficie botn (62, Z 61 151) se selecciona elmecanismo de giro. El freno de sujecin abre al desviar la pa-lanca (3).
Pulsando sobre la superficie botn (73, Z 61 151) se conectala marcha rpida.
Girar hacia la izquierda (L, Z 54 334): Basclese la palanca(3) hacia la izquierda.
Girar hacia la derecha (R, Z 54 334): Basclese la palanca(3) hacia la derecha.
Conectar el movimiento de giro con ayuda de giro:
Pulsando la superficie botn (62, Z 61 151) se selecciona elmecanismo de giro.Pisar el pedal (19, Z 58 035).El freno de sujecin del mecanismo de giro abre al desviar lapalanca de mandos (3) en la direccin deseada.Soltar lentamente el pedal.
La funcin ayuda de giro puede utilizar para determinar con
exactitud el inicio de un movimiento de giro, p.ej. al girar cercade una pared.
Posicionar equipo de la gra por encima de la carga
Pulsando la tecla (8, Z 58 035) en la palanca de mandos (2, Z 58035) se abre el freno de sujecin del mecanismo de giro. Elequipo de la gra puede posicionarse ahora encima de la grafijada en el equipo al iniciar la tarea de levantar la carga.
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7
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Z 58 035
18
3
19
2
8
Z 58 036
3 1 2
4 8
18 18
18
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Maniobras de giro y frenado de la superestructura 7
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7.3 Frenado de la superestructura
(Z 58 035)
Colocar la palanca de mandos (3) lentamente en posicincero.
No refrene la superestructura nunca conectando el movi-miento contrario.
El freno de sujecin por fuerza de muelle no sirve para refre-nar la superestructura.
Freno de sujecin
(Z 58 036)
El freno de sujecin se mantiene siempre cerrado al no realizarningn movimiento de giro.
El freno de sujecin se abre por:
desviacin de la palanca de mandos (3)
pulsando una de las teclas (4 o 8) en una de las palancas demando (1 o 2).
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7
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Z 54 604
A A
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7.4 bloqueo mecnico del freno de sujecin en posicinabierta
Antes de inicar esta tarea asegrese que no existen ob-stculos en el rea de giro!
Unicamente con la gra apoyada y en posicin horizontalest permitido bloquear el freno de sujecin en posicinabierta.
Con equipo superlift montado no est permitido bloquear elfreno de sujecin en posicin abierta.
Para permitir el movimiento automtico de la superestructura endireccin del viento al estacionar la gra durante un intervalode tiempo ms largo, tiene que encontrarse suelto el freno de su-jecin. Esto es especialmente importante en casos con plumnauxiliar montado.
Secuencia de trabajo
Para este trabajo tiene que posicionar una segunda persona enel mecanismo de giro. Esta persona debe tener contacto visualo por habla con el conductor de la gra.
1. Pisar el pedall (19)
2. Abrir el freno de sujecin, pulsando y manteniendo pulsadauna de las teclas (4 o 8) en las palancas de mando (1 o 2).
3. Empujar hacia dentro la palanca (A, Z 54 604) con el frenoabierto.
4. Soltar la tecla (4 o 8) el freno de sujecin se mantieneabierto, a pesar de desconectarse la presin hidrulica paraabrir el freno.
5. Soltar el pedal (19).
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Z 58 907
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Manejo de los dispositivos de seguridad 8
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8.1.1 Limitador de momento de carga (LPC)
El limitador de momento de carga sirve de ayuda de manejo.Este equipo informa al conductor de la gra sobre datos impor-tantes de la misma, como longitud y ngulo de pluma, altura decabeza de poleas, carga nominal, carga total suspendida de la
pluma, etc. y avisa al acercarse la gra a un estado de sobre-carga.
Este equipo de seguridad no sustituye la capacidad de deci-sin y la experiencia del conductor de la gra, as como laaplicacin de procedimientos de trabajo aceptados y segu-ros para el uso de la gra.El conductor de la gra sigue siendo el responsable para elmanejo seguro de la gra.
8.1.1.1 Funcin
Si se supera el momento de carga permitido / la carga permitidaal levantar carga o al bajar la pluma con carga, se desconectanlos movimientos de aumento del momento de carga, al igual quelos movimientos de reduccin del momento de carga y la tareade elevar carga suspendida del gancho. Se permite el movi-miento bajar carga suspendida del gancho.
PELIGRO DE ACCIDENTES!Queda prohibido estrictamente puentear el limitador demomento de carga para poder utilizar la gra a una cargasuperior de la premitida segn su capacidad de carga refle-jada en las tablas de carga! Est prohibido levantar carga con el limitador de mo-mento de carga puenteado !
El limitador de momento de carga debe activarse nica-mente en casos de emergencia. No utilice nunca el limitadoren el trabajo normal!Esto significa, que ANTES de levantar una carga el conduc-tor de la gra tiene que haberse asegurado, que no se super-ar la capacidad de carga de la gra al levantar la carga encuestin. Cargas demasiado pesadas, que superan la capa-
cidad de carga de la gra no deben levantarse a pesar de en-contrarse montado un limitador de momento de carga!
An sin carga debe utilizarse el equipo de la gra nica-mente en reas de capacidades de carga autorizadas parala gra.
Antes de levantar carga debe conocer su peso. El dispositivo desegruidad no debe utilizarse para determinar el peso de la carga(vase cap. 8.1.10)
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Z 58 921
14
80
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Manejo de los dispositivos de seguridad 8
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Antes de iniciar un trabajo tiene que ajustar el conductor dela gra el limitador de momento de carga a la configuracinactual de la gra. Esto significa, que cada cambio en la confi-guracin de la gra debe ser introducido en el limitador demomento de carga por el conductor de la gra.
Este ajuste se realiza mediante seleccin del tipo de funcio-namiento (descripcin detallada a partir de pg. 8.1.5).Para poder trabajar automticamente, tiene que encontrarseel limitador de momento de carga ajustado correctamente altipo de funcionamiento / a la configuracin de la gra actual.Confirmando la configuracin de la gra se responsabilizael conductor de la misma del ajuste correcto.
Una vez desconectado el estado de sobrecarga por el limitadorde momento de carga se pueden realizar movimientos de reduc-cin del momento de carga, para mover una carga suspendidalibremente hasta salir del rea de sobrecarga y volver a encon-trarse en el rea normal de trabajo. Para ello tiene que accionarla superficie de contacto (80) y el pedal (14). Los movimientos dereduccin del momento de carga deben ser liberados nica-mente, si de sta manera
no se produce ninguna situacin de peligro. Tnga en cuentasto antes de accionar la superficie de contacto (80) y el pedal(14).
Peligro de accidente lmites del limitador de momento decarga !A pesar de funcionar correctamente el limitador de mo-mento de carga, y encontrndose este ajustado a la confi-guracin de gra correcta, puede darse el caso que no fun-ciona el limitador en las situaciones siguientes:
capacidad de carga del suelo insuficiente en el lugar deestacionamiento de la gra
errores cometidos al apoyar
efectos del viento
traccin en direccin oblcua
efectos inmicos, p.ej. al realizar movimientos ridos dela gra y refrenar repentinamente
trabajos de montaje, al resultar cargas como demaisadopesadas, una vez que se encuentran colgando libre-mente de la gra
levantar en caso de sobrecarga mediante el mecanismode basculacin
al realizar un trabajo en conjunto con varias gras.
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incidence
EQ / DM / P
Run over P Disabling injury, but reversible in the short term (3 days maximum) 2 4 8 Medium
JSA, training on procedure,keep max
speed at 15 km/h, use a banksman to guide, walk
on authorized and clear routes.
1 2 2 Imperceptible
Hit by P Fatal or potentially fatal accident 8 4 32 High
JSA, Daily talk , delimitate work area, keep
safe distance when working, use PPE, keep
materials organized and use tools properly.
4 2 8 Medium
Roll over P Fatal or potentially fatal accident 8 4 32 High
JSA, daily talk, delimitate work area, keep safe
distance when working, place on safe and leveled
ground.
4 2 8 Medium
Exposure to U.V. P Disabling injury, but reversible in the short term (3 days maximum) 4 4 16 MediumUse sunblock, clothes with log sleeves and keep
continuous hydration.2 2 4 Low
Entrapment P Disabling injury, but reversible in the short term (3 days maximum) 2 4 8 Medium
JSA, walk on clear routes, keep organization and
cleanliness, training on procedure, keep roads
clear, signposting. Use appropriate PPE and tools
for the task. (helmet, gloves, safety shoes, dark or
clear safety goggles and reflective vest).
2 2 4 Low
Crushing P Moderate impact with associated legal requirements 2 4 8 Medium
JSA, daily talk, walk on clear routes, keepAST .
Charla diaria , transitar por vias despejadas,
mantener el orden y aseo
1 2 2 Imperceptible
Overexertion DM/P Disabling injury, but reversible in the short term (3 days maximum) 8 4 32 HighJSA, daily talk, max. Load of 50 kg., keep proper
posture when working, distribute load evenly.4 2 8 Medium
Exposure to U.V. P Fatal or potentially fatal accident 8 4 32 HighUse sunblock, clothes with log sleeves and keep
continuous hydration.4 2 8 Medium
Hit by P Moderate impact with associated legal requirements 2 4 8 Medium
JSA, daily talk, delimitate work area, keep safe
distance when working, use PPE, keep materials
organized, use tools properly.
2 2 4 Low
Crushing P Moderate impact with associated legal requirements 2 4 8 MediumJSA, daily talk, walk on clear routes, keep
organization and cleanliness.4 2 8 Medium
Exposure to U.V. P Disabling injury, but reversible in the short term (3 days maximum) 8 4 32 HighUse sunblock, clothes with log sleeves and keep
continuous hydration.2 2 4 Low
Fall at different level P Fatal or potentially fatal accident 8 4 32 High
JSA, walk on clear routes, keep organization and
cleanliness, training on procedure, keep roads
clear, use signposting. Use appropriate PPE and
tools for the task. (helmet, gloves, safety shoes,
dark or clear safety goggles and reflective vest).
4 2 8 Medium
Fal l at same l evel DM/P Disabli ng injury, but reversible i n the short term (3 days maxi mum) 4 4 16 Medi um
JSA, daily talk, walk on clear routes, keep
organization and cleanliness. In order to move on
safety meshes or metal framing there must be
wooden thick planks intalled over them.
2 2 4 Low
Exposure to U.V. P Moderate impact with associated legal requirements 2 4 8 MediumUse sunblock, clothes with log sleeves and keep
continuous hydration.2 2 4 Low
Overexertion P Disabling injury, but reversible in the short term (3 days maximum) 4 4 16 MediumJSA, daily talk, max. Load of 50 kg., keep proper
posture when working, distribute load evenly.2 2 4 Low
Installation of wire
straps/slings
Lifting structure (Boom)Mechanical handling of
materials, fall of objects
Handling of material,
works at heights.
Written by: Ronald Garrido Signature
HAZARDS IDENTIFICATION AND RISKS EVALUATION
EEC - CTN - P3- F/2
REV. A
Area(s): General Project Month: September 2014
Approved by: Rodrigo Ramrez Signature:
Risks Evaluation
Area Subsystem Specialty Activity Name Control Measures C P Final EvaluationIncidence Potential MR First Evaluation MRActivities Critical Tasks PROBABLE EFFECTS C P
Placing crane structure
on
definitive place
Protruding structures
and
equipments, and
vehicles
movement
Crane positioning
(crawler)
Manual handling of
materials, fall of objects
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Entrapment P Fatal or potentially fatal accident 8 4 32 High
JSA, daily talk, delimitate work area, keep safe
distance when working, use PPE, keep materials
organized, use proper tools. Do not walk under
suspended load.
4 2 8 Medium
Hit by DM/P Disabling injury, but reversible in the short term (3 days maximum) 4 4 16 Medium
JSA, daily talk, delimitate work area, keep safe
distance when working, use PPE, keep materials
organized, use proper tools.
2 2 4 Low
Fall at same level P Fatal or potentially fatal accident 8 4 32 HighJSA, daily talk, walk on clear routes, keep
organization and cleanliness.4 2 8 Medium
Exposure to U.V. P Moderate impact with associated legal requirements 2 4 8 MediumUse sunblock, clothes with log sleeves and keep
continuous hydration.1 2 2 Imperceptible
Overexertion P Disabling injury, but reversible in the short term (3 days maximum) 4 4 16 MediumJSA, daily talk, max. Load of 50 kg., keep proper
posture when working, distribute load evenly.2 2 4 Low
Fall at different level P Fatal or potentially fatal accident 8 4 32 High
JSA, walk on clear routes, keep organization and
cleanliness, training on procedure, keep roads
clear, use signposting. Use appropriate PPE and
tools for the task. (helmet, gloves, safety shoes,
dark or clear safety goggles and reflective vest).
4 2 8 Medium
Hit by DM/P Disabling injury, but reversible in the short term (3 days maximum) 4 4 16 Medium
JSA, daily talk, delimitate work area, keep safe
distance when working, use PPE, keep materials
organized, use proper tools.
2 2 4 Low
Fall at same level P Fatal or potentially fatal accident 8 4 32 HighJSA, daily talk, walk on clear routes, keep
organization and cleanliness.4 2 8 Medium
Exposure to U.V. P Moderate impact with associated legal requirements 2 4 8 MediumUse sunblock, clothes with log sleeves and keep
continuous hydration.1 2 2 Imperceptible
Hit by DM/P Disabling injury, but reversible in the short term (3 days maximum) 4 4 16 Medium
JSA, daily talk, delimitate work area, keep safe
distance when working, use PPE, keep materials
organized, use proper tools.
2 2 4 Low
Run over P Disabling injury, but reversible in the short term (3 days maximum) 2 4 8 Medium
JSA, training on procedure, keep max. Speed at
15 km/h, walk on clear routs, keep organization
and cleanliness, use signposting.
1 2 2 Imperceptible
Fall at different level P Fatal or potentially fatal accident 8 4 32 High
JSA, walk on clear routes, keep organization and
cleanliness, training on procedure, keep roads
clear, use signposting. Use appropriate PPE and
tools for the task. (helmet, gloves, safety shoes,
dark or clear safety goggles and reflective vest).
4 2 8 Medium
Hit by DM/P Disabling injury, but reversible in the short term (3 days maximum) 4 4 16 Medium
JSA, daily talk, delimitate work area, keep safe
distance when working, use PPE, keep materials
organized, use proper tools.
2 2 4 Low
Fall at same level P Fatal or potentially fatal accident 8 4 32 HighJSA, daily talk, walk on clear routes, keep
organization and cleanliness.4 2 8 Medium
Exposure to U.V. P Moderate impact with associated legal requirements 2 4 8 MediumUse sunblock, clothes with log sleeves and keep
continuous hydration.1 2 2 Imperceptible
Fall at different level P Fatal or potentially fatal accident 8 4 32 High
JSA, walk on clear routes, keep organization and
cleanliness, training on procedure, keep roads
clear, use signposting. Use appropriate PPE and
tools for the task. (helmet, gloves, safety shoes,
dark or clear safety goggles and reflective vest).
4 2 8 Medium
Fal l at same l evel DM/P Disabli ng injury, but reversible i n the short term (3 days maxi mum) 4 4 16 Medi um
JSA, daily talk, walk on clear routes, keep
organization and cleanliness. In order to move on
safety meshes or metal framing there must be
wooden thick planks intalled over them.
2 2 4 Low
Exposure to U.V. P Moderate impact with associated legal requirements 2 4 8 MediumUse sunblock, clothes with log sleeves and keep
continuous hydration.2 2 4 Low
Overexertion P Disabling injury, but reversible in the short term (3 days maximum) 4 4 16 MediumJSA, daily talk, max. Load of 50 kg., keep proper
posture when working, distribute load evenly.2 2 4 Low
Manual handling of
materials
Installation of wire
straps/ slings
Lifting, assembly of
components and
elements
Lifting, assembly of
elements and
components
Handling of materials
and equipment
Mechanical handling of
materials, fall of objects,
handling of
materials.
Leveling and Torque
BOILER
1AND
2
ASSEMBLYAND
TRANSPORTATIONOF400TONTEREXDEMAGC
RANE
Assembly and
Transportation
Transportation of
elements and
components
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Entrapment P Fatal or potentially fatal accident 8 4 32 High
JSA, daily talk, delimitate work area, keep safe
distance when working, use PPE, keep materials
organized, use proper tools. Do not walk under
suspended load.
4 2 8 Medium
Hit by DM/P Disabling injury, but reversible in the short term (3 days maximum) 4 4 16 Medium
JSA, daily talk, delimitate work area, keep safe
distance when working, use PPE, keep materials
organized, use proper tools.
2 2 4 Low
Fall of mat erial s DM/P Disabli ng injury, but reversible i n the short term (3 days maxi mum) 4 4 16 Medi um
JSA, daily talk, delimitate work area, keep safe
distance when working, use PPE, keep materials
organized, use proper tools.
2 2 4 Low
Fall at same level P Fatal or potentially fatal accident 8 4 32 HighJSA, daily talk, walk on clear routes, keep
organization and cleanliness.4 2 8 Medium
Exposure to U.V. P Moderate impact with associated legal requirements 2 4 8 MediumUse sunblock, clothes with log sleeves and keep
continuous hydration.1 2 2 Imperceptible
Hit by DM/P Disabling injury, but reversible in the short term (3 days maximum) 4 4 16 Medium
JSA, daily talk, delimitate work area, keep safe
distance when working, use PPE, keep materials
organized, use proper tools.
2 2 4 Low
Run over P Disabling injury, but reversible in the short term (3 days maximum) 2 4 8 Medium
JSA, training on procedure, keep max. Speed at
15 km/h, walk on clear routs, keep organization
and cleanliness, use signposting.
1 2 2 Imperceptible
Fall at different level P Fatal or potentially fatal accident 8 4 32 High
JSA, walk on clear routes, keep organization and
cleanliness, training on procedure, keep roads
clear, use signposting. Use appropriate PPE andtools for the task. (helmet, gloves, safety shoes,
dark or clear safety goggles and reflective vest).
4 2 8 Medium
Hit by DM/P Disabling injury, but reversible in the short term (3 days maximum) 4 4 16 Medium
JSA, daily talk, delimitate work area, keep safe
distance when working, use PPE, keep materials
organized, use proper tools.
2 2 4 Low
Fall at same level P Disabling injury, but reversible in the short term (3 days maximum) 8 4 32 HighJSA, daily talk, walk on clear routes, keep
organization and cleanliness.4 2 8 Medium
Exposure to U.V. P Moderate impact with associated legal requirements 2 4 8 MediumUse sunblock, clothes with log sleeves and keep
continuous hydration.1 2 2 Imperceptible
Fall at different level P Fatal or potentially fatal accident 8 4 32 High
JSA, walk on clear routes, keep organization and
cleanliness, training on procedure, keep roads
clear, use signposting. Use appropriate PPE and
tools for the task. (helmet, gloves, safety shoes,
dark or clear safety goggles and reflective vest).
4 2 8 Medium
Fal l at same l evel DM/P Disabli ng injury, but reversible i n the short term (3 days maxi mum) 4 4 16 Medi um
JSA, daily talk, walk on clear routes, keep
organization and cleanliness. In order to move on
safety meshes or metal framing there must be
wooden thick planks intalled over them.
2 2 4 Low
Exposure to U.V. P Moderate impact with associated legal requirements 2 4 8 MediumUse sunblock, clothes with log sleeves and keep
continuous hydration.2 2 4 Low
Overexertion P Disabling injury, but reversible in the short term (3 days maximum) 4 4 16 MediumJSA, daily talk, max. Load of 50 kg., keep proper
posture when working, distribute load evenly.2 2 4 Low
Entrapment P Fatal or potentially fatal accident 8 4 32 High
JSA, daily talk, delimitate work area, keep safedistance when working, use PPE, keep materials
organized, use proper tools. Do not walk under
suspended load.
4 2 8 Medium
Hit by DM/P Disabling injury, but reversible in the short term (3 days maximum) 4 4 16 Medium
JSA, daily talk, delimitate work area, keep safe
distance when working, use PPE, keep materials
organized, use tools properly.
2 2 4 Low
Fall of mat erial s DM/P Disabli ng injury, but reversible i n the short term (3 days maxi mum) 4 4 16 Medi um
JSA, daily talk, delimitate work area, keep safe
distance when working, use PPE, keep materials
organized, use tools properly.
2 2 4 Low
Transportation of
elements and
components
Installation of wire
straps/ slings
Manual handing of
materials
Lifting, assembly of
elements and
components
Lifting and assembly of
components
Handling of materials
and equipment
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Instructivo de Trabajo del Proyecto
TRASLADO, ARMADO Y DESARME
GRA TEREX DEMAG 400 Ton CC 2400-1
Doc.No. : PWI-EQ-008
Rev. : F
Pg : 2 DE 26
TABLA DE CONTENIDOS
Seccin Descripcin
1 Propsito
2 Alcance
3
4
5
6
Responsabilidades
Clasificacin de riesgo
Equipo de proteccin personal requerido
Equipos, materiales y herramientas a utilizar
7 Referencias
8 Instrucciones de trabajo
9 Seguridad y Prevencin
10 Anexos
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Instructivo de Trabajo del Proyecto
TRASLADO, ARMADO Y DESARME
GRA TEREX DEMAG 400 Ton CC 2400-1
Doc.No. : PWI-EQ-008
Rev. : F
Pg : 3 DE 26
1. PROPSITO
El propsito de este instructivo es definir el traslado, armado, desarme,reparaciones y cambio de configuracin de la Gra Terex Demag CC2400-1 dentro
de las instalaciones de la obra para la ejecucin de actividades de construccin de
la Planta Termoelctrica Cochrane para un desempeo consistente y seguro de los
trabajos.
2. ALCANCE
Este instructivo se puede aplicar a la ejecucin de trabajos de traslado, armado,
desarme, reparaciones y cambio de configuracin de la Gra Terex Demag CC
2400-1 para ejecucin de actividades de la construccin de la Planta Termoelctrica
Cochrane para un desempeo consiste y seguro de los trabajos.
3. RESPONSABILIDADES
3.1. Gerente de Obra
El Gerente de Obra es completamente responsable de la ejecucin de todos los
trabajos que se efecten en faena. Tambin es responsable de verificar que todos
los trabajos se desarrollen de acuerdo a este Plan de construccin, as como
tambin de gestar dichos trabajos de construccin. Es responsable de asignar
todos los recursos necesarios para desarrollar las actividades de manera segura.
3.2. Gerente construccin de proyecto
El gerente de construccin del Proyecto Cochrane es responsable de observar y
supervisar los trabajos de acuerdo al plan de construccin (CP).
3.3. Gerente de calidad de proyecto
El gerente de calidad de proyecto es responsable de revisar y supervisar de
acuerdo con lo acordado en este plan de construccin.
3.4. Departamento de construccin
Es responsable de obtener la aprobacin de este procedimiento, de difundido,
hacerlo conocido y aplicado por todo trabajador involucrado en la tarea referida.
Proveer recursos necesarios para cumplir este procedimiento de forma certera.
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Instructivo de Trabajo del Proyecto
TRASLADO, ARMADO Y DESARME
GRA TEREX DEMAG 400 Ton CC 2400-1
Doc.No. : PWI-EQ-008
Rev. : F
Pg : 4 DE 26
Proveer apoyo a miembros del equipo con el fin de conocer individual y
colectivamente su desarrollo cumpliendo con estndares de comportamientoesperados y metas asociadas a cero daos.
3.5. Departamento de HSE
Aconsejar las operaciones de los gerentes y a la lnea de supervisin con
respecto a la seguridad descrita en este procedimiento de modo que sea
implementado y realizado de forma correcta.
Aconsejar e informar que los estndares indicados en este documento sean
apropiadamente implementados.
Asistir en el entrenamiento de los trabajadores quienes utilizarn herramientas
cumpliendo con los estndares de este procedimiento.
Informar a los trabajadores de los resultados de accidentes e incidentes.
Informar a POSCO, preliminarmente, por medio de va telefnica sobre todos
los incidentes en el rea de trabajo y proveer informacin bsica de la
investigacin de estos incidentes durante las primeras dos horas.
3.6. Supervisor de Equipos Mviles
Responsable de dar cumplimiento a este procedimiento e instructivos que
pudiesen ser generados. Darlo a conocer al personal directo involucrado,
controlando su cumplimiento.
Mantener una copia de este procedimiento de trabajo en el terreno.
Mantener un registro auditable de la toma de conocimiento de este
procedimiento.
Velar por la salud e integridad fsica del personal presente en las tareas
resguardando y promoviendo el uso obligatorio de los elementos de seguridad.
Instruir a su personal a cargo en forma clara y precisa sobre las materias
consideradas en este procedimiento.
Controlar el cumplimiento de los elementos de proteccin personal y correcta
ejecucin de los trabajos de su personal a cargo.
Mantener y asegurar durante toda la jornada laboral, las condiciones sanitarias
bsicas en los frentes de trabajo (agua, baos).
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7/25/2019 Instruction- Transport, Assembly and Disassembly of Terex Demag 400 Ton Crane Cc 2400-1
73/129
Instructivo de Trabajo del Proyecto
TRASLADO, ARMADO Y DESARME
GRA TEREX DEMAG 400 Ton CC 2400-1
Doc.No. : PWI-EQ-008
Rev. : F
Pg : 6 DE 26
Dar a conocer este procedimiento en materia de seguridad y asegurar que el
personal involucrado en las tareas se encuentre en conocimiento de este. Verificar que las condiciones bajo las que se desarrollan estas tareas sean las
ms seguras y adecuada.
Controlar y revisar diariamente el Anlisis Seguro de Trabajo (AST).
En caso de identificar un factor de riesgo cualquier trabajador, sin importar su
posicin, tiene el derecho y el deber de paralizar los trabajos.
Informar inmediatamente a Posco sobre todos los incidentes ocurridos en faena
y entregar los antecedentes bsicos de la investigacin dentro de las 2 primeras
horas.
3.9. Conductores y/u Operadores (Trailer, Forklift etc.)
Tomar conocimiento y dar cumplimiento a lo establecido en este procedimiento.
Comunicar de forma inmediata a su supervisor directo de cualquier situacin
que impida su desempeo en las tareas encomendadas.
Utilizar de forma correcta los implementos de proteccin personal.
Realizar check list de los equipos antes de operar para realizar sus trabajos.
Portar siempre la licencia de conductor. Si el conductor tiene una licencia
inapropiada no podr operar el vehculo.
Respetar velocidad mxima de 15 Km/h.
Estar atento a las condiciones del trnsito respetando en todo momento las
sealticas establecidas en el proyecto.
3.10. Riggers.
El Rigger debe poseer una certificacin al da.
El rigger debe hacer cumplir toda la informacin entregada en el Plan de Izaje
de la Maniobra.
El Rigger debe poseer conocimientos tcnicos y prcticos referidos a los trabajos
con maniobras, manejo e izaje de cargas con gras. Apoya al operador de gra
en la direccin de maniobras mediante el uso de seales reglamentarias, silbato
y radio de comunicacin.
El Rigger debe contar con entrenamiento y capacitacin formal por un
organismo autor