REPAIRS IN MAINTEANACEopen_jicareport.jica.go.jp/pdf/12290987_02.pdfsuch as electromagnets or...

REPAIRS IN MAINTEANACE

Repair

Repair means responding to the breakdown of equipment and undertaking work to correct the problem in order to return the equipment to a working condition.

Before equipment can be repaired, you need to be aware that there is a problem! Therefore, there should be a clearly understood system for reporting faults and breakdowns and equipment users should be encouraged to report faults and breakdowns as soon as possible. If there is no back-up equipment, a breakdown will mean that the service the equipment was providing will come to a halt.

Simple repairs can be done by the in-house or external maintenance and repair team. If the equipment is repaired where it is used, it is important that the team is trained to work safely and that they don't create hazards for staff.

More complex repairs will be carried out by specialised maintenance personnel. In all these situations, it is important to keep equipment users informed of how long their equipment will be unavailable.

Some items of equipment will be found to be damaged beyond repair. For others, spare parts may no longer be available as the equipment has become outdated. These will have reached the end of their lives and must be taken out of service (decommissioned or retired) and be replaced if the service they provide is to continue. Equipment that is being decommissioned should be disposed of safely and according to proper disposal procedures.

Remember to update your records accordingly.

Maintenance is one of the largest controllable operating costs in capital intensive industries. It isalso a critical business function that impacts on commercial risk, plant output, product quality,production cost, safety, and environmental performance. For these reasons, maintenance is regarded in best practice organisations not simply as a cost to be avoided, but together with reliability engineering, as a high leverage business function. It is considered a valuable business partner cont ributing to asset capability and continuous improvement in asset performance.

The dilemma that many of us face (and mostly not of our own doing), is that we are managers in organizations which barely have sufficient resources to keep the plant working, let alone find ways of improving reliability. When this is the case, scarce maintenance resources are rationed and breakdowns consume resources first. Preventive maintenance suffers, which inevitably results in more breakdowns and the cycle continues. In addition to lost productivity through unplanned maintenance, the "fix-it-quickly" mentality promotes "band aid maintenance", or temporary repairs, that often exacerbate the situation. Temporary repairs take additional labour to correct, or in the worst case, fail before correction. Often in an effort to control costs, personnel numbers are reduced and morale declines as the fewer remaining personnel almost give up in despair. With this, work standards drop. The vicious cycle feeds on itself and gradually organizations become almost entirely reactive. This situation is depicted in Figure 1.

• More repeat work

• Backlog grows

• PM is missed

• More preventable failures

• Resources taken by Breakdowns

• Band-Aid Maintenance

• Morale Declines

• Head / Budget Reduction

• Standards fall Figure 1 the Vicious Cycle of Maintenance

In such organizations, it seems that the level of plant availability drops to the stage where it stabilizes at a low level - a level where it is not breaking down because it is not running; i.e. it is being repaired! For many, the obvious solution is to seek to increase personnel numbers. However, this approach is not often the best. In today's economic climate, the management culture is mostly focused on cost reduction and managers seeking only to increase staff numbers, rarely succeed. Today many Asset Managers are embarking on an improvement program focusing on improving the maintenance processes and increasing the effectiveness or productivity of asset and human resources. Improving maintenance processes involves process re-engineering and increasing resource effectiveness in the following way: � Removing all maintenance tasks that serve no purpose or are not cost effective. � Eliminating any duplication of effort where different groups are performing the same Preventive Maintenance (PM) to the same equipment. � Moving to a mostly condition based maintenance philosophy. � Adding maintenance tasks to manage economically preventable failure modes 1 that historically have been run to failure. � Spreading the workload around the technicians and operators.

The long-term vision is to adopt such process in a way that achieves this goal in a systematic way and which can remain as a ‘living program’ to capture the benefits of future learning and technical advances on a continuing basis.

An introduction to CRANES

What Is a Crane?

• A crane is a mechanism that uses a collection of simple machines to both raise and lower objects, and also move them horizontally. They are always equipped with at least a winder; cables, ropes or chains; and sheaves. Both sheaves and the winder are a form of pulley.

Lifting

• Cranes can use a combination of simple machines to gain mechanical advantage and lift objects. The first is the lever, used in the balance-style crane. The crane's beam is balanced at the fulcrum, allowing it to lift heavier objects with a smaller amount of force. The second is a jib-style crane, which uses pulleys to achieve mechanical advantage (but note that all cranes use pulleys--in this case, the pulleys are the main source of mechanical advantage). The third way a crane can lifts objects is by use of a hydraulic cylinder, either directly or in powering a balance or jib

Hydraulic Cranes

Hydraulic cranes come in a wide variety of styles and models, each one with a specific

purpose. This article will provide you with a brief introduction to these fascinating

machines.

Hydraulic cranes are heavy equipment used primarily for lifting. There are two basic necessities of their design: they must be able to lift a certain amount of weight and they must be able to do so while remaining stable. While cranes have been used throughout the centuries these days they feature a more technical design and there are several different types available. Each type of crane has its own strong points and weaknesses and as such is best suited towards certain types of applications. It is important to understand things when purchasing them so you have a good chance of making the right choice.

In order to lift such heavy loads, hydraulic cranes make use of three important parts, the lever, the pulley, and the hydraulic cylinder. The lever is basically a horizontal beam that acts as the fulcrum. When a heavy object is loaded onto the smaller end it may be lifted using a relatively small amount of force that is applied to the opposite end and in the opposite direction. Next there is the pulley, also known as a jib, which is a tilted strut that supports a pulley block. This fixed block has cable wrapped around it several times which is either pulled by hand or a machine. This way a force equal to the weight of the load is able to be created by using a mechanical advantage. Finally there is the hydraulic cylinder which lifts the load either directly or indirectly.

There are several different types of hydraulic cranes, and knowing the differences between them can help you to choose the best one for you.

• The railroad crane – is largely used for maintenance work on railroads, as such it has flanged wheels so it may travel upon the tracks. There are simple ones that may be mounted onto a rail car, or more complicated models that must be custom designed.

• The tower crane – is a modern balance crane that can be either fixed on the ground or attached to buildings or other structures. They are typically chosen for their height and lifting capacity and are an essential part of constructing tall buildings.

• The self-erecting crane – is a special type of tower crane that can actually lift itself from the ground which allows the next segment of crane to be placed. Thus they can be assembled easily without outside help.

• The telescopic crane – uses a number of tubes fitted one inside the other in its boom. A hydraulic system extends and compresses these tubes so that the overall length of the boom may be altered. These are best for short term rescue or construction jobs.

• The manual crane – is not in use as much since newer hydraulic cranes models which use electricity are available. However they are still sometimes used when power would not be possible or cost effective.

MOBILE CRANES

(a) Truck mounted

(b) Crawler mounted

(c) Rail mounted locomotive

(d) Floating cranes

(e) Sky cranes

Mobile crane (power driven) includes all type of traveling jib cranes, such as truck mounted, crawler mounted, and locomotive crane on rails. Mobile cranes are hoisting devices mounted on rubber tyred trucks, rollers or railroad wheels. Most of these cranes are full-rotating. Their mountings make them a distinctive group.

• Truck, crawler and locomotive cranes have now been highly developed for industrial use and they all have many possibilities of services to any plant or terminal that has heavy handling to do.

• The choice of crane, whether a truck, caterpillar or locomotive crane is a matter of determining the equipment which will perform the work most economically.

• Where greater flexibility of movement is needed, where clearance between buildings is sight, where there is free and dependable ground and where it is necessary to "walk close to the hob", a crawler or truck crane should be considered.

• A valuable characteristic of truck, crawler and locomotive cranes is the different ways in which a standard model can be put to use by the mere change of attachments, such as electromagnets or buckets for handling of bulk materials.

• Performances factors in which various cranes differ include lifting capacity, radius of operation, hoisting speed, speed of travel and speed of rotation of the boom.

• Lifting capacity of models usually purchased for industrial use ranges from 5 to 30 tonnes.

The radius of operation depends, of course, on the length of the boom. Auto-lift models with booms up to 18 m long are standard. Boom up to 30 m long are used on special work.

The group of trackless cranes is made up mainly of pillar cranes mounted on trucks, automobiles or tractors and intended for traveling on dirt, gravel and asphalt roads.

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EQUIPMENT SAFETY CHECKLIST

This checklist can be adapted for use to assist in the identification of potentially hazardous equipment.

Faculty/Dept _______________________ Location of machine_______________

Machine _______________________ Manufacturer_______________

Inspection Team______________________ Date of Inspection____________________

Information, Instruction and Safe Use

1. Are there written instructions covering:

a) any unusual hazards or complicated features? Y N N/A

b) where appropriate, emergency shutdown? Y N N/A

2. a) Has instruction in readily comprehensible form (written or

verbal) on all hazards been passed on to all those who use

the equipment?

Y N N/A

b) Have any written instructions provided by the manufacturer

been passed on to users?

Y N N/A

3. a) Have all users of the equipment been given adequate training

in correct use, risks and precautions?

Y N N/A

b) Are young persons (under 18s) given additional training and

instruction?

Y N N/A

c) Is a training record kept which verifies this? Y N N/A

4. Is the equipment being used in accordance with the

manufacturer’s instructions?

Y N N/A

5. If it has been adapted, is the adaptation suitable and safe? Y N N/A

6. Is the equipment used in an appropriate environment? (e.g.

ventilation, damp, flammable conditions)

Y N N/A

7. Does the location allow the equipment to be used safely?

(consider space around moving parts and possible distractions to

the operator)

Y N N/A

8. If the equipment may be moved, is the weight known? Y N N/A

9. a) Are the start and stop controls clearly marked? Y N N/A

b) Are other operating controls, and the contents of any

containers, clearly marked?

Y N N/A

10. Are there clear warning notices or markings (e.g. to wear PPE,

restriction on use, list of authorised users) where appropriate?

Y N N/A

11. Does any work equipment provided after 5th December 1998

conform with Community requirements (CE marked)?

Y N N/A

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Maintenance and Inspection

12. Is the equipment tested at appropriate intervals:

a) for electrical safety? Interval: ______________________

(refer to the Electricity at Work Regulations 1989)

Y N N/A

b) for any safety devices? Interval: ______________________ Y N N/A

13. Does the safety of the work equipment rely on correct

installation/re-installation (e.g. mobile scaffolds)?

Y N N/A

14. Could deterioration of the equipment lead to an unsafe

condition?

Y N N/A

15. a) Is the equipment inspected at regular intervals? Y N N/A

b) Are the inspections recorded? Y N N/A

c) Is there a register of persons competent to carry out these

inspections?

Y N N/A

16. If inadequate maintenance could cause the equipment, guards or

other protection to fail in a dangerous way, is there a system of

planned preventative maintenance, including where appropriate

the periodic replacement or refurbishing of items before they

reach the end of their useful life?

Y N N/A

17. a) Have clear maintenance instructions been given to those

responsible for maintaining the equipment?

Y N N/A

b) Have all maintenance operations been assessed for risk? Y N N/A

c) Is a register or other maintenance record kept? Y N N/A

Specific Hazards

18. Is protection adequate in relation to:

a) items falling from the equipment? Y N N/A

b) items being ejected? Y N N/A

c) overturning? Y N N/A

d) collapse? Y N N/A

e) overheating or fire? Y N N/A

f) disintegration? Y N N/A

g) explosion? Y N N/A

19. Is the equipment made stable where appropriate by bolting,

clamping or tying?

Y N N/A

20. Is there sufficient general and (where necessary) local lighting? Y N N/A

21. a) Is there protection against contact with hot or very cold

temperature, so far as appropriate?

Y N N/A

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b) If the possibility of such contact is unavoidable has

appropriate instruction and training been given?

Y N N/A

22. In the case of pressurised equipment, is there a written scheme

of examination? (This must be provided by 1.7.94 – Pressure

Systems and Transportable Gas Containers Regulations 1989).

Y N N/A

23. If gas fumes or dust is released when the equipment is used, is

there:

a) local exhaust ventilation, tested annually? Y N N/A

b) a COSHH specific assessment? Y N N/A

Dangerous Parts of Machinery

24. Are all dangerous parts of machinery adequately guarded? Y N N/A

25. Are all guards sound and in good working order? Y N N/A

26. Do guards permit an adequate view of the operation where this

is necessary?

Y N N/A

27. Is it difficult to bypass or disable guards? Y N N/A

28. Can the machinery only be started when a specific labelled start

device is used? (N.B. the normal cycle of automated machinery

is exempt from this requirement.)

Y N N/A

29. Is it impossible to start the machine just by resetting a safety

device?

Y N N/A

30. Is there a readily accessible stop device which stops the

machinery in a safe way?

Y N N/A

31. Where appropriate (i.e. where in a foreseeable emergency it

could help), is there a prominent, easily accessible emergency

stop device?

Y N N/A

32. Can controls be operated safely and easily? Y N N/A

33. Is there any system of work which ensures that nobody is in a

dangerous position when machinery is about to be started?

Y N N/A

34. Does the start device need to be activated to start the machine if:

a) the power fails? Y N N/A

b) a control or safety device fails to trip out? Y N N/A

35. If the power is isolated, does the machinery come to rest safely

without the possibility of access to dangerous parts?

Y N N/A

36. Can the equipment be securely isolated from power, to prevent

inadvertent reconnection:

a) by removing a plug from a socket which is easily visible to

the person at risk?

Y N N/A

b) by locking it off? Y N N/A

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Woodworking Machinery

37. Is suitable “limited cutter projection tooling” used where

necessary?

Y N N/A

38. a) Has the machine been assessed for the need to fit braking

devices?

Y N N/A

b) If braking devices are required, have they been fitted? Y N N/A

39. Is the safe working speed or the minimum saw blade diameter

displayed?

Y N N/A

40. a) Are anti-kickback devices fitted to planing machines? Y N N/A

b) If not, are suitable notices displayed? Y N N/A

Mobile Work Equipment

41. Are there clear and concise instructions forbidding the carriage

of persons on mobile work equipment, unless the work

equipment has been proved to be suitable?

Y N N/A

42. Has the equipment been assessed to ensure that all tasks can be

carried out safely? (Consider seat belts, falling object protection,

etc.)

Y N N/A

43. Is the work equipment fitted with Roll-Over Protection where

necessary?

Y N N/A

44. Is the drive shaft between the work equipment and any

accessory adequately protected against seizure and accidental

contact with the ground?

Y N N/A

Power Presses

45. a) Is there a system for thorough examination in place? Y N N/A

b) Are all examination reports retained and available for

inspection (2 years from date of examination)?

Y N N/A

46. a) Is there a system in place whereby a nominated competent

person carries out the inspection of guards and protection

devices as required by Regulation 33?

Y N N/A

b) Is the current certificate of inspection displayed by the power

press, and superseded certificates held for six months?

Y N N/A

Lifting Equipment

47. Is the work equipment classified as “lifting equipment”? Y N N/A

48. If “yes”, has an assessment under LOLER 98 been completed? Y N N/A

(Refer to Lifting Operations & Lifting Equipment Workbook for

guidance.)

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Summary

Action to be taken, in order of priority Action completed

(signature)

Date

Date by which action is to be taken: ______________________

Date for review (maximum interval 5 years): ______________________

Lead Inspector

Name: __________________________ Signature: _________________ Date: ___________

Manager Responsible for Action

Name: __________________________ Signature: _________________ Date: ___________

How to Maintain a Forklift Forklifts are the ideal equipment for moving heavy loads in an industrial

setting. As with every machine, the various mechanical parts of a forklift also

tend to wear out with continuous use. This wearing out process is especially

critical with the moving parts, thus necessitating the need for a stringent

forklift maintenance program.

Outlined below are a few points to help you create your own forklift

maintenance program.

1.

1

Keep all moving parts well lubricated. Most moving joints, or parts, of the forklift

are greased. This is done to prevent the harmful effects of friction. Ensure that all

these fittings are greased on a regular basis, making sure to remove all worn out ball

bearings.

2

Check fluid levels regularly. There are various fluids that help the engine and other

working parts of the forklift to run efficiently. These include the transmission and

hydraulic fluids, coolants, as well as motor oil. Check these fluids regularly, albeit

depending on how often the forklift is being used. Daily checks are necessary if the

forklift is used on a daily basis.

2.

3

Keep your forklift charged or fueled. Forklifts may be powered by battery, liquid

propane (L.P.) gas, diesel fuel or gasoline. If your machine uses a battery, then make

sure to ensure that the battery is fully charged always. Also, make sure the tank is

always full, if your forklift uses gas or fuel.

3.

4

Keep Forklift Gauges Functioning Properly. Gauges and lights found on the

instrument panel of the forklift give an indication when some part is malfunctioning.

Therefore, attention must be paid to these instruments and the appropriate

measurements taken, when they indicate any faults. Doing so will forestall more

expensive repairs.

4.

5

Keep Forklift Tires in Good Shape. In the process of forklift maintenance, another

important aspect that should be checked daily is the tires. If the tires use air, ensure

that the correct air pressure is maintained in them. In case the tires are solid rubber

ones, make sure that there are not any gashes present. Failure with the tires could lead

to an unbalanced ride, potentially leading to damage of the goods being carried.

FORKLIFTS

THE BASIC FEATURES OF A FORKLIFT.

Familiarize yourself with the picture below labelled with the important forklift features and also find a small description of them. We will now run through them individually.

• Mast: The mast is the vertical support that permits raising and lowering the load.

• Carriage: A support structure where the forks are attached or mounted.

• Back Rest: Attached to the carriage and prevents the load shifting backwards, it protects the mast cylinders hoses as well as preventing any goods falling through the mast and hitting the operator.

• Fork (Tynes): The cantilevered arms attached to the load carriages that engage the load.

• Lift Cylinder: Controls the amount by which the mast structure, forks and carriage may be raised or lowered in the vertical.

• Overhead Guard: A framework/roof, providing overhead protection for the operator from falling objects.

• Tilt Cylinder: Controls the amount by which the mast structure, forks and carriage may be tilted beyond the vertical position, forward or backward.

• Rating Plate: This is used to inform users of the maximum load a forklift can legally carry.

• Counter Weight: The weight installed by the manufacturer to give stability to the machine under load.

Since their introduction in the early decades of the 20th Century, lift trucks have increasingly played a powerful role in the recycling industry as well as more generally in materials handling. This article provides an overview of lift trucks, including their evolution, various types, and considerations for safe operation.

History of Lift Trucks

Powered industrial trucks, commonly called forklifts or lift trucks, first emerged in the late 19th Century. These were low lift trucks that raised platforms just a few inches high. Typically these were used for moving material within a shop, such as work-in-progress. High lift trucks first emerged in the late 1910s, and truck design improvements continued to take root. In the 1930s, tier trucks allowed the stacking of loads, allowing for greater storage efficiency.

Because of the tough economic times of the 1930s, however, labour was freely available while capital for investment was much harder to come by. This slowed the growth of forklift usage. Then in World War 2, the use of forklift trucks became a strategic part of the war effort. With manpower shortages resulting from wartime enlistment, the forklift and an operator (and increasingly female operators as the War progressed) could do the work of many men, dramatically increasing productivity. After the end of

World War ll, lift trucks emerged as a mainstay of material handling equipment.

There is a broad selection of lift trucks, designed to best meet the needs of various material handling applications. The seven major lift truck classifications in the U.S. include:

• Class I: Electric Motor Rider Trucks • Class II: Electric Motor Narrow Aisle Trucks • Class III: Electric Motor Hand Trucks or Hand/Rider Trucks • Class IV: Internal Combustion Engine Trucks (Solid/Cushion Tires) • Class V: Internal Combustion Engine Trucks (Pneumatic Tires) • Class VI: Electric and Internal Combustion Engine Tractors • Class VII: Rough Terrain Forklift Trucks

Load Capacity

The maximum weight (materials) a forklift can carry at a given “load centre”, with the mast held in a vertical position. The load rating is usually expressed in kilograms or pounds and the standard load centre in millimetres or inches. This will be presented on the rating plate which was shown in the forklift diagram in Part 1.

Load Centre

The load centre describes the distance from the face of the forks to the centre of gravity of the load. The centre of gravity of any object is the imaginary point about which the weight of the object is evenly distributed. Forklifts do not have a fixed centre of gravity, the centre of gravity moves as the machine performs certain tasks such as:

• Pick up or put down loads. • As a load is lifted and lowered, the combined centre of gravity will also

move up and down. • As the mast is moved forward and back, the combined centre of

gravity also moves forward and back. • As the mast is tilted forward and back, the combined centre of gravity

moves forward and back.

Stability Triangle

All forklifts regardless of size, weight or wheel quantity have a ‘stability triangle’. The stability triangle is the area under the forklift which it must keep its centre of gravity within for the truck to be stable. If the centre of gravity moves outside the stability triangle, the forklift will tip.

Maneuverability

Maneuverability is an extremely important topic that must be covered and understood when researching and learning about forklifts as it is typically overlooked until it is too late.

Tilting Angle:

The tilting angle is the maximum angle in which a mast can tilt forward and backward. The tilting angle varies when dealing with different forklifts, masts and attachments and is also limited at high mast to maintain truck stability. This is useful to know as depending on what materials you are carrying, you may require a higher tilt angle to ensure stable maneuverability and avoid any loss of loads.

Right Angle Stacking Aisle:

The right angle stacking aisle is the terminology to describe the amount of load a forklift can carry and turn to a 90 degree angle. When dealing with racking and loading your materials on to shelves this is the most important piece of information you need to know, as it will tell you the maximum load you can carry, it can also help by telling you the distance in which your shelving needs to be apart.

Gradeability:

The angle of a ramp/slop a forklift can travel up/down on. An important factor to take in to consideration is whether you forklift is carrying a load or not which will affect the gradeability.

Tyre maintenance is commonly overlooked and it is often confusing when it comes to knowing when to replace forklift tyres. Today we will determine when a forklift’s tyres need to be replaced and the importance of knowing when to replace them.

Forklifts need to be regularly serviced; there is no substitute for good maintenance. It ensures forklifts can perform at optimum levels; it can detect and rectify minor problems before they affect productivity, and will prolong a forklifts life. This week’s blog will look at the importance of maintenance and will provide maintenance schedules and tips.

If you are in the market for a forklift part, ensuring you purchase the correct one is important in guaranteeing the productivity of your business. This blog will highlight important tips you will need to consider when purchasing

forklift parts as well as the different benefits of new and used parts, which you can use as a reference when choosing between the two.

When running an efficient operation, it’s important to keep in mind the right time to replace older, less efficient forklifts. This can reduce your maintenance costs, improve your productivity and most importantly, save money and maximize your return on investment.

These pictures will explore the benefits of maintaining and replacing forklifts at the optimal time in order to maximise their efficiency and in turn increase your return on investment.

There are various types of forklift tyres but the most common are solid or pneumatic. Each tyre has a different tread, compound and ply rating which help to ensure the tyre used will best suit the application. By keeping your forklift tyres in good shape, you will reduce the stress and wear on the transmission as well as the forklift driver. Safety is also significantly improved, along with fuel efficiency.

Make Your Battery Last” is a two part series to educate you on the basics of forklift battery maintenance. In part one, we will discuss charging and maintaining a forklift battery and then continue through to part two, covering cleaning and safety with a quick summary to finish off.

Forklift Truck Maintenance

Forklift

Forklifts are an integral part of the distribution, warehousing and industrial industries. This equipment is intended to endure heavy use during many years of service. To maximize the effective lifespan of the equipment and eliminate costly down time, a proper service routine and schedule is essential.

Forklift Maintenance Checklist

How to Maintain a Forklift

Standard Maintenance

Propane and gas forklifts will require regular oil changes and engine filter changes. Unlike an automobile, a forklift's maintenance schedule is not based on the number of miles traveled. With a forklift, maintenance should be scheduled based on the number of hours of service. This requires daily hour meter readings to be recorded. Each model and style of forklift will have different requirements. Check the owner's manual to determine the manufacturer’s suggested maintenance schedule. On average a unit should be scheduled for maintenance every 200 hours of operational time. Keeping the oil and filters in good condition will help to increase the unit's motor life.

Hydraulics

Forklifts use a hydraulic system to raise and lower their loads. These systems have several major components that must be monitored closely. A hydraulic failure can result in not only costly material damage, but also personal harm to operators and others working in the area. Hydraulic hoses must be checked regularly for signs of cracking or excessive wear. If a problem is found, the forklift should be removed from service until repairs are completed. The hydraulic fluid levels need to be checked on a regular basis and the hydraulic filters should be changed based on the manufacturer's recommendations. Keeping the hydraulic system in good condition will help prevent down time, unsafe work conditions and will reduce wear and tear on many system components.

Tires

Depending on the terrain conditions where the forklift is being operated, forklift tires can have a very long lifespan. After a period of time the tires may begin to crack or separate from the rim. This must be monitored closely; in extreme cases it can adversely affect the forklift's overall stability. Very few in-house maintenance systems have the equipment necessary to remove and press on new tires. This will normally require an outside source to come in and perform the change-outs. To help reduce down time and increase the cost effectiveness of the change-out, all tires needing service should be replaced at one time, eliminating the need for multiple service calls.

How to Maintain a Forklift

A forklift is an industrial vehicle that has a pronged platform that can be raised

and lowered. Forklifts are ideal for moving heavy loads. Whether you use one

on your job or have one at home for occasional jobs, maintain it well and

prolong its life.

• Forklift Truck Maintenance

Instructions

o 1

Check the hydraulic fluid, motor oil and transmission fluid regularly in order to maintain a forklift properly. How often you check fluid levels will depend on how often the forklift is used. If used daily, then check daily. For occasional forklift use, weekly or monthly checks are sufficient.

o 2

Make sure that all grease fittings are greased regularly. On a forklift, this mainly includes all of the moving joints.

o 3

Keep the battery fully charged on an electric forklift. If your forklift runs on LP gas, make sure the tank stays full in order to maintain it efficiently.

o 4

Pay attention to the gauges and warning lights on the forklift. Any light or gauge that indicates a problem should be checked out immediately. Failure to do so could result in more costly repairs.

o 5

Inspect controls regularly. If the controls feel slack or loose, the forklift could need hydraulic fluid or there could be a leak in one of the lines.

o 6

Look at the tires daily. Some forklift tires require air. Others are just solid pieces of rubber. If the forklift tires require air, make sure the air pressure in the tires is correct. If your tires are just solid rubber, check for gashes in the tire. This could cause an unstable ride and possibly damage whatever you are moving

The Importance of Training and Safe Operation

Operator training is a requirement in much of the world, and with good reason. It seems that almost daily there are reports of injuries or fatalities involving operators of lift trucks or pedestrians in their proximity. Data from the Bureau of Labor Standards (which always lags) indicated 54 forklift related fatalities in 2010 where the forklift was the primary injury source and another 56 where the forklift was the secondary source.

Training Requirement

OSHA requires employers to "develop and implement a training program

based on the general principles of safe truck operation, the types of

vehicle(s) being used in the workplace, the hazards of the workplace

created by the use of the vehicle(s), and the general safety requirements of

the OSHA standard." By the end of training, operators must demonstrate

the ability to perform their job safely in their workplace evaluation. Training

involves formal and practical components. OSHA requires refresher training

every three years, as well as at any time that an operator demonstrates a

deficiency in safe lift truck operation. Safe Lift

Truck Operation

Safe lift truck operation involves several steps, including:

• Pre-Operation (pre-operation inspection and operational inspection, removal from service and maintenance requirements)

• Traveling & Maneuvering (safe travel practices and seatbelt use, tipover, mount/dismount, stop/start, speed, turning, navigating inclines, parking, and visibility.)

• Workplace Considerations (Physical conditions, ramps and grades, uneven terrain, loading docks, pedestrians, narrow aisles, elevators, and enclosed or hazardous areas.)

Maintaining Operator Safety after Training

The reality is that operators who are injured or killed on the job are usually trained. This is why effective supervision is an important component of safety programs, and that operator engagement be maintained through the development of an effective workplace safety culture.

The fast and efficient transfer of cargo between ships and land-based modes of transport is the goal of ports throughout the world. Customized ship to shore solutions is required to enhance the efficiency of traffic movement through all terminals where variations dictate the need for flexibility in design. The KPA range of port equipment offers a number of flexible options for access and for the management of traffic when loading or unloading ships.

Short harbour stop is a benefit to allow for cost saving operations at sea.

Thursday, August 24, 2017 1

.

SHIP TO SHORE GANTRIES OFFLOADING CARGO


NEW RUBBER TYRED GANTRY CRANES – AT THE

YARD


THANK YOU THANK YOU THANK YOU THANK YOU

THE END


Page | 1

INFRASTRUCTURE MAINTENANCE.

CONCRETE MATERIAL:

4.1 Introduction

Concrete is an intimate mixture of mineral aggregate and binding material such as

Portland cement. The aggregate should be clean, hard, and durable, Graded from

coarse to fine materials to increase density by filling voids. When strengthened

with steel rods in structures, it is termed reinforced concrete (R.C) and is more

widely used than any other material today. Its popularity over the last hundred

years has been due to many factors, not the least .Being the ease with which it

may be moulded, the concrete can simply be poured between shuttering or

formwork and left to set. Its great strength is largely due to the cement used in its

composition. The reader will need to know a great deal about this material and is

strongly urged to consult the many publications and periodicals dealing with the

subject.

Ordinary Portland cement is manufactured from limestone and clay ground

together with water to form slurry which is burnt to a high temperature and then

ground to powder. It is normally sold in 50kg paper bags. 100kg steel drums are

also supplied. These are superior I humid climates but of course are more

expensive. Apart from being cheaper and easier to handle, paper bags can be re –

used to provide shade and protection and sometimes has a re – sale value where

a paper is scarce.

There are several types of cement, normal Portland cement, which sets in a

matter of hours, being the most widely used. Quick setting cement can, however,

be manufactured if required. The quality of the cement should be tested

according to B.S. 12, especially if supplies are imported from new or previously

untried sources. Special cement used sometimes in humid conditions is called

hydrophobic cement. This can be stored quite safely in damp conditions for long

periods without becoming lumpy and is used in the same way as normal cement.

it is worth consideration in countries where ordinary cement on site may cost up

to three times factory price. When cement is scarce, air – set, or lumpy bags

should not be discarded altogether; they may be broken down with shovel and

used for temporary floors, loading bays, hard standings, and similar work

Page | 2

Aggregates are either crushed stone or gravel. Crushed stone is normally better,

but sand may have to be added. Hand – broken stone is very good if obtainable

and B.S.882 gives tests for suitable aggregates. Among other items they should

not contain loam, loose laterite, dirt, or be coated with fine dust. Some stone

quarries are equipped with washing plant for aggregates; if not the contractor

may have to set up his own where labour plentiful, the simplest way is to shovel

the stone into wicker baskets on to which water is hosed. The baskets are then

head – panned to the stockpile. This method has the additional advantage of

cooling the aggregate.

Coarse aggregate is that which is retained on a 4. 7 mm sieve, after the fine

aggregate has passed through. The normal size for reinforced concrete is 20 mm.

the particle size distribution of soils ranging from clay to boulders is shown in

chart form in Volume 2. The use of sea sand should be avoided if at all possible.

Pit sand is best but should be free from roots, loams, fibres, and vegetable growth.

Cool drinking water should be used for preference in the mixing. Sea water is

suitable for plain concrete but is apt to rust steel when used to make reinforced

concrete. It can also cause efflorescence. Aggregate exposed to strong sunlight

should be water – sprayed before use.

4.2 Storage

Stock piles of sand and aggregate should be as large as possible and the bottom

500 mm should not be used. The materials should not be dumped straight on the

ground. Laterite soil creates stains in the concrete which show in the finished

work. If a hard surface is not available, then a thin concrete slab should first be

laid. The sand and aggregate stock piles should be separated by a barrier of stout

planks or concrete block-work.

On large works, especially in hot sunlight or during rainy season, it pays to erect a

large single – pitch open shed or roof over the stockpile and the concrete mixer.

Hot materials make a poor concrete. Apart from keeping the material cool and

dry, a cover provides welcome shade for the concreting team.

Proper storage of cement is important. To dump the bags on dry ground next to

the concrete mixer may be In order in hot dry climates or at some times of the

Page | 3

year, but precautions may have to be taken against damp, humidity and , of

course, theft. A water proof sheet over bags on a concrete floor is not sufficient

protection. A shed, preferably without windows and with a door on the lee side

away from prevailing winds and rains, should be adequate. A boarded floor raised

above the ground on short pillars is desirable. Bags should not be stacked above

man – height and they should be used up in rotation. Where cement is imported

this is imperative.

Humidity can be a serious problem in some areas and to use bags quickly is the

best way to prevent cement from becoming lumpy. Another method is to use

hydrophobic cement, although it is advisable to get a laboratory – tested samples

first. Different types of cement should not be used together on the same site (see

also Volume 3)

4.3 Mixing

Concrete may be mixed by hand or machine. Manual mixing is common in many

areas. To obtain the correct proportion of materials a gauge box is usually used

(Fig. 4.2). Thus, for a mix of 4: 2: 1, four boxes of coarse aggregate, two boxes of

fine aggregate or sand, and one box of cement are measured out on a dry

platform or banker board and mixed together. The material should be turned over

completely with shovels twice and twice wet, where the use of local materials

render this possible. Water is added through a watering can or spray for good

mixing.

Gauge boxes are sometimes bottomless. In this case the empty box is filled level

with aggregate and lifted vertically. The pile is roughly levelled and the empty box

replaced on the pile and refilled as necessary. This is suitable when the materials

can be stockpiled near the mixing bay

Machine mixing is now practiced universally, and there is a wide range of suitable

equipment available. For medium – sized jobs, mixers are normally of two types –

tilting drum and non – tilting. A tilting drum has only one opening and the drum

may be raised or lowered as it revolves. It is fed by tipping the materials into

drum while it revolves in a raised position. The non- tilting drum has two openings,

one at the front and other at the back. Further reference to these is made in

Volume 2.

Page | 4

As the concrete is mixed in the drum, the dry materials are measured into skip or

hopper ready for the next batch. The wet concrete is delivered from the front

opening by means of a chute. After this has been done, the skip is raised

mechanically from the ground to enable it to empty the dry materials into the

back opening of the drum. After a short period of dry mixing, water is added in

the correct proportions. Mixing time varies, but is roughly about two minutes

altogether. The reader, however, is advised to check this with the maker’s printed

instructions

For efficient operation, proper maintenance and cleanliness is essential. The drum

should be thoroughly hosed out daily and the engine periodically maintained.

4.4 Batching

Tis operation is concerned with the measurement of dry materials and requires

careful attention. To measure quantities by the shovel is wasteful and inaccurate.

The simplest way of measuring materials is to use the gauge box (Fig. 4.2) which

can be made to the old imperial ft3

in volume, or the size can be worked out to

suit a 50 kg bag of cement. Thus, for a 4: 2: 1 mix, using a bag as a measure, the

box would be 0.071m3

in volume. This would give a cubic box with 420mm sides.

The mix would then consist of two boxes of coarse aggregate, one box of fine

aggregate and one bag of cement. Many building supervisors still prefer the old

single cubic foot box complete with bottom as it is uncomplicated, easily handled,

and can be used additionally for other proportions. Only one size of box should,

however, be in use on the site if confusions is to be avoided.

Some machine mixers are fitted with skips or hoppers which weigh the materials,

thus eliminating the need for measurement (see Volume 2). A large dial records

the weight of the cement, sand, and aggregate as each is placed in the skip. When

operated by a trained operative working under a capable site supervisor, it is

quick and effective. The weight of the materials, however, needs to be checked

daily against the volume as the moisture content can vary, particularly after heavy

rain or after washing the aggregate.

Weigh – batch mixers, however, are not popular in all areas and through

ignorance, this type of equipment is not always used, even though it may be in

good working order. Site supervisors employing illiterate crews often prefer to

use gauge boxes. To them this is not only an accurate and reliable measure, but it

Page | 5

overcomes the problem of having regularly to check and maintain the weighing

mechanism. Large projects, however, frequently have weigh – batch mixers.

Sometimes special mechanical hand shovels are also provided which scoop the

aggregate from the stockpile towards the mixer and load it directly into the skip

(Volume 2). This can effect a big saving in time and labour.

4.5 Bulking

When sand or fine aggregate is damp, it normally swells or bulks, and on

important work the proportions are adjusted daily to allow for this. This bulking

factor varies with the weather, but as a general rule may be taken to be 25 per

cent in damp or humid conditions. Thus, using a 50 kg bag of cement and a

nominal mix of 1:2:4 by volume, increases Volume sand from 2 to 2.5 metric

Volume. The measuring boxes while the coarse aggregate would remain the same.

Sand which is either wet or very dry does not bulk at all.

Fig 4.1 Slump test

A 300mm

B 200mm

C 1000mm

D Slump

Fig 4.2 Gauge box with bottom (size: 1 ft3 or 0.028m

3)

Fig 4.3 Concrete pad base

A Lean concrete blinding

B Steel setting – out rods (left in)

C 80 mm x 80mm starter frame

Fig 4.4 Column formwork with yokes

A 30 mm formwork

B 75 mm x 75 mm yokes at 380 mm centres

C 16 mm diameter bolts

Page | 6

D Wedges

Fig 4.5 and 4.7a Column formwork with clamps

A 30mm formwork

B 30mm stiffeners

C Steel clamps (see Fig 4.6) at 380mm centres

Fig 4.6 Steel clamp

57mm x 8mm x 711mm (obtainable in various lengths)

Fig 4.7b Column form cut to receive a beam.

END

By Jared Okwar

Lectures using JRPA Operation Manual Lectures using JRPA Operation Manual Lectures using JRPA Operation Manual

Maintenance Management of Civil Facility

Knowledge on Mechanized Cargo Handling

Laws and Regulations related to Cargo

HandlingKinds & Characteristics of Cargo Handling

EquipmentElectric & Hydraulic Control of Cargo

Handling Equipment

Maintenace & Inspection of Cargo

Handling Equipment

Repair of Cargo Handling Equipment

Maintenance Management of Civil Facilities

(includng Attached Facilities)

Compilation Method of Port Statistics

A Training Course for One (1) Week for

Two (2) Trainees

Setting of a personal target by each trainee in advance

Action Plan prepared by each trainee and Proposal for the next technical assistance by the experts

Port Statistics

i-2) Maintenance of Cargo Handling

Equipment & Civil Facility

Entry/Exit Procedures and Documentation

Safety in Cargo Handling

Lectures on Monitoring Items which are conducted by JRPA

Training will be implemented on only the most important aspects of port management and operation

due to limited resources

A. Cargo Handling

B. Maintenance for Cargo Handling Equipment & Civil Facilities

C. Port Procedures and Statistics

i) to maintain know-how and skills acquired during the former Technical Assistance

ii) to help facilitate the commencement of the grant aid project and succeeding technical assistanceObjective

Priority Field

Two (2) Training

Cource

i) Operation and Mantenance of Cargo Handling Equipment & Maintenance of Port Facilities

ii) Port Procedures and Statistics

i-1) Training on Mechanized Cargo

Handlingii) Port Procedures and Statistics

A Training Course for Two (2) Weeks for Four (4) Trainees

Items to be collected as Port Statistics

Laws and Regulations related to Port

Statistics

Personal Target

& Follow-up

Bandali C

olleg

eJIC

A

Experts

Subjects

Port Procedures

Practical Exercise for Compilation of Data

using Computer

Maintenance of Cargo Handling Equipment

Dangerous Cargo Handling

Method for Cargo Handling

Cargo Handling using Folklift and its

Operational Exercise

Maintenance & Repair of Asphalt

Pavement and its Practical Exercise

Cargo Handling using Crane and its

Operational Exercise

Maintenance & Repair of Civil Facilities

and its Practical ExerciseMaintenace & Repair of Interlocking and

its Practical Exercise

Training in Bandari

Core Member

To maintain the know-how and skills acquired

during the previous technical assistance and to

help facilitate the commencement of the grant

aid project and succeeding technical assistance.

JRPA

JRPA Staff JRPA Staff

Your Roles after going back to JRPA

Monitoring after leaving of

the project team

May XX, 2015

Akira KOYAMA

OCDI

Monitoring is very important for the nest step

The JICA Project Team asked JRPA around two years ago to monitor the following items and to report the following items to the JICA South Sudan Office.

1. Progress of the authorization of river port policy and regulation

2. Establishment of a tariff committee

3. Periodical measurement of water level

4. Periodical updating of the equipment ledger

5. Recording of barges accommodated

6. Cleaning of port area as a routine work

Monitoring Items

Reporting system of monitoring items is as follows

A sustainable reporting system for monitoring:

• Results of monitoring have to be reported to JICA South Sudan Office every three months.

• Responsible person for reporting is Mr. Simon of DTR for item 1 & 2 and Mr. Emmanuel of JRPA for item 3,4,5 & 6.

• Formats for reporting are prepared by the JICA project team.

Reporting of Monitoring Items

Monitoring items under JRPA

Monitoring ItemLeader for

ReportingInterval

3. Periodical measurement of water

levelMr. James Wani Every two (2) weeks

4. Periodical updating of the

equipment ledgerMr. David Wani Once a month

5. Recording of barges accommodated Mr. Charles Once a month

6. Cleaning-up of port area as a

routine workMr. Santo Once a month

JRPA is responsible for the following monitoring items.

Leaders of each monitoring item have to report the

results to Mr. Emmanuel. The leader for each monitoring

item and interval for reporting are shown in the table

below.

Formats for monitoring is prepared by the team

Monitoring Item 3: Water Level Survey

Monitoring Item 4: Equipment Ledger

Monitoring Item 5: Barges accommodated

Monitoring Item 6 : Cleaning of Port Area

Monitoring Item 1: Progress of the authorization

of river port policy and regulation

Date (dd/mm/yy)

Progress of Status Remarks

Policy

Regulation

Policy

Regulation

Policy

Regulation

Policy

Regulation

Mr. Simon has to report the results of monitoring to the JICA

South Sudan office every three months.

Monitoring Items under DRT

Reporting Format

Monitoring Item 2: Establishment of a tariff

committee

Mr. Simon has to report the results of monitoring to the JICA

South Sudan office every three months.

Monitoring Items under DRT

Date

(dd/mm/yy)Progress/Status for establishment Remarks

Reporting Format

Than you for your Attention

Akira KOYAMA

OCDI

[email protected]

Regulation on the Use of the

Public Property

May 27, 2017

Akira KOYAMA

OCDI

Contents� What is a port?

� Regulation on the Use of

the Public Property

What is a Port?

2

A Port is a place where ships load and unload

goods or shelter from storms. (Oxford English-

English Dictionary)

“Harbours means any harbour, whether natural

or artificial, and any port, haven, estuary, tidal or

other river or inland waterway navigated by

going ships, and included a dock, a wharf, and in

Scotland a ferry or boatslip being a marine

work,” (Harbour Act 1964, United Kingdom)

What is a Port?

• Basic and Essential Infrastructure for

Economic Activities

• Consolidated Body comprising Port

Facilities/Equipment and a Certain Area

(land area and water area)

• Various Activities are conducted by using

the Facilities/Equipment in the Area.

3

What is a port?

• Port is a public property similar

to a road, airport, railway and

the like.

• Port is one of the most basic

infrastructures to support the

economic activities and daily lives

of people.

• Port is a infrastructure which

everyone has the right to use

equally.

• Port has more roles and functions

than most types of infrastructure.4

Regulation on the Use of Public Property

Principle of Regulation

�Article 1. Public property shall be maintained

in good condition and be dedicated to use by

the public.

Application for use of public property

�Article 2. Those who intend to use public

property shall complete an application form

and submit it to the port manager.

5

Extent of permission of use

� Article 3. Use of public property shall be limited to the following cases.

i. to operate a restaurant or a shop on the public property for staff of port office or other customers.

ii. to be used for transportation business, water supply, electric supply or gas supply or other public service when there is no suitable alternative location

iii. to be used by the national or local governments for public purpose

iv. to erect an emergency facility or shelter in the event of a disaster or emergency

v. to be used by the port when the port manager deems it necessary or essential


6

Decision of user

� Article 4. A port manager shall not allow a person to use public property unless that person has sufficient capital, is trustworthy, and has the necessary to skills to follow the conditions of usage.

Notification of permission or refusal of application

� Article 5. When a port manager receives an application for usage of public property, he shall promptly decide whether to approve or deny the application and inform the applicant of his decision.


7

Issue of usage permission � Article 6. When a port manager shall issue a permit, following

items shall be written in the permit.

(1) Banking account of the public property

(2) Place and address

(3) Category

(4) Volume and indication of area to be permitted to use

(5) Purpose and way of use

(6) Length of validity

(7) Usage fee and method of payment

(8) Conditions of use

(9) Conditions for withdrawal

(10) Return of public property

(11) Compensation for damage

(14) Other issues


8

Duration of public property use

�Article 7. Duration of public property use shall

be one year. However, permission for usage

can be renewed. In cases where the period of

used is deemed unreasonably short, a port

manager has the discretion to set the duration

period at three years.


9

Amount of fee for use of public property

� Article 8. Amount of fee for use of public property shall be set in the following manner

i. land fee shall be set by a port manager based on the standard calculated amount by multiplying land price by 2.5/1,000 and referring to leasing fees of land in neighboring areas of the public property.

ii. house fee shall be set by a port manager based on the standard calculated amount by multiplying estimated price of house by 5.6/1,000 and referring to leasing fees of houses in neighboring areas of the public property.

iii. fee of items other than land or house shall be set by the port manager


10

Deadline for payment of fee

�Article 9. Deadline for payment shall be designated by the port manager.

Revision of public property use fee

�Article 10. When the amount of fee does not meet actual market price, the port manager shall revise it.


11

Obligation of public property user� Article 11. A user of public property shall comply with the

conditions listed below

i. a public property user shall maintain the public property in good condition.

ii. the public property shall be used only for the purpose stipulated on the permit

iii. the public property user shall not allow a third party to use it

iv. public property user shall not renovate or repair any facilities

v. When a port manager wishes to conduct a survey on the status of property use or request the users to report on the status of property use, user shall not refuse nor impede the survey or fail to report.


12

Cancellation of permission

� Article 12. A port manager shall cancel the permit for usage when the following occurs.

i. in case that national government or state government decides to use the property for public purpose.

ii. in case that a user fails to pay the usage fee for a period of three months.

iii. in case that a user violates the agreement on public property use


13

Invalidation of permit

�Article 13. When the permit shall be invalidated when the following occurred;,

i. in case that user dies or goes missing

ii. in case that legal person as a user be abolished

Compensation for damages

�Article 14. A user of public property shall pay compensation when he damages or loses public property by accident or by mistake, or by violating the agreement.


14

Dear My Friends

15

Thank you for your Attention

16

Akira KOYAMA, OCDI,

[email protected]

Regulation on Cargo Handling

Service Provider

May XX, 2017, Akira KOYAMA, OCDI

Contents1. Regulation on Cargo

Handling Service Provider

2. Port Transport Business

Act

3. Criteria of Port related

Business

1. Regulation on Cargo Handling

Service ProviderIｎ a draft of new river port act, regulation on cargo handling service provider in river port area is stipulated that;

• Any entity who is going to provide cargo handling service in river port area shall obtain permission from RSS.

• Cargo handling service means any activity related to movement or stock of cargo in river port area.

• RSS shall prepare and publish conditions for which permission is given to an entity. The conditions include safety measures of cargo handling , and measures to protect good environment of river port area.

• RSS shall give permission to the said entity, if the entity satisfies the said conditions.

• When an entity with permission violates any of the said conditions, RSS can confiscate its permission.


Service Provider

• Port cannot operated only by JRPA. Cargo is handled by stevedoring companies, shipping companies, etc.

• In most of the ports in the world, port related service providers are not entirely free to do their business in the ports. Some forms of regulation are normally imposed.

• This is because, without any regulation, some of “ bad companies” might do bad conducts in the ports, hampering proper operation of the port.


Service Provider

• One common method of the regulation is

“ granting permission system”.

• When granting permission, it would be

necessary to prepare clear conditions,

specifically securing safety of cargo handling and

protecting environment in river ports are

essential.

• Details of the permission procedure and criteria

for permission has to be determined.


Service Provider

• Based on stipulation of the draft of new act on

River port, criteria for certificate shall be

determined and introduced in consideration

with securing safety and preserving environment

in the port.

• Further discussion will be needed to finalize

regulation on cargo handling service before the

completion of the expansion project of Juba river

port.

2. Port Transportation Business Act

• Japan has enacted an act on port transportation business.

Article 1: Purpose

The purpose of this act is to establish the order relating to port transportation, to undertake sound development of the port transportation business and to thereby promote public welfare.

Article 2: Definition

“Port transportation” shall mean any operation which is carried out to respond to other person’s demand and falls under any one of the following business.


Article 3: Classification of Port Transportation Business

The port transportation business shall be classified into the following categories.

① General port transportation business

② Port stevedoring business

③ Lighter transportation business

④ Raft transportation business

⑤ Tallying business

⑥ Surveying business

⑦ Measuring business


② Port stevedoring business is to load cargo onto

a ship or unload cargo from a ship in a port.

Taking account of the present Juba river port,

stevedoring business is a key.


① General cargo transportation business is to carry out a series of operations such as reception of cargo from the ship/the shipper or delivery of cargo to the shipper/the ship transported by the ship in a port.

③ Lighter transportation business is to transport cargo by a lighter in a port.


④ Raft transportation business is to transport timbers made a raft in a port or to carry timbers into a timber pond in the form of raft.

⑤ Tallying business is to count the numbers of cargo shipped at the time of loading or unloading the cargo, or certifying the reception or delivery thereof.

2. Port Transportation Business Act⑥ Surveying business is to certify, check and survey with

respect to loading of shipped cargo.

⑦ Measuring business is to calculate the cubic capacity or weight of shipped cargo at the time of loading or unloading the cargo or certifying the same.


Article 4: Certificate

Any person who intends to carry out port transport business shall obtain certificate of the Minister of Transport for each category of port transportation business and for each port.

Article 5: Application of Certificate

Any person who intends to obtain certificate for port transportation business shall submit to the Minister of Transport an application stating the following details:


1) Name or trade name and address;

2) Category of port transportation business;

3) Ports

4) Business plan as prescribed by the Ministry of Transport Ordinance.

• The applicant under the preceding Paragraph shall be accompanied with a document stating an income and expenditure estimate on the business and other details prescribed by the Ministry of Transport Ordinance.


Article 6: Criteria for Certificate

The Minister of Transport shall, when he

intends to grant certificate for port

transportation business, examine whether the

application satisfies the following criteria or not.

1) The applicant has, at least, such facilities and

laborers as described by the Ministry of

Transport Ordinance for each category of port

transportation business and port.


Article 6: Criteria for Certificate

2) That the business in question has an

appropriate plan to perform the business.

3) That the management is in such style as can

clarify the scape of responsibility of the person

who carries put the business in question.

4) That the business in question has a sound

financial base.


Article 7: Fares and Charges

1. Any person engaged in port transportation business shall, in accordance with the provisions of the Ministry of Transport Ordinance, decide fares and charges and obtain approval of the Ministry of Transport. This shall also apply to any revision in the fares and charges.

2. The Ministry of Transport can order to the entity engaged in port transportation business any revision in the fares and charges when the fares and charges are discriminated unfairly against specific users and has a possibility to raise unfair competitions among port transportation business entities.

3．．．．Criteria of port related Business

• The government and/or the port management body should regulates port related businesses. What kind of criteria can the PMB prepare when a private company requests permission to conduct business in the port?

• Purposes of regulating port related business are to prevent a bad company from entering into port business, to prevent an oversupply of service providers, to provide good services to port users as well as to ensure that a company can conduct port business safely and in an environmentally sound manner.

3．．．．Criteria of Port related Business

• Preparation of criteria for according permission to a private company is very important to attain the purposes of regulating port related business.

• By preparing criteria, transparency and fair treatment can be secured and it will allow the government and/or port management body who has an authority to grant permission (Competent Authority) to easily make a judgment on which company is eligible for undertaking port related business.

• It is not necessary to examine a new act for criteria of port related business; however preparation of criteria itself is very important as mentioned above to judge the ability of an applying company properly and fairly.


Possible or envisaged criteria are as follows; however this is only one example.

Criteria for a cargo handling service provider (port stevedoring business)• Whether a company has a workable plan for cargo handling

• Whether a company has well maintained facilities and equipment

• Whether a company has skilled and sufficient labors

• Whether a company has measures to secure safety and

• conduct business in an environmentally sound manner

• Whether a company has a table of proper fares and charges*

• Whether a company has a reporting system of its activities to JRPA

• Whether a company has a contingency plan such as an accident, oil spill, fire and so on

(*: regarding “fares and charges”, an important issue is whether they are regulated fares and charges or not.)


• Warehousing business is closely related to

cargo handling service and port related

business includes miscellaneous services

other than those services such as warehousing

business, water/fuel supply, garbage collection,

kiosk, tug boat, towing and so on.

• Therefore, clear criteria or rules are required

to manage and operate the port smoothly and

efficiently.

Thank you for your Attention

Akira KOYAMA, OCDI, [email protected]

AGREEMENT

1

Draft for Consultation

AGREEMENT between JUBA RIVER PORT ADMINISTRATION and

STAKEHOLDERS of Juba River Port

Preamble

WHEREAS Juba River Port Administration (hereinafter referred to as “JRPA”) and the

Stakeholders of Juba River Port (Shipping Companies, Small Boats Union, Loaders’ Union, and

Truck’s Union) are jointly undertaking to determine the general rules of the use of the jetty area;

WHEREAS the Parties hereby covenant make a commitment to ensure the effective

implementation and monitoring of the general rules of the use of the jetty area;

The Parties have agreed on the following;

General Rules for the Use of the Jetty Area

Sec. 1 (General Application)

Anyone who wishes to use the Jetty area shall understand and comply with the rules of Juba

River Port Administration (JRPA).

Sec.2 (Definition)

i. Jetty area means the area where a jetty covered with steel plates is located.

ii. A floating property includes any barge, small boat, pusher and other floating body.

Sec.3 (Procedure for the Use of the Jetty Area)

i. Anyone who wishes to use the Jetty area shall submit an application to JRPA and obtain

written permission from JRPA prior to the use of the Jetty area (Application form is

attached in this agreement).

ii. Application forms are available at JRPA office.

Sec.4 (Procedure for the Use of the Jetty)

i. Anyone who wishes to use the jetty shall submit an application to JRPA and obtain a

written permission from JRPA prior to the use of the Jetty (Application form is attached in

this agreement).

ii. Application form is available at JRPA office.

iii. Arrival notice of a floating property shall be submitted to JRPA by 2 pm one day before

arrival.

iv. Written departure notice shall be submitted by 2 pm one day before departure.

AGREEMENT

2

Sec.5 (Usage Charge for the Jetty area)

Anyone who wishes to use the jetty shall be levied usage charge in accordance with the type,

size and duration of a floating property, and the type of cargoes.

Rates of usage charges for the jetty area are indicated in the Tariff Table (set forth previously by

JRPA).

Sec. 6 (Manner of the Use)

i. All the users shall use the port facilities and equipment in the Jetty area in a safe and

efficient manner.

ii. All the users shall clean the place and the facilities and equipment at their own expense

upon completion of the use of the Jetty area

Sec. 7 (Mooring Rules)

i. Anyone who uses the jetty shall moor his floating property in a safe and secure manner.

ii. JRPA has a right to order the owner or a person to moor the floating property in a safe and

secure manner.

iii. No one is to leave unmoored floating property unattended in the port.

iv. A floating property should not impact on adjacent area and facility.

v. A moored floating property should prepare cushions between the jetty and the hull of the

floating property to prevent damage of the facility.

Sec. 8 (Removal of floating property)

JAPR has a right to order the removal of floating properties when;

i. A floating property stays idly after the cargo handling operation without a justifiable

reason.

ii. A floating property poses a threat and/or inconvenience to other floating properties.

Sec. 9 (Prohibited Activities)

The following activities are prohibited in the Jetty area.

i. Causing damage to port facilities and equipment

ii. Leaving debris, waste and harmful materials

iii. Idling and parking of vehicles

iv. Excessive noise and emissions

v. Smoking and burning wood pieces and other flammable materials

Sec.10 (Responding Duty)

All the users have to respond to the inquiry of JRPA concerning the use of the Jetty area.

Sec.11 (Cargo Handling)

AGREEMENT

3

Anyone who handles cargo in the jetty area shall deploy necessary number of loaders with

safety measure to handle cargo and prepare proper cargo handling machine or equipment which

handles cargo efficiently and protect loaders from injury.

Sec. 12 (Handling of Dangerous Cargo)

i. Anyone who handles dangerous cargo shall notify JRPA prior to handling such dangerous

cargo.

ii. JRPA has to grant the authorization to such a cargo handling operator prior to proceeding

and will order the operator to prepare necessary measures such as installation of

extinguishers.

iii. JRPA has to inform the firefighting offices and comply with their regulation, if necessary.

Sec. 13 (Occupation of Water Area)

Anyone who intends to occupy water area in front of the jetty area shall obtain permission from

JRPA

Sec. 14 (Compensation)

Anyone who damages the port facilities and equipment in the Jetty area has to pay

compensation.

Sec. 15 (Penalty)

Anyone who violates this rule may be subject to penalties in accordance with /////////.

Sec. 15 (Come into force)

This agreement shall come into force on the day after the date of its last signature.

Signed by

Zubeir

Port Manager

Juba River Port

(Shipping Compay)

AGREEMENT

4

Abministration

(Shipping Company)

(Shipping Company)

(Small Boat Union)

(Loaders’ Union)

(Driver’s Union)

Annex1: Application form for the use of the jetty area

Annex2: Application form for the use of the jetty

AGREEMENT

5

Annex 1

APPLICATION FORM FOR the USE of THE JETTY AREA

To Port Manager of JUBA River Port Administration

I would like to submit the application for using the jetty area.

I pledge to comply with “General Rules for the Use of the Jetty Area” issued on the date ///////////////.

Applicant

Name of Company

Contact Person

Mobile & E-Mail

Duration of

the Use

From

To

Use of the Crane Yes or No

Type of Vehicles and Cargo

Machine / Equipment brought in

Received by

JUBA River Port Administration

AGREEMENT

6

Annex 2

APPLICATION FORM FOR THE USE OF THE JETTY

To Port Manager of JUBA River Port Administration

I would like to submit the application for the use of the jetty.

I pledge to comply with “General Rules for the Use of the Jetty Area” issued on the date ///////////////.

Applicant

Name of Company

Contact Person

Mobile & E-Mail

Duration of

the Use

From

To

Name & Number of Barge

Name of Pusher Boat

Type & Volume of Cargo

Received by

JUBA River Port Administration

Port Statistics(Overview of the Statistics)

May 27, 2017. Akira KOYAMA, OCDI

Contents1. What is Port Statistics?

2. Importance of Port Statistics

3. 4 Fundamental Principal of Official Statistics

4. Statistics System in Japan

5. Port Statistics (Survey in Port & Harbor)

6. Showing Statistics Results in Visual Formats

7. Application of Statistics Results

8. Port Statistics in the Worlds

1. What are Statistics?

Statistics refer to the collection, classification, analysis,

and interpretation of quantitative facts , or their data.

� Official Statistics are critical information for rational

decision making

� 4 Fundamental Principles of Official Statistics

Statistics Act in JapanStatistics Act in Japan

In GeneralIn General

Systematic Neutrality & Reliability

Accessibility Confidentiality2


With statistics, we can UNDERSTAND what is

actually happening in/out of ports, and

in/out of the country.

Also, we can GUESS what

Will happen in the future.

Port Management can be more

efficient and effective.3


2) To use facilities more efficiently

Expensive, takes time …

1) To increase Capacity

Relatively-easy, cost saving, limited effect …

3) To raise TariffDepress demands, possible opposition …

Approaches to coping with Congestion

For example, in the case that congestion has

occurred in the port area.

4


Lack of

Berthing

Capacity

?

Lack of

Berthing

Capacity

?

Lack of

Gate/Road

Capacity ?

Lack of Container

Storage

Capacity ?

Lack of Crane

Capacity ?

Lack of Crane

Capacity ?

5

3. 4 Fundamental Principles of

Official Statistics

Official statistics shall be developed systematically

through mutual cooperation and the appropriate sharing

of roles among administrative organizations, etc.

SystematicSystematic

Official statistics shall be produced with appropriate and

reasonable methodologies, so as to ensure neutrality

and reliability.

Neutrality & ReliabilityNeutrality & Reliability

6

3. 4 Fundamental Principles of

Official Statistics

Official statistics shall be easily accessible to citizens for

effective use.

AccessibilityAccessibility

Confidential matters concerning individuals or juridical

persons, or other organizations that were used for

producing official statistics shall be protected.

ConfidentialityConfidentiality

7


Recognizing that official statistics are critical

information for rational decision making,

The purposes of this Act are;

� to promote systematic and efficient development of

official statistics,

� to ensure the usefulness thereof through specifying

basic matters concerning the production and

provision of official statistics, and

� thereby to contribute to the sound development of

the national economy and enhancement of the

living standards of citizens.

Statistics Act : Article 1 (Purpose)Statistics Act : Article 1 (Purpose)

8

[e.g.]

・Census,

・System of National Accounts,

・Port Statistics etc.


Primary

statistics

Processed

statistics

Made from Original

Survey

Made from

Administrative

Record

Information

[e.g.]

Trade Statistics

(compiled from

Customs’ data)

Fundamental statistics(designated by MIC*)

Compiled from Primary

statistics in order to be

easily understood.

MIC*: Minister of Internal Affairs and Communications

Other statistical Surveys

[Statistics associated with port and harbor]

•・ Total Pathway Survey of International Container

Cargos etc.

General statistics


・Especially important statistics designated by Minister of

Internal Affairs and Communications[for example] Census, System of National Accounts, Port Statistics etc.

・There are penalties for those who fail to cooperate in surveys.[for example]

Penalty of 500,000 yen or less in a case where questionnaires are not returned

・Other statistical surveys conducted by governments [e.g.]

Total Pathway Survey of International Container Cargos

・No penalties.

Fundamental statistics

General statistics

Port relate Statistics


Name of investigation

Enforcement grounds Contents of investigation Frequency

Survey on Port and

Harbour

Fundamental

statistics

General and fundamental data of ports

・Number of vessels

・Number of passengers

・Volume of cargo

・Items of cargo etc.

Every year

Total Pathway

Survey of

International

Container Cargoes

General

statistics

Details of the total pathway of

International Container Cargos

・Origin/Destination City

・Loaded/Unloaded Ports

・Transshipment Ports etc.

Every five

years

Total Pathway

Survey of Unit-load

Cargoes

General

statistics

Details of the flow of Export-Import and

domestic Unit-load Cargoes


・Loaded/Unloaded Ports etc.

Every five

years

Total Pathway

Survey of Bulk

Cargoes

General

statistics

Details of the flow of Export-Import

and domestic Bulk Cargose


・Loaded/Unloaded Ports etc.

Irregular

（first investigation

in 2009) 11

� Survey Items & their target periods

(monthly/Annually)

� Prescribed formats for Questionnaire / Summary

Sheet

� Defined terms

:Vessel Types (merchant vessel, ferry, fishing craft, others )

: Cargo Items (agricultural and fishery products, mineral

ores,……)

� Instruct to fill-in the formats

� Compiling & Official Release

4. Establishing Statistics System

Systematic / Reliable Statistics 12

National Government

Port Management Body (Prefectural Governments/Municipalities)

� Release dates (both monthly and annual) are

stipulated in the Ordinance

� Formats are not prescribed in advance

� Official Release contains the outline of the survey as

well as data tables

� Almost all PMBs release statistics even though they

are not obliged to

� Statistics results are available on their internet sites

� Information for shipping companies and PR (public

relations) are possible reasons

4. Establishing Statistics System(Official Release in Japan)

13

5. Port Statistics

(Survey on Ports & Harbors)

Ports support the economy and lives of citizens

Port Statistics Indicate Current Status

14

5. Port Statistics(Survey on Ports & Harbors)

� in order to grasp the situations of ports and harbors

� In order to compile fundamental data for developing

and managing ports and harbors

Purpose of Survey on Ports & Harbors

i. Vessels entered

ii. Passengers

iii. Cargoes

iv. Cargo handling

v. Mooring and anchoring

Target Ports and Survey items

CATEGORY B PORT:

relatively small ports

CATEGORY A PORT :

relatively large portsyearlyyearlyyearlyyearly

monthlymonthlymonthlymonthly

15

5. Port Statistics (Survey on Ports & Harbors)

Port statistics compiled by MLIT

based on data received from prefectures

Central Government (MLIT)

Summary sheet

Questionnair

e

Compiled

Report

“Port

Statistics”

Local Government

(Prefectures)

Local Government

(Prefectures)

Parties obligated to

report data

Port managersPort transport Port transport

operatorsShip operators Etc.

Statistical Surveyor

16

6. Showing Statistics Results

in Visual Formats

Statistics Results in a table format

2007 2008 2009 2010 2011 2012

Container

(TEU)11,208 12,069 16,493 18,823 21,771 23,122

Passenger 24,404 34,779 9,258 38,680 32,829 33,834

17

� Table enables a brief explanation in texts or bullet points.

� Table reduces work volumes when there are a lot of common

items such as figures.

� Table is effective in explaining figures & descriptions contained

with in a long text

South Sudan Value

ITEMS Males Females Total

Literacy rate, 15-24 years

Ratio of literate females to males, 15-24 year olds

Estimated life expectancy at birth

Infant mortality rate per 1,000 live births (under 1)

Child mortality rates (1- 4 years)

Maternal mortality rate (per 100,000)

Total fertility rate

Proportion of births attended by skilled health personnel

Total population, urban

Total population, rural

Statistics Results in a table format

18

0

10000

20000

30000

2007 2008 2009 2010 2011 2012

Container

0

20000

40000

60000

2007 2008 2009 2010 2011 2012

Passenger

6. Showing Statistics Results

in Visual Formats

Statistics Results in a graph format

19

� Graph makes trends easier to grasp as statistics are presented in

visual formats

� Typical graph formats are “Circle Graph”, ”Bar Chart” and “Line

Chart”

� Table is effective when we explain the entire spectrum and

feature

Circle Graph Bar Chart Line Chart

Breakdown & Composition Ratio Match-up Figures Changes of Figures


20

Circle Graph

Bar Chart

Line Chart

Breakdown & Composition Ratio

Match-up Figures

Changes of Figures

[Basic Type]

[Basic Type]

[Basic Type]

0

2

4

6

8

10

0%

50%

100%

0

10

20

Area Chart

Class names

&

Their percentages

Class names

&

their figures

0

5

10

15

20

0

5

10

15

20

0

5

10

15

20

grouping names

&

their series figures


21

Composition of International Cargoes in Japan

Total Total Volume1.3b t

Container250m t, 21%

Dry Bulk440m t, 36%

Liquid Bulk400m t, 32%

Minor BulkMinor Bulk110m t, 9%

Break Bulk140m t, 11%

Crude OilCrude Oil180m t, 15%

Petroleum Product

50m t, 4.0%

Gas (LNG,LPG etc.)

160m t, 13%

CoalCoal170m t, 14%

Iron OreIron Ore130m t, 11%

GrainGrain30m t, 2.3%

Fuel CoalFuel Coal110m t, 9.5%

Material CoalMaterial Coal60m t, 5.0%

WheatWheat8m t, 0.6%

Corn etc.Corn etc.15m t, 1.2%

OthersOthers6m t, 0.4%

Reference: Survey on Port and Harbor (Port Statistics)

(2011)

Trade Statistics(2011)

7. Application of Statistical Results

22

Container Volumes by Ports

Shimizu

(414)

Yokkaichi

(172)

Mizushim

a

(103)

Isewan

(2,675)

Hanshin

(4,191)

Niigata

(175)

Keihin

(6,986)

(Unit: thousand TEU)

● in the figure indicates harbors which handle less than

100 thousand TEU foreign trade containers.

Tomakomai

(196)

Hiroshima

(142)

Reference: Survey on Port and Harbor(2012)

Hokubu

Kyusyu

(1,325)

7. Application of Statistical Results

Composition of Container Cargoes in Japan

0

20

40

60

80

100

120

140

160

1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

Million tons

0

20

40

60

80

100

120

1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

Millio tonsContainer Cargos

Container Cargos Import

Export

Reference) Survey by port manager and Survey on Port and Harbor

Agricultural and marine products

Metals and machinery products

Forest products Mineral ProductsChemical products

Light industry products

Miscellaneous industry products

Special products Products that cannot be classified

Trend of Container Throughput at Port of Sendai-Shiogama

（TEU)

Post-disaster situation at Port of Sendai-

Shiogama

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug

2010 2011 2012

8,898 8,386

11,226

9,912 10,019

8,547

10,840

9,149 9,217

10,117

10,937

9,573

8,805

9,973

3,000

0 0 0 0 0

1,016 1,413

3,289 3,045

4,490

5,073

7,255

9,927

6,349

8,089 7,680

7,204

0

2,000

4,000

6,000

8,000

10,000

12,000

Reference) Survey by port manager and Survey on Port and Harbor

Great East Japan

Earthquake

8. Port Statistics in the world

Issuing Institution and Methods in Major Nations

Issuing institution

A part of whole fields statistics in

the nation

Respective Ports Statistics on Cargo Volumes

National

Governme

nt etc.

Singapore, Oman,

New Zealand

USA, Canada, Mexico, Panama, Brazil,

Chile, Japan, South Korea, Hong Kong,

Taiwan, Malaysia, Indonesia, India,

Australia, European Union, Turkey,

Israel, Egypt

Public

Institution

China, The Philippines, Thailand,

Vietnam, Saudi Arabia, Russia, South

Africa

not

availableArgentina, UAE, Sri Lanka

26

Egypt

Name of Statistics : "Statistics-Port Traffic“

Publisher : Maritime Transport Sector, Ministry of

Transport

Frequency : Annual, Monthly

Language : Arabic, English

ALL CARGO

Total Volume by Ports by Items by partner countries

Metric Ton by ports nil nil

CONTAINER CARGO

Total Volume by Ports by Items by partner countries by sizes

Transshipment

countries

TEU

(Laden/empty

),

Metric Ton

by ports nil nil nilgiven in

breakdown


27

� Many countries in the world developed port-related statistics

and release summary of statistical results (not all the data)

officially.

� Among the countries and regions, there are some discrepancies

in terms of cargo units (metric ton/freight ton/revenue ton),

cargo items classification and definitions of partner country

(trade partner/destination or provenance country)

� In the case of container cargo, there are also discrepancies in

terms of treatment of empty container, size of container and

transshipment container.

Brief Summary


28

Is every member fine? My good friends

29

Thank you for your

Attention

Akira KOYAMA, OCDI, [email protected]

REPAIRS IN MAINTEANACEopen_jicareport.jica.go.jp/pdf/12290987_02.pdfsuch as electromagnets or...

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