STANDARD OPERATING PROCEDURE FOR

VRC INSTALLATION

VERTICAL RECIPROCATING CONVEYOR

TECHNOVISION ENGINEERS PVT LTD.

ADDRESS:-GAT No-1559-1560, DEHU ALANDI ROAD, SHELARVASTI, CHIKHALI, PUNE.
MAHARASHTA – 412114.
CONTACT NO:- +91 9225345039, E-mail :contactus@technovisionengrs.com

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 TABLE OF CONTENTS
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SR.NO TITLE PAGE NO

1 INTRODUCTION 3

2 INSTALLTION CONSIDERATION 4

3 CHECK LIST BEFORE 5

START OF INSTALLATION

4 INSTALLATION PROCEDURE 7

5 INSPECTION AND COMMISSIONING 13

REPORT

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 1. INTRODUCTION
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Your lifting unit is an industrial Vertical Reciprocating Conveyor (VRC).It will lift or lower
materials up to its rated capacity from one level to the next. Please be advised that this unit is for
materials only, no personnel must ride the VRC, it may result in injury or death.

The information and illustrations in this manual are intended only as an aid to understanding
the VRC’s step by step guide or installation procedure and risk analysis.

Technovision Engineers PVT LTD has an ongoing improvement program, therefore, we

reserve the right to change our product based upon these findings. In addition, the components may
vary based upon the equipment and option ordered. Technovision Engineers is confident that this
new VRC will provide many years of reliable service. Please contact us if you have any questions.

WHAT DO I DO WHEN I HAVE A PROBLEM? CALL US OVER TELEPHONE?

TECHNOVISION ENGINEERS PVT LTD.

ADDRESS:-GAT No-1559-1560, DEHU ALANDI ROAD, SHELARVASTI, CHIKHALI, PUNE.
MAHARASHTA – 412114.
CONTACT NO:- +91 9225345039, E-mail :contactus@technovisionengrs.com

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 2. INSTALLATION CONSIDERATIONS
---------------------------------------------------------------------------------------------------------
a. First Aid: Provision of a suitable First Aid Box at site

b. Emergency Exit: Awareness to all workers on Emergency Exits and procedures

c. Risk Assessments: For every task of installation, identify the Risk involved and the
necessary steps taken to reduce the same to acceptable levels.

d. Personal Protective Equipment: This include the following but not limited to

 Helmets

 Safety Shoes

 Gloves

 Reflective Jackets

 Double Harness Safety Belts for Height work more than 2 mtrs

 Safety Goggles if required

 Hearing Protection if required

e. Site Handling tools / Equipment: This include the following but not limited to

 Measuring Tape

 Plumb Bob with wire

 Metal Hammer

 Socket Drilling Machines with Various Drill bits / Hammer Drill Machine

 Hand Pallet Trucks

 Hydra / Manually Operating Chain Pulley block for Frame Lifting

 Scissor Lift if applicable

 Spanner Set

 Allen Key Set

 Impact Wrenches

 Single Phase Welding Machine

 Trolleys

 LASER Measurement instruments

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 3. CHECK LIST BEFORE START INSTALLATION
---------------------------------------------------------------------------------------------------------

3.1 Layout and Elevation Drawings

The final layout and GA drawings of the system should be discussed with the Client as per Site
conditions.

3.2 Area Demarcation

The installation Area and the assembly area has to be identified for the smooth flow of installation
and that area should be clearly marked with warning that Work is in progress.

3.3 Site Survey and Floor Marking

The flooring of the warehouse would be checked for flatness and waviness using Leveling
instrument. The assembly of VRC on irregular floor surfaces can pose a Safety Hazard for employees
and materials stored.

The clear height availability needs to be checked before installing the system.

The system need to be installed on a concrete slab and minimum floor slab thickness should be 150
mm to support the grouting of columns/uprights. Floor level variation should not be more than ±5
mm.

Note: Customer should verify the thickness of floor slab with Landlord based on total designed load
and responsible for providing proper cement floor with adequate strength for installation.

Marking of start point as per drawing with reference to Wall / Pillars. Marking of total Layout with
Storage in floor using permanent markers

Level

Mark Center Line Here

Center of Opening
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Marking is done by using a thin strong thread / Wire (Line Dori) by stretching it between the end
points marked. This line is marked on the floor & a transparent tape is stuck over it on the floor to
ensure retention of marking on the floor.

3.4 Unloading Of Vehicle / Materials Count & Storeing Material

Site Accessibility: The approach roads for Vehicles to reach the site will be cross checked for receipt
of Materials.

Review and count all materials while unloading and compare them with the Packing List and BOM /
delivery challan to make sure receipt of correct materials at site. Shortages if any will be informed
to plant for necessary replenishment. Inspect the materials to check the damages in transit and
necessary actions will be initiated for replacement if any.

Unloaded material should be stored at nearer position to the site.

Note- Customer should verify this activity.

Unloading Of Vehicle

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 4. INSTALLATION PROCEDURE
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4.1 Point to be noted
 Always use Reflector Jackets as required.
 Do not climb the system without suitable Harness
 Use Material handling equipment like Fork Lift, Hydra etc... wherever possible
 Ensure that the components used for climbing or standing are strong enough to hold the
workmen weight.
 Project Supervisor or engineer has to ensure that the workers thoroughly understand how
components should be handled and assembled. If necessary, checklist to be used.

4.2 Hanging of Chail Pulley Block

Hang the chain pulley block with the help of J hook which is provided by Customer / Existing
fabricated truss with help of wire rope and U Clamp.

4.3 Fixing Of Structure

Fixing of structure (i.e H frames for all the Modules, Rear / Front Frames for the modules) to be done
by means of Chain Pulley block / Hydra.

Fixing of structure

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4.4 Fixing Of H Beam Inside The Structure.
Fixing of H Beam (LH/RH) to be done by means of Chain Pulley block / Hydra.

H Beam

H Beams Lh/ RH

H Beam Inside The Structure

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4.5 Positioning / Assymbley of Bear box
After fixing of of Both LH and RH H Beam, Gear Box assy to lifted and mounting to be done on
Structure with help of Chain Pulley Block or Hydra

Gear Box Assy

4.6 Positioning of Carriage Assembley

Carriage to be positioned inside the structure with help of Fork Lift / Hand Pallet Truck.

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4.7 Inserting Of Cam Assembley
Insert cam Assy inside the H Beam and attach to the Carriage. Site Engineer should Check the gap
between Wheel Block and H Beam. After Confimation attach Cam Assy with Carraige with help of
Hardware to provided with VRC.

Check Guide Angle

to Guide Angle

Inserting Of Cam Assembley

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4.8 Attaching The Doors
Only after aligning of Cam Assy attach all door (Landing and Carriage ) for all the Modules.

Doors

4.9 Installing Chains and Adjust The Chain Tensioners

Only Install Lifting Chain and Tensioning chain as per the length given in the BOM and adjust Chain
Tensioners.

Install and Adjust

Install The Chains Install and Adjust Chain Tensioners
Slack Chain Sensors

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4.10 Fixing of Railing and Maintenance Platform
Fix Railing and Maintenance Platform .

4.11 Grouting
Only after alignment and leveling, you can start with proper anchoring. It is important that all the
Columns / Uprights have to be grouted for the proper functioning of the system.

Grouting

4.12 Electrical Wiring & Signage Fixing

Do Electrical wiring and Fix all the Limit Switches. Fix all the safety Sign Board and Take trail.

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Technovision Engineers Pvt. Ltd.
Housekeeping Policy

Hazards in onsite work are everywhere. When natural hazards onsite are compounded with
clutter of debris and tools, the hazard level increases, making the likelihood of an incident
increase. A worksite with poor housekeeping procedure creates an environment that is unsafe to
yourself and your co-workers.

Maintaining good housekeeping onsite can reduce the likelihood of accidents and/or incidents
from occurring. The positive effect of good housekeeping practice far outweighs the extra effort.
Everyone onsite must do their part to ensure that the jobsite is clean, orderly, and free of
potential hazards.

The most common injuries that occur on a jobsite, from poor housekeeping, are Slips, Trips, and
Falls. Workers may slip, trip, or fall because of;
• Trash and/or debris
• Misplaced tools or equipment
• Tools and equipment that are not properly coned, barricaded, or caution taped
• As a result, workers could suffer cuts, sprains, broken bones, and severe head injuries.

The employees shall take the following steps to maintain safe onsite work environment;

• Remove debris and trash to create a safe work environment.

• Clean as you work to prevent overload of debris, tools, and equipment.
• Place generated waste into containers, in a designated area.
• Keep pathways clear from obstruction.
• Keep worksite neat and orderly.
• Store tools and equipment out of the way.
• Place protective cones, barricades, and caution tape across areas where workers could
slip, trip, or fall.
• Use sand or drying agent in wet or slippery areas.
• Only work in areas that have proper lighting.

If everyone does their part and works together to ensure that a worksite is clean and orderly,
everyone can feel safer if at the workplace. Make good housekeeping practices a habit to protect
yourself and others from potential injuries.

1
 Risk Assessment for Vertical Reciprocating Conveyor (VRC)

Customer Name Flipkart

Prepared By Technovision Engineers PVT LTD

Technovision Engineers Pvt Ltd Email Id- contactus@technovisionengrs.com

 Risk Assessment for Vertical Reciprocating Conveyor (VRC)

Major Work Activity Potential Hazards Risk Possible Controls Controlled

Score Risk Score
Material reaching at site. 1. Vehicle accident H 1. All vehicles entering into site must be in good L
Vehicle Entry. 2. Damage of equipment’s and condition.
property 2. Driver with valid driving license.
3. Person injury 3. Aware the driver to obey all the traffic rules inside
4. Road accident the site.

Material Unloading, storage and shifting.
1. Material Fall M 1. Material handling safety to be followed and material L
2. Cut injury to be kept properly.
3. Body injury. 2. Team work required when unloading material.
Proper PPE to be worn. Surrounding area to be free
from traffic and person movements.
3. Dedicated supervision to be provided. HPT or Fork
lift to be provided while shifting material when
required.

Manpower mobilization into work 1. Personal Injury (Body injury) M 1. Site Supervisor shall identify the hazards before
area start of work. L
2. Site Supervisor will brief this risk and control
measures before start of work to entire working
crew.
3. Only Inducted and trained workers should be
allowed on site.
4. Tool box talk & safe work Procedure should be
explained to workers.
5. Work should be carried under continues
supervision
6. Proper PPE’s (Helmet, safety shoes, reflective
jackets, hand-gloves etc) to be checked by Site
Supervisor

Technovision Engineers Pvt Ltd Email Id- contactus@technovisionengrs.com

 Risk Assessment for Vertical Reciprocating Conveyor (VRC)
Mobilization of Frames and Boxes to the
Actual Site
Mobilization of equipment’s & Power Tools (Tools
and Tackles)
Technovision Engineers Pvt Ltd
1. Personal Injuries M 1. Site Supervisor will ensure work area while L
2. Material Damage discussion with client.
3. Property Damage. 2. Site Supervisor will ensure all Workers are
wearing PPE’s like Helmet, safety shoes,
reflective jackets, hand-gloves etc
3. Working areas to be barricaded with soft
barricade and display boards
1. Personal injury 1. All electrically operated tools, equipment shall be
2. Fatality H checked by Site Supervisor and electricians L
3. Fall of Object mutually before first use.
4. Property Damage 2. Site Supervisor shall check all equipment’s, tools
5. Slip, Trip and Fall and tackles visually each and every day.
6. Electrical shock 3. All plug top shall be industrial type (IP44)
domestic electrical connections are not allowed
at site; this shall be ensured by safety officer /
Site Supervisor.
4. No joints on cable are allowed at site this shall be
ensured by electrician and safety officer. Joint
point to be connected with industrial male
female connectors only.
5. Site Supervisor shall ensure no faulty equipment
shall be used at site.
6. Site Supervisor shall ensure all rotating part of
equipment shall be safe guarded.
7. Site Supervisor shall remove all defective tools
from site or keep in controlled area locked.
8. ELCB/RCCB 30-mile Amp as per rating capacity to
be used.
9. Safety officer/electrician shall provide double
earthling on metallic body equipment’s.
Email Id- contactus@technovisionengrs.com
 Risk Assessment for Vertical Reciprocating Conveyor (VRC)
In case of emergency 1. Body injury
2. Fatality
3. Slip, Trip and fall.
Height Work 1. Fall Hazard
2. Body Injury due to Falling of
Material
Lifting of Frames / Structure / Assembly 1. Body Injury due to fall of
1. Unpacked material. material.
2. Frame shifting. 2. Leg injury due to material
3. Lifting of Material with help of Chain Pulley. shifting.
4. Or Lifting of Frames with help of Farana 3. Slip and Trip.
4. Noise.
5. Chances of Toppling.
Technovision Engineers Pvt Ltd
1. Awareness shall be created about emergency
evacuation plan by Site Supervisor.
H 2. Assembly points shall be explained to workers by L
safety officer / Site Supervisor.
3. Briefing shall be given at the time of induction &
at regular intervals.
4. Discuss with client for Emergency vehicle shall be
easily available at site in case off Emergency.
5. Trained first aider/Trained fire fighters shall be
available at site.
M 1. While work on overhead Site Supervisor shall L
ensure workers are wearing Proper Double Harness
Safety Belts.
2. Working area should barricaded with soft Barricade.
3. A signal man should require to ensure traffic free
area.
4. Height work should be done with trained worker
with proper safety belt will disconnect sling belt
from the frame at on height.
5. Ensure no one is working below the lifting work
area.
M 1. Conducting daily tool box talk by Supervisor. L
2. Trained / Authorizes person for working activity.
3. Deploy dedicated supervisor or controller to avoid
any unauthorized person entry in installation area.
4. Area should be barricaded to avoid outside hazard
which will affect activity.
5. Area should be clear and free from obstruction.
6. Electrical cable should not be on floor and it should
be kept at height to prevent trip hazard and to
prevent cable damage due to sharp edge contact by
frame which results electrical shock.
7. No nut bolts on floor and should kept on suitable
place only.
Email Id- contactus@technovisionengrs.com
 Risk Assessment for Vertical Reciprocating Conveyor (VRC)

8. All work-related PPE to be worn for shifting frame.

9. All the equipment’s should be in good condition
and no lose cable having industrial plug top and
extension board with 30mA ELCBS.
10. Ensure all the bolts for rope are well tightened
before lifting with chin pulley block.
11. Ensure working condition of Self Locking System of
Chain pulley Block before start of Work.
12. All lifting tools (Sling, Belt, Chain.) certified with TPI
and daily checked by supervisor before start the
work.
13. All the unnecessary material should remove from
area before start of work.
14. Ensure good communication between Farana
operator and Erection team by site supervisor.
15. Ensure Farana is in Good condition before start of
work.
Welding & Finishing H 1. Site Supervisor shall identify the hazards before
1. Chance of Fire start of work. L
2. Skin burn injury 2. Site Supervisor shall ensure no flammable
3. Eye Injury due to substance / paper near to the welding area.
3. Site supervisor shall ensure fire extinguisher and
welding
other safety and firefighting equipment avilable
4. Personal injury
near to the area.
5. Electrical Shock
4. Client / Safety Supervisor pre informed to start
6. Hand / Finger Injury
welding activity.
5. Ensure bucket of water near to working area to cool
overheated parts.
6. Welder / Operator must wear long sleeve or arm
cover to prevent skin injury.
7. Welder / Operator must wear welding screen or
welding helmet to avoid eye injury.
8. All electrically operated tools, equipment shall be
checked by Site Supervisor and electricians
mutually before first use.

Technovision Engineers Pvt Ltd Email Id- contactus@technovisionengrs.com

 Risk Assessment for Vertical Reciprocating Conveyor (VRC)

9. All plug top shall be industrial type (IP44) domestic

electrical connections are not allowed at site; this
shall be ensured by safety officer / Site Supervisor.
10. No joints on cable are allowed at site this shall be
ensured by electrician and safety officer. Joint point
to be connected with industrial male female
connectors only.
11. Site Supervisor shall ensure no faulty equipment
shall be used at site.
12. Safety officer/electrician shall provide double
earthling on metallic body equipment’s.
13. Safety officer shall ensure all rotating part of
equipment shall be safe guarded

Anchoring 1. Trained workers should be allowed for alignment

activity
2. Before use the power tools, ensure all the electrical L
1. Hammering drill to be 1.Noise M cable and equipment’s in good condition.
used 350 W single 2.Headache 3. Machine should undergo the check list.
phase. 3.Dust issue 4. Used of job specific PPE. ( Safety harness, goggle,
2. Hammering of 5.Fall from height Nose Mask, ear plug).
expansion bolt.
3. Tighten of bolts.
Painting / Touchup work 1. Fire Hazard. M 1. Storage of paint away from fire source. L
2.paint solvents may create 2. Ensure Proper PPEs ( Nose mask, safety helmet,
respiratory problems safety shoes, hand gloves, safety goggle)
3. Skin disease due to spillage. 3. Ensure Fire extinguisher kept (DCP-5 kg) paint
storage area.
4. Ensure good housekeeping
provide dust bin.

Technovision Engineers Pvt Ltd Email Id- contactus@technovisionengrs.com

 ESCALATION MATRIX FOR VRC- Service

Sr No Name Designation Phone No Email

1 Parmeshwar Zambare Incharge Service 9588499970 parmeshwar.zambare@technovisionengrs.com

2 Suresh Gopalkrishnan CEO 9765490171 suresh.gopalkrishnan@technovisionengrs.com

3 Sameer Patil Director 9822196618 sameer.patil@technovisionengrs.com

 Risk Assessment for Vertical Reciprocating Conveyor (VRC)

Electrical
Use of Welding/ Cutting machine/drilling
machine/Grinding Machine.
1. Electric shock, Electrocution
2.Burn injury
3. Person body injury
4. Eyes Injury
5.Electrical short circuit
6. Explosion of electrical panel
boards & equipment.
7. Fire hazard
1. Before start the work first tool box training given to
all workers.
2. Ensure Safety sign provided in every panel boards
&equipment
3. Ensure all machines area in good working condition
H 4. Ensure No loose connections in electrical equipment L
panel boards.
5. No Joints in power cable.
6. Ensure Proper PPEs & fire protection equipment
provide suitable fire extinguisher.
7. Ensure every panel board & extension board has
ELCB (30mA).
8. Provide check list & safe Tag for machine and
equipment’s.
9. Give proper training to the workers about electrical
safety & hot work safety

Prepared by Reviewed Approved

Signature Signature Signature

Technovision Engineers Pvt Ltd Email Id- contactus@technovisionengrs.com

 ESCALATION MATRIX FOR VRC- Service

Sr No Name Designation Phone No Email

1 Parmeshwar Zambare Incharge Service 9588499970 parmeshwar.zambare@technovisionengrs.com

2 Suresh Gopalkrishnan CEO 9765490171 suresh.gopalkrishnan@technovisionengrs.com

3 Sameer Patil Director 9822196618 sameer.patil@technovisionengrs.com