SAFETY TRAINING CRANES AND HOISTS

Crane &Hoist Operator…………

Safety Training,,,,,,,,,,,,,,,,,,

QUALIFICATIONS

• 11-3.1.3 Qualifications for Operators of Floor-Operated Cranes or Carriers

• Personnel shall be required by the employer to pass a practical operating examination. Qualification shall be limited to the specific type of equipment for which examined.

The Users Responsibilities

All candidate for the Crane and Hoist operation job should be in the interest of safety and be able to meet the minimum requirements before being considered for training.

The basic requirements are as follows:

Must pass Hearing and Vision Testing per State Requirements.

Age

Most state laws, which govern the operations, require that a person shall have passed their 18th birthday before being allowed to operate an overhead crane.

VisionStandard visual acuity of 20/20 should be met. This can be measured by a number of devices. Color vision should be

checked and field of vision should be determined.

.Reaction Time

Measures how quickly the person reacts to a set of signals or to an emergency. (The Up Button sticks closed)

Distance Judgement

Measurement of depth perception is important for Crane Operators.

Hearing

Several devices are available to test hearing ability. The person should be able to meet standard requirements.

General Health

The company doctor should determine the physical fitness of the individual. Any tendencies toward heart trouble, epilepsy, dizzy spells, diabetes, high blood pressure, or physical defects should be studied to determine physical fitness. If the doctor approves

of an individuals physical condition, the candidate should be considered as having passed this phase of the requirements.

Physical Examination

A urinalysis and blood serology test should be given to every candidate for a Crane Operator’s job. If the individual meets

standard requirements they can be considered as having passed this phase of the requirements.

Literacy

Most state laws that govern the operations, site that an individual must be able to read and write in English before

being allowed to operate an overhead crane.

This list is the minimum suggested requirements generally recognized by most states.

SAFETY RULES

There are many safety rules that have been set up to be observed by Crane Operators. However, if you follow these

rules you will observe most of the necessary precautions while operating your crane.

.

• THE OPERATOR MUST KNOW WHERE THE MAIN LINE POWER DISCONNECT IS LOCATED.

• MAIN DISCONNECT MUST BE CLEARLY MARKED AND FLOOR ACCESSABLE AND LOCKABLE

• On floor- or remote-operated cranes, a disconnectdevice of the enclosed type shall be provided in theleads from the runway conductors. This device shouldbe mounted on the bridge near the runway collectors.

1. No one but a regularly authorized operator is

allowed to use any crane.

2. Before moving trolley or crane bridge, be sure that the hook is high enough to Clear all obstacles.

3. Under no circumstances permit your crane to “bump” into

another crane or run the bridge or

trolley into end stops.

Do not run into the End StopsOn Top Running or Underhung

Cranes

Underhung End Stops

Where the track is suspended from hanger rod 'assemblies, restraining means shall be provided to

prevent the hanger rod nuts from backing off the

hanger rods. AWAYS LOOK AT NUTS

4. The operator SHALL NOT leave their position at the controls while a load is suspended.

• 5. Hoist Chains/Wire Rope SHALL NOT be wrapped around the load. Slings must be utilized.

• .6. Do not carry load over people on floor; sound warning devices if crane is equipped to warn persons nearby.

7. 8. 9. 7. Do not allow anyone to ride on a load carried by the crane

or on the crane hook. 8. Do not drag slings, chains, or lifting devices out from under loads that have been landed.

9. If you are asked to do something that you DO NOT believe is safe, you should refuse to do it and call your foreman/supervisor in charge for advice.

10. An Operator MUST NOT operate a crane if he/she is not physically fit to do so.

11. Check all capacities for Max load you can pick, “Never overload”

Check all Capacities

Never Overload!!

12. In case of a problem always STOP operation and open the power switch.

If your crane fails to respond correctly call your foreman/supervisor.

Attempting to get out of difficulty by repeating the operation may make the condition worse instead of better

13. When your crane is down for repairs, assist the repairman. After completion of any repair, make sure that bolts, tools, ect. have been removed so that no injury to personnel or damage to equipment will result from falling objects when the crane is returned to service.

14. Never go on top of the crane or permit anyone else to do so without opening the main switch and placing a warning tag or lock on it. If you find a main switch with a warning tag or lock DO NOT close the switch.

NOTE: Unless you are the one who opened the switch and are absolutely sure there is no one on the crane or crane runway.

• Crane operators must follow the signals given to them only by authorized persons (THE ASSIGNED RIGGER) and should ignore directions given by others during operation of their equipment.

• The only EXCEPTION to this rule is if ANYONE commands them to EMERGENCY STOP.

• The operator should stay focused of your surroundings-be aware of any unusual sounds or warnings.

Cranes and Hoists are designed to make “Vertical lifts” of loads ONLY.

DO NOT angle/side load unless it has been determined by a qualified person not to pose a hazard to equipment or personnel.

All employees are to read B30.16

• Employer is to have a copy of the manufacturers manual on site!

TOP RUNNING CRANES RUN ON TOP OF ALL RAILS

• UNDERHUNG CRANES • HOISTS RUNNING ON THE BOTTOM OF THE

FLANGE OF A BEAM IS CALLED AN UNDERHUNG SYSTEM.

JIB HOIST MANUAL

WALL MOUNT JIB

• THE HOIST DRUM WILL HAVE TWO FULL WRAPS OF ROPE LEFT ON THE DRUM AT THE LOWEST POSTION.

• LIMIT SWITHES ARE NOT USED AS A OPERATING STOP.

• Limit switch - a switch that is operated by some part or motion of a power-driven machine or equipment to alter the electric circuit associated with the machine or equipment.

Lever Activated

Lever Activated

GEARED LIMIT

Load Protector

Use of two Cranes

• (i) When two or more pieces of equipment are used to lift a load, one qualified person shall be in charge of the operation. This person shall analyze the operation and instruct all personnel involved in the proper positioning and rigging of the load and the movements to be made.

Hand Signals

Load Marking

• 11-1.1.1 Rated Load Markings — Crane• The rated load of the crane shall be marked on

the crane, and if the crane has more than one hoisting unit, each hoist shall have its rated load marked on the hoist or its load block so that the rated load marking shall be legible from the ground or floor. The combined load on all hoists on the crane shall not exceed the rated load of the crane.

OPERATION• THE CAPACITY OF THE CRANE OR

HOISTING SYSTEM SHALL BE CLEARLY MARKED ON EACH SIDE OF CRANE.

• WARNING DEVICES SHALL BE USED TO WARN EMPLOYEES OF CRANE MOVEMENTS.

• WARNING DEVICES ARE REQUIRED ON CAB & REMOTE CONTROLLED CRANES. Bells, Buzzers, Lights, Ect

• WHEN OPERATING A CRANE OR HOIST THE OPERATOR WILL NEVER JOG OR REVERSE THE LOAD TO CAUSE THE LOAD TO SWING

• MOVE TROLLEY OR BRIDGE TO MEET LOAD AT SWING OF TRAVEL.

CHECKING THE LOAD AND MOTOR BRAKES

• LIFT THE LOAD A FEW INCHES OFF THE GROUND. Stop the lift and see if the load stops and holds.

• If the load keeps going, even if it is a few inches, the motor brake is to loose and needs adjusted.

• ONLY LIFT THE LOAD HIGH ENOUGH TO CLEAR ANY OBJECT IN YOUR PATH.

• NEVER EXCEED THE LOAD RATING ON YOUR SYSTEM.

• Must be clearly marked on each side of Beam

• When load is lifted over 5 feet, head protection is required.

• Operators should be trained in the use of fire extinguisher

KNOW THE LOAD

• THE OPERATOR IS NEVER TO EXCEED THE CAPACITY OF THE CRANE.

• Look on shippers tag for the weight or weigh the item on shipping scale

• If unsure always ask !

PATH OF OPERATOR

DAILY INSPECTION

1910.179

B30.2 OPERATION

• Daily inspections shall be performed by the crane operator prior to beginning shift and through observation during normal operation.

       

IN PLANT PRE-OPERATION SAFETY EXAMOVERHEAD CRANE PREOPERATION CHECK

LIST

1. TAGGED CRANE OR HOIST Check that crane or hoist is not tagged out -of-order

2. Control Devices Test run that all motions agree with control device marking.

OPERATING CONTROLS

ALL LABLES MUST BE LEGABLE

MUST HAVE STRAIN RELIEF ATTACHED

PENDENT MUST NOT HAVE ANY CRACKS

Need to be Color Coded, Shock resistant

Need to be permanently identified by function and direction

Pendent Warning tags

• 11-1.1.3 Warnings• On floor-operated hoists, warnings are to

be inaccordance with ASME B30.16.

• All Electric power or air-power hoists shall have affixed to the hoist, load block,or controls, a label or labels displaying information concerning operating procedures. B30.16 16-1.1.4

IN PLANT PRE-OPERATION SAFETY EXAMOVERHEAD CRANE PREOPERATION CHECK

LIST

3. Brakes - Check that all motions do not have excessive drift and that stopping distance is normal.

UPPER LIMIT SWITCH

• 4. HOISTS HAVE TWO BRAKING MEANS, LOAD & MOTOR BRAKE

• 5. TWO BLOCKING LOWER BLOCK COMES IN CONTACT WITH UPPER HOIST HOUSING

• 6. THE TROLLEY IS USED TO MOVE HOIST IN ONE OF TWO DIRECTIONS

• 7. THE BRIDGE IS USED TO MOVE THE HOIST & TROLLEY IN DIFFERENT DIRECTIONS

IN PLANT PRE-OPERATION SAFETY EXAMOVERHEAD CRANE PREOPERATION CHECK

LIST 8. Hooks - Check for damage, cracks, nicks,

gouges, deformations of the throat opening not to exceed (5%), wear on the saddle not to exceed 10% Check load bearing point , and hook has 0 deg twist

from the plane of the unbent hook. Check lower hook bearing for freedom of movement.

9. Hook Latch - If hook latch is required, check for proper operation.

Inspect All Hooks Even Hand Hoists

Pre Operation Inspection

10. Wire Rope - Check for broken wires, broken strands, kinks, any deformation or damage to rope structure. (Check for reduction in diameter)

Maximum Broken Wires 12 per lay, 4 per Strand

Check for Reduction in Diameter

Wire Rope Checks

• Wire rope check for internal or external corrosion

• Inner wire breakage

• Rope Stretch

• Loosening or tightening of rope lays

Damaged WIRE Ropes

Wire Rope Construction

NEVER USE A BAD ROPE!

Check Sheaves for Rope Prints

Outside Wires

Pre Operation Inspection

11. Hoist Chain - Check for cracks, nicks, gouges, wear and stretch-check that the chain is in the upper and lower sprockets and in the chain guide.

HOIST CHAIN IS GRADE 8 / CASE HARDEN

CHECK CHAIN FOR SCRAPING AT AREA OF USAGE

IF IN ANY QUESTIONS ASK SOME ONE.

Chain Saddle Wear

Chain Inspection

UPPER CHAIN SPROCKET

Take Chain to floor then check it.

Lower Block Checks

• 12. Check Sheaves Upper and Lower, Check Hook in block assembly. Check the Hook Bearing for free movement. Check Sheave Guard for damage

• 13. Check the Sheave pin and Sheaves for Proper Movement. Does the Lower Pin Rotate when the Hoist is raised?

• 14. Load testing to 100% to 125% max.

PART #2 OPERATION CHECK LIST

– 15. Reeving- Check that the wire rope is properly reeved and that rope parts are not twisted around each other

CHECK FOR PROPER WIRE ROPE REEVING

PART #2 OPERATION CHECK LIST

• 16. Limit Switches- Check that all upper limit devices stops the lifting motion of the hoist load block before striking any part of the hoist or crane. Check all limiting devices for proper operation. Trolleys ,Bridges, robot arms ect.

GEARED LIMIT

Manual Limit

Daily Checks

• 17. Oil leakage- Check for any sign of oil leakage on the crane and on the floor beneath the crane.

• 18. Unusual Sounds- Check for any unusual sounds from the crane or hoist mechanism while operating the crane or hoist.

• 19. Warning and Safety Labels- Check that all warning and other safety labels are not missing and are legible.

• 20. Housekeeping and Lighting- Check area for accumulation of material to prevent tripping or slipping

SPAN = CENTER OF CRANE WHEEL TO CENTER OF CRANE WHEEL

SKEWING= ONE SIDE OF BRIDGE IS AHEAD OF OTHER SIDE OF BRIDGE

ROPE DRUM= MUST HAVE TWO WRAPS ON DRUM AT LOWEST POINT.

Daily Operation Checks Part # 1

TAGGED CRANE OR HOIST - Check that crane or hoist is not tagged out –of- order Control Devices - Test run that all motions agree with control device marking. Brakes - Check that all motions do not have excessive drift and that stopping

distance is normal.

Hooks - Check for Damage, Cracks, Nicks, Gouges, Deformations of the throat opening, Wear on the saddle or load bearing point, and Twist. Refer to the manual furnished by the original crane manufacture

Hook Latch - If hook latch is required, check for proper operation.

Wire Rope - Check for broken wires, broken strands, kinks, any deformation or damage to rope structure. (no reduction in diameter)

Hoist Chain - Check for cracks, nicks, gouges, wear and stretch-check that the chain is in the upper and lower sprockets and in the chain guide.

Daily Operation Checks Part # 2

• Reeving- Check that the wire rope is properly reeved and that rope parts are not twisted about each other

• Limit Switches- Check that all upper limit device stops the lifting motion of the hoist load block before striking any part of the hoist or crane.

• Oil leakage- Check for any sign of oil leakage on the crane and on the floor beneath the crane.

• Unusual Sounds- Check for any unusual sounds from the crane or hoist mechanism while operating the crane or hoist.

• Warning and Safety Labels- Check that all warning and other safety labels are not missing and are legible.

• Housekeeping and Lighting- Check area for accumulation of material to prevent tripping or slipping

PENDENT MOUNT PRE CHECK LIST

• References• ASME/ANSI B30.2, "Overhead and Gantry Cranes (Top Running

Bridge, Single or Multiple Girder, Top Running Trolley Hoist)." • ASME/ANSI B30.9, "Slings." • ASME/ANSI B30.10, "Hooks." • ASME/ANSI B30.11, "Monorails and Under hung Cranes." • ASME/ANSI B30.16, "Overhead Hoists (Under hung)." • ASME/ANSI B30.17, "Overhead and Gantry Cranes (Top Running

Bridge, Single Girder, Under hung Hoist)." • ASME/ANSI B30.20, "Below-the-Hook Lifting Devices." • ASME/ANSI B30.21, "Manually Lever Operated Hoists." • Code of Federal Regulation, Title 29, Part 1910.179, "Overhead and

Gantry Cranes." • Code of Federal Regulation, Title 29, Part 1910.184, "Slings." • Code of Federal Regulation, Title 29, Part 1926.550, "Cranes and

Derricks." • Mechanical Engineering Department Design Safety Standards, Chapter

2.2, "Lifting equipment." • CMAA Specification No. 70, Specifications for Electric Overhead

Traveling Cranes. • CMAA Specification No. 74, Specifications for Top-Running and

Under-Running Single-Girder Electric Overhead Traveling Cranes Utilizing Under Running Trolley Hoist.

• NFPA 70, Article 610, Cranes and Hoists.