osha r l ti c o tiosha regulations, crane operation ... · osha r l ti c o tiosha regulations,...

OSHA R l ti C O tiOSHA R l ti C O tiOSHA Regulations, Crane Operation & Rigging Awareness

OSHA Regulations, Crane Operation & Rigging Awareness

© 2008 Konecranes, Inc.

Konecranes in ShortKonecranes in Short

Sales EUR 1.2 billion (2008)

8500 Employees in More than 42 Countries

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The Largest Crane Service Company in the WorldGroup Headquarters


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Last updated 10-1-06

Business AreasBusiness Areas

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Cranes


Services Equipment Cranes

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Process Crane ApplicationsProcess Crane Applications

Paper Mill Steel Processing


Power Station Waste-to-Energy 3

Standard Lifting EquipmentStandard Lifting Equipment

Electric Overhead Traveling (EOT) Cranes


Capacity 1 - 80 tons1

Wire Rope and Chain HoistsWire Rope and Chain Hoists

CXT Wire Rope Hoists800 kg - 80 tons

XN Chain Hoists250 - 7500 kg

CXT Explosion ProofWire Rope Hoists500 kg - 80 tons


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OSHA Rules & RegulationsOSHA Rules & Regulations

Who can operate a Overhead Crane or Hoist 1910.179(a)(35) States: "Designated" means selected or ( )( ) g

assigned by the employer or the employer's representative as being qualified to perform specific duties.

1910.179(b)(8) Designated personnel - Only designated personnel shall be permitted to operate a crane covered by this section.

© 2008 Konecranes, Inc. 5

Inspection GuidelinesInspection Guidelines Inspection of Overhead Cranes & Hoist -1910.179 (j)(1) InitialInspection of Overhead Cranes & Hoist 1910.179 (j)(1) Initial

inspection. Prior to initial use all new and altered cranes shall be inspected to insure compliance with the provisions of this section.

A crane which has been idle for a period of 1 month or more but A crane which has been idle for a period of 1 month or more, but less than 6 months, shall be given an inspection conforming with requirements of paragraph (j)(2) of OSHA before placing in service. A crane which has been idle for a period of over 6 months shall be A crane which has been idle for a period of over 6 months shall be given a complete inspection conforming with requirements of paragraphs (j)(2) and (3) of OSHA before placing in service. S db h ll b i d l i ll i Standby cranes shall be inspected at least semi-annually in accordance with requirements of paragraph (j)(2) and (m)(2) of OSHA before placing in service.


Inspection FrequencyInspection Frequency

1910.179(j)(1)(ii) Inspection procedure for cranes in regular serviceis divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the critical components of the crane and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated

fas "frequent" and "periodic" with respective intervals between inspections


Frequent inspectionFrequent inspection

Frequent inspection – Pre-Shift, Daily, and monthly intervals. 1910.179(j)(1)(ii)(b) it is a visual and operational inspection done to notice any defects which might appear between regular inspections. This is required every shift.

Documentation: Hook, Chain, & Wire Ropes Inspection: Monthly inspection with a certification record which includes the date of inspection, the signature of the person who performed the inspection and the serial number, or other identifier, of the hook, chain or wire rope.

1910.179 (l)(1) Preventive maintenance. A preventive maintenance ( )( ) pprogram based on the crane manufacturer's recommendations shall be established.


Periodic InspectionsPeriodic InspectionsPeriodic InspectionsPeriodic Inspections 1910.179(j)(1)(ii)(b) Periodic inspection - 1 to 12-month intervals. Consisting (j)( )( )( ) p g

of the Frequent Inspection along with checking the structural, signs & labels, connections points, sheave, drums, shafts, axles, wheels, couplings, brakes, all devices, electrical components, wiring, covers, guards, bumpers, end trucks, trolley & runway rail, Runway structure, conductors system, , y y , y , y ,below the hook lifting devices, etc. This documentation is required to remain at a facility for a minimum of 3 years.

Once a component does not meet the proper standards then the owner/ employer has up to a maximum of(1) year to make the repairemployer has up to a maximum of(1) year to make the repair.

Section 5(a)(1) of the OSH Act, often referred to as the General Duty Clause, requires employers to "furnish to each of his employees employment and a place of employment which are free from recognized hazards that are p p y gcausing or are likely to cause death or serious physical harm to his employees". Section 5(a)(2) requires employers to "comply with occupational safety and health standards promulgated under this Act".


Crane Safety Pre QuizCrane Safety Pre Quiz

• What are the three main parts of a crane?

What is the first check to do at the controls of a crane?

• What are the three main parts of a crane?

What is the first check to do at the controls of a crane?• What is the first check to do at the controls of a crane?

• Runaway crane!! E-stop does not work? What do you do?

• Is a broken strand on a wire rope dangerous? Why?

• What is the first check to do at the controls of a crane?

• Runaway crane!! E-stop does not work? What do you do?

• Is a broken strand on a wire rope dangerous? Why?p g yp g y


h illh illWhat Will You Learn?What Will You Learn?

• Perform Daily Operator Checklist Procedure.Inspection of Crane & Equipment before starting• Inspection of Crane & Equipment before starting

• Rigging the load before a lift• The Rules of a Safe & Efficient Operatorp• Hand Signals• Understand basic rigging principals.


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Crane Accident Data OSHACrane Accident Data OSHACrane Accident Data - OSHACrane Accident Data - OSHA1. Loss of load due to poor rigging. 34%2 P f i i i t 22%2. Performing minor maintenance or inspection work while load in motion.

22%

3. Operating the crane without proper signals or authorization

18% signals or authorization.4. Failure of defective boom, rope or sheave.

14%

5. Failure due to overloading. 4%g %6. Handling load too near stationary equipment.

2%

7. Other causes. 6%


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DAILY CRANE OPERATOR CHECKLISTPre Operation Checks

DAILY CRANE OPERATOR CHECKLISTPre Operation ChecksPre Operation ChecksPre Operation Checks

ANSI B30.16-1.1.4Operating Procedure Label shall be affixed to all hoists HAND CHAIN, ELECTRIC OR AIR POWERED1 Th d WARNING th l d d i d t b i th l b l t th tt ti f1. The word WARNING or other legend designed to bring the label to the attention of an

operator. 2. Cautionary language against:

• a) lifting more than rated load• b) operating hoist with a twisted kinked or damaged chain• b) operating hoist with a twisted, kinked, or damaged chain• c) operating damaged or malfunctioning hoist• d) lifting people or loads over people• e) operating hoist with other than manual power• f) removing or obscuring warning label• g) operating a rope hoist with a rope that is not properly seated in its groove

3. If any abnormal condition or malfunction is found, report the problem to your supervisor.1) Visually inspect the ground for any hydraulic

or oil LEAKS Note all safety guards are in place.

• ? Are there any warning signs in place?• ? Is someone working on the crane?• ? Are any disconnects locked or tagged out? • Do not remove tags or locks from disconnects!


• Do not remove tags or locks from disconnects!411

4) With the EMERGENCY STOP POWER OFF BUTTON pushed in (if no stop b tt th ll i it h) t th t l f ll tibutton, then pull main power switch),operate the controls of all motions. Check that no motion occurs. The operator shall verify the SAFETY or EMERGENCY CONTROL will STOPS operation of ALL motions when a dangerous situation develops.

5) The operator checks each joystick or pushbutton of all controls for smooth h i l ti ti i STICKING BINDINGmechanical operation noticing any STICKING or BINDING .

6) Power is applied by pulling out the EMERGENCY STOP button and pressing the START button.Check Warning Devices if there are any (Strobes, bells, sirens). Using low speeds check that motions MOVE according to the labels onUsing low speeds, check that motions _MOVE according to the labels on controls.Up is up, down is down. Travel motions of bridge and trolley shall move in the directions indicated.Be aware of the braking action of all motions. Be aware of any unusual noises.

7) Drive the hook up and stop before activating upper limit. 7) Drive the hook up and stop before activating upper limit. SLOWLY inch the inch the hook into the upper limit stop position. The limit switch should cause the hook into the upper limit stop position. The limit switch should cause the hoisting motion to stop at the upper limit of travel.hoisting motion to stop at the upper limit of travel.

8) OSHA law states that the upper limit shall be tested every SHIFT In normal8) OSHA law states that the upper limit shall be tested every _SHIFT. In normal crane operation, the hoist Upper Limit is not to be used as an OPERATINGcontrol for stoppingthe load. It is to be considered as an Emergency limit switch only. In conditions where an


Upper Limit is used to limit up travel as part of crane operation, an ultimate or _BACKUP_ Upper Limit is installed.

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9) Drive hook to eye level to check the Hook Block.) y• Check the Hook Block for _CRACKS_ . Verify that the Hook

Block has the CAPACITY rating of the hoist. If the hook has a Latch, check that it is not malfunctioning and will keep loose _LIFTING_ _EQUIPMENT_ in the saddle of the hook.A crane Hook shall be discarded if: Throat opening is. A crane Hook shall be discarded if: Throat opening is stretched _15_ % or greater _10_ degree twist. Saddle wear of _15_ %.

• Check the Sheaves in the hook block for WEAR , CRACKS & CORRISON. Study the way the rope lays in the sheaves. Continuous overloading of a crane will result in the ropeContinuous overloading of a crane will result in the rope wearing a _PATTERN_ into the sheave surface.

10) The most important and critical component on a crane is the _WIRE_ _ROPE_.Three principles Parts of a Wire RopeD)CORE E) _WIRE_ F) _STRAND_

ANSI B30.2-2.4.2 - “A wire rope should be changed h th 12 d l di t ib t d b kwhen there are _12_ randomly distributed broken

wires in one lay, or _4_ broken wires in one strand of one lay. Check the wire rope for kinking or crushing .


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11) When possible, check _END_ connections of wire ) p _ _rope and chains. Check the Hoist Chain for excessive _WEAR , gouges, nicks, corrosion, STRETCH , distorted _LINKS_ . _TWIST. Powered hoists are allowed a _1.5____ % stretch. ***

12) Check running ropes for proper REEVING . Wire rope must be laying in the _LAND_ of the drum. A minimum of_2_ wraps of rope will be on the drum before attempting a lift.

13) The _CAPACITY_ ratings of load attachments or under the hook lifting devices shall be observed. “The rated load of the lifting device shall be marked on the main structure where it is visible.”


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SLING SAFETY *** OSHA 1910.184 c) Slings ***SLING SAFETY *** OSHA 1910.184 c) Slings ***Ch k Wi R Sli hi ki ki b k• Check Wire Rope Slings - crushing, kinking, broken wires

• Check Chain Slings - excessive wear, twist, stretch, distorted links

• Check Shackles & Eyebolts - bent or worn• Damaged or defective slings shall not be used.• Do not shorten slings by using knots or bolts.• Sling legs shall not be kinked.• Slings shall not be overloaded.• Slings used in a basket hitch shall have loads

balanced.• Securely attach slings to the load.• Slings shall be protected from sharp edges.

Keep all obstructions away from suspended loads• Keep all obstructions away from suspended loads.• Keep all personnel away from lifted or about to be

lifted loads.• Keep hands away from between the load and the

sling.Sh k l di i hibit d• Shock loading is prohibited.

• Do not pull a sling from under a load when the load is resting on the sling.

• Inspect slings before use.


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HANDLING THE LOADHANDLING THE LOAD• The crane operator is RESPONSIBLE for the safety of the lift.• The operator shall know the crane (bridge) lifting _CAPACITY_ and the lifting

capacity of each _HOIST_• The crane operator SHALL know the Weight of the Load about to be lifted.p g• Note the load ratings of lifting attachments -_SLINGS_ / _CHAINS_ /_BELOW_

the hook lifting devices.• WHAT CAN I LIFT?• The Ruling Factor -THE _LOWEST_ CAPACITY RATING g• Even if you are working with a rigger, you should understand safe rigging

practices. • When using slings or chains, lifting angles are critical. • The recommended SAFE lifting angle for a sling leg is _60_ degrees.• All three sides are the same length.

• SHOCK LOADING• Rapid Lowering > Sudden Stop =SHOCK LOAD!!!p g p• Unbalanced Load > Load Drops to Balance• Hoist Wire Rope > Stretched• SHOCK LOADING EFFECT IS MAGNIFIED IN SLING LEGS!!!

• SLING LEG STRESS


• SLING LEG STRESS• At a 30 degree sling angle, a 1000 pound load is subjecting a 2000 pound

load on the sling.916

ATTACHING THE LOAD - BASIC RIGGINGATTACHING THE LOAD - BASIC RIGGINGATTACHING THE LOAD - BASIC RIGGINGATTACHING THE LOAD - BASIC RIGGING


Angle Effects Loading on the Sling 17

Hand SignalsHand Signals


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Hand SignalsHand Signals


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Load is ready to be liftedLoad is ready to be lifted

• Slings shall be fully seated in the saddle of the hook.

• If there is a latch, it should be closed.• Ensure load is rigged properly.• No tools or loose material have been

left on the load.• Nobody on the load. • Everyone is clear of the load and

aware that the load is being movedaware that the load is being moved

• Runaway Crane!!!• Stop Button Does Not Work!!!• What Do You Do???• What Do You Do???• FIRST - WARN Personnel !!!• Should the Safety Stop button

malfunction, the operator’s only option is to switch OFF (open) the MAIN RUNWAY DISCONNECT_MAIN_ _RUNWAY DISCONNECT

(power switch).

• Do you know where the Runway?


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THE RULES OF A THE RULES OF A SAFE & EFFICIENT OPERATORSAFE & EFFICIENT OPERATOR

• Start all motions slowly. Stop slowly. Learn to judge the drift of each travel motion. Handle the load in a safe manner. Hook is high enough to clear any obstructionto clear any obstruction.

• Bridge should be brought in position so that it is directly over the load. • Floor Operated - automatic brake. • Judging distances reduces use of bridge brakes. • Start the bridge slowly and bring it up to speed gradually.• Reduce bridge speed before stopping - skidding of wheels when

stopping will result in flat spots.• Minimize inching (jogging) - causes wear to bridge motors, electric

brakes, and contactors (control switches).• Load swing is a PENDULUM ACTION of the load swinging back g g g• and forth on a flexible connection between crane and load.• Load swing is possible in both the _BRIDGE or TROLLEY directions. • Applying power to the bridge motor starts the crane immediately but the

load lags behind. When slowing down or decelerating, the MOMENTUMof the load causes it to swing ahead exerting a pulling force on theof the load causes it to swing ahead exerting a pulling force on the crane.

• The swing is greater when the length of the load from the crane is greater.

• Uncontrollable swinging of the load will result from traveling in high speed and then SUDDEN STOPPING


speed and then _SUDDEN_ _STOPPING.

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