Overhead And Gantry Crane Program And Standard Operating .
Overhead and Gantry Crane ProgramandStandard Operating ProcedureFor theUniversity of DaytonMarch 2012University of Dayton,300 College ParkDayton, Ohio 45469-2905Phone (937) 229-4503Fax (937) 229-4395http://campus.udayton.edu/ UDCampusPlanning/EHSRM/
TABLE OF .XIV.XV.XVI.XVII.XVIII.General Requirements .3Cabs .3Footwalks and Ladders . . 4Stops, Bumpers, Rail Sweeps and Guards .4Guards for Hoisting Ropes .5Brakes . .5Electrical Equipment . 6Hoisting Equipment . 8Warning Device . . 9Inspection . .9Testing . .11Maintenance .11Rope Inspection . 12Handling the Load 13Definitions 14Appendix A: Operational Safety Rules 18Appendix B: Crane Frequent Inspection Checklist 21Appendix C: Standard Operating Procedure Overview 222
I.General requirements.This procedure applies to overhead and gantry cranes, including semi gantry, cantilever gantry, wallcranes, storage bridge cranes, and others having the same fundamental characteristics. These cranes aregrouped because they all have trolleys and similar travel characteristics.New and existing equipment. All new overhead and gantry cranes constructed and installed on or afterAugust 31, 1971, shall meet the design specifications of the American National Standard Safety Codefor Overhead and Gantry Cranes, ANSI B30.2.0-1967.Modifications. Cranes may be modified and rerated provided such modifications and the supportingstructure are checked thoroughly for the new rated load by a qualified engineer or the equipmentmanufacturer. The crane shall be tested in accordance with Section XI.Wind indicators and rail clamps. Outdoor storage bridges shall be provided with automatic rail clamps.A wind-indicating device shall be provided which will give a visible or audible alarm to the bridgeoperator at a predetermined wind velocity. If the clamps act on the rail heads, any beads or weld flash onthe rail heads shall be ground off.Rated load marking. The rated load of the crane shall be plainly marked on each side of the crane, and ifthe crane has more than one hoisting unit, each hoist shall have its rated load marked on it or its loadblock and this marking shall be clearly legible from the ground or floor.Clearance from obstruction. Minimum clearance of 3 inches overhead and 2 inches laterally shall beprovided and maintained between crane and obstructions in conformity with Crane ManufacturersAssociation of America, Inc, Specification No. 61. Where passageways or walkways are providedobstructions shall not be placed so that safety of personnel will be jeopardized by movements of thecrane.Clearance between parallel cranes. If the runways of two cranes are parallel, and there are no interveningwalls or structure, there shall be adequate clearance provided and maintained between the two bridges.Designated personnel. Only designated personnel shall be permitted to operate a crane covered by thissection. Designated personnel must go through training for a crane initially, and refresher training everythree years, per industry consensus.Fire extinguishers. The UD ESO shall insure that operators are familiar with the operation and care offire extinguishers provided. Please call ESO at 229-4503 for training or replacement/inspection of fireextinguisher.II.Cabs.Cab location. The general arrangement of the cab and the location of control and protective equipmentshall be such that all operating handles are within convenient reach of the operator when facing the areato be served by the load hook, or while facing the direction of travel of the cab. The arrangement shall3
allow the operator a full view of the load hook in all positions. The cab shall be located to afford aminimum of 3 inches clearance from all fixed structures within its area of possible movement.Access to crane. Access to the cab and/or bridge walkway shall be by a conveniently placed fixedladder, stairs, or platform requiring no step over any gap exceeding 12 inches. Fixed ladders shall be inconformance with the American National Standard Safety Code for Fixed Ladders, ANSI A14.3-1956.Necessary clothing and personal belongings shall be stored in such a manner as not to interfere withaccess or operation.Tools, oil cans, waste, extra fuses, and other necessary articles shall be securely stored and shall not bepermitted to lie loose in or about the cab.Fire extinguisher. Carbon tetrachloride extinguishers shall not be used.Lighting. Light in the cab shall be sufficient to enable the operator to see clearly enough to perform hiswork.III.Foot walks and ladders.Location of foot walks. If sufficient headroom is available on cab-operated cranes, a foot walk shall beprovided on the drive side along the entire length of the bridge of all cranes having the trolley runningon the top of the girders. Where foot walks are located in no case shall less than 48 inches of headroombe provided.Construction of foot walks. Footwalks shall be of rigid construction and designed to sustain a distributedload of at least 50 pounds per square foot. Footwalks shall have a walking surface of antislip type.NOTE: Wood will meet this requirement. The inner edge shall extend at least to the line of the outsideedge of the lower cover plate or flange of the girderLadders and stairways. Gantry cranes shall be provided with ladders or stairways extending from theground to the foot walk or cab platform. Stairways shall be equipped with rigid and substantial metalhandrails. Walking surfaces shall be of an antislip type. Ladders shall be permanently and securelyfastened in place and shall be constructed in compliance with 1910.27. Hands shall be free fromencumbrances while personnel are using ladders. Articles which are too large to be carried in pockets orbelts shall be lifted and lowered by hand line.IV.Stops, bumpers, rail sweeps, and guards.Trolley stops. Stops shall be provided at the limits of travel of the trolley. Stops shall be fastened toresist forces applied when contacted. A stop engaging the tread of the wheel shall be of a height at leastequal to the radius of the wheel.Bridge bumpers. A crane shall be provided with bumpers or other automatic means providingequivalent effect, unless the crane travels at a slow rate of speed and has a faster deceleration rate due tothe use of sleeve bearings, or is not operated near the ends of bridge and trolley travel, or is restricted to4
a limited distance by the nature of the crane operation and there is no hazard of striking any object inthis limited distance, or is used in similar operating conditions. The bumpers shall be capable ofstopping the crane (not including the lifted load) at an average rate of deceleration not to exceed 3 ft/s/swhen traveling in either direction at 20 percent of the rated load speed.The bumpers shall have sufficient energy absorbing capacity to stop the crane when traveling at a speedof at least 40 percent of rated load speed. The bumper shall be so mounted that there is no direct shearon bolts. Bumpers shall be so designed and installed as to minimize parts falling from the crane in caseof breakage.Trolley bumpers. A trolley shall be provided with bumpers or other automatic means of equivalenteffect, unless the trolley travels at a slow rate of speed, or is not operated near the ends of bridge andtrolley travel, or is restricted to a limited distance of the runway and there is no hazard of striking anyobject in this limited distance, or is used in similar operating conditions. The bumpers shall be capableof stopping the trolley (not including the lifted load) at an average rate of deceleration not to exceed 4.7ft/s/s when traveling in either direction at one-third of the rated load speed.When more than one trolley is operated on the same bridge, each shall be equipped with bumpers orequivalent on their adjacent ends. Bumpers or equivalent shall be designed and installed to minimizeparts falling from the trolley in case of age.Rail sweeps. Bridge trucks shall be equipped with sweeps which extend below the top of the rail andproject in front of the truck wheels.V.Guards for hoisting ropes.If hoisting ropes run near enough to other parts to make fouling or chafing possible, guards shall beinstalled to prevent this condition.A guard shall be provided to prevent contact between bridge conductors and hoisting ropes if they couldcome into contact.Guards for moving parts. Exposed moving parts such as gears, set screws, projecting keys, chains, chainsprockets, and reciprocating components which might constitute a hazard under normal operatingconditions shall be guarded. Guards shall be securely fastened. Each guard shall be capable ofsupporting without permanent distortion the weight of a 200-pound person unless the guard is locatedwhere it is impossible for a person to step on it.VI.Brakes.Brakes for hoists. Each independent hoisting unit of a crane shall be equipped with at least one selfsetting brake, hereafter referred to as a holding brake, applied directly to the motor shaft or some part ofthe gear train.5
Each independent hoisting unit of a crane, except worm-geared hoists, the angle of whose worm is suchas to prevent the load from accelerating in the lowering direction shall, in addition to a holding brake, beequipped with control braking means to prevent overspeeding.Holding brakes. Holding brakes for hoist motors shall have not less than the following percentage of thefull load hoisting torque at the point where the brake is applied. 125 percent when used with a controlbraking means other than mechanical. 100 percent when used in conjunction with a mechanical controlbraking means. 100 percent each if two holding brakes are provided. Holding brakes on hoists shall haveample thermal capacity for the frequency of operation required by the service. Holding brakes on hoistsshall be applied automatically when power is removed. Where necessary holding brakes shall beprovided with adjustment means to compensate for wear. The wearing surface of all holding-brakedrums or discs shall be smooth. Each independent hoisting unit of a crane handling hot metal and havingpower control braking means shall be equipped with at least two holding brakes.Control braking means. A power control braking means such as regenerative, dynamic or countertorque braking, or a mechanically controlled braking means shall be capable of maintaining safelowering speeds of rated loads. The control braking means shall have ample thermal capacity for thefrequency of operation required by service.Brakes for trolleys and bridges. Foot-operated brakes shall not require an applied force of more than 70pounds to develop manufacturer’s rated brake torque. Brakes may be applied by mechanical, electrical,pneumatic, hydraulic, or gravity means. Where necessary brakes shall be provided with adjustmentmeans to compensate for wear. The wearing surface of all brakedrums or discs shall be smooth. Allfoot-brake pedals shall be constructed so that the operator’s foot will not easily slip off the pedal. Footoperated brakes shall be equipped with automatic means for positive release when pressure is releasedfrom the pedal. Brakes for stopping the motion of the trolley or bridge shall be of sufficient size to stopthe trolley or bridge within a distance in feet equal to 10 percent of full load speed in feet per minutewhen traveling at full speed with full load. If holding brakes are provided on the bridge or trolleys, theyshall not prohibit the use of a drift point in the control circuit. Brakes on trolleys and bridges shall haveample thermal capacity for the frequency of operation required by the service to prevent impairment offunctions from overheating.Application of trolley brakes. A drag brake may be applied to hold the trolley in a desired position onthe bridge and to eliminate creep with the power off.Application of bridge brakes. On cab-operated cranes with cab on trolley, a bridge brake of the holdingtype shall be required. On all floor, remote and pulpit-operated crane bridge drives, a brake ofnoncoasting mechanical drive shall be provided.VII.Electric equipment.General. Wiring and equipment shall comply with subpart S of this part. The control circuit voltageshall not exceed 600 volts for a.c. or d.c. current. The voltage at pendant push-buttons shall not exceed150 volts for a.c. and 300 volts for d.c. Where multiple conductor cable is used with a suspendedpushbutton station, the station must be supported in some satisfactory manner that will protect the6
electrical conductors against strain. Pendant control boxes shall be constructed to prevent electricalshock and shall be clearly marked for identification of functions.Equipment. Electrical equipment shall be so located or enclosed that live parts will not be exposed toaccidental contact under normal operating conditions. Electric equipment shall be protected from dirt,grease, oil, and moisture. Guards for live parts shall be substantial and so located that they cannot beaccidently deformed so as to make contact with the live parts.Controllers. Cranes not equipped with spring-return controllers or momentary contact pushbuttons shallbe provided with a device which will disconnect all motors from the line on failure of power and willnot permit any motor to be restarted until the controller handle is brought to the “off” position, or a resetswitch or button is operated. Lever operated controllers shall be provided with a notch or latch which inthe “off” position prevents the handle from being inadvertently moved to the “on” position. An “off”detent or spring return arrangement is acceptable. The controller operating handle shall be located withinconvenient reach of the operator. As far as practicable, the movement of each controller handle shall bein the same general directions as the resultant movements of the load. The control for the bridge andtrolley travel shall be so located that the operator can readily face the direction of travel. For flooroperated cranes, the controller or controllers if rope operated, shall automatically return to the “off”position when released by the operator. Pushbuttons in pendant stations shall return to the “off” positionwhen pressure is released by the crane operator. Automatic cranes shall be so designed that all motionsshall fail-safe if any malfunction of operation occurs.Remote-operated cranes shall function so that if the control signal for any crane motion becomesineffective the crane motion shall stop.Resistors. Enclosures for resistors shall have openings to provide adequate ventilation, and shall beinstalled to prevent the accumulation of combustible matter too near to hot parts. Resistor units shall besupported so as to be as free as possible from vibration.Provision shall be made to prevent broken parts or molten metal falling upon the operator or from thecrane.Switches. The power supply to the runway conductors shall be controlled by a switch or circuit breakerlocated on a fixed structure, accessible from the floor, and arranged to be locked in the open position.On cab-operated cranes a switch or circuit breaker of the enclosed type, with provision for locking in theopen position, shall be provided in the leads from the runway conductors. A means of opening thisswitch or circuit breaker shall be located within easy reach of the operator. On floor-operated cranes, aswitch or circuit breaker of the enclosed type, with provision for locking in the open position, shall beprovided in the leads from the runway conductors. This disconnect shall be mounted on the bridge orfoot walk near the runway collectors. One of the following types of floor-operated disconnects shall beprovided:Nonconductive rope attached to the main disconnect switch.An undervoltage trip for the main circuit breaker operated by an emergency stop button in thependant pushbutton in the pendant pushbutton station.7
A main line contactor operated by a switch or pushbutton in the pendant pushbutton station.The hoisting motion of all electric traveling cranes shall be provided with an overtravel limitswitch in the hoisting direction.All cranes using a lifting magnet shall have a magnet circuit switch of the enclosed type with provisionfor locking in the open position. Means for discharging the inductive load of the magnet shall beprovided.Runway conductors. Conductors of the open type mounted on the crane runway beams or overhead shallbe so located or so guarded that persons entering or leaving the cab or crane foot walk normally couldnot come into contact with them.Extension lamps. If a service receptacle is provided in the cab or on the bridge of cab-operated cranes, itshall be a grounded three-prong type permanent receptacle, not exceeding 300 volts.VIII. Hoisting equipment.Sheaves. Sheave grooves shall be smooth and free from surface defects which could cause ropedamage. Sheaves carrying ropes which can be momentarily unloaded shall be provided with closefitting guards or other suitable devices to guide the rope back into the groove when the load is appliedagain. The sheaves in the bottom block shall be equipped with close-fitting guards that will preventropes from becoming fouled when the block is lying on the ground with ropes loose. Pockets andflanges of sheaves used with hoist chains shall be of such dimensions that the chain does not catch orbind during operation. All running sheaves shall be equipped with means for lubrication. Permanentlylubricated, sealed and/or shielded bearings meet this requirement.Ropes. In using hoisting ropes, the crane manufacturer’s recommendation shall be followed. The ratedload divided by the number of parts of rope shall not exceed 20 percent of the nominal breaking strengthof the rope. Socketing shall be done in the manner specified by the manufacturer of the assembly. Ropeshall be secured to the drum as follows:No less than two wraps of rope shall remain on the drum when the hook is in its extreme lowposition.Rope end shall be anchored by a clamp securely attached to the drum, or by a socketarrangement approved by the crane or rope manufacturer.Rope clips attached with U-bolts shall have the U-bolts on the dead or short end of the rope.Spacing and number of all types of clips shall be in accordance with the clip manufacturer’srecommendation. Clips shall be drop-forged steel in all sizes manufactured commercially. Whena newly installed rope has been in operation for an hour, all nuts on the clip bolts shall beretightened.Swaged or compressed fittings shall be applied as recommended by the rope or cranemanufacturer.8
Wherever exposed to temperatures, at which fiber cores would be damaged, rope having anindependent wire rope or wire-strand core, or other temperature-damage resistant core shall beused.Replacement rope shall be the same size, grade, and construction as the original rope furnishedby the crane manufacturer, unless otherwise recommended by a wire rope manufacturer due toactual working condition requirements.Equalizers. If a load is supported by more than one part of rope, the tension in the parts shall beequalized.Hooks. Hooks shall meet the manufacturer’s recommendations and shall not be overloaded.IX.Warning device.Except for floor-operated cranes a gong or other effective warning signal shall be provided for eachcrane equipped with a power traveling mechanism.X.Inspection.Inspection classification. Initial inspection. Prior to initial use all new and altered cranes shall beinspected to insure compliance with the provisions of this policy / procedure.Inspection procedure for cranes in regular ser
These cranes are grouped because they all have trolleys and similar travel characteristics. New and existing equipment. All new overhead and gantry cranes constructed and installed on or after August 31, 1971, shall meet the design specifications of the American National Standard Safety Code for Overhead
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