Overhead Crane Safety And Prevention - Washington State
Overhead Crane Safetyand PreventionOverhead CraneSafety andPreventionFunding and support for this project has been provided by theState of Washington, Department of Labor & Industries, Safety & Health Investment Projects
Overhead Crane Safetyand PreventionTraining ObjectivesPart I – Crane Basics Types of Cranes The Parts of the Crane Inspecting the Crane Maintaining the CranePart II – Crane Safety Communication Basic Crane Safety Crane Safety Tools Warning Markers and Hand SignsPart III – Safe Crane Operational Procedures Loads and Lifts Testing Operational Qualifications Conduct of Operators
Overhead Crane Safetyand PreventionPart ICrane Basics
Overhead Crane Safetyand PreventionTypes of CranesGantry CranesBridge CranesJib CranesMonorail Cranes
Overhead Crane Safetyand PreventionTypes of CranesGantry CranesA type of crane that is built upon a bridge-like overheadstructure (gantry).
Overhead Crane Safetyand PreventionTypes of CranesBridge CranesAn overhead crane that consists of parallel runways with atraveling bridge.
Overhead Crane Safetyand PreventionTypes of CranesMonorail CranesA type of overhead crane thattravels suspended on a single rail.
Overhead Crane Safetyand PreventionTypes of CranesJib CranesA type of crane where a horizontal beam extends out to lift andmove a load along the beam.
Overhead Crane Safetyand PreventionCrane OperatorsHoist OperatorThe employee that uses the hoist tolift, lower, and move a load bymeans of an overhead crane.RiggerThe employee that isresponsible for balancingand securing the load to thehook, and will direct thehoist operator during thelift.
Overhead Crane Safetyand PreventionThe Parts of the CraneHoisting MechanismsWire RopeHoist BlockHookHoistDrum
Overhead Crane Safetyand PreventionThe Parts of the CraneEndTrucksOverhead PartsBridgeTrolleyRunawayBeamPendantBumpers
Overhead Crane Safetyand PreventionThe Parts of the CraneSafety PartsPower SupplyLoad RatingFire Extinguisher
Overhead Crane Safetyand PreventionInspecting the CraneInspections are one of the tools thatare used to help prevent machinebreakdowns and accidents.Three Types of Inspections:1. Day-To-Day (Daily) Inspections2. Frequent Inspections3. Periodic Inspections
Overhead Crane Safetyand PreventionInspecting the CraneDay-to-Day InspectionsDay-to-Day inspections should be smallinspections that occur before thebeginning of a shift or before using thecrane for the first time each work day.Day-to-Day inspections should include:-Inspect the wire rope for abnormalities and/ordamage.-Inspect the drum for proper rope alignment.-Inspect the area around the machine for anyindication of leaking or dripping fluids.-Inspect the block and hook for any cracks ordamage.-Visually inspect any bumpers for damage orabnormalities.- Visually inspect Limit Switches forabnormalities and test for proper functionality.
Overhead Crane Safetyand PreventionInspecting the CraneFrequent InspectionsFrequent Inspections are visual examinations by the operator or other designatedpersonnel with written records not required.Frequent Inspections should include:-Operating mechanisms for proper operation, proper adjustment, and unusual sounds.-Upper-Limit device(s) in accordance with ASME standards.-Tanks, Valves, pumps, lines and other parts of air or hydraulic systems for leakage.-Hooks and hook latches (if used) in accordance with ASME standards.-Hoist ropes and end connections in accordance with ASME standards.-Rope and proper spooling on the drum(s) and sheave(s).
Overhead Crane Safetyand PreventionInspecting the CranePeriodic InspectionsPeriodic Inspections are visual inspections of the equipment in place by a designatedperson making records of apparent external conditions to provide the basis for acontinuing evaluation.Periodic Inspections should include:-Deformed, cracked or corroded members.-Loose or missing bolts, nuts, pins or rivets.-Cracked or worn sheaves and drums.-Worn, cracked, or distorted parts.-Excessive wear of brake system parts.-Excessive wear of drive chain sprockets and excessive drive chain stretch.-Deterioration of controllers, master switches, contacts, limit switches, and pushbutton stations.-Gasoline, diesel, electric, or other power plants for proper operation.-Motion-limit devices that interrupt power or cause a warning to be activated.-Rope reeving for compliance with crane manufacturers design.-All function, instruction, caution, and warning labels or plates for legibility andreplacement.
Overhead Crane Safetyand PreventionInspecting the CraneCranes Not in Regular ServiceCranes that have been sitting idle for aperiod of 1 month or more, but lessthen 1 year, should have a FrequentInspection before entering service.Cranes that have been sitting idle for aperiod of 1 year or more, should have aPeriodic Inspection before enteringservice.
Overhead Crane Safetyand PreventionInspecting the CraneWire Rope InspectionsProperly inspecting the rope, and keeping an eye out for changes in the rope, isimportant to maintaining a safe work environment.
Overhead Crane Safetyand PreventionWire Rope InspectionsWavinessWaviness is a deformation in which the longitudinal axis of thewire rope takes the shape of a helix under either a loaded orunloaded condition.
Overhead Crane Safetyand PreventionWire Rope InspectionBasket/Lantern Deformation (Birdcage)A basket, or lantern, deformation, also known as a birdcage,develops when the outer layer of strands in the wire ropebecomes longer than the inner layer(s).
Overhead Crane Safetyand PreventionWire Rope InspectionCore Protrusion/DistortionA core protrusion is a special type of basket or lanterndeformation. In this case the rope imbalance is indicated by aprotrusion of the core of the wire rope.
Overhead Crane Safetyand PreventionWire Rope InspectionStrand Protrusion/DistortionA strand protrusion, or distortion, is when one of the outerstrands of the wire rope protrudes out.
Overhead Crane Safetyand PreventionWire Rope InspectionWire ProtrusionWhen certain wires, or groups of wires, will rise up on the side ofthe rope opposite to the sheave groove in the form of loops.
Overhead Crane Safetyand PreventionWire Rope InspectionLocal Increase in Diameter of RopeA local increase in rope diameter can occur and might effect arelatively long length of the rope.
Overhead Crane Safetyand PreventionWire Rope InspectionFlattened PortionA flattened portion of a rope is a section of the rope that has lostits circular form.
Overhead Crane Safetyand PreventionWire Rope InspectionKinksA kink is a deformation created by a loop in the rope which hasbeen tightened without allowing for rotation about its axis.
Overhead Crane Safetyand PreventionWire Rope InspectionOther Kink ExamplesNegative KinkPositive Kink
Overhead Crane Safetyand PreventionMaintenanceMaintenance Topics with Overhead Cranes:1. Preventive Maintenance2. Maintenance Procedures3. Adjustments and Repairs4. Rope Maintenance and Replacement
Overhead Crane Safetyand PreventionMaintenancePreventivePreventive Maintenance ismaintenance that is conducted beforean issue is identified.This includes, but is not limited to:- Fluid Replacement- Frequently Worked Parts- Pads- Hoses- Warning Devices and Signs
Overhead Crane Safetyand PreventionMaintenanceMaintenance ProceduresThe following precautions shall be taken before performing any maintenance on acrane:(1) The crane shall be moved to a location where it will cause the least interferencewith other cranes and operations in the area.(2) If a load is attached to the crane, it shall be landed.(3) All controllers shall be placed in the off position.(4) A lockout/tagout procedure shall be performed.(5) Warning signs and barriers shall be utilized on the floor beneath the cranewhere overhead maintenance work creates a hazard.(6) If the runway remains energized, stops or a signalperson, located full-time at avisual vantage point for observing the approach of an active crane, shall beprovided to help the persons performing maintenance with the machine.(7) A guard or barrier shall be installed between adjacent runways for the length ofany established work area.
Overhead Crane Safetyand PreventionMaintenanceAdjustments and RepairsThe following list is an example of components that might need adjustment orrepairs:(1) operating mechanisms on the crane(2) limit devices(3) control systems(4) brakes(5) damaged or worn hooks(6) critical parts that are cracked, broken,bent, or excessively worn(7) pitted or burned electrical contacts(8) function, instruction, caution, and warning labels
Overhead Crane Safetyand PreventionMaintenanceWire Rope Maintenance and ReplacementWhile maintenance precautions onthe rope can be taken, the strainon the rope will eventually lead tothe need for it to be replaced.If left in service long enough, wireropes will deteriorate andeventually break.
Overhead Crane Safetyand PreventionPart IICrane Safety Communications
Overhead Crane Safetyand PreventionBasic Crane Safety1. No one but a regularly authorized operator is allowed to use any crane.2. Do not carry a load over people on the floor. Sound warning devices to alertpersons nearby.3. Do not allow anyone to ride on a load carried by the crane or on the crane hook.4. Never try to stop the load with your hands or body.5. Inspect equipment daily before use. Always keep an eye out for changes in theequipment and safety area.6. Never pull a hoist by the pendant cable.7. Never leave the controls unattended while a load is suspended. Lower the load tothe floor if it is necessary to leave the controls.8. Before moving the trolley or bridge, be sure that the hook is high enough to clearall obstacles.9. Do not drag slings, chains, or lifting devices out from under loads that have beenlanded.10. If you are asked to do something that you do not feel comfortable or safe about,contact a foreman or supervisor for advice.
Overhead Crane Safetyand PreventionCrane Safety ToolsThe following section discusses some of thesafety tools used around overhead cranes inthe workplace. Tagged Crane or HoistWarning DevicesWarning Signs and MarkingsHand Signals
Overhead Crane Safetyand PreventionCrane Safety ToolsTagged Cranes and HoistsA crane, and/or equipment, thatis shutdown for variousreasons should be locked outand tagged out.Do not operate or use anyequipment that is lockedand/or tagged out. Speakwith a supervisor or foremanregarding the operations ofany equipment.
Overhead Crane Safetyand PreventionCrane Safety ToolsWarning DevicesA warning device is any device thathelps bring attention to people in thearea of the crane being in operation.(1) Manually operated gong(2) Power-operated bell, siren, or horn(3) Rotating beacon(4) Strobe light
Overhead Crane Safetyand PreventionWarning Signs and MarkingsWarning signs and markings should be present in allworkplaces operating a crane to communicate dangersand hazards with the machine.
Overhead Crane Safetyand PreventionHand SignalsStandardHand signals are used when voicecommunications cannot be heard.
Overhead Crane Safetyand PreventionHand SignalsStandardHoistLowerWith forearm vertical, forefingerpointing up, move hand in smallhorizontal circle.With arm extended downward,forefinger pointing down, move hand insmall horizontal circle.
Overhead Crane Safetyand PreventionHand SignalsStandardBridge TravelTrolley TravelArm extended forward, hand open andslightly raised, make pushing motion indirection of travel.Palm up, fingers closed, thumb pointingin direction of motion, jerk handhorizontally.
Overhead Crane Safetyand PreventionHand SignalsStandardStopEmergency StopArm extended, palm down, move armback and forth horizontally.Both arms extended, palms down, movearms back and forth horizontally.
Overhead Crane Safetyand PreventionHand SignalsStandardMultiple TrolleysMove SlowlyHold up one finger for block marked “1”and two fingers for block marked “2”.Regular signals follow.Use one hand to give any motion signaland place other hand motionless in frontof hand giving the motion signal.
Overhead Crane Safetyand PreventionHand SignalsStandardMagnet is DisconnectedCrane operator spreads both hands apart – palms up.
Overhead Crane Safetyand PreventionHand SignalsSpecialIn some cases more communication is neededpast the standard hand signals.1. Special operations may require additions toor modifications of standard signals.2. Special signals shall be agreed upon andunderstood by the signal person and theoperator.3. Special signals shall not conflict withstandard signals.
Overhead Crane Safetyand PreventionDiscussion: Can you identify the safetyviolations in this drawing?
Overhead Crane Safetyand PreventionPart IIISafe Crane Operational Procedures
Overhead Crane Safetyand PreventionLoadsAs much as we discuss safety with thecrane itself, the preparation andhandling of the load is just as much of afactor in the safety of a lift.
Overhead Crane Safetyand PreventionLoadsLoad Marking and Weight of LoadsLoad Markings are posted on all sides of the crane and onthe hoist block.Knowing the load weight is important topreventing accidents with the lift.
Overhead Crane Safetyand PreventionLoadsAttaching the LoadImportant Factors:1. Use appropriate sling/hardware (Work Load Limit)2. Sling Angle3. Center of Gravity Alignment
Overhead Crane Safetyand PreventionLoadsMoving the Load1. The appointed person directing the lift shall ascertain that the load and hoistdevices are attached and functioning properly.2. During the lift there should be no sudden acceleration or deceleration of the load.3. Cranes shall not be used for side pulls except when specifically authorized.4. The operator should avoid carryingloads over people.5. The load shall not be lowered belowthe point where two wraps of roperemain on the hoisting drum.6. No suspended load should ever be leftunattended by the crane operator.
Overhead Crane Safetyand PreventionPlanned Engineered LiftsIn the case that a lift needs tobe made that is heavier thenthe rated load of the crane aplanned engineered lift may bepossible. These lifts shall betreated as a special andseparate event.
Overhead Crane Safetyand PreventionTestingWhile inspections are visual assessments of the crane and equipment, tests examinethe operation and function of the machine.
Overhead Crane Safetyand PreventionTestingOperational TestsOperational testing are tests that examine the operation of all ofthe crane parts without a load.(1)Lifting and lowering(2)Trolley travel(3)Bridge travel(4)Hoist-limit devices(5)Travel-limiting devices(6)Locking and indicating devices
Overhead Crane Safetyand PreventionTestingLoad TestsA load test examines the cranes abilityto lift and move a load.(1) Hoist the test load a distance toassure that the load is supported.(2) Transport the test load by means ofthe trolley for the full length of thebridge.(3) Transport the test load by means ofthe bridge for the full length of therunway.(4) Lower the test load, and stop andhold the test load with the brakes.
Overhead Crane Safetyand PreventionOperational QualificationsEach type of crane and work setting have differentqualifications for operating overhead cranes.Cranes shall be operated only by the following qualified persons:(1)Designated persons(2)Trainees under the direct supervision of a designated person(3)Maintenance and test personnelCheck with your employer for more information on the requirements for workingwith overhead cranes in your workplace.
Overhead Crane Safetyand PreventionOperational QualificationsFloor and Remote OperatorsFloor and Remote HoistOperators shall be requiredby the employer to pass apractical operatingexamination.The use of remote-controlequipment involves such a widevariety of service requirement andconditions that each installationshould be carefully analyzed.
Overhead Crane Safetyand PreventionOperational QualificationsCab Operators(1) Have vision of at least 20/30 inone eye and 20/50 in the other(2) Be able to distinguish color(3) Be able to hear adequately for aspecific operation(4) Have sufficient strength,endurance, agility, coordinationand speed of reaction to meetthe demands of the equipment operation(5) Not have evidence of physical defects or emotional instability that couldrender hazard to the operator or others(6) Not have any evidence of being subject to seizures or loss of physicalcontrol
Overhead Crane Safetyand PreventionConduct of the Operators(1) The operators and employees shall not engage in any practice that will divertattention while actually engaged in operating the crane.(2) When physically, or otherwise unfit, an operator shall not engage in the operationof the equipment.(3) The operator shall be familiar with, and follow all signals from appropriate peopleduring a lift.(4) Each operator shall be responsible for those operations under the operator’scontrol.(5) Each operator shall activate the warning device before starting the bridge/trolley,and intermittently during travel of the crane.
Overhead Crane Safetyand PreventionConduct of the Operators(6) The operator shall not close the main switch until certain that no worker is on oradjacent to the crane.(7) The operator shall be familiar with the equipment and its proper care.(8) Contacts with runway stops or other cranes shall be made with extreme caution.(9) Before the operator performs any maintenance work on the crane, the operatorshall lock and tag the main switch in the de-energized position.
Overhead Crane Safetyand PreventionPart IVCase Studies
Overhead Crane Safetyand PreventionCase Study #1An employee was being trained for the first time inthe work area by the head mechanic. The employeewould replace the mechanic when he went on vacation.The employee and the mechanic were on top of theoverhead crane doing repairs. The overhead craneoperator signaled to the mechanic that he needed to passover the mechanic and the employee. They both bentdown on the catwalk. As the first section of the overheadcrane passed over them, the bottom of the crane knockedthe wire cutter off the gear box. The employee stood upto see what fell. The mechanic tried to tell him to getback down before the second section of the crane passedover; however, the employee was struck in the head andkilled.
Overhead Crane Safetyand PreventionCase Study #1 - Questions1. Identify the safety failure in this accident.The crane should not have passed overhead of the workerson the catwalk.2. What safety Maintenance Precaution shouldhave been added to this situation?A signal person with full view of the operation shall be providedto help the persons performing maintenance with the machine;The crane shall be moved to a location where it will cause theleast interference with other cranes and operations in the area.
Overhead Crane Safetyand PreventionCase Study #2An employee was working inside a large concrete pipemold setting up the core. The core was put in place by anoverhead bridge crane. The employee had unhooked thecore from the slings and the crane operator, operatingfrom a cab, had moved the cab over the mold to makesure it was straight. The operator was moving the cabback toward the wall and raising the block out of themold at the same time. He accidentally raised the blockall the way up. The upper limit switch failed to work; ittwo-blocked and broke the wire rope, dropping a morethan 300 lb block back down inside the mold. The loadstruck the employee, breaking his neck. He washospitalized.
Overhead Crane Safetyand PreventionCase Study #2 - Questions1. Identify a failure point in this accident.Limit Switch failure, Employee working too close tothe overhead load.2. What kind of preventative measure couldhave identified the limit switch failure?Testing of the lim
Overhead Crane Safety and Prevention Basic Crane Safety 1. No one but a regularly authorized operator is allowed to use any crane. 2. Do not carry a load over people on the floor. Sound warning devices to alert persons nearby. 3. Do not allow anyone to ride on a load carried by the crane or on the crane hook.
Double Girder Overhead Traveling Crane Double Beam EOT Crane P r o d u c t s & S e r v i c e s. MATERIAL HANDLING CRANES Material Lifting Crane Heavy Duty Crane Electric Overhead Travel Crane Single Beam Crane P r o d u c t s & S e r v i c e s. GANTRY CRANE Portable Gantry Crane Heavy Duty Gantry Crane Semi
Traveling Crane Electric Overhead Cranes EOT Girder Crane O u r P r o d u c t s. ELECTRIC CRANES Overhead EOT Crane EOT Overhead Crane Material Handling EOT Crane Overhead Traveling Crane O u r P r o d u c t s. OTHER PRODUCTS: Wire Rope Hoist Free Standing Cranes Material Handling
o 3.3.9 Bulk-handling crane o 3.3.10 Loader crane Overhead crane: An overhead crane, also known as a bridge crane, is a type of crane where the hook-and-line mechanism runs along a horizontal beam that it self runs along two widely separated rails. Often it is in a long factory building and runs along rails along the building's two long walls .
An Electric Overhead Traveling Crane or an Overhead travelling crane, also known as an Overhead crane or as a Suspended crane is a crane, which you usually see inside a factory or a warehouse. It travels on rails high above the ground. It normally has three different movements, which are driven by electric motors. Hoist is the drive lifting .
Double Box Girder of Eot Crane A 10 -ton capacity overhead crane of overall length 12.5m was selected for design optimization. Initially the self-mass of crane girder was found to be 7.3 tons. The configuration of the overhead crane is shown in Fig. 1.The overhead crane consists of two girders, two end carriage assemblies
Double girder overhead crane Single girder overhead crane Electric Hoist Çift Kiriş Arabalı Portal Vinçler Monoray Arabalı Portal Vinçler Topal Portal Sistemleri Portal Vinçler Gantry Crane Double Girder Gantry Crane Single Girder Gantry Crane Semi-Gantry Crane Pergel Vinç Duvara Monte Pergel Vinç Duvarda Hareket Eden Pergel Vinç
2. Crane Equipments 11 7\. Incell Crane "l-h 30/5-ton Electric Overhead Crane 'C}. 3-ton Electric Overhead Crane 5K 2-ton Electric Monorail Hoist n\. 30-ton Fixed Hoist Hj-. 3-ton Electric Suspension Crane Chapter 2. Overview of Technology Development Status 12 Section 1. Design Requirements 1. General 2. Crane Design Requiremenrs 7\. Over Head .
IN ARTIFICIAL INTELLIGENCE Stuart Russell and Peter Norvig, Editors FORSYTH & PONCE Computer Vision: A Modern Approach GRAHAM ANSI Common Lisp JURAFSKY & MARTIN Speech and Language Processing, 2nd ed. NEAPOLITAN Learning Bayesian Networks RUSSELL & NORVIG Artificial Intelligence: A Modern Approach, 3rd ed. Artificial Intelligence A Modern Approach Third Edition Stuart J. Russell and Peter .
