This document discusses safety procedures for crane operation. It begins with case studies of past crane accidents and then outlines hazards, dos and don'ts, and highlights of safety procedure HSE-S-228. Key points include only moving loads within a crane's capacity, keeping people clear of loads, and ensuring cranes and operators are certified. Operators must be trained and use standard hand signals with a competent signal person. Lifting plans are required for heavy lifts, multi-crane, or lifts over infrastructure.

1. SAFETY IN CRANE OPERATION
CONTENTS
• CASE STUDY
• HAZARDS IN CRANE OPERATION
• DO AND DO NOT
• HIGH LIGHTS ON HSE-S-228
(PROCEDURE FOR SAFE MATERIAL HANDLING)

2. SAFETY IN CRANE OPERATION
CASE STUDY # 1
A CRANE HITTING LPG LINE ….
•A crane hit against LPG pipe line while the crane was
marching below the overhead line. The line got bent.
•Negligence of...
•Goal post installed

3. SAFETY IN CRANE OPERATION
CASE STUDY # 2
A HYDRA GOT OVERTURNED…
A hydra (mobile crane) got overturned while
unloading support angles from a trailer. As soon as the
material was lifted from the trailer by 2 feet, a signal
was given by the trailer helper to move the trailer. As
the trailer started to move forward, the support angle
welded to the trailer body got entangled with the
suspended load of the hydra. The load was pulled with
the trailer resulting in the toppling of the hydra.

4. SAFETY IN CRANE OPERATION
CASE STUDY # 3
CRUSHED IN BETWEEN
THE CRANE PLATFORM & COUNTERWEIGHT…
A crane driver and a rigger were to lower a piece of
pipe into a well. After the crane was positioned, the
crane driver assured himself that the rotating cage
was free of people and obstacles and entered the
control cabin. Then, he slewed the jib crane to pick-up
the piece of the pipe. In the mean time, the rigger
climbed up the right-hand outrigger crane support
and leaned over the crane platform to reach the wire

5. SAFETY IN CRANE OPERATION
CASE STUDY # 3
CRUSHED IN BETWEEN
THE CRANE PLATFORM & COUNTERWEIGHT…
…..When the driver started slewing the crane, the
rigger was crushed between the crane platform and
the counterweight. The victim was found lying on the
crane platform and taken to hospital, where the
doctors diagnosed a fracture of the pelvis. The victim
died the next day.

6. SAFETY IN CRANE OPERATION
HAZARDS IN CRANE OPERATION
• OVERTURNING
• CONTACT WITH OVERHEAD
ELECTRICAL CABLES, PIPELINES
• CRANES HITTING WITH PERSONS
• SUDDEN RELEASE OF LOAD FROM
CRANE HOIST DRUM WHILE LIFTING
• IGNITION SOURCE FROM EXHAUST IN
HAZARDOUS AREA

7. SAFETY IN CRANE OPERATION
DO NOT
• WALK UNDER LOAD OR PERMIT OTHERS TO
DO SO.
• PARK NEAR EGDES OF PIT
• MOVE CRANE SO THAT IT HITS OVERHED
PIPELINES, ELECTRIC CABLES.
• LEAVE CRANE UNATTENDED WHILE LOAD IS
SUSPENDED.
• PICK-UP LOAD BEYOND ITS CAPACITY

8. SAFETY IN CRANE OPERATION
DO NOT
• EXCEED SPEED BEYONG 20 KM/HR.
• MOVE CRANE WITHOUT COMPETENT
SIGNAL MAN.
• PERMIT PERSONS TO RIDE ON BARE HOOK
OR A LOAD SUSPENDED FROM HOOK
• SLEEP INSIDE CABIN WHILE ON DUTY

9. SAFETY IN CRANE OPERATION
DO
• FAMALERISE YOURSELF WITH THE CRANE
• CHECK SWL (SAFE WORKING LOAD)
• FOLLOW STANDARD CRANE SIGNALS
• USE CORRECT LIFTING TACKLES
• LOWER BOOM TO GROUND LEVEL WHEN
NOT IN USE AS FAR AS POSSIBLE
• GET “ROAD CLOSURE PERMIT” IN CASE
HEAVY CRANE MOVEMENT ON ROAD IS
LIKELY TO CAUSE BLOCKAGE FOR
MOVEMENT OF THE EMRGENCY VEHICLES.

10. SAFETY IN CRANE OPERATION
DO
• ENSURE THAT AT LEAST 3 WINDINGS OF
ROPES AVAILABLE ON ROPE DRUMS.
• HAVE PROPER WARNING SIGNAL LIKE RED
FLAGS & LIGHTS WHILE TRAVELLING.
• MAINTAIN MINIMUM SAFE DISTANCE (6.0 M)
WHILE WORKING OR TRAVELLING NEAR
OVERHEAD CABLES.
•ENSURE ALL SAFETY DEVICES SUCH AS
REVERS HORN, LIMIT SWITCH ARE WORKING

11. SAFETY IN CRANE OPERATION
HIGHLIGHTS ON HSE-S-228
(PROCEDURE FOR SAFE MATERIAL HANDLING)
• SECTION-7 (Page # 10 to 23)
• 5-ANNEXURES
Annex. 3 Form # 10
Annex. 6a Standard hand signals for mobile cranes
Annex. 6b Standard hand signals for EOT/Semi-
gantry cranes
Annex. 7 Checklist for mobile crane / suspended
persons platform
Annex. 8 Checklist for EOT / semi-gantry / Jib
cranes / monorails

12. SAFETY IN CRANE OPERATION
HIGHLIGHTS ON HSE-S-228
(PROCEDURE FOR SAFE MATERIAL HANDLING)
SECTION 7.1.1
GENERAL SAFETY GUIDE LINES FOR CRANES
•Weight / Load, Radius, elevation, centre of gravity
•Approach to crane and equipment
•Counterweight required
•Trained crane driver & competent signal man
•Capacity chart/over load indicator
(capacity of crane at different radii for different boom angle)
•Boom angle Indicator
•Safety devices (General & operational)

13. SAFETY IN CRANE OPERATION
HIGHLIGHTS ON HSE-S-228
(PROCEDURE FOR SAFE MATERIAL HANDLING)
SECTION 7.1.3
REQUIREMENT FOR CRANE DRIVER & SIGNAL MAN
•Valid Access Pass
•Safe Driving Certificate
•Safety Inspection Certificate
•Medical examination once in a year for driver below 40 years
and once in six month for drivers of 40 years and above

14. SAFETY IN CRANE OPERATION
HIGHLIGHTS ON HSE-S-228
(PROCEDURE FOR SAFE MATERIAL HANDLING)
SECTION 7.3
LIFTING OF PERSONS BY CRANES
Suspended Personnel Platform(Proper cage)
•Limited to capacity of six persons
•FOS = 5
•Name Plate (empty & total loads, number of persons)
•Standard railing
(mid rail = 600 mm, hand rail = 1200 mm, toe guard = 100 mm)
•Enclosed sides of platform floor to mid rail

15. SAFETY IN CRANE OPERATION
HIGHLIGHTS ON HSE-S-228
(PROCEDURE FOR SAFE MATERIAL HANDLING)
SECTION 7.4
LIFTING / HOISTING PLAN
Hoisting Plan by the hoisting supervisor & reviewed by
plant maintenance, P&M cell & HSE department.
•Multi-crane lift (Lifting operations using more than one crane)
•Lifting Load more than 15.0 tons
•Deploying crane of capacity more than 150 tons
•Erection & dismantling of heavy duty crane (>50.0. Tons)
•Lifting over live process equipment or pipes
•Use of more than 80% crane rating

16. SAFETY IN CRANE OPERATION
HIGHLIGHTS ON HSE-S-228
(PROCEDURE FOR SAFE MATERIAL HANDLING)
SECTION 7.4
LIFTING / HOISTING PLAN
Review and approval by a qualified independent lifting
specialist
•Lifting Load more than 100 tons
•Load with wind area more than 100 m2
•Deploying crane of capacity more than 150 tons
•Boom or Jib length more than 100 meters

17. SAFETY IN CRANE OPERATION
HIGHLIGHTS ON HSE-S-228
(PROCEDURE FOR SAFE MATERIAL HANDLING)
COLOR CODING FOR CRANE INSPECTION
• 1 YEAR RED
• 2 YEAR YELLOW
• 3 YEAR BLUE
• 4 YEAR RED