overhead_crane_operator_safety_manual.ppt

Overhead Crane Operators
Overhead Crane Operators

Note:- 1) Crane weight and wheel loads are approx. Values given to evaluate size of supporting
Note:- 1) Crane weight and wheel loads are approx. Values given to evaluate size of supporting
structure.
structure.
2) Pendent push button is suspended from Hoist / crab.
2) Pendent push button is suspended from Hoist / crab.
3) Hook approach: a) Hook position is assumed at center of rope drum
3) Hook approach: a) Hook position is assumed at center of rope drum
b) Dimensions given are without consideration of DSL and its location
b) Dimensions given are without consideration of DSL and its location
4) A. C. Disc brakes are provided for all motors
4) A. C. Disc brakes are provided for all motors
5) For SG - EOT Hoist with Electric Trolley will be supplied. For DG - EOT Hoist with crab assembly
5) For SG - EOT Hoist with Electric Trolley will be supplied. For DG - EOT Hoist with crab assembly
will be supplied.
will be supplied.
6) Dimensions E & F will change for higher lifts.
6) Dimensions E & F will change for higher lifts.
7) For every fraction of spans above the specified span Dimensions of nearest higher span shall be
7) For every fraction of spans above the specified span Dimensions of nearest higher span shall be
applicable.
applicable.
8) Cranes can be offered to suit higher size of runway rails on request.
8) Cranes can be offered to suit higher size of runway rails on request.
9) Data tolerance + 10%
9) Data tolerance + 10%
10) For SG - EOT Diameter of long travel wheel is 150 and 250 for cranes upto 3Tx12 mtrs. and 5Tx3
10) For SG - EOT Diameter of long travel wheel is 150 and 250 for cranes upto 3Tx12 mtrs. and 5Tx3
mtrs to 10T x 12 mtrs. respectively.
mtrs to 10T x 12 mtrs. respectively.
11) (L) Lift on crane = Height of Rail (R) + C - K
11) (L) Lift on crane = Height of Rail (R) + C - K
Selection Of Over Head Crane

@ An overhead crane
@ An overhead crane
operator’s job is very
operator’s job is very
important
important
@ Employers and employees need to be
@ Employers and employees need to be
aware that all cranes are different and may
aware that all cranes are different and may
have specific operating, safety, inspection and
have specific operating, safety, inspection and
maintenance requirements.
maintenance requirements.
@ It is essential that you have the
@ It is essential that you have the
manufacturers operating manuals
manufacturers operating manuals

OVERHEAD CRANE
OVERHEAD CRANE
SAFETY
SAFETY

OVERHEAD AND GANTRY CRANE
OPERATION
OPERATION
 Hoist operators must inspect equipment daily
Hoist operators must inspect equipment daily
before use.
before use.
 Do not operate a crane or hoist if limit switches,
Do not operate a crane or hoist if limit switches,
steel ropes, chains or other components are worn
steel ropes, chains or other components are worn
or in disrepair.
or in disrepair.
 Replace nylon or web slings immediately if
Replace nylon or web slings immediately if
excessively worn.
excessively worn.

OPERATION
 Associates in the direction of travel
should be warned to move and remain
clear of a lifted load at all times.
 Loads should not be suspended over personnel
below.
 Under no circumstances may anyone ride the
hook or load.
 Directional movement should be made
smoothly and deliberately. Avoid rapid
movements in any direction.

OPERATION
 Do not exceed the rated load
capacity of the crane, hoist,
chain, cable, slings, or other
component.
 Slings, load chains and other lifting devices must
be fully and securely seated in the hook before
moving a load. Remove slack from the sling,
chain, or cable before lifting a load.

OPERATION
 Use the following practices to avoid swinging
loads:
 Locate the hoist directly above the
lifting point of the load before lifting.
 Lower loads directly below the hoist.
 Keep hoisting ropes vertical. Do not
pull or push the load.
 Maintain two full wraps of cable on the
hoisting drum.

OPERATION
 When lifting loads at or near capacity, test the
hoist brakes by returning the master switch or
push button to the “OFF” position after raising
the load a few inches off the floor. If the brakes
do not hold, lower the load to the floor slowly
and do not operate the crane. Report the
situation immediately and DO NOT USE until
repaired.

OPERATION
 Ensure that all loads are lifted high enough to
clear obstructions before moving the bridge or
trolley. Whenever possible, maintain a minimum
clearance of one foot above loads and to the sides.
Raise the load only to the height necessary to
clear lower objects.
 Never pull a hoist by the pendant
cable.

OPERATION
 Never leave the controls unattended while a load
is suspended. If it becomes necessary to leave the
controls, lower the load to the floor.
 Familiarize yourself with the location of the
disconnect switch.
 If loss of electrical power occurs, place controls
in the “OFF” position to prevent unexpected
startup upon restoration of power.

OPERATION
 Disconnect power to a hoist that is
unsafe or in need of repair. Arrange to
have the disconnect switch locked and
the control panel tagged with an “Out
of Order” or “Do Not Operate” tag.
Never operate a hoist that has been
tagged with an “Out of Order” or “Do
Not Operate” tag, or is your opinion,
UNSAFE TO OPERATE…

HOISTS / CRANES
Daily Inspection Checklist
 Check for any loose or missing parts.
 Check end stops. End stops prevent the
trolley from running off the beam.
 Know the location of disconnect
switch that will cut the power off
only to the hoist or crane. Be sure
it is readily accessible and not blocked.

HOISTS / CRANES
 Make sure all control buttons are
labeled to indicate their function.
Operate each button to make sure
it functions properly, releases
immediately, and does not stick.
N
N
W
W
S
S
E
E
 Check upper hoist limit switch by slowly raising
the block to trip the switch.
 Lower the hoist block to activate the lower limit
switch if the hoist is so equipped, leaving at least
one turn of rope on the take-up drum.

HOISTS / CRANES
 Make sure wire rope is properly seated in its
drum and sheave grooves without any slack or
overlapping.
 Operate the crane or hoist several feet in each
direction that it travels. Listen for any unusual
noises. Look for any jerky movements.
 When moving an A frame hoist, take care to
ensure that the wheels on each side stay on the
track.

HOISTS / CRANES
 Check all hooks. Hooks should not be cracked,
stretched, bent, or twisted. Each hook must have
a safety latch that automatically closes the
throat of the hook. If the latch is bent, spring
is broken, or is otherwise damaged the latch must
be repaired before use. Hooks should rotate
freely in block assembly without any “grinding”
felt or heard.

HOISTS / CRANES
 Check the block assembly for structural damage
or cracks in any components. Sheaves should
rotate freely without any grinding felt or heard
coming from the bearings. The sheave guard
must be unbroken and intact. No part of the
sheave guard should be in contact with the wire
rope or sheave.

HOISTS / CRANES
 Check the wire rope by lowering the block to the
lowest level and looking for the following conditions.
If any of these conditions are observed, they should be
reported immediately.
 Reduced diameter of the rope. This may indicate
the rope has been stretched, has lost its inner core
support, or has worn outside wires.
 Any number of broken strands of wires.
 Kinked, crushed, cut, or
“bird caged” wiring, or wiring
with heat damage.

HOISTS / CRANES
 Check load chain for damage, wear at contact
points, cracks, or distorted (bent, twisted, or
stretched) links. Inspect all mechanical coupling
links to insure linking pins are secure and in good
condition. Report unsafe conditions immediately.

HOISTS / CRANES
 Check the condition and capacity
of nylon or synthetic web slings.
Capacity ratings must be legible
on the manufacturer’s label. The
capacity of the sling being used
must be adequate for the load and
attachment method. Replace
slings immediately if excessive
wear occurs.

@ The minimum qualifications for an
@ The minimum qualifications for an
employee selected to operate a crane are as
employee selected to operate a crane are as
follows:
follows:
* Corrected vision
* Corrected vision
* Effective use of all 4 limbs
* Effective use of all 4 limbs
* Sufficient height to operate the controls & in
* Sufficient height to operate the controls & in
to the working area.
to the working area.
* coordination between eyes, hands, and feet.
* coordination between eyes, hands, and feet.
* Be free of known convulsive disorders and
* Be free of known convulsive disorders and
episodes of unconsciousness.
episodes of unconsciousness.
* Every 3 Year medical Fitness Check up is
* Every 3 Year medical Fitness Check up is
necessary
necessary

Sample Permit
Sample Permit
CRANE OPERATOR PERMIT
(Firm Name)
Operator’s Name:
Operator’s Number:
Is Authorized To Operate: (Insert Type of crane/Crane(s) Authorized)
Restrictions: (Explanation of Restrictions)
Date Issued: (Month-Day-Year
Date Expiring (Month-Day-Year)
By Issuing Authority: _______________________________________________
Title

Personal Protective Equipment
Personal Protective Equipment
Head Protection
Head Protection
PROPER
PROPER
CLOTHING &
CLOTHING &
DRESS
DRESS
Safety Foot
Safety Foot
Wear
Wear
Hearing Protection
Hearing Protection
Face Protection
Face Protection
Hand Protection
Hand Protection
Respirators
Respirators
Fall Protection
Fall Protection
Special Clothing
Special Clothing

Shift/Operator Inspection Checks
Shift/Operator Inspection Checks
Inspection Item
Inspection Item Description of Inspection Check Points
Description of Inspection Check Points
Tagged Crane or Hoist
Tagged Crane or Hoist Check that crane or hoist is not tagged with an out-of-order sign.
Check that crane or hoist is not tagged with an out-of-order sign.
Control Devices
Control Devices Test run that all motions agree with control device markings.
Test run that all motions agree with control device markings.
Brakes
Brakes Check that all motions do not have excessive drift and that stopping distances are
Check that all motions do not have excessive drift and that stopping distances are
normal
normal
Hook
Hook Check for damage, cracks, nicks, gouges, deformations of the throat opening, wear
Check for damage, cracks, nicks, gouges, deformations of the throat opening, wear
on saddle or load bearing point, and twist. Refer to the manual furnished by the
on saddle or load bearing point, and twist. Refer to the manual furnished by the
original manufacturer of the crane.
original manufacturer of the crane.
Hook Latch
Hook Latch If a hook latch is required, check for proper operation.
If a hook latch is required, check for proper operation.
Wire Rope
Wire Rope Check for broken wires, broken strands, kinks, and any deformation or damage to
Check for broken wires, broken strands, kinks, and any deformation or damage to
the rope structure.
the rope structure.
Revving
Revving Check that the wire rope is properly revved and that rope parts are not twisted about
Check that the wire rope is properly revved and that rope parts are not twisted about
each other.
each other.
Limit Switches
Limit Switches Check that the upper limit device stops lifting motion of the hoist load block before
Check that the upper limit device stops lifting motion of the hoist load block before
striking any part of the hoist or crane.
striking any part of the hoist or crane.
Oil Leakage
Oil Leakage Check for any sign of oil leakage on the crane and on the floor area beneath the
Check for any sign of oil leakage on the crane and on the floor area beneath the
crane.
crane.
Unusual Sounds
Unusual Sounds Check for any unusual sounds from the crane or hoist mechanism while operating
Check for any unusual sounds from the crane or hoist mechanism while operating
the crane or hoist
the crane or hoist
Warning and Safety Labels
Warning and Safety Labels Check that warning and other safety labels are not missing and that they are legible.
Check that warning and other safety labels are not missing and that they are legible.
Housekeeping and
Housekeeping and
Lighting
Lighting
Check area for accumulation of material, trip or slip hazards, and poor lighting
Check area for accumulation of material, trip or slip hazards, and poor lighting

@ A hoisting limit switch on a crane or hoisting device
@ A hoisting limit switch on a crane or hoisting device
must not be used as an operating control unless the
must not be used as an operating control unless the
crane is also equipped with a backup limit switch.
crane is also equipped with a backup limit switch.
Operating Points
Operating Points
@ A load must not be lowered below a point where
@ A load must not be lowered below a point where
less than 2 full wraps of wire rope remain on the
less than 2 full wraps of wire rope remain on the
hoisting drum.
hoisting drum.
@ If there is doubt, safety of a crane or hoisting, the
@ If there is doubt, safety of a crane or hoisting, the
operator must immediately stop the crane and report the
operator must immediately stop the crane and report the
condition creating the doubt to the supervisor.
condition creating the doubt to the supervisor.
@ An operator must only respond to signals from the
@ An operator must only respond to signals from the
employee directing the lift
employee directing the lift
@ Compressed gases can only be lifted by a cradle or
@ Compressed gases can only be lifted by a cradle or
enclosed platform.
enclosed platform.

Standard Hand Signals For Controlling Overhead
And Gantry Cranes
And Gantry Cranes
HOIST. With forearm vertical,
HOIST. With forearm vertical,
forefinger pointing up, move
forefinger pointing up, move
hand in small horizontal circle
hand in small horizontal circle
LOWER. With arm extended
LOWER. With arm extended
downward, forefinger pointing
downward, forefinger pointing
down, move hand in small
down, move hand in small
horizontal circle.
horizontal circle.

And Gantry Cranes
And Gantry Cranes
BRIDGE TRAVEL. Arm extended
BRIDGE TRAVEL. Arm extended
forward, hand open and slightly
forward, hand open and slightly
raised, make pushing motion in
raised, make pushing motion in
direction of travel.
direction of travel.
TROLLEY TRAVEL. Palm up,
TROLLEY TRAVEL. Palm up,
fingers closed, thumb
fingers closed, thumb
pointing in direction of
pointing in direction of
motion, jerk hand horizontally.
motion, jerk hand horizontally.

And Gantry Cranes
And Gantry Cranes
STOP. Arm extended, palm
STOP. Arm extended, palm
down, hold position rigidly.
down, hold position rigidly.
EMERGENCY STOP. Arm
EMERGENCY STOP. Arm
extended, palm down,
extended, palm down,
move hand rapidly right
move hand rapidly right
and left.
and left.

And Gantry Cranes
And Gantry Cranes
MULTIPLE TROLLEYS. Hold up
MULTIPLE TROLLEYS. Hold up
one finger for block marked “1”
one finger for block marked “1”
and two fingers for block
and two fingers for block
marked “2”. Regular signals
marked “2”. Regular signals
follow.
follow.
MOVE SLOWLY. Use one hand to give
MOVE SLOWLY. Use one hand to give
any motion signal and place other
any motion signal and place other
hand motionless in front of hand
hand motionless in front of hand
giving the motion signal. (Hoist Slowly
giving the motion signal. (Hoist Slowly
shown as an example.)
shown as an example.)

And Gantry Cranes
And Gantry Cranes
MAGNET IS
MAGNET IS
DISCONNECTED.
DISCONNECTED.
Crane operator
Crane operator
spreads both hands
spreads both hands
apart – palms up.
apart – palms up.

Inspection
Inspection
The inspection procedure for cranes in regular
The inspection procedure for cranes in regular
service is divided into 2 general classifications:
service is divided into 2 general classifications:
@ Monthly to quarterly or at intervals of 100
@ Monthly to quarterly or at intervals of 100
hours of use, whichever comes first.
hours of use, whichever comes first.
@ Annually or at intervals of 500 hours of use,
@ Annually or at intervals of 500 hours of use,
whichever comes first.
whichever comes first.
The inspections cover topics outlined in
The inspections cover topics outlined in
the standard or manufacturers guidelines.
the standard or manufacturers guidelines.

Maintenance
Maintenance
# A preventative maintenance program will be
# A preventative maintenance program will be
established and the program will be based on the
established and the program will be based on the
manufacturer’s recommendations
manufacturer’s recommendations
# Application is reviewed by a qualified person.
# Application is reviewed by a qualified person.
Before adjustments or repairs are made on a
crane, all of the following precautions must be
taken:
1. The crane will be moved to a location where
1. The crane will be moved to a location where
it will cause the least interference with other
it will cause the least interference with other
moving equipment on the track or rails and
moving equipment on the track or rails and
operations in the area.
operations in the area.

2. Controllers will be placed in the “off” position.
2. Controllers will be placed in the “off” position.
3. The main switch will be placed in the “off”
3. The main switch will be placed in the “off”
position or “open” position and LOCKED OUT,
position or “open” position and LOCKED OUT,
except where power is necessary to adjust or
except where power is necessary to adjust or
service the crane
service the crane
4. A warning sign or “out of order” sign will be
4. A warning sign or “out of order” sign will be
placed at the operator control station.
placed at the operator control station.
5. A Caution Board will be provided while
5. A Caution Board will be provided while
maintenance is performed on the crane.
maintenance is performed on the crane.

In the event of power failure
In the event of power failure
@ The operator must place all controllers in the “off”
@ The operator must place all controllers in the “off”
position.
position.
@ When an operator leaves a crane unattended he
@ When an operator leaves a crane unattended he
must land any attached load.
must land any attached load.
@ Place the controllers in the “off” position, and open
@ Place the controllers in the “off” position, and open
the main switch.
the main switch.
@ Before closing a main switch the operator must
@ Before closing a main switch the operator must
make sure all controllers are in the “off” position.
make sure all controllers are in the “off” position.
@ The main switch does not need to be opened on a
@ The main switch does not need to be opened on a
pendant-controlled crane if the crane is left unattended
pendant-controlled crane if the crane is left unattended
for short periods.
for short periods.

overhead_crane_operator_safety_manual.ppt

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