Bahrain Overhead Crane Training

1

OVERHEAD CRANE

OPERATOR

TRAINING COURSE

For the benefit of business and people

2

Course Introduction 1

Chapter 1 Course Introduction

Introduction

3

Course Introduction 1

Your tutor(s)

Experienced safety professionals

Experienced surveyors

Experienced trainers

Introduction

4

1

Bureau Veritas Group

Established in 1828

More than 18,000 people

More than 600 offices

Introduction Course Introduction

5

Course Introduction 1 Introduction

WELCOME TO BUREAU VERITAS

OVERHEAD CRANE OPERATOR

TRAINING COURSE

6

DAY ONE

RIGGING / SLINGING

1. COURSE INTRODUCTION

2. GENERAL

3. SWL & WLL

4. LOAD WEIGHT CALCULATIONS

5. CENTRE OF GRAVITY

6. LIFTING TACKLE TYPES & INSPECTION AREAS

7. KINDS OF HITCHES

8. ANGLES OF LIFTING

9. MULTI-LEG SLING METHOD OF RATING

10. RIGGING EQUIPMENT “GOOD & BAD PRACTICES”

11. HAND SIGNALS

SUMMARY

7

DAY TWO

OVERHEAD CRANE

1. CRANE CLASSIFICATION

2. CRANE TYPES

3. ELECTRIFICATION

4. TROLLEY TYPES

5. CAB CONTROLLERS

6. CRANE TERMINOLOGY

7. HOIST ASSEMBLY

8. LIMIT SWITCHES

9. TROLLEY CONTROLLERS

10. BRIDGE CONTROLLERS

11. THREE MOVEMENT COORDINATION

12. MAGNET HOISTING

13. PRE OPERATION CHECKS

SUMMARY

8

DAY THREE

1. PRACTICAL TRAINING (RIGGING)

2. PRACTICAL TRAINING (OPERATORS)

3. PRACTICAL EXAM (RIGGING)

4. PRACTICAL EXAM (OPERATORS)

5. WRITTEN EXAM (RIGGING)

6. WRITTEN EXAM (OPERATORS)

7. COURSE CLOSING

SUMMARY

9


Document prepared by BUREAU VERITAS ABU DHABI

This course has been produced to BRITISH STANDARDS and

Lifting Equipment Engineers Association (LEEA – UK)

BS 7121, BS 302, BS 1290, BS 6210

ISO 4309& ANSI B30

French National Institute for Search and Safety.

BUREAU VERITAS TECHNICAL GUIDE AL4

BUREAU VERITAS TECHNICAL GUIDE AL10

BUREAU VERITAS TECHNICAL SHEET AL-PR-T-005

10


Course structure:

» Tutorials

» Discussions

» Video Illustration

» Practical Assessment

» Examination

11

1

Successful delegates will be able to understand:

· Lifting Appliances & Lifting Tackle types;

· Colour Coding system;

· SWL & WLL;

· Kinds of Hitches;

· Centre of Gravity;

· Load Weight calculations;

· Different types of Cranes;

· Crane Operator Manual and Log Book;

· Limit Switches;

· Safe Load Indicator;

. Vertical Angle (sling angle);

. Cranes Signals & Communication Systems;

· Good & Bad Rigging Practices;

· Crane identification;

Introduction Course Benefits

· Crane Equipment Records;

· Overhead Crane Types;

· Crane Brakes;

· Crane Safety Features;

· Crane Operator Controls;

· Crane Operator Precautions;

12

1 Introduction

PHYSICAL FITNESS (EYESIGHT,

HEARING AND GENERAL HEALTH).

CONVERSANT WITH ENGLISH LANGUAGE.

FAMILIARITY WITH CRANES AND LIFTING OPERATIONS IN CONSTRUCTION SITE / INDUSTRIAL YARDS ACTIVITIES.

Course Pre-Requisites

ALL PARTICIPANTS SHALL WEAR P.P.E.

BEFORE COURSE STARTING.

OVERHEAD CRANE & NECESSARY

LIFTING ACCESSORIES SHALL BE

AVAILABLE FOR PRACTICAL TRAINING

ON SITE.

13

1

THIS IS A TWO – DAY COURSE

DAY ONE

Timing : 07:00 - 15:00

Coffee/Tea breaks : 9:00 – 9:15


Pray Time : 12:30 – 13:00

Lunch : 15:00

Tutorials & Discussions : 3 1/2 HOURS

Video Illustration : 1/2 HOUR

Practical Training : 2 1/2 HOURS

Written Examination : 1/2 HOUR

Introduction Course Timing & Structure

14

1 Introduction Course Timing & Structure

THIS IS A TWO – DAY COURSE

DAY TWO

Timing : 07:00 - 15:00



Pray Time : 12:30 – 13:00

Lunch : 15:00

Tutorials & Discussions : 3 1/2 HOURS

Practical Training : 3 HOURS

Written Examination : 1/2 HOUR

15

1

Facilities

Safety rules & evacuation routes

Courtesy (mobile phones, pagers)

Local arrangements

Course House Rules Introduction

16

GENERAL

- PERSONAL PROTECTIVE EQUIPMENT

- LIFTING TACKLE & LIFTING APPLIANCES

- COLOUR CODING

2

17

GENERAL 2 P. P. E.

PERSONAL PROTECTIVE EQUIPMENT

THE BANKSMEN, RIGGERS & CRANE OPERATORS

SHOULD WEAR THE REQUIRED P. P. E. AND AS

FOLLOWS:

- HELMET

- SAFETY SHOES

- COVERALL

- WORK VEST

- GLOVES

- AND SPECIAL REQUIREMENTS AS APPLICABLE

(SUCH AS EAR PLUGS, GAS MASK, GLASSES

ETC.)

18

GENERAL 2

A) LIFTING TACKLE TYPES:

- WIRE ROPE SLINGS

- CHAIN SLINGS

- SHACKLES

- EYEBOLTS

- SYNTHETIC WEBBING SLINGS

- TURN BUCKLES

- HOOKS

- RINGS AND LINKS

LIFTING EQUIPMENT COMPRISES OF:-

../A D C O PICTURE/WIRE ROPE SLINGS PICTURE.doc

../A D C O PICTURE/CHAIN SLINGS PICTURE.doc

../A D C O PICTURE/SHACKLES PICTURE.doc

../A D C O PICTURE/EYEBOLT PICTURE.doc

../A D C O PICTURE/WEBBING SLINGS PICTURE.doc

../A D C O PICTURE/TURNBUCKLES PICTURE.doc

../A D C O PICTURE/HOOK PICTURE.doc

../A D C O PICTURE/LINK PICTURE.doc

19

GENERAL 2

B) LIFTING APPLIANCES TYPES:

- CRANES

- FORKLIFTS

- PULLEY BLOCKS

- CHAIN HOISTS

- TIRFORS

- CHAIN BLOCKS

- CONTAINERS

- BASKETS

LIFTING EQUIPMENT COMPRISES OF:-

../A D C O PICTURE/MOBILE CRANE PICTURE.doc

../A D C O PICTURE/FORKLIFT PICTURE.doc

../A D C O PICTURE/PULLEY BLOCK PICTURE.doc

../A D C O PICTURE/CHAIN LEVER HOIST PICTURE.doc

../A D C O PICTURE/TIRFOR PICTURE.doc

../A D C O PICTURE/CHAIN BLOCK1 PICTURE.doc

../A D C O PICTURE/CONTAINER PICTURE.JPG

../A D C O PICTURE/BASKET PICTURE.JPG

20

GENERAL 2 COLOUR CODING

- EACH COMPANY HAS ITS OWN COLOUR CODING SYSTEM FOR ALL LIFTING EQUIPMENT.

- ALL LIFTING EQUIPMENT IS SUBJECT TO A SIX MONTHLY INSPECTION AS PER ARTICLE 20 OF

UAE MINISTERIAL ORDER NO. 32 OF 1982.

- COLOUR CODING IS IMPORTANT TO IDENTIFY THAT THE SLINGING MATERIALS HAVE BEEN

TESTED AND CERTIFIED BY A COMPETENT PERSON.

- REMEMBER DO NOT USE LIFTING APPLIANCES IF THERE IS:

“NO SWL (SAFE WORKING LOAD), ID/NO. AND COLOUR CODE”

ADNOC GROUP OF COMPANIES HAVE THE FOLLOWING COLOUR CODING SYSTEM:

JANUARY 2004 – JUNE 2004 PASTEL ORANGE

JULY 2004 – DECEMBER 2004 GRASS GREEN

JANUARY 2005 – JUNE 2005 TRAFFIC WHITE

JULY 2005 – DECEMBER 2005 SIGNAL BLUE

21

SWL (SAFE WORKING LOAD)

WLL (WORKING LOAD LIMIT)

3

22

3 SWL & WLL WHAT IS SWL & WLL ?

SWL (SAFE WORKING LOAD)

IS THE MAXIMUM LOAD THAT CAN SAFELY BE LIFTED OR LOWERED UNDER

PARTICULAR SERVICE CONDITIONS AS CONFIRMED IN TESTS AND EXAMINATION

RECORDS AND SHOULD NOT BE EXCEEDED.

WLL (WORKING LOAD LIMIT)

IS THE MAXIMUM LOAD THAT AN ITEM OF LIFTING EQUIPMENT IS DESIGNED TO

LIFT OR LOWER AS DETERMINED BY THE MANUFACTURER.

../A D C O PICTURE/SWL OF ROUND SLING.JPG

../A D C O PICTURE/WLL SHACKLE PICTURE.JPG

23

LOAD WEIGHT CALCULATIONS

4

24

4 LOAD WEIGHT

CALCULATIONS

IF YOU DO NOT KNOW THE LOAD

WEIGHT, WHAT U WILL DO?

LOAD WEIGHT:

• KNOW THE LOAD WEIGHT BEFORE RIGGING IT.

• MAY BE MARKED ON THE LOAD.

NEVER RIG A LOAD IF YOU DO NOT KNOW HOW MUCH IT WEIGHS.

CALCULATING LOAD WEIGHT:

IF YOU CANNOT FIND THE WEIGHT LISTED, YOU CAN ESTIMATE THE WEIGHT BY:

- CALCULATING THE VOLUME IN CUBIC METER.

- MULTIPLYING THE VOLUME BY THE DENSITY OF THE MATERIAL .

25

4 LOAD WEIGHT

CALCULATIONS

STANDARD SHAPES

LOAD SHAPE FORMULA FOR CALCULATION OF VOLUME SHAPES

RECTANGULAR SOLID LENGTH X WIDTH X HEIGHT

SOLID CYLINDER 3.14 X LENGTH X (RADIUS)2

THICK WALLED PIPE 3.14 X (R12 – R2

2) X LENGTH

THIN WALLED PIPE 3.14 X DIAMETER X LENGTH X THICKNESS

SPHERE 4.19 X (RADIUS)3

PYRAMID 0.25 X LENGTH X BASE X HEIGHT

STANDARD SHAPED LOADS

26

4 LOAD WEIGHT

CALCULATIONS

COMPLEX SHAPES

COMPLEX SHAPED LOADS

In some cases as shown in the picture on

right side, it is best to imagine the whole

shape enclosed by a rectangle and calculate

the volume of the rectangle.

Assumed total volume = l x b x h

FOR IRREGULAR SHAPED LOADS SEVERAL CALCULATIONS MAY BE REQUIRED TO

DETERMINE THE TOTAL WEIGHT.

For the load shown on left side, add the

calculated volumes of each of the two

rectangular solids to determine the

weight of the load.

Total volume = (l1 x b x h1)+ (l2 x b x h2)

27

4 LOAD WEIGHT

CALCULATIONS

MATERIAL TABLE

MATERIAL POUNDS / CUBIC FOOT KILOGRAMS / CUBIC METER

Aluminium 170 2700

Brass 530 8500

Brick 130 2100

Coal 90 1450

Copper 550 8800

Concrete 150 2400

Earth 100 1600

Iron - Steel 480 7700

Lead 700 11200

Magnesium 110 1750

Oil 50 800

APPROXIMATE WEIGHTS OF COMMON MATERIALS

Paper 70 1120

Water 62 1000

Wood 50 800

28

4 LOAD WEIGHT

CALCULATIONS

LOAD CELL (DYNAMOMETER)

WHEN YOU HAVE TO CALCULATE THE LOAD WEIGHT, IT IS SAFER TO OVER- ESTIMATE.

BETTER TO CHECK THE LOAD WEIGHT BY LOAD CELL (WEIGHING SCALE)

29

CENTRE OF GRAVITY

5

30

CENTRE OF GRAVITY WHAT IS COG ?

REGULAR SHAPES

COG IN THE MIDDLE

5

IS THE CENTRE OF LOAD BY WEIGHT AND THE POINT THAT LOAD WILL BE BALANCED

31

CENTRE OF GRAVITY

EFFECT OF CENTRE OF GRAVITY MISALIGNMENT ALIGNMENT OF CENTRE OF GRAVITY

5

IF LOAD SHIFTS OR TIPS OVER MORE THAN 5º IT SHOULD BE SET DOWN

EACH SLING LEG SHOULD BE STRONG ENOUGH TO SUPPORT THE

ENTIRE LOAD IN CASE OF LOAD UNBALANCED

IRREGULAR SHAPES

COG NOT IN THE MIDDLE

IRREGULAR SHAPES

32

CENTRE OF GRAVITY LOAD STABILITY

FIG (A) FIG (B)

5

LOAD WILL BE BALANCED IF THE CENTRE OF GRAVITY IS DIRECTLY BENEATH CRANE HOOK

AND IF POSSIBLE; BELOW OR LEVEL WITH ATTACHMENT POINTS. FIG (A)

WHEN THE LOAD CENTRE OF GRAVITY IS ABOVE OR LEVEL POINT WITH SLING ATTACHMENT, A

GREATER STABILITY OF THE LOAD CAN BE ACHIEVED WHEN ANGLE BETWEEN THE

HORIZONTAL AND SLING LEG, IS SUBSTANTIALLY GREATER THAN THE ANGLE FORMED

BETWEEN THE HORIZONTAL AND CENTRE OF GRAVITY. FIG (B)

33

LIFTING TACKLE TYPES &

THE INSPECTION AREAS

6

34

LIFTING TACKLE TYPES

6 WIRE ROPES

STEEL WIRE ROPES

Description

FLEXIBLE ELEMENT.

PERMITS THE TRANSFER OF

STRAIN TO PULL, LIFT OR HANG.

COMPOSED OF STRANDS SPUN

HELICALLY AROUND A METALLIC

OR TEXTILE CORE.

STRAND STEEL WIRES ARE

SPUN HELICALLY AROUND A

METALLIC CORE.

35


WIRE ROPES

THE PITCH

THE PITCH IS THE NECESSARY ROPE LENGTH FOR THE STRAND

TO COMPLETE ONE ROTATION AROUND THE CORE. IT IS ALSO

CALL LAY LENGTH.

6

36


6 WIRE ROPES

TYPE OF CORES TEXTILE METALLIC

DESCRIPTION THE TEXTILE CORE IS GENERALLY MADE

WITH SOME KIND OF SYNTHETIC FIBRES

MORE RESISTANT IN THE TIME THAN THE

NATURAL FIBRES.

THE METALLIC CORE IS

GENERALLY MADE WITH 7X7

STEEL WIRE ROPE.

ADVANTAGE GIVE A GOOD FLEXIBILITY TO THE ROPE.

ACT AS INTERNAL LUBRICATOR.

GIVE A HIGHER BREAKING

LOAD TO THE ROPE.

GIVE A BETTER

RESISTANCE TO CRUSHING

DISADVANTAGE POOR RESISTANCE TO CRUSHING POOR FLEXIBILITY

THE CORE :

37


6 WIRE ROPES

CLASSIFICATION OF WIRE ROPE

CLASSIFICATION OF WIRE ROPE

38


6 WIRE ROPES

PREFORMING

FORMING THE FINISHED STRAND INTO THE HELICAL SHAPE .

39


6 WIRE ROPES

DIAMETER MEASUREMENT

40

6

REDUCTION IN WIRE ROPE DIAMETER WIRE BREAKS NEAR FITTINGS & INSIDE A ROPE

WIRE ROPES INSPECTION LIFTING TACKLE TYPES

NORMAL UNDAMAGED ROPE

ONE ROPE LAY

STRETCHED ROPE SHOWS INCREASED LAY LENGTH

UNDAMAGED ROPE SECTION

DAMAGED ROPE SECTION

STRANDS TAKE AN OVAL SHAPE IF

THE CORE HAS FAILED

TYPICAL VALLEY

BREAKS ARE SERIOUS

SOCKET MUST BE REPLACED

IF THERE IS ONE BROKEN

WIRE NEAR FITTING

WATCH FOR BROKEN WIRES IN THIS AREA

DUE TO CORE DETERIORATION DISCARD ROPE IF THERE IS

DECREASE BY 3% OF THE NOMINAL ROPE DIAMETER FOR

ROTATION-RESISTANT ROPES OR 10% FOR OTHER ROPES.

DUE TO EXTERNAL WEAR DISCARD ROPE IF THERE IS

DECREASE BY 7% OR MORE OF THE NOMINAL ROPE DIAMETER.

41

6

THE EASIEST WAY TO

DETECT INSIDE WIRE

BREAKS IS “LISTENING”

HOLD A LENGTH OF ROPE

UP TO YOUR EAR AND BEND

IT BACK AND FORTH, IF YOU

HEAR POPPING VOICE,

THERE ARE LIKELY BROKEN

WIRES INSIDE THE ROPE

TO ENSURE THAT

YOUR NON-ROTATING

ROPE IS FREE FROM

INTERNAL WIRE

BREAKS

REPLACE THE ROPE IF THERE ARE

- 6 OR MORE RANDOM BROKEN WIRES IN ONE LAY

- 3 OR MORE BROKEN WIRES IN ONE STRAND OF A ROPE LAY

- 1 BROKEN WIRE AT THE FITTING

WIRE ROPES INSPECTION LIFTING TACKLE TYPES

TO CHECK IF YOUR ROPE

HAS BROKEN WIRES

THE EASIEST WAY IS

“LOOKING”

42

6 LIFTING TACKLE TYPES

Due to heavy corrosion

the wires breaks when

you bend the rope

Extrusion of steel core (discard immediately)

Basket (bird cage) deformation of multi-strand construction

(discard immediately)

DEFECTS

WIRE ROPES DEFECTS

43


Local increase in diameter of langs lay wire rope caused by distortion

of the steel core resulting from shock loading (discard immediately)

Severe kink with extrusion of fibre core (discard immediately)

DEFECTS

WIRE ROPES DEFECTS

44


A wire rope which has been kinked during installation (discard immediately)

Outer strands take the place of the fibre core which has disintegrated (discard immediately)

Flattened portion of multi-strand rope caused by mis-coiling on a drum (discard immediately)

DEFECTS

WIRE ROPES DEFECTS

45


flattened portion due to local crushing (discard immediately)

Example of severe bend (discard immediately)

DEFECTS

WIRE ROPES DEFECTS

46

6

WIRE ROPE SLINGS

DIFFERENT

CONFIGURATIONS

WIRE ROPE ASSEMBLIES LIFTING TACKLE TYPES

47

CHAINS ASSEMBLIES 6

PIPE SLING CASE GRAB SLING WITH

SHORTENING CLUTCH

DRUM SLING

DIFFERENT CHAIN SLING

CONFIGURATIONS


48

CHAIN LINK’S INSPECTION AREAS 6 LIFTING TACKLE TYPES

MEASURE THE REMAINING MATERIAL

AND DISCARD IF IT IS LESS THAN

ALLOWED BY MANUFACTURER.

49

WEBBING SLINGS 6 LIFTING TACKLE TYPES

SYNTHETIC FIBRES

(WEBBING SLINGS / BELTS):

THREE BASIC MAN-MADE

MATERIALS, PROCESSED AS

SYNTHETIC FIBRES, ARE USED TO

MANUFACTURE ROPES, AND FLAT

WOVEN WEBBING FOR MAKING

SLINGS AND FOR THE

MANUFACTURE OF ROUND

SLINGS, THESE ARE:

POLYAMIDE (NYLON)

POLYESTER

POLYPROPYLENE

50

6

ACID DAMAGE

HEAT DAMAGE

CUTS

CUTS & TENSILE DAMAGE

ABRASION DAMAGE

FACE CUTS

PUNCTURES & SNAGS

TENSILE BREAK

ILLIGIBLE OR MISSING TAG

WEBBING SLINGS DEFECTS LIFTING TACKLE TYPES

51

SHACKLES & THE INSPECTION AREAS 6

BOW SHACKLES DEE SHACKLES

SAFETY ANCHOR SAFETY PIN SAFETY ANCHOR SAFETY PIN


CHECK FOR WEAR

CHECK FOR WEAR AND STRAIGHTNESS

CHECK THAT PIN IS ALWAYS SEATED

CHECK THAT SHACKLE IS NOT OPENING UP

SHACKLE

INSPECTION

AREAS

52

EYEBOLTS 6

EYEBOLTS TYPES


SWL IN AXIAL LOADING IS LOWER

BUT AT INCLINED LOADS ARE

ABOUT DOUBLE THOSE OF

COLLAR EYEBOLTS

SWL IN AXIAL LOADING IS HIGHER

BUT AT INCLINED LOADS ARE

ABOUT HALF OF EYEBOLT WITH

LINK

IS EXTREMELY LIMITED IN ITS

USE FOR LIFTING PURPOSES

(ONLY FOR ELECTRICAL

INDUSTRY)

EYEBOLT WITH LINK

SHANK

THREAD RUNOUT

COLLAR

LINK

COLLAR EYEBOLT

SHANK

THREAD RUNOUT

COLLAR

EYE

RAISED FLAT

AREAS FOR

MARKING

UNDERCUT

SHANK

COLLAR

EYE

DYNAMO EYEBOLT

53

EYEBOLT’S INSPECTION AREAS 6

EYEBOLTS INSPECTION AREAS


CHECK FOR

CRACKS AND

WEAR

CHECK FOR

STRAIGHTNESS

FROM SIDE VIEW

CHECK FOR

SHANK

STRAIGHTNESS AND

THREAD

SOUNDNESS

54

HOOK’S INSPECTION AREAS 6 LIFTING TACKLE TYPES

CHECK FOR WEAR AND

DEFORMATION

CHECK FOR CRACKS AND

TWISTING

DISCARD IF TWISTED 10º OUT

OF PLACE

CHECK FOR WEAR AND

CRACKS

CHECK FOR SIGNS OF

“OPENING UP”

DISCARD IF THROAT IS

OPENED BEYOND THE

MANUFACTURER’S

SPECIFICATIONS BY 15%

LOOSE GEAR HOOK

55

TURNBUCKLES & THE INSPECTION

AREAS 6

TURNBUCKLES AND FITTINGS


TURNBUCKLES

INSPECTION AREAS

CHECK FOR CRACKS AND BENTS

CHECK FOR THREAD DAMAGE

AND BENT RODS



AND BENT RODS



AND BENT RODS

CHECK FOR CRACKS AND DEFORMATION

EYE JAW STUB HOOK (HAS REDUCED

CAPACITY)

JAW AND EYE COMBINATION

JAW AND JAW COMBINATION

HOOK AND HOOK COMBINATION

HOOK AND EYE COMBINATION

56

TEA / COFFEE BREAK

TIME (15 MIN.)

57

KINDS OF HITCHES

SINGLE VERTICAL HITCH

BRIDLE HITCH

BASKET HITCH

CHOKER HITCH

7

58

HITCHES TYPES

BRIDLE HITCH (2-3-4-LEG)

BASKET HITCH CHOKER HITCH

BASKET ANGLE FACTOR = 1.4 CHOKER ANGLE FACTOR = 0.8

7

SINGLE VERTICAL HITCH

59

ANGLES OF LIFTING

8

60

ANGLES OF LIFTING SLING (VERTICAL) ANGLE

RELATIONSHIP

OF SLING

(VERTICAL)

ANGLE AND

SWL

THE SLING ANGLE

(VERTICAL ANGLE)

BETWEEN 2 SLINGS

MUST PREFERABLY

NOT BE LARGER

THAN 120º

RECOMMENDED

SLING

(VERTICAL)

ANGLES ARE

BETWEEN 0-90 º

THIS ALSO

APPLIES TO

CHAINS, ROPES

AND HOISTING

UNITS

8

61

9 MULTI-LEG SLINGS

METHOD OF RATING

62

2 – LEG SLING 9

DETERMINATION OF CAPACITY – 2-LEG SLING

AS PER THE UNIFORM LOAD RATING MATHOD OF MULTI LEG SLINGS

SWL OF THE 2-LEG SLING IS DETERMINED BY THE FOLLOWING:

SWL OF THE 2-LEG = 1.4 x WLL (OF SINGLE VERTICAL LEG)

MULTI-LEG SLING METHOD

OF RATING

63

3 – LEG SLING 9



LOAD MAY BE SUPPORTED BY ONLY 2 LEGS WHILE THE 3RD ONE BALANCES IT ONLY.

THEREFORE SWL OF THE 3-LEG SLING IS DETERMINED BY THE FOLLOWING:



OF RATING

64

4 – LEG SLING 9



LOAD MAY BE SUPPORTED BY ONLY 3 LEGS WHILE THE 4TH ONE BALANCES IT ONLY.

THEREFORE SWL OF THE 4-LEG SLING IS DETERMINED BY THE FOLLOWING:



OF RATING

65

RIGGING EQUIPMENT

GOOD & BAD PRCTICES

10

66

NEVER USE A LIFTING GEAR THAT IS NOT STAMPED WITH SWL

GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT 10

67


USE OF CHOKERS

GOOD – NO CUTTING ACTION ON RUNNING LINES

BAD – BOLT

ON RUNNING

LINE CAN

WORK

LOOSE

BAD – CUTTING

ACTION OF EYE

SPLICE ON

RUNNING LINE

68


HOOKS’ DIRECTION

GOOD – HOOKS

ARE TURNED OUT

BAD – HOOKS

OPENING ARE TURNED IN

YES

NO

69


DOUBLE SLINGS SHALL BE USED WHEN HOISTING TWO OR MORE PIECES OF MATERIAL

OVER 12 FT LONG

RIGHT – LOAD OVER 12 FT LONG

WRONG – LOAD OVER 12 FT LONG

LIFTING OF BUNDLES

70

GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT

ENSURE THAT SLINGS ARE PROTECTED FROM SHARP CORNERS ON

HEAVY ITEMS

10

CONTACT RADIUS

SHOULD BE EQUAL TO 1

ROPE LAY OR 7 TIMES

ROPE DIAMETER

71

GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT

WIRE ROPE CLIPS – WRONG WAY WIRE ROPE CLIPS – RIGHT WAY

10

72


GOOD PRACTICE

PACK THE PIN WITH

WASHERS TO CENTRALIZE

THE SHACKLE

HOOK PACKAGE

POOR PRACTICE

NEVER ALLOW SHACKLE TO

BE PULLED AT AN ANGLE –

THE JAW WILL OPEN UP

THEORETICAL

IF THE LOAD SHIFTED, THE ROPE

WILL UNSCREW THE SHACKLE PIN

DO NOT USE SCREW PIN SHACKLES IF THE PIN

CAN ROLL UNDER LOAD AND UNSCREW

THE LOAD WILL BEND THE BOLT

NEVER

REPLACE

SHACKLE PIN

WITH BOLT

73


WHEN YOU LIFT

HEAVY BULK LOADS,

KEEP IT CLOSE TO

GROUND AS MUCH

AS POSSIBLE

CHECK YOUR CRANE

CHECK YOUR SLING

CHECK YOUR LOAD

BALANCE

USE TAGLINE TO CONTROL BULKY LOADS

74


HOOK SHOULD BE

SWIVELED (ROTATE)

FREELY

TO PREVENT WIRE

ROPES TWISTING &

CRUSHING

75


LAND YOUR LOAD ON

WOODEN BLOCKS

TO

REMOVE YOUR SLINGS

EASIER

PROTECT YOUR SLINGS

SECURE ALL LOOSE

SLINGS BEFORE YOU LIFT

76


USE YOUR 4-LEG

OR 5-LEG SLING

WITH MAX. SLING

ANGLE OF 90º

REMEMBER

SWL MARKED ON

YOUR SLING

BETWEEN 0-90º

USE SHACKLE IF YOU

PUT 2 SLINGS OR

MORE ON CRANE

HOOK

PUT THE SHACKLE PIN

ON CRANE HOOK

77


HANDLING DRUMS

78


USE SPREADER BEAM TO DISTRIBUTE THE LOAD

79


WATCH YOUR HAND WHILE

HANDLING CASING BE CAREFUL WHILE OPENING

CASING BUNDLE

80


WATCH

YOUR

HANDS

BE SURE THE LOAD

PROPERLY OVERLAPPED USE PALLET FORKS

81


LIFTING

PLATE WITH

HORIZONTAL

CLAMPS

GOOD HANDLING

DANGEROUS HANDLING

HANDLING PLATES

LIFTING PALLET WITH

VERTICAL CLAMPS

82

HAND SIGNALS

11

83

11 HAND SIGNALS BASIC HAND SIGNALS

84


85


86


87


88

VIDEO ILLUSTRATION

(SAFE RIGGING, LIFTING & MATERIAL HANDLING)

TIME (35 MIN.)

../AVSEQ01.DAT

89

TEA / COFFEE BREAK

TIME (15 MIN.)

90

PRACTICAL TRAINING

TIME (1.0 HOUR)

91

WRITTEN EXAMINATION

TIME (1/2 HOUR)

92

DAY TWO

OVERHEAD CRANE

1

93

CRANE CLASSIFICATION

1

94

CRANE SERVICE CLASSIFICATIONS OVERHEAD CRANE 1

THERE ARE SIX SERVICE CLASSIFICATIONS OF E.O.T. CRANES:

CLASS A1 (STAND-BY SERVICE):

IT OPERATES AT SLOW SPEED AND ALWAYS SITS IDLE FOR LONG PERIODS; (POWER

HOUSE, NUCLEAR REACTOR AND TURBINE ROOM).

CLASS A2 (INFREQUENT USE):

IT OPERATES AT SLOW SPEED AND LIGHT LOADS TO FULL CAPACITY WITH SEVERAL

LIFTS PER DAY; (PUMP ROOMS AND LABORATORIES).

CLASS B (LIGHT SERVICE):

IT OPERATES AT SLOW SPEED WITH AN AVERAGE 50% LOAD CAPACITY AND 2-5 LIFTS

PER HOUR; (WAREHOUSES, LIGHT FABRICATION AND REPAIR SHOP).

CLASS C (MODERATE SERVICE):

IT OPERATES AT 50% LOAD CAPACITY AND 5-10 LIFTS PER HOUR; (TYPICAL MACHINE

SHOP).

CLASS D (HEAVY DUTY):

IT OPERATES AT HIGH SPEED WITH 65% LOAD CAPACITY AND 10-20 LIFTS PER HOUR;

(STEEL FABRICATION SHOP, FOUNDRIES).

CLASS E (SEVERE SERVICE):

IT OPERATES AT HIGH SPEED WITH FULL LOAD AND 20 OR MORE LIFTS PER HOUR;

(SCRAP YARD, FERTILIZER AND CEMENT PLANTS).

95

CRANE SERVICE CLASSIFICATIONS OVERHEAD CRANE 1

THERE ARE ANOTHER THREE SERVICE CLASSIFICATIONS OF E.O.T. CRANES:

NORMAL SERVICE:

IT OPERATES AT LESS THAN 85% LOAD CAPACITY WITH NO MORE THAN 10 LIFTS PER

HOUR.

HEAVY SERVICE:

IT OPERATES AT 85 – 100% LOAD CAPACITY WITH 10 LIFTS PER HOUR.

SEVERE SERVICE:

EITHER NORMAL OR HEAVY SERVICE UNDER ABNORMAL OPERATING CONDITIONS.

96

CRANE TYPES

2

97

CRANE TYPES OVERHEAD CRANE 2

TYPICAL E.O.T. CRANE – TOP RUNNING

3 – MOVEMENTS

Hoisting

Cross Travel

Long Travel

BRIDGE STRUCTURE

THE RUNWAY ON WHICH THE CRANE RUNS UP AND DOWN THE PLANTARE CALLED RAILS

THESE RAILS ARE ATTACHED TO THE BUILDING COLUMNS ON EITHER SIDE OF THE BAY

98


GANTRY CRANE

3 – MOVEMENTS

Hoisting

Cross Travel

Long Travel

99


SEMI GANTRY CRANE

3 – MOVEMENTS

Hoisting

Cross Travel

Long Travel

100


OVERHEAD TRAVELING CRANE

3 – MOVEMENTS

Hoisting

Cross Travel

Long Travel

HOISTING

CROSS TRAVEL

BRIDGE OR LONG TRAVEL

101


WALL CRANE

3 – MOVEMENTS

Hoisting

Cross Travel

Long Travel

102


CANTILEVER GANTRY CRANE

103


OVERHEAD CAB OPERATED CRANE

104


PENDANT CONTROL CRANES

CANTILEVER GANTRY CRANE

GANTRY CRANE

OVERHEAD FLOOR OPERATED CRANE

SEMI GANTRY CRANE

105


CAB OPERATED CARRIER

CAB OPERATED CRANE

CAB OPERATED CRANE

PENDANT CONTROL CRANE

106


WALL MOUNTED PUSH BUTTON

SEMI GANTRY CRANE

DROP SECTION

INTERLOCKING SYSTEM

107


UNDERHUNG STACKER CRANE

FLOOR OPERATED STACKER CAB OPERATED STACKER

108

ELECTRIFICATION EXAMPLES

3

109

ELECTRIFICATION EXAMPLES OVERHEAD CRANE 3

ELECTRIFICATION EXAMPLES

110

TROLLEY TYPES

4

111

TROLLEY TYPES OVERHEAD CRANE 4

TROLLEY TYPES

BUCKET CRANE

5-MOTION DOUBLE TROLLEY MAGNET CRANE

7-MOTION TRIPLE TROLLEY

112

TROLLEY TYPES OVERHEAD CRANE 4

CAB ON TROLLEY

TRAILER CAB

2-MOTOR DOUBLE HOOK

113

CAB CONTROLLERS

5

114

TYPICAL CAB CONTROLS OVERHEAD CRANE 5

TYPICAL CAB CONTROL

1) FAN SWITCH

2) HEATER SWITCH

3) ELEVATOR

4) STATUS LIGHT / PUSH-PULL SWITCH

5) MGNET CONTROLLER

6) AUXILIARY TROLLEY CONTROLLER

7) AUXILIARY HOIST CONTROLLER

8) MAIN TROLLEY CONTROLLER

9) BRIDGE CONTROLLER

10) MAIN HOIST CONTROLLER

11) BRIDGE DYNAMIC BRAKE PEDAL

12) BELL PEDAL

13) LIGHT SWITCH

14) CRANE LIGHT SWITCH

15) MAIN SWITCH

16) MEATER SWITCH

115

TYPICAL CAB CONTROLS OVERHEAD CRANE 5

CRANE CONTROL PEDALS AND BUTTONS

THESE CONTROLS AND SWITCHES ARE THOSE

COMMONLY FOUND IN EOT CRANES,

ALTHOUGH THE ACTUAL CONTROLS AND

SWITCHES AND THEIR POSITIONS WILL VARY

FROM CRANE TO CRANE.

LEFT/RIGHT/CENTRE CAB LAYOUT

116

CRANE TERMINOLOGY

6

117

OVERHEAD CRANE TERMINOLOGY OVERHEAD CRANE 6

BRIDGE:

THE BRIDGE IS MADE UP OF GIRDERS

THAT ARE CONNECTED ON EACH END

TO WHEEL TRUCKS.

BRIDGE TRAVEL IS THE CRANE

MOVEMENT FROM ONE END OF A

BUILDING RUNWAY TO THE OTHER.

BUMPERS:

ARE LOCATED ON BOTH SIDES OF

THE BRIDGE AND TROLLEY TO

PREVENT OVERTRAVEL.

CAB:

IS USUALLY HUNG UNDER THE

BRIDGE AND CONTAINS THE CRANE

CONTROLS.

CAB OPERATED CRANE

TYPICAL E.O.T. CRANE – TOP RUNNING

118


CENTERING:

LOADING AND UNLOADING IS ACCOMPLISHED IN 3

MOTIONS:

• CENTER BRIDGE OVER LOADING AREA

• CENTER THE TROLLEY OVER LOADING AREA.

• LOWERING AND RAISING OF HOIST OVER THE LOAD.

CONTROLS:

CONTROLLERS IN THE CAB GIVE MOTION TO THE

BRIDGE, TROLLEY AND HOIST. CONTROL CABINETS

ARE LOCATED ON THE WALKWAY OF THE BRIDGE.

CONTROLS ALSO CAN BE PENDANT OR REMOTE.

CRANE BRAKING (MECHANICAL):

IS APPLIED BY FOOT PRESSURE ON A BRAKE PEDAL.

CRANE BRAKING (ELECTRICAL):

IS APPLIED MECHANICALLY WHEN THE HOIST IS NOT

POWERED.

GANTRY CRANE

PENDANT CONTROL CRANE

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CRANE BRAKING (DYNAMIC):

EDDY CURRENT BRAKING OCCURS WHEN THE HOIST

IS BEING LOWERED WITH A LOAD.

DRIVE MOTORS:

THE BRIDGE MOTOR DRIVES THE BRIDGE AND A

TROLLEY MOTOR DRIVES THE TROLLEY. THE HOIST

MOTOR POWERS THE LOAD BLOCK.

FESTOON:

POWER CABLES ARE HUNG IN DRAPED CURVES ON

THE CRANE.

HOIST:

THE HOIST MECHANISM RAISES AND LOWERS THE

LOAD. IT IS A DRUM MOUNTED ON THE TROLLEY

WHICH IS SPOOLED WITH WIRE ROPE AND IS DRIVEN

BY A MOTOR AND A GEARING SYSTEM.

120


HOIST (AUXILIARY):

THIS HOIST IS SIMILAR TO THE MAIN HOIST BUT HAS

LESS LIFTING CAPACITY.

HOIST BLOCK:

IT CONSISTS OF SHEAVES, SHEAVE PINS, BEARINGS,

SWIVEL AND HOOK SUSPENDED BY THE HOIST WIRE

ROPE.

HOIST MOVEMENT:

THE LOAD BLOCK IS RAISED AND LOWERED BY THE

OPERATOR CONTROLS.

HOOK:

IS CONNECTED TO THE HOIST BLOCK AND IS USED

FOR LIFTING LOADS. A HOOK SAFETY LATCH

PREVENTS THE SLINGS OR CHAINS FROM SLIPPING OFF

THE HOOK.

HOOK BLOCK ASSEMBLY

121


INCHING:

IT IS VERY SHORT MOVEMENTS ACCOMPLISHED BY APPLYING MOTOR POWER

FOR A FRICTION OF A SECOND THEN QUICKLY REMOVING THE POWER TO STOP

THE BRIDGE, TROLLEY OR LOAD MOVEMENT AFTER IT HAS MOVED A SLIGHT

DISTANCE .

IDLER:

IS AN END TRUCK OR BOGIE WHEEL THAT DOES NOT DRIVE.

LOAD SWING:

IS MOVEMENT OF THE BLOCK AND LOAD CAUSED BY ACCELERATION OR

DECELERATION OF THE CRANE.

MAIN LINE SHAFT:

IT IS THE MOTOR POWERED SHAFT DRIVING THE BRIDGE.

MECHANICAL LOAD-BRAKE:

THIS IS A DRAG BRAKE WHICH IS ENGAGED ONLY WHILE LOWERING. WHEN

HOISTING, THE BRAKE RELEASES, THEREBY ELIMINATING THE DRAG ON MOTOR.

122


MONORAIL:

THIS IS A SINGLE RAIL WITH A HOIST.

PENDANT CONTROL:

THIS IS THE OPERATORS CRANE CONTROLLER BOX HANGING FROM THE

BRIDGE OR TROLLEY BY A CABLE. THE PENDANT BOX MUST BE SUPPORTED SO AS

TO ELIMINATE ANY STRAIN ON THE ELECTRICAL CONNECTIONS.

PLUGGING:

IS THE USE OF THE REVERSE MOTOR POWER TO STOP A FORWARD-MOVING

LOAD.

RAIL RUNWAYS:

ARE FLOOR TRACKS OR TRACKS SUPPORTED BY BEAMS ON THE SIDE OF THE

BUILDING ON WHICH THE CRANE CAN TRAVEL OVER THE WORK AREA.

SKEWING:

WHEN THE CRANE GIRDERS ARE NOT PERPENDICULAR TO THE RUNWAY RAILS

AND ONE END OF THE CRANE IS AHEAD OF THE OTHER. THIS CONDITION SHOULD

BE IMMEDIATELY CORRECTED.

123


SLACK OUT:

THIS OCCURS WHEN THE INITIAL LIFTING TENSION IS APPLIED TO THE HOIST

WIRE ROPE AND THE LOAD CHAINS OR SLINGS.

REEVING:

THIS IS THE SYSTEM OF WIRE ROPE CONNECTING THE UPPER AND LOWER

SHEAVES ON THE HOISTING BLOCKS.

TROLLEY:

THIS IS A FRAME WHICH CONSISTS OF END TRUCKS, A DRIVE MOTOR, A HOIST

MOTOR, A DRUM WITH WIRE ROPE AND A HOIST BLOCK. IT IS OPERATED

THROUGH CONTROLLERS AND IT TRAVELS ON RAILS ACROSS THE BRIDGE

STRUCTURE, WHILE SUPPORTING THE LOAD.

WALKWAY:

THIS IS AN ISLEWAY ACROSS THE SPAN OF THE BRIDGE GIRDERS. IT ALLOWS

ACCESS TO THE TROLLEY, AND TO THE BRIDGE DRIVE MECHANISM.

124

TEA / COFFEE BREAK

TIME (15 MIN.)

125

HOIST ASSEMBLY

7

126

HOIST ASSEMBLY OVERHEAD CRANE 7

HOIST ASSEMBLY:

IT CONSISTS OF HOIST MOTOR, SPEED

REDUCER, HOIST BRAKE, DRUM, WIRE ROPE,

HOIST BLOCK AND HOOK.

IT MAY BE FOUND AS FOLLOWS:

• SINGLE TROLLEY – SINGLE HOIST

• SINGLE TROLLEY – DOUBLE HOIST

• DOUBLE TROLLEY – SINGLE HOIST SINGLE TROLLEY – SINGLE HOIST

SINGLE TROLLEY – DOUBLE HOIST DOUBLE TROLLEY – SINGLE HOIST (EACH)

127

HOIST ASSEMBLY OVERHEAD CRANE 7

WIRE ROPE ANCHORAGE:

THE BASIC MINIMUM REQUIREMENTS IS

THAT THERE BE NOT LESS THAN 2 WRAPS OF

WIRE ROPE ON THE HOIST DRUM WHEN THE

LOAD BLOCK IS AT ITS LOWEST POSITION.

IT MAY BE 5 WRAPS AS PER:

• LOCAL RULES; AND / OR

• MANUFACTURER RECOMMENDATION

THE MOST COMMON TYPE OF WIRE ROPE

USED IN EOT CRANES IS 6 x 37 CLASSIFICATION.

SHEAVES IN THE BLOCK MUST BE EQUIPPED

WITH CLOSE FITTING GUARDS TO PREVENT

THE WIRE ROPE FROM FOULING IF THE BLOCK

IS LYING ON THE FLOOR WITH SLACK LINES.

ALL HOOKS SHOULD HAVE SAFETY LATCH TO

RETAIN SLINGS AND LIFTING ATTCHMENTS

WIRE ROPE TO DRUM ATTACHMENTS

SHORT AND LONG BLOCK TYPES

128

HOIST BRAKES OVERHEAD CRANE 7

HOIST BRAKES:

TO HOLD THE LOAD STATIONARY WHEN THE

HOIST CONTROLLER HANDLE IS IN THE “OFF”

POSITION, THE BRAKE IS AUTOMATIC, AND IS

APPLIED BY A SPRING WHEN THE POWER IS

OFF.

THE BRAKE IS RELEASED ELECTRICALLY

WHEN THE CONTROLLER HANDLE IS MOVED

TO RAISE OR LOWER THE LOAD.

DE-ENERGIZED BRAKE

ENERGIZED BRAKE

129

HOIST CONTROLLERS OVERHEAD CRANE 7

LIFTING:

HEAVY LOAD SHOULD BE LIFTED MORE SLOWLY

THAN LIGHT ONE.

P1: START THE EMPTY HOOK

P2: START EMPTY HOOK AND MEDIUM SIZE LOAD

P3: START EMPTY HOOK, MEDIUM AND HEAVY LOAD

P4: FURTHER MOVEMENT FOR ALL

LOWERING:

USE P2, P3 & P4 WHEN LOWERING HEAVY LOAD

P1: INCH THE LOAD DOWN

P2: LOWER ALL LOADS

P3: FURTHER INCREASE IN SPEED

P4: FURTHER LOWERING TO HIGHEST SPEED. POINT BY POINT LOWERING

POINT BY POINT LIFTING

130


DYNAMIC LOWERING:

IT IS AN AUTOMATIC FEATURE OF THE CONTROLLER WHICH DRIVES THE EMPTY

HOOK OR LIGHT LOAD DOWN AND HOLDS A HEAVY LOAD.

TO PREVENT HEAVY LOADS FROM LOWERING TOO QUICKLY, TWO SYSTEMS ARE

USED:

1) MECHANICAL

2) ELECTRICAL

CRANE OPERATOR SHOULD REPORT ANY FAULT TO THE SUPERVISOR SUCH AS

OVERSPEEDING DURING LOWERING AT ANY POINT.

LOAD RAISING:

WHEN RAISING A HEAVY LOAD; USE THE FIRST POINT OF CONTROLLER TO TAKE

THE SLACK OUT OF THE ROPE.

TEST HOIST BRAKE AND IF YOU HAVE ANY PROBLEM, LOWER THE LOAD AND

CALL YOUR SUPERVISOR.

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INCHING THE LOAD:

START AND STOP THE HEAVY LOAD IN SLOW SPEED.

WHEN REACHING THE LANDING POINT; USE THE FIRST (SLOW) SPEED.

132

LIMIT SWITCHES

8

133

LIMIT SWITCHES OVERHEAD CRANE 8

HOIST LIMIT SWITCH TYPES:

TO PREVENT OVER-HOISTING; CRANES

ARE REGULARLY EQUIPPED WITH SOME

TYPE OF HOISTING LIMIT SWITCH.

THREE BASIC TYPES ARE USED:

PADDLE OR LEVER TYPE (FIG. B)

WEIGHTED SWITCH TYPE (FIG. C)

ROTATING OR GEARED TYPE (FIG. D)

LIMIT SWITCHES DISCONNECT POWER

FROM THE MOTOR AND

AUTOMATICALLY SET THE ELECTRIC

HOLDING BRAKE.

PADDLE OR LEVER TYPE

WEIGHTED SWITCH TYPE

134


LOWER LIMIT SWITCH TYPES:

IF LOWER LIMIT SWITCH IS FITTED TO

THE HOIST; IT WILL BE USUALLY BE

THE ROTATING TYPE WHICH WILL STOP

THE LOWERING MOVEMENT AFTER A

SET NUMBER OF REVOLUTIONS

IF NOT FITTED; THE MOTOR MAY RUN

AFTER THE HOOK TOUCHES THE

FLOOR, THE WIRE ROPE WILL RUN OFF

THE HOISTING DRUM AND THEN WIND

UP IN THE OPPOSITE DIRECTION.

IF THIS OCCURS STOP THE WORK

IMMEDIATELY, YOU MAY DAMAGE THE

WIRE ROPE, DROP THE LOAD AND

DAMAGE THE CRANE.

AT LEAST 2 FULL WRAPS SHOULD

REMAIN ON THE DRUM WHEN THE

HOOK IS AT ITS LOWEST POSITION.

LOWER LIMIT SWITCH

ROTATING OR GEARED TYPE

135


LIMIT SWITCH TEST:

THE OPERATOR SHOULD CHECK THE LIMIT SWITCHES WITHOUT LOAD AT THE

BEGINNING OF EACH SHIFT.

LIMIT SWITCHES ARE FOR EMERGENCY SITUATION ONLY.

NEVER CHANGE THE LIMIT SWITCH SET UP (ONLY QUALIFIED PERSONS).

MOVE THE CRANE TO A CLEAR PLACE.

RAISE THE BLOCK UP JUST BELOW THE LIMIT SWITCH AND OFF CONTROLLER.

USE THE FIRST POINT HOISTING (PROCEED CAREFULLY).

IF THE BLOCK DOES NOT OPERATES; REPORT TO YOUR SUPERVISOR (SHOULD BE

REPAIRED AND RESETED BY A QUALIFIED PERSON).

IF OPERATES PROPERLY; LOWER THE HOOK HALF WAY TO THE FLOOR.

MOVE THE HOIST UP TO THE LIMIT SWITCH AT FULL SPEED.

IF NOT FUNCTIONING; CHECK BRAKE OR LIMIT SWITCH.

136

TROLLEY CONTROLLER

9

137

TROLLEY CONTROLLERS OVERHEAD CRANE 9

TROLLEY BRAKE:

THE ELECTRIC BRAKE OPERATES AUTOMATICALLY SIMILAR TO THE HOIST

MOTOR BRAKE. POWER THROUGH THE MOTOR RELEASES IT. WHEN POWER IS

CUT OFF THE BRAKE WILL BE APPLIED BY A SPRING TO STOP THE TROLLEY.

THE TROLLEY BRAKE IS MANDATORY ON CAB OPERATED CRANES WHEN THE CAB

IS ATTACHED TO THE TROLLEY, EITHER AS A TRAILER TYPE OR OVERHANGING

TYPE. (ON OTHER TYPES THE TROLLEY BRAKE IS OPTIONAL.

TROLLEY CONTROLLER PLUGGING:

IF NO TROLLEY BRAKE FITTED, THEN APPLY REVERSE POWER TO THE MOTOR.

138

TROLLEY CONTROLLERS OVERHEAD CRANE 9

TROLLEY STOPPING:

THERE IS NO LIMIT SWITCHES AT THE TROLLEY ENDS ON MOST CRANES,

BUMPERS USUALLY USED (FIG. A). A SELDOM USED WHEEL STOP (FIG B).

WHEN STOPS ARE USED, AVOID STRIKING AT HIGH SPEED (TROLLEY MAY BE DE-

RAILED).

DO NOT OPERATE THE TROLLEY OVER LONG DISTANCES USING INTERMEDIATE

POINTS AS THIS HEATS UP THE MOTOR.

139

BRIDGE CONTROLLERS

10

140

BRIDGE CONTROLLERS OVERHEAD CRANE 10

HYDRAULIC BRAKE SYSTEM

BRIDGE BRAKING SYSTEM:

CAB OPERATED BRIDGE BRAKE USUALLY IS HYDRAULIC TYPE.

WHEN STOPPING, PUT CONTROLLER TO OFF POSITION FOR SOME DISTANCE THEN

APPLY BRAKE GRADUALLY.

141


BRIDGE BRAKING SYSTEM:

WHERE THE BRIDGE IS OPERATED BY MAGNETIC HOLDING BRAKES, THE BRIDGE

MAY BE STOPPED BY THE USE OF PLUGGING.

BUMPERS USUALLY FITTED TO THE CORNERS OF THE CRANE AND SHOULD NOT BE

USED TO STOP THE CRANE (ONLY FOR SAFETY MEASURE).

142


MANUAL CONTROLLER:

DO NOT OPERATE THE BRIDGE OVER LONG DISTANCES UP AND DOWN THE

RUNWAY WITH THE CONTROL HANDLE PART WAY BETWEEN THE OFF AND FULL

ON POSITIONS. THIS HEATS UP THE CONTROLLER EXCESSIVELY. IF THE BRIDGE

TRAVELING TOO FAST, RETURN THE CONTROLLER TO OFF AND COAST. RE=APPLY

POWER AS NEEDED.

143

THREE MOVEMENT COORDINATION OVERHEAD CRANE 10

HOIST / TROLLEY / BRIDGE MOVEMENTS:

ALWAYS KEEP THE ONE HAND ON THE HOIST CONTROLLER TO STOP THE HOOK.

TROLLEY AND BRIDGE MOTIONS MUST NOT BE STARTED UNTIL THE LOAD IS OFF

THE GROUND AND WILL SAFELY PASS BY, OR OVER FLOOR EQUIPMENT OR

OBSTACLES.

3 MOVEMENTS REQUIRE SUFFICIENT EXPERIENCE FOR CRANE OPERATOR.

FOR NEW OR INEXPERIENCED OPERATOR, 3 MOVEMENTS MAY BE PRACTICED

ONLY WITHOUT A LOAD AND WHEN THERE ARE NO CRANES IN THE RUNWAY.

144

MAGNET HOISTING

11

145

MAGNET HOISTING OVERHEAD CRANE 11

MAGNET PARTS HOISTING WITH MAGNET

146


MAGNET SAFETY GUIDELINES:

DO NOT USE THE MAGNET AS A HAMMER TO BREAK UP PACKED MATERIAL.

KEEP THE MAGNET AS DRY AS POSSIBLE.

DO NOT COOL IT OFF WITH WATER.

STORE IT UNDER COVER AND OFF THE GROUND.

KEEP THE TERMINAL BOX CLOSED AND DO NOT ALLOW IT TO GET WET.

KEEP THE CHAIN LINKS GREASED TO PREVENT FRICTION AND WEAR.

WATCH TEMPERATURE WHEN HANDLING HOT MATERIALS, CHANGE THE MAGNET

IF ONE OVERHEATS (HEAT WILL DAMAGE THE MAGNET).

LOWER THE MAGNET CAREFULLY (MAGNET IS COSTLY).

CHECK MAGNET BOLTS FOR TIGHTNESS.

NEVER USE THE MAGNET TO TRANSPORT OXYGEN OR HIGH PRESSURE CYLINDER

NEVER SLING ANOTHER LOAD TO THE HOOK WITH ATTACHED MAGNET,

NEVER TRANSPORT ANYTHING ON THE TOP OF THE MAGNET.

PREVENT UN-NECESSARY SWINGING OF THE MAGNET WITH LOAD,

147


THE OPERATOR SHOULD ENSURE THAT THE POWER HAS BEEN DISCONNECTED

BEFORE HOOKING / UNHOOKING MAGNET PLUGS.

LIFT, MOVE AND LOWER AS SOON AS POSSIBLE (THE MAGNET WILL GET HOT).

148

PRE-OPERATION CHECK

12

149

PRE-OPERATION CHECK OVERHEAD CRANE 12

150

CLASSROOM QUESTIONS

&

DISCUSSION

TIME (1.5 HOUR)

151

TEA / COFFEE BREAK

TIME (15 MIN.)

152

PRACTICAL TRAINING

TIME (1.5 HOUR)

153

PRACTICAL TRAINING

TIME (1.5 HOUR)

154

WRITTEN EXAMINATION

TIME (25 MIN.)

155

COURSE APPRAISAL

TIME (5 MIN.)

156

OVERHEAD CRANE TRAINING COURSE COURSE CLOSING 13

BUREAU VERITAS THANK YOU

FOR YOUR KIND ATTENTION

Bahrain Overhead Crane Training

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