WELCOME

Overhead Crane OperatorsOverhead Crane Operators

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Electrical

Mechanical

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 drum3) Hook approach: a) Hook position is assumed at center of rope drumb) Dimensions given are without consideration of DSL and its locationb) Dimensions given are without consideration of DSL and its location4) 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 - K11) (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 SAFETYSAFETY

OVERHEAD AND GANTRY CRANE OVERHEAD AND GANTRY CRANE OPERATIONOPERATION

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.

OVERHEAD AND GANTRY CRANE 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.


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.


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.


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.


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.


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.


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.


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.

NN

WW

SS

EE

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.


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.


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.


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.


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.


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.


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 necessarynecessary

Sample PermitSample 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 EquipmentPersonal Protective EquipmentHead ProtectionHead Protection

PROPER PROPER CLOTHING & CLOTHING & DRESSDRESS

Safety Foot Safety Foot WearWear

Hearing ProtectionHearing Protection

Face ProtectionFace Protection

Hand ProtectionHand Protection

RespiratorsRespirators

Fall ProtectionFall Protection

Special ClothingSpecial Clothing

Shift/Operator Inspection ChecksShift/Operator Inspection ChecksInspection ItemInspection Item Description of Inspection Check PointsDescription of Inspection Check Points

Tagged Crane or HoistTagged 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 DevicesControl Devices Test run that all motions agree with control device markings.Test run that all motions agree with control device markings.

BrakesBrakes 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 normalnormal

HookHook 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 LatchHook Latch If a hook latch is required, check for proper operation.If a hook latch is required, check for proper operation.

Wire RopeWire 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.

RevvingRevving 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 SwitchesLimit 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 LeakageOil 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 SoundsUnusual 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 hoistthe crane or hoist

Warning and Safety LabelsWarning 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 LightingLighting

Check area for accumulation of material, trip or slip hazards, and poor lightingCheck 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 PointsOperating 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 OverheadStandard Hand Signals For Controlling OverheadAnd Gantry CranesAnd 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.


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.


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.


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.)


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

InspectionInspection

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.

MaintenanceMaintenance# 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.

VIJAY VYAS

WELCOME

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