SLB Lifting

3-Day SLB
Onshore Site Lifting Supervisor

Instructor Lecture Notes
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Lecture Notes | 3-Day SLB Onshore Site Lifting Supervisor www.nsl-aberdeen.com
Contents
i. Course Pre-requisites
ii. Training Course Requirements
iii. Course Duration
iv. Successful Completion
v. Instructor / Delegate Ratio
vi. Instructor / Assessor Qualifications Experience
vii. Safety
viii. Unsafe Acts
ix. Weather Conditions / Equipment Problems
x. Training Outcome
xi. Lesson Plan
Day 1
1. Course Introduction and Registration

2. Course Aim and Objectives
3. Course Contents
4. Management of Lifting Operations
5. Types of Cranes
6. Stability and Mechanical Principles
7. Line Pull and Line Speed
8. Travelling and Access
9. Ground Conditions and Loadings
Confirming Questions
Play Mobile Cranes for Land Operations Movie
10. Site and Environmental Hazards
11. Wheels, Tracks and Outriggers
12. Crane Structure
13. Booms / Jibs
14. Limiting and Indicating Devices
15. Load Charts / Range Diagrams
Load Chart Questionnaire Answers

Day 2
Day 1 Confirming Questionnaire Answers

16. Hoists, Slew Ring and Sheaves
17. Wire Ropes
18. Wire Rope Terminations
19. Spooling and Reeving
20. Headache Balls and Sheave Blocks
21. Controls, Gauges and Crane Motions
22. Initial, Pre-Start Up and Pre-Operational Checks
23. Principles of Operation
24. Practical Crane Demonstration / Exercise
25. Maintenance and Refuelling
26. Periodic Inspection and Testing
27. Record Keeping
Day 3
Day 2 Confirming Questionnaire Answers

28. Man-Riding Operations
29. Static and Dynamic Lifts
30. Tandem Lifts
31. Acronyms, Definitions and Terminology
32. Previous Incidents, Causes and Lessons Learned
33. Roles and Responsibilities (Crane Operator, Banksman and Slingers)
34. Communications (Hand Signals and Two-Way Radios)
35. Lifting Planning (Schlumberger specific)
36. Practical Crane Exercises

i. Course Pre-requisites
Delegates attending this training course should have 5-years experience in lifting operations
and possess the following abilities:
• Motivation and confidence for public speaking

• Good attitude toward others
• Ability to communicate with others
• Literate, numerate and fluent in English

In addition, successfully completed Mechanical Lifting level 1 online test in QUEST and are
knowledgeable and / or experienced in the following subjects:
• Country Specific Legislation / Regulations

• Safe Systems of Work
• Industry Guidelines and Company Procedures for Lifting Operations
• Crane Operations
• Rigging and Lifting Operations (Use of Portable Lifting Equipment)
• Management / Supervision of Personnel
• Assessment Techniques and Protocols
• Basic Knowledge of Geometry, Mathematics and Chart Reading
ii. Training Course Requirements
• Classroom (size to suit number of delegates)

• Desks and chairs
• Writing implements and note pads
• Adequate heating, air conditioning and lighting
• Projector or suitable display screen
• Instructor dry wipe board or similar
• Training course material, e.g. slide, forms, questionnaires, etc.
• Company lifting polices / procedures
• Practical exercise / demonstration area
• Certified mobile crane
• A range of loads, obstacles and lifting accessories used during practical crane
exercises
• Samples of equipment for classroom
iii. Course Duration
The course requires a minimum of 24 hours to complete, delivered over a 3-day period.
iv. Successful Completion
A score of 80% or above is required to be achieved in the theoretical elements and in the
continual assessment during the practical elements of the course.

v. Instructor / Delegate Ratio
It is recommended that the maximum and minimum number of delegates attending this
course is twelve and two respectively.
vi. Instructor / Assessor Qualifications Experience
Instructional staff shall have demonstrable experienced in the course subject. In addition,
have experience and / or completed training in instructional / lecture techniques
Assessors shall hold a recognized Skills Assessor’s award.
vii. Safety
The Instructor and delegates shall wear appropriate PPE during the practical elements of
the training course. In addition, the Instructor shall assess the practical training area and
equipment before training commences to ensure that it is free from potential hazards.
viii. Unsafe Acts
The training course shall be halted if at any time the Instructor believes an unsafe act is about
to be committed or has been committed. Training shall only resume after the delegate has
been instructed in the correct mode of operation or course of action.
ix. Weather Conditions / Equipment Problems
The Instructor shall use an anemometer to check wind speed and weather conditions to
ensure they are within the cranes acceptable operating limits.
The Instructor is responsible and has the final decision in determining if weather conditions
and the equipment are suitable to proceed with training.
Training shall be suspended if adverse weather conditions or equipment problems arise.

Training shall only resume, from the point of suspension, when weather conditions have
returned to within normal operating limits and equipment technical problems have been
resolved.

x. Training Outcome
Successful delegates will be issued with a certificate of training. Each certificate should
contain the following information:
• Course Title
• Elements covered during the training
• Delegate’s Name
• Course Dates
• Certificate Number
• Instructor / Assessors Signature
Upon completion of the course, the Instructor shall remind delegates that the certificate of
training alone does not make them competent and that it only forms part of their competence
development.

xi. Lesson Plan
Day 1
Content 0830 – 1000 Approximate Duration
Introduction & Registration 15 minutes
Course registration form F001
Course Aim, Objectives & Content 15 minutes
Management of Lifting Operations 15 minutes
Types of Cranes 15 minutes

Stability & Mechanical Principles 30 minutes
Break 15 minutes
Line Pull & Line Speed 15 minutes
Travelling & Access 15 minutes
Ground Conditions & Loadings 75 minutes
Lunch 1 hour
Mobile Cranes for Land Operations Movie 15 minutes
Site and Environmental Hazards 45 minutes
Wheels, Tracks & Outriggers 15 minutes
Crane Structure & Booms / Jibs 15 minutes
Limiting & Indicating Devices 30 minutes
Break 15 mins
Load Charts / Range Diagrams 45 minutes
Confirming Questions & Load Chart
Load Chart Questionnaire F002 45 minutes
Feedback 15 minutes

Day 2
Introduction 15 minutes
Day 1 Confirming Questionnaire F003 10 minutes
Questionnaire Feedback 20 minutes
Hoists, Slew Ring & Sheaves 15 minutes
Wire Ropes & Terminations 30 minutes
Break 15 minutes
Spooling and Reeving 15 minutes
Headache Balls & Sheave Blocks 15 minutes
Controls, Gauges & Crane Motions 15 minutes
Initial, Pre-Start Up &
30 minutes
Pre-Operational Checks
Principles of Operation 30 minutes
Lunch 1 hour
Practical Crane Demonstration / Exercise 150 minutes
Mobile Crane Visual Inspection Checklist F004
Break 15 minutes
Maintenance Refuelling 15 minutes
Periodic Inspection & Testing 30 minutes
Record Keeping 15 minutes
Feedback 15 minutes

Day 3
Introduction 5 minutes
Day 2 Confirming Questionnaire F005 15 minutes
Questionnaire Feedback 15 minutes
Man-Riding Operations 15 minutes
Static & Dynamic Lifts 15 minutes
Tandem Lifts 15 minutes
Acronyms, Definitions & Crane Terminology 15 minutes
Break 15 minutes
Previous Incidents, Causes &Lessons
30 minutes
Learned
Roles and Responsibilities (Crane Operator,
15 minutes
Banksman & Slingers)
Communications
15 minutes
(Hand Signals & Two-Way Radios)
Lifting planning
45 minutes
(Schlumberger specific)
Lifting Plan - Routine Lifting Operation F006
Lifting Plan – Non-Routine Lifting Operation F007
Lunch 1 hour
Lift planning Exercise 30 minutes
Lifting Plan - Routine Lifting Operation F006
Mobile Crane On-site Pre-use Checklist F008
Practical Crane Exercises 90 minutes
Break 15 mins
Practical Crane Exercises 30 minutes
Delegate Practical Assessment Record F009
Written Questionnaire F013 60 minutes
Delegate Assessment Summary Record F010
Feedback 15 minutes

Day 1

1. Course Introduction and Registration
Have slide number one on the overhead projector and leave it up during your introduction
and course registration.
Your introduction should include:
•
Welcoming the delegates and confirming that they are attending the correct course

Note | At this point, have the delegates complete the course registration form, reminding
them to record their name as they wish it to appear on their certificate.
• Introducing yourself, which should include some relevant information about your
past experience with the course subject
• Asking delegates to switch off their mobile phones
• Asking delegates to introduce themselves
• An overview of the facility, site safety procedures, breaks and meal times, smoking
policy, etc.
• An overview of the course content and timings (emphasize delegate time keeping)
• The course’s aims and objectives
• Informing delegates that there will be written tests during and at the end of the
course
• Informing delegates that during the final course questionnaire they will be allowed to
refer to their notes and handouts
• Informing delegates that they will be under continuous assessment during the
practical elements of the course
• Advising delegates of the complaints and appeals process
• Explaining to delegates that this is a pass / fail course
• Explaining the course’s development history
• Advising delegates that they will be organized into small groups to complete course
exercises

In addition, during the course you should encourage questions. Speak clearly and slowly
as, although you are familiar with the subject, it may be relatively new to some and wherever
possible also emphasize the importance of competence, thorough planning, and risk
assessment.
Finally, keep in mind that everyone is different, each Instructor has their own style of
presentation but a good Instructor will be:
• Warm and understanding rather than cold and aloof

• Organized and businesslike rather than unplanned and disorganized
• Stimulating and imaginative rather than dull and routine
• Knowledgeable and experienced in the subject matter
• Approachable and above all;
• Enthusiastic

2. Course Aim and Objectives
Aim
The course aim is to provide personnel with the necessary knowledge and understanding to
facilitate safe mobile crane lifting operations.
Objectives
At the end of training, delegates will be able to:
•
Understand mobile crane stability and mechanical principles
•
Assess the suitability of ground conditions
•
Identify individual crane components and understand their function / safe use
•
Read and understand load charts
•
Identify crane lifting accessories and understand their function / safe use
•
Understand crane control functions
•
Understand the initial, pre-start up and pre-operational checks
•
Identify the safe / unsafe operation of a mobile crane
•
Plan lifting operations
•
Identify and mitigate hazards
•
Identify and understand maintenance and certification requirements
•
Understand man-riding, static, dynamic, blind and tandem lifting requirements
•
Communicate using hand signals and two-way radios

The course includes written confirming questionnaires, at the beginning of day two and three,
verbal confirming questions during the lecture, a final written questionnaire and continual
assessment during the practical elements to measure and record learning and understanding.

3. Course Contents
Day 1
• Management of Lifting Operations
• Types of Cranes
• Stability and Mechanical Principles
• Line Pull and Line Speed
• Travelling and Access
• Ground Conditions and Loadings
• Site and Environmental Hazards
• Wheels, Tracks and Outriggers
• Crane Structure and Booms / Jibs
• Limiting and Indicating Devices
• Load Charts / Range Diagrams
• Load Chart and Range Diagram Exercise

Day 2
• Day 1 Confirming Written Questionnaire
• Questionnaire Feedback
• Hoists, Slew Ring and Sheaves
• Wire Ropes and Terminations
• Spooling and Reeving
• Headache Balls and Sheave Blocks
• Controls, Gauges and Crane Motions
• Initial, Pre-Start Up and Pre-Op Checks
• Principles of Operation
• Practical Crane Demonstration / Exercise
• Maintenance and Refuelling
• Periodic Inspection and Testing
• Record Keeping
Day 3
• Day 2 Confirming Written Questionnaire
• Questionnaire Feedback
• Man-Riding Operations
• Static and Dynamic Lifts
• Tandem Lifts
• Acronyms, Definitions and Terminology
• Previous Incidents and Lessons Learned
• Roles and Responsibilities (Crane Operator, Banksman and Slingers)
• Communications (Hand Signals and Two-Way Radios)
• Lifting Planning (Schlumberger specific)
• Lift Planning Exercise
• Practical Crane Exercises: Permit to Work
Supervision of a Lifting Operation
Pre-operational Checks
Crane Operations
• Written Questionnaire

4. Management of Lifting Operations
Lifting operations are hazardous and require disciplined management to avoid harm to people
or damage to equipment and the environment. To accomplish this, the management of lifting
operations must address:
• Training and Competence

• Equipment and;
• Safe Operating Procedures
In effect, to ensure that all lifting operations are competently planned, appropriately super-
vised and carried out safely.
To simplify this process personnel should consider the following stages:
Prepare: Personnel roles and responsibilities

Equipment suitability
Categorize: Levels of competence

Type of lifting plan
Level of supervision
Risk Assess: Identify all the hazards

Determine who or what might be harmed / damaged
Evaluate the risks and decide on precautions / controls
Record and implement the assessment findings
Review the residual risk
Review and update when necessary
Plan: Method statement

Drawing
Materials list
Controls
Authorize: Approval and authorization
Execute: Safe operating procedures

Supervision

Management of Change
Learn: Monitor and review

Record
Feedback

4. Types of Cranes
Mobile full-slewing
crane on wheels
Truck mounted boom crane with lattice fly jib

extension and outriggers
Crawler mounted lattice boom crane
The most common cranes on land are mobile cranes, which are normally fitted with a tele-
scopic boom. They travel from site to site to perform lifts and have to put down outriggers
before lifting. Their ability to move with a load is very limited and so they are generally restrict-
ed to lifts within their safe operating radius in any particular location. Crawler cranes are also
mobile and are usually to be found in construction yards. They can travel with a load as long
as the ground is reasonably level. Usually these cranes have lattice booms but newer models
may have telescopic booms.
They may also come with a superlift capability when very heavy loads are required to be lifted.
This is a connected tray (lower chassis) with more counterweights that can be lifted from
the ground so that the upper chassis can slew round. For example, in the standard boom /
counterweight configuration the lifting capacity may be 800 tonnes at 7m radius but with the
superlift the capacity could rise to 1,000 tonnes at 14m.

Crawler Crane with Superlift
Mini cranes or spider cranes, as they are generally known, offer a wide range of applications,
being specifically designed for confined and restricted access operations. These cranes
are commonly used for glass installations, internal lifting, rooftop maintenance, plant
maintenance, steel installations, tandem lifting, in-between floor operations, etc. They can
be controlled either from an onboard Operators seat or from a distance using a radio remote
control or optional radio remote control with digital feedback.
Spider Crane

Truck Mounted Crane
The primary function of a truck mounted crane, also commonly known as a HIAB, Lorry
Loader or Palfinger, is to unload materials from the delivery vehicle on which they are
mounted. They also remove the need for a mobile crane to be supplied on site. However,
personnel must remember that this type of equipment is still a crane and requires an
appropriate level of competence and control to operate.
Truck Mounted Crane

6. Stability and Mechanical Principles
Cranes are able to lift loads by applying the principles of leverage and mechanical advantage.
Leverage is the process by which a lever multiplies a force and is therefore related to me-
chanical advantage, which is the increase in force (or torque) that you gain by using a device
or tool. When using a lever, a small amount force is applied over a long distance, which en-
ables you to lift a larger force only a small distance.
The cranes own weight (crane leverage) is balanced against the load being lifted at the tip-
ping point (or fulcrum) allowing it to remain stable, and therefore safely lift / move the load, so
long as the crane’s weight is greater than the load’s leverage (moment) on the crane.
The crane’s lifting capacity is reduced when the boom is lowered because the distance from
the load to the tipping point / fulcrum is increased, therefore increasing the load moment. This
can then lead to instability if the crane’s capacity / load moment is exceeded. Instability can
also occur when the crane has no load on the hook and the boom is at its minimum radius
(backwards stability).
Cranes Centre Tipping Axis Loads Centre

of Gravity of Gravity
I N S TR U C T O R C L A S S R O O M DEM O
WARNING!

Hence, it is critical that the Crane Operator has the ability to understand and correctly use
a crane’s load chart and rated capacity indictor (load moment indicator). Each crane’s load
chart specifies the rated capacity and operational limitations of that machine for every permis-
sible configuration necessary for safe operation.
The term load moment is an engineering term, which refers to the product of a force and it’s
moment arm. The moment arm is the perpendicular distance between the force (weight of
the load) and the crane’s centre of rotation. Therefore, with a one thousand unit force act-
ing at a ten unit radius (as shown), the load moment is the product of these two factors; ten
thousand units.
1000
10

The manufacturers of modern cranes are now using higher yield steels to create stronger
and lighter cranes. First, this has resulted in the structurally limited portion of the load chart
increasing. This is the first portion of the load chart where a structural failure can occur before
the cranes stability is overcome. Second, lighter booms with more elastic steels, boom de-
flection has increased therefore when load is applied the radius increases.
With this increase in radius, as stated previously, there will be a proportional increase in the
load applied to the crane. Therefore, it is critical that the Crane Operator, not only knows the
weight of the load, but also the exact radius of the load.
no load
load
real load radius

Boom Deflection
A crane will tip when the overturning moment (of the load and boom about the tipping ful-
crum) exceeds the crane’s resisting moment (of the machine weight about the tipping ful-
crum).
The principal factor controlling load capacity for cranes is stability against tipping. Crane load
ratings are established when a crane load stability test is performed under controlled condi-
tions to determine the tipping load.
The crane capacity is based on a percentage of the tipping load / maximum structural capac-
ity. Schlumberger mobile cranes shall be operated up to 75% of their designed tipping load /
maximum capacity.

However, it is also possible for a crane to overturn with smaller loads when operating in windy
conditions or on sloping ground, or if the crane is not operated smoothly.
The Crane Operator must always:
• Use the crane manufacturer’s load chart

• Know or can calculate the weight of each load
• Before beginning a lift, follow the manufacturer’s procedures for proper outrigger
deployment to ensure that the crane is properly set up and level
• Ensure outrigger pads are supported on firm, stable surfaces before beginning a lift
• Check the condition of the ground and supporting material regularly and as often as
possible to ensure the crane remains on firm, stable ground
The Crane Operator must never use visual signs of tipping as an indicator of lift capacity.

7. Line Pull and Line Speed
In general, the lifting capacity of a crane depends on the rated line pull capacity of the winch,
the tensile strength of the wire rope and the number of parts of rope (falls).
Each turn of the rope around the full circumference of the drum is called a wrap. Rope is
wrapped around the drum, starting at one end flange and progressing to the other flange,
which is called a layer.
The line pull capacity of the winch varies depending on the amount of wire fitted to the winch
drum. The first layer of wire rope offers the maximum line pull and as you hoist in, the winch
becomes progressively less powerful with each layer of wire rope on the drum. If the load to
be lifted is greater than the line pull capacity of the winch, the rope can be reeved between
the boom head and hook block. This should be done as many times as is necessary.
Reeving enables forces to be multiplied. The winch line pull (P) is multiplied by the number of
falls passing between the two blocks (the lead line should not be included).
Note | To be exact a percentage has to be added to overcome friction, which is generally ac-
cepted to be:
• Sheaves with roller bearings - 4% per sheave

• Sheaves with bronze bushes - 8% per sheave
P P P P P P
W
W W W W W
Single Fall Double Fall Three Fall Four Fall Five Fall Six Fall
Reeving
By using this method, a heavier load can be lifted but line speed and distance is reduced pro-
portional to the number of falls used. For example, on a single part line the hook speed is the
same as the line speed but as more parts of line are used the hook speed is reduced.
It is the Crane Operator’s responsibility to ensure that the number of falls is sufficient to carry
out the lift safely. The required number of falls for each lift can be found in the manufacturers
handbook.
I N S TR U C T O R C L A S S R O O M DEM O
WARNING!

8. Travelling and Access
Crane mobility, in general, is either by means of wheels or crawler tracks.
Note | Any mobile crane, which is required to work on a company worksite must meet with
the minimum requirements specified on the mobile crane on-site pre-use checklist.
Certain types of crane can even travel on public highways but only after certain elements are
configured beforehand, for example:
• Retract and stow boom sections

• Retract and pin outriggers
• Secure outrigger foot-plates
• Correctly stow grillage
• Secure any loose items
• Set suspension correctly
• Switch on flashing amber lights
• Adhere to the National Road Traffic Regulations
Speed limits must be obeyed. Special care must be taken to observe, for example weight
limits, width and height restrictions (bridges) etc. Remember, you will need to plan your route.
Note | Heavy cranes and ballast trucks may need to be escorted by Police. It is the
responsibility of the crane company to follow the correct procedure.
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Factors that need to be considered and controls implemented when re-positioning and when
carrying out pick and carry operations include:
• Ground bearing pressure

• Ground conditions e.g. potholes, undulations, rail tracks, etc.
• Underground services e.g. drainage, pipelines, etc.
• Structures e.g. buildings, power lines, barriers, etc.
• Tyre pressures
• Suspension movement
• Banksman / Signaler guiding the crane and who remains in sight of the Crane
Operator all times but not in the path of the crane or the load
• The slew brake or lock is applied
• Travelling slowly to prevent excessive load swing
• Load positioned as low as possible
• Reversing alarm and flashing warning light are both functioning
The majority of the above considerations and controls also apply when travelling / re-
positioning a crane when it is not lifting a load.

9. Ground Conditions and Loadings
The ground conditions must be suitable to support the crane under fully loaded conditions.
The ground should always be firm and level. Care should be taken to ensure there are no
dangers to or from underground services, such as gas mains, pipelines, electrical cables,
water mains etc.
The Crane Operator, along with the site owner / operator, must check that the type of ground
can withstand the bearing pressure transmitted through the outriggers when the crane is
lifting a load. Additional care is also needed when working next to exposed edges such as
quaysides, but even more so, near the edges of excavations.
The outrigger load enters the supporting surface at 45 degrees, so it is imperative that the
outrigger is positioned no closer to the edge of the excavation than a distance slightly greater
than the depth of the excavation.
D2 must be
greater than D1
(aim for 2 x D1)
45º
ok
depth= D1
load path
Outrigger position

In geotechnical engineering, the ground bearing capacity is:
“The capacity of soil to support the loads applied to the ground”
Before any crane or lifting operation can take place the Competent Person must establish the
Ground Bearing Pressure (GBP) of the site (or area where the crane and load will be situated).
This information can be gained from:
• Method statements
• Geotechnical Engineering
• Physical inspections and load tests (carried out previously)
• Employing organisation (client / land owner)
Refer to the chart below, for guidance only, regarding soil presumed bearing values.
Non-cohesive Soils kN/m2 lbs/in2
Dense gravel or dense sand and gravel > 600 > 87
Medium dense gravel or medium dense sand and gravel < 200 to 600 < 29-87
Loose gravel or loose sand and gravel < 200 < 29
Compact sand > 300 >43.5
Medium dense sand 100 to 300 14.5-43.5
Loose sand (depending on degree of looseness) < 100 < 14.5
Cohesive Soils
Very stiff bolder clays and hard clays 300 to 600 43.5-87
Stiff clays 150 to 300 21.5-43.5
Firm clay 75 to 150 10.5-21.5
Soft clays and silts < 75 < 10.5
Very soft clay Not applicable
Peat Not applicable
Made ground Not applicable
Note | As GBP is an exerted force and not a weight, it is should be stated as:

Newtons per metre squared = N/m²
Or
KiloNewtons per metre squared = kN/m²
So how does 1kg become a force? It simply has the force of gravity acting upon it.
What is the force of gravity? 9.8N/kg (rounded up to 10)
Therefore, to change any weight into GBP (or force) we simply multiply by 10.

Once the GBP of the site has been established you then have to determine the overall weight
that is going to be applied to the ground. This is calculated by adding the gross load weight
to the gross crane weight:
Gross weight of the load equals adding all these elements together:
• Nett weight of the load

• Fittings
• Oils / lubricants
• Attachments
• Lifting accessories
• Hook block etc.
Plus a calculated Factor of Safety of 25% (if the Nett load is not known)
Gross weight of the crane equals adding all these elements together:
• Nett weight of crane

• Additional ballast not transported upon the carrier
• Additional jib attachments (lattice boom sections, fly jib, back mast etc.)
• Weight of mats / timber supports etc.
Next, calculate the overall area of matting that will make contact with the ground.
Area of mats = length of mat x width of mat x number of mats
For crawler cranes, to find the track area making contact with the ground:
Area = Length of track x width of track x 2
The resultant figure is the total area that will make contact with the ground in m².
Note | Due to the low pressures exerted by the tracks of a crawler crane, it is not very
common to use mats under the tracks, but if necessary, you must calculate the area of the
mats and not the tracks.
With area of contact and the overall weight established the GBP can be determined using:
GBP = overall weight ÷ area of contact
The resultant figure is the force that will be exerted into the ground through all the mats or
tracks.

To calculate the highest possible force that could be exerted through any mat or track at any
given radius, use the following:
GBP = overall weight ÷ area of one mat or track for crawler crane
The resultant figure would only be possible if the crane was being fully supported on one
outrigger mat or track.
As this would mean that the crane would be unstable and in a tipping situation it is
considered more accurate to calculate the force exerted through the mat or track when 75%
of the overall weight is applied, therefore:
GBP = 75% of overall weight ÷ area of one mat or track
To confirm the suitability of a crane for any lifting operation, the GBP of the crane and load
must exert less force than the ground can actually withstand, in other words:
Overall crane and load GBP must be less than the GBP of the site
If the crane exerts more GBP than the ground can withstand, or if the crane does not come
equipped with mats as standard, then to calculate the size of mats required use the following:
Area of each mat = gross load weight + gross crane weight ÷ GBP (of ground)
The resultant figure will be the area required for EACH mat in m².
Note | In practice round figures up to the nearest practicable size, for example do not specify
mats at 2.137m x 3.333m, instead round these up to 2.5m x 3.5m.
This not only makes it easier for the crane owner but also increases the area of contact
between the crane and the ground along with reducing the overall GBP being applied.

(Answers to be rounded to two decimal places whenever possible)
1. Calculate the area of a circular mat with a radius of 75cm?
Area = πr²
= 3.142 x (0.75 x 0.75)
= 3.142 x 0.56
= 1.76m²
2. Calculate the area of a circular mat with a diameter of 75cm?
Area = πr²
= 3.142 x (0.375 x 0.375)
= 3.142 x 0.14
= 0.44m²
3. Calculate the area of a square mat that is 2.5m x 2.5m?
Area = Length x Breadth

= 2.5 x 2.5
= 6.25m²
4. Calculate the area of a set of 1.75metre x 2.5metre mats?
Area = Length x Breadth x Number of mats

= 1.75 x 2.5 x 4
= 4.375 x 4
= 17.5m²

5. Calculate the gross weight of the following:
Crane (8 axle) = 12te per axle

Ballast = 250te
Hook-block = 7.25te
Load = 175te
Contents of load = 0.00te
Lift Accessories = 3.833te
1 x Outrigger mat = 0.44te
GROSS WEIGHT = 533.84te
If the crane in the previous question was sitting on mats that are 2m x 2m, what is the ground
pressure being exerted through all of the mats?
Gross weight = 533.84te

Area of mats = 2m x 2m x 4 mats
= 16m²
GBP = 533.84 ÷ 16
= 33.36te / m²
6. Using the following information, calculate the minimum size of mats required if the GBP is
150kN/m².
• 350te capacity mobile crane with 6 axles @ 15te per axle

• 155te of ballast (12.5te carried on the chassis)
• Hook-block weighing 2,148kgs
• Spreader beam weighing 0.85te
• Load requires eight shackles weighing 1.75kgs each
• Two wire slings weighing a total of 38kgs
• Load weight unconfirmed but believed to be between 17.5te and 24.5te.
Option 1 – 75% rule
Crane weight = 6 axles x15te per axle

= 90te
+ ballast weights = 142.5te (155te – 12.5te carried on chassis)
+ hook-block = 2.148te
Gross crane weight = 234.65te
Lifting accessories = 0.92te (0.85te + 0.014te + 0.038te)
Load Weight = Maximum assumed weight + additional FOS

= 24.5te + 25% (variable on competency)
= 24.5te + 6.125te
= 30.63te (estimated)
Total gross weight = 234.65te + 0.92te + 30.63te
= 266.2te

Area of each mat = 75% of gross weight ÷ GBP
= (75% of 266.2te) ÷ (150kN/m² ÷ 10)
= 199.66te ÷ 15te / m²
= 13.31 m²
Size of square mat = √13.31 m²

= 3.65m x 3.65m
Rectangular mats = 3m x 4.5m (13.5m²)
Option 2 | 100% rule
Crane weight = 6 axles x15te per axle

= 90te
+ ballast weights = 142.5te (155te – 12.5te carried on chassis)
+ hook-block = 2.148te
Gross crane weight = 234.65te
Lifting accessories = 0.92te (0.85te + 0.014te + 0.038te)
Load Weight = Maximum assumed weight + additional FOS

= 24.5te + 25% (variable on competency)
= 24.5te + 6.125te
= 30.63te (estimated)
Total gross weight = 234.65te + 0.92te + 30.63te

= 266.2te
Area of each mat = 100% of gross weight ÷ GBP

= (100% of 266.2te) ÷ (150kN/m² ÷ 10)
= 266.2te ÷ 15te / m²
= 17.75 m²
Size of square mat = √17.75 m²

= 4.21m x 4.21m
Rectangular mats = 3.75m x 4.75m (17.81m²)

Play
Mobile Cranes for
Land Operations Movie

10. Site and Environmental Hazards
Risk / Hazard Assessment is essential for reducing the likelihood of having an accident and
the severity of that accident should it occur.
When a lifting operation is identified, one of the first steps is to establish what it will involve.
This initial assessment should identify the need for any additional form of assessment or if the
task cannot be carried out safely. If the identified risks / hazards cannot be reduced to as low
as reasonably practicable then the task should be revised.
Following the initial assessment, the next step is to:
• Identify all the hazards

• Determine who or what might be harmed / damaged and any impact to the
environment
• Evaluate the risks and decide on precautions / controls
• Record and implement the assessment findings
• Review the residual risk
• Review and update when necessary
Remember, the higher the risk, the greater degree of control and supervision required.
Note | A new risk assessment may not be required for every lift. However, Schlumberger
require that there is at least a generic lifting HARC for every type of lift, which shall be
reviewed before hand to ensure that it is still relevant.
The success of any risk / hazard assessment depends largely upon how effectively it is
communicated to everyone involved or affected by the lifting operation. Therefore, risk /
hazard assessments should be thoroughly conveyed to everyone at the toolbox talk.
Depending on the type of crane being used, precautions must be taken to ensure the safety
of the Operator and all personnel in the vicinity of the crane operation.
Cranes working in close proximity to overhead power lines should be positioned no

closer than a distance equal to the length of crane boom, plus 15m (50ft), measured along
the ground. This may be reduced to 10m (30ft) if the cables are supported on wooden or
concrete poles. Always inform and consult with the electricity company when working close
to overhead power lines.
In addition, never travel the crane in the vicinity of overhead power lines / cables unless
guided by an experienced Signaller, keeping them in view at all times.
When a crane must travel underneath an overhead power line / cable the crossing route
should be clearly marked and “goal posts” erected each side of the crossing’s approach, to
ensure that the boom or moving parts are lowered to a safe height.
Note | Schlumberger QHSE standard 020, hazard analysis and risk control shall be used.

If at any time the crane makes electrical contact you should observe the following
precautions:
• Remain inside the cab if safe to do so and get someone to inform the power
company
• Take no action until they have confirmed that conditions are safe
• Tell all other personnel to keep away and not to touch any part of the crane, rope or
load
• Try, unaided, and without anyone approaching the crane to back off until it is well
clear of the power line / cable
• If it is essential to leave the cab because of some other reason, for example fire, to
avoid being electrocuted, jump clear of the crane, as far away as possible. Avoid
touching the crane and the ground at the same time. Try and land with feet together
then make short jumps away from the crane, keeping your feet together
• The Power Company should be informed of the situation immediately, but until
assistance arrives, an attendant should remain in a safe position to warn of the
dangers
In addition, a crane boom can act as a conductor and attract a lightning strike during a
thunderstorm. If there are clear signs of an approaching thunderstorm, lifting operations must
cease and all personnel should be moved out of the vicinity of the crane, until the possibility
of danger passes. If the crane is struck by lightning it can be seriously damaged both
structurally and mechanically. A thorough examination must be carried out before a crane
struck by lightning is returned to service.
Adverse weather conditions, for example wind speed / gusty conditions, exert additional
forces to the crane and the load, which can affect both the strength and stability of the crane
and safe handling of the load (winds may swing suspended loads out of balance and radius).
The crane’s duty chart will specify the maximum wind speed at which the mobile crane must
be taken out of service. However, the Operator may decide to take the crane out of service at
a lower wind speed due to the type of load being lifted.
Note | The Operator has the responsibility for making this decision, in conjunction with the
site supervision, which shall not be overridden by site management.Therefore, it is important
that the Operator regularly monitors the wind speed, using an anemometer, which will give an
early warning of rising wind speeds and gusts.
The majority of forecasted wind speeds are for a height of 10m above ground and should
be corrected for greater heights. In open countryside, wind speed increases with height as
shown in the table below:
Height above ground (m) 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Wind speed multiplier 1.00 1.1 1.17 1.22 1.26 1.29 1.32 1.35 1.37 1.39 1.41 1.43 1.44 1.46 1.47
Additional site and environmental hazards that need to be considered:
• Position of other equipment (simultaneous operations)

• Location of live plant and structures
• Poor visibility, extreme heat or cold
11. Wheels, Tracks and Outriggers
Tyres / wheels need to be checked periodically and before travelling, to ensure:
• It is securely attached (wheel nuts)

• The legally acceptable depth of tread and the condition of the side walls
• It is inflated to the correct pressure, as stated by the manufacturer
Note | Always ensure the tyres are correctly fitted before inflation and when checking the
pressure. Pressure readings may vary due to the ambient temperature. Therefore, pressure
readings should be consistently taken at the coolest part of the day.
In addition, tyres will be subjected to different loads during operation. Therefore, a

programme of tyre rotation should be implemented as per the manufacturers guidelines.
Crawler cranes will generally apply considerably less point load to the ground than a crane
on outriggers with no mats. This is because there is a large
area of track in contact with the ground. However,
for heavy lifts and where the ground has poor load
bearing capacity, bog mats or other supporting
materials should be used.
Wheel with Pneumatic Tires
The following items should be inspected periodically for mechanical damage, wear, cracking,
etc:
• Drive Wheel
• Wheels / Guides
• Track Linkage plates
• Mechanical connections
• Pins
Caterpillar Track

The ground pressure applied by a crawler crane is different to that applied by a crane on
outriggers. It is sometimes assumed that the ground pressure will be the same at any place
where the track is in contact with the ground. However, in practice this is rarely the case.
When the crawler crane is being used with a

suspended load, the ground pressure will be
greater towards the front of the crane.
If there is no load suspended on the crane, theground

pressure will be greater towards the rear of the crane.
As the boom slews around the ground pressure

will be greater over one end of the track.
If the boom continues to slew around until it is

at right angles to the track. The ground pressure
will be distributed over the nearest track to the load.

The outriggers on a mobile crane provide stability to the crane when lifting loads. Irrespective
of the ground conditions, mats or other means of distributing the load should always be
placed under the outriggers.
Load is transmitted to the ground beneath the crane as point loads through the outrigger /
stabilizer beams and mats, instead of the tyres.
When using the outriggers, they should be extended in accordance with the duty charts to
the positions marked on the beams. The jacks should be extended sufficiently to level the
crane with all the crane tyres clear of any supporting surface.
Note | On Schlumberger sites crane outriggers shall always be fully extended during lifting
operations.
Hydraulic Outrigger
On modern cranes push button, level control systems automatically level the crane during
setting up. Older models may have levers and bubble level indicators.
54 63
101 102
Outrigger / Crane Levelling Control

12. Crane Structure
Mobile cranes must be designed in accordance with applicable regulations, acceptable

engineering principles and relevant technical standards to ensure the mobile crane is without
risk to health and safety. In addition, if the crane is designed for travel on public highways
the crane shall be subject to the requirements for braking, steering, lighting, seat belts, fire
extinguisher, etc, specified in the applicable road traffic regulations.
They should be fitted with a means of access that allows the Crane
Operator to safely access the crane cabin and applicable areas where
maintenance is required. This should include access to enable windows
and windscreens to be regularly cleaned to give the Operator a clear field
of view at all times.
The design of the crane should also take account of the extended periods
of time the Crane Operator spends in the seat. The seating should be
comfortable, have adequate back support and be height adjustable.
The crane counterweights are critical in ensuring the cranes stability.

A counterweight, which is too light for a load can cause the crane to
Operator’s Chair
overturn in the direction of the suspended load.
Additionally, a crane can fall over backwards when:
• The counterweight is too heavy for the boom configuration

• The crane is travelling up a slope with the boom in an upright position
• On soft ground when inadequate timbers or mats are placed under the outrigger
below the counterweights
• Outriggers are not extended or lowered into position correctly
On smaller mobile cranes, the counterweight is fixed and cannot be easily removed. However,
on larger cranes counterweights are designed to be removed when smaller boom and lifting
configurations are used or when travelling on roads. Therefore, it is very important to attach
the correct type and number of counterweights to the crane according to the manufacturers
instructions.
Where the crane is fitted with a rated capacity limiter, the input into this system must be
correct for the counterweight and boom configuration on the crane and related to that shown
on the appropriate load chart.

13. Booms / Jibs
A crawler type crane is usually fitted with a lattice type boom.
The lattice boom, in its basic configuration comes in two sections, the foot and head, which
may be lengthened by inserting one or more intermediate sections.
The boom hoist, floating (luffing) sheaves and pendants (wire ropes) connected at the boom
head, are used to raise and lower the boom.
Basic lattice boom with ‘A’ frame
A telescopic crane has a boom that consists of a number of tubes fitted one inside the other,
raised by the main luffing ram or rams. Extended or retracted using a double acting hydraulic
ram in conjunction with double pulley block system of ropes or a single-action telescoping
ram with hydraulic interlocking devices.
Ram & Pully Single Action Inter-locking

In addition to the main boom there are different combinations of attachments that can be
used.
A fly jib is a short lattice jib, consisting of top and bottom taper sections that are pinned or
bolted together. The main purpose of the fly jib is to increase the overall length (increasing
the height) of the main jib. The fly jib can be set in line with the main jib or offset at a angle,
allowing it to reach over a structure (increasing the radius). However, because of the
increased stresses induced at the fly jib attachment point, only a reduced load can be lifted.
Note | The boom length is the distance between the centre of the boom foot pins and
the centre of the boom head shaft. Whereas, the crane’s radius is the horizontal distance
between the cranes centre of rotation and a vertical line through the hook block.
A luffing fly jib is a development of the fixed offset fly jib and is also of a lattice construction.
A luffing fly jib is normally used with the main jib set at the maximum angle of elevation, to
enable the crane to reach over a structure. To ensure that the main boom with a luffing jib
configuration is not used at an angle other than that specified by the manufacturer, a limit
switch should be fitted.
Note | The boom angle is measured from the horizontal (0 degrees) for example, maximum
radius; boom angle 20 degrees, minimum radius; boom angle 82 degrees (as shown on the
range diagram).
Telescopic jib cranes can also be fitted with manually set extension sections. These sections
can significantly affect the rated capacity of the crane and can place restrictions on the duty
chart.
Wind effect can be significant on a luffing jib configuration; therefore a safe system of work
should cover any precautions to be taken if the wind speed exceeds the safe limit.
When using an extension, jib deflections may be greater than expected so the anticipated
load weight should be increased by a minimum factor of 10% to account for this.
Main jib extensions have several forms and may have other names for example power pinned
fly, swing around, lattice extension etc.

14. Limiting and Indicating Devices
Limiting devices are fitted to mobile cranes for the purpose of stopping a specific crane
motion before it moves out of its limits into an unsafe situation. Indicating devices are used to
relay real time information and to warn the Operator, either visually, audibly or both together,
that the crane may be approaching its set limits or an unsafe situation. These devices may be
used individually, or together, for specific crane motions.
Limiting and indicating devices are intended as an aid to Crane Operators. They should not
be relied upon or used to replace the crane’s load chart and operating instructions under any
circumstances. The Operator should always approach any limit with caution, bearing in mind
that they may have become damaged. Sole reliance on limiting and indicating devices can
cause an accident.
A Rated Capacity Limiter (RCL) prevents overloading of the crane by stopping all relevant
crane functions when an overload is detected. Rated capacity (SWL) means the maximum
load that may be attached and handled by the crane, and may not include the weight of the
hook block, falls of rope, slings, rigging hardware and fly jibs.
The limiter should prevent:
• Hoisting of a load, within the tolerance of 100% to 110% of the maximum rated
capacity
• The radius being increased when the load exceeds 100% to 110% at the particular
radius
Motion limiting devices shall be fitted to mobile cranes to prevent physical damage to the
crane due to the movement of the crane, or parts of the crane, past their designed range of
motion. These devices can trigger braking, deceleration and stopping, when the following
permissible positions have been reached:
• The highest position of the hook (anti-two block)

• The lowest position of the hook
• The upper (backstop) and lower boom positions
• The end positions of a telescoping or movable boom
• A slewing / rotation limit
Limiting systems may be mechanical, electrical, pneumatic or hydraulic in nature.
In addition to limiting devices the crane may be fitted with a Gross Overload / Over Moment
Protection System (GOPS), Ultimate Protection System (UPS) or an emergency load / hook
release or lowering device. These are designed and fitted, as the name suggests, to prevent
gross overload / structural collapse. Manufacturers utilise different systems to achieve this, so
it important that the Crane Operator understands the system fitted to their crane.

Load Moment Indicators (LMI) or Rated Capacity Indicators (RCI) measure and display
the weight / mass of the load being lifted. They may also display the working parameters of
the crane. The indicator assists the Crane Operator to stay within the load chart and safe
working capacity of the crane, and gives, in most cases, a visual warning when approaching
the rated capacity and visual and audible warning when the crane is overloaded.
Listed next are several abbreviations, names and manufacturers producing load indicators
along with common abbreviations.
Manufacturers:
• Weighload
• Wylie
• ECKO
• ACS
• MIPEG
• EPIC HOOK LOAD (T)
5.6 ALARM
Abbreviations and names: WAVE (ft) RADIUS (ft)

ACK
TEST
P 31
• SLI | Safe Load Indicator TIME
• ASLI | Automatic Safe Load Indicator SWL (T)

WAVE
• RCL | Rated Capacity Limiter 15 FALLS
• RCI | Rated Capacity Indicator

• LMI | Load Moment Indicator
• LML | Load Moment Limiter Load Indicator
They can also be categorised into three groups:
• Mechanical
• Hydrostatic
• Electronic
Note | A hydrostatic load cell is a closed loop system that uses a thin film of fluid, held
between the base and head of the load cell. Weight applied to a hydrostatic load cell is then
transmitted as a precise signal.
The Crane Operator is responsible for adjusting the indicator during particular duties, hence
must have a competent knowledge of the equipment fitted. The indicator must always be
kept in good working order and calibrated at least annually.

The most common method that a Crane Operator can use to confirm the radius is by reading
the radius indictor, which should be fitted on all mobile cranes. The simplest form of radius
indicator is a quadrant (a quarter of a circle) shaped scale, which is fixed to the boom.
scale
TYPE - HLC - 25
35 FT BOOM
Radius Load
Feet Tons
10 19.2
pivot
12 16.7
15 11.65
20 6.75
25 5.0
30 3.9
adjustment 35 3.15
Max
Radius Indicator
A weighted pointer, which gravity keeps in the same position, will indicate the radius of
the crane line in any boom position. Radius indicators may also be calibrated / marked to
indicated capacity at the corresponding radius.

An optional addition can be a rope speed indicator, which indicates the speed of spooling
and the length of rope, on or off the drum.
wind sensor angle sensor
hoist limit switch
angle sensor
cable drum
Inductive Sensor
Length Sensor
Example of Crane Limiters and Indicators

15. Load Charts / Range Diagrams
A range diagram is a chart, which is used to convert boom angle to radius or vice-versa.
82º 80º
70º
60º
50º
40º
Height Above Ground
30º
20º
Distance From Centre Line Of Rotation

Example of Range Diagram

The load chart for mobile cranes should clearly identify the lift point location and the
corresponding rated capacity for that position.
The rated capacity is based on the strength and stability of the crane and takes into account
the stresses applied to the pendants, boom, outriggers, slew ring, etc. Short radii are
governed by the boom and outrigger strength, whilst, at longer radii, stability is the governing
factor. Hydraulic cranes may have a bold line drawn through their chart, dividing it into two
sections (or shaded area). Capacities above the line are based on structural strength with
capacities below the line being based on the crane’s stability.
An appropriate and durable load chart shall be fixed inside the Operator’s cab and display, for
example the following information:
• Manufacturer’s name
• Crane model
• The full and complete range of manufacturer’s crane load ratings
• Lift positions i.e. front, back, side (quadrants)
• Any limitations and caution / warning notes
• Tyre pressures
• Boom lengths
• Boom angle
• Radii
• Track or outrigger width, where this is variable
• Deductions for attachments
• Recommended reeving
Warning | The Crane Operator must not exceed the capacities detailed in the load chart.
On some mobile cranes, there may be several load charts for differing boom and
counterweight configurations. Two important factors that are sometimes overlooked when
reading a load chart are:
• The need to subtract the mass of the hook block and rigging from the capacity of
the crane, unless they are noted on the load chart
• The need to subtract the mass of the fly jib from the capacity of the main hook
unless this is allowed for and noted on the load chart

Using the load chart when the weight of the load is known:
• Add the weight of hook block to load weight, when applicable

• Add the weight of the rigging to load weight (if the load is pre-rigged, the weight of
slings and shackles is usually included in load weight)
• Confirm boom angle / radius, both hoisting and lowering if different
• Locate capacity of crane in proper column on load chart
• If the angle, radius or load weight falls between chart values, do not estimate, use
the safer lower valve
• Remember to use the correct static or dynamic capacity
• Do not exceed the lowest rated capacity for the lift. For example: if the lift moves
from a being static to dynamic, use the lower dynamic capacity
Using the load chart when the weight of the load is estimated:
• Confirm boom angle / radius

• Locate capacity of crane in proper column on load chart
• Subtract weight of hook block from capacity, when applicable, check / adjust zero
setting on load indicator
• Hoist load carefully, monitor capacity load indicator (counteracting boom deflection)
• If capacity is reached on load indicator before the load rises, the lift must not be
completed at this radius, slowly lower the load and disconnect from the crane

Main Boom Load Ratings on Outriggers Extended and Down 360º or Retracted and Down Front/Rear
19.5 ft (5.49m) 20.5-30 ft 31 ft (9.45m) 32-42 ft 43ft (13.11m) 44-54 ft 55 ft (16.76m) 56-66 ft 67 ft (20.42m)
Boom (6.24-9.14m) Boom (9.75-12.80m) Boom (13.41-16.46m) Boom (17.07-20.12m) Boom
Boom Boom Boom Boom
Radius Boom Rated Rated Boom Rated Rated Boom Rated Rated Boom Rated Rated Boom Rated
ft (m) Angle Load Load Angle Load Load Angle Load Load Angle Load Load Angle Load
(deg) lbs (kg) lbs (kg) (deg) lbs (kg) lbs (kg) (deg) lbs (kg) lbs (kg) (deg) lbs (kg) lbs (kg) (deg) lbs (kg)
8.5 58 44000 26500 71 26500 25400 76 25400 19500 79 19500 - - -

(2.59) (19 958) (12 020) (12 020) (11 520) (11 520) (8850) (8850)
10 52 40000 26500 68 26500 25400 74 25400 19500 78 19500 - - -

(3.05) (18 140) (12 020) (12 020 (11520) (11520) (8850) (8850)
12 44 33800 25300 64 25300 24200 72 24200 17600 76 17600 14500 78 14500

(3.66) (15 330) (10 570) (10 570) (10 980) (10 980) (7980) (7980) (6580) (6580)
14 33 28500 22900 59 22900 22600 69 22600 16100 74 16100 13200 77 13200

(4.27) (12 930) (10 390) (10 390) (10 250) (10 250) (7300) (7300) (5990) (5990)
16 0 23700 20900 55 20900 20000 66 20000 14800 71 14800 12200 75 12200

(4.88) (10 750) (9480) (9480) (9070) (9070) (6710) (6710) (5530) (5530)
18 - - 19300 50 19300 17900 63 17900 13700 69 13700 11200 73 11200

(5.49) (8750) (8750) (8120) (8120) (6210) (6210) (5080) (5080)
20 - - 17800 45 17800 16100 60 16100 12800 67 12800 10400 71 10400

(6.10) (8070) (8070) (7300) (7300) (5800) (5800) (4720) (4720)
22 - - 16400 39 16400 14600 56 14600 12000 64 12000 9700 69 9700

(6.71) (7440) (7440) (6620) (6620) (5440) (5440) (4400) (4400)
24 - - 14700 31 14700 13300 53 13300 11200 62 11200 9100 67 9100

(7.32) (6670) (6670) (6030) (6030) (5080) (5080) (4130) (4130)
26 - - 13200 22 13200 12300 49 12300 10600 60 10600 8600 66 8600

(7.92) 5990) (5990) (5580) 5580 (4810) (4810) (3900) (3900)
27.5 - - 11600 0 11600 11600 47 11600 10200 58 10200 8200 64 8200

(8.38) (5260) (5260) (5260) (5260) (4630) (4630) (3720) (3720)
30 - - - - - 9900 42 10500 9400 55 9400 7700 62 7700

(9.14) (4490) (4760) (4260) (4260) (3490) (3490)
32 - - - - - 8800 37 9800 8700 52 8700 7300 60 7300

(9.75) (3990) (4450) (3950) (3950) (3310) (3310)
34 - - - - - 7800 32 8700 8100 49 8100 6900 58 6900

(10.36) (3540) (3950) (3670) (3670) (3130) (3130)
36 - - - - - 7100 26 7800 7600 46 7600 6600 56 6600

(10.97) (3220) (3540) (3450) (3450) (2990) (2990)
38 - - - - - 6500 18 7000 7000 43 7100 6300 53 6300

(11.58) (2950) (3180) (3180) (3220) (2860) (2860)
39.5 - - - - - 6400 0 6400 6400 41 6800 6100 52 6100

(12.04) (2900) (2900) (2900) (3080) (2770) (2770)
42 - - - - - - - - 5700 36 6300 5800 49 5800

(12.80) (2590) (2660) (2630) (2630)
44 - - - - - - - - 5300 32 5800 5600 47 5600

(13.41) (2400) (2630) (2540) (2540)
46 - - - - - - - - 4900 28 5300 5300 44 5300

(14.02) (2220) (2400) (2400) (2400)
48 - - - - - - - - 4600 23 17600 4800 42 5000

(14.63) (2090) (7980) (2180) (2270)
50 - - - - - - - - 4400 16 16100 4400 39 4700

(15.24) (2000) (7300) (2000) (2130)
51.5 - - - - - - - - 4000 0 4000 4000 37 4600

(15.70) (1810) (1810) (1810) (2090)
54 - - - - - - - - - - - 3800 33 4200
(16.46) (1720) (1910)
56 - - - - - - - - - - - 3600 29 3900
(17.07) (1630) (1770)
58 - - - - - - - - - - - 3400 25 3600
(17.68) (1540) (1630)
60 - - - - - - - - - - - 3200 20 3300
(18.29) (1450) (1510)
63.5 - - - - - - - - - - - 2800 0 2800

(19.35) (1270) (1270)
Example of Load Chart

1. What is the minimum boom radius and angle?
8.5ft (2.59m) and 58 degrees
2. With a boom length of 43ft, what is the crane capacity, in lbs, at a radius of 16ft?
20,000lbs
3. With a boom length of 16.76m, what is the crane capacity, in kg, at a radius of 12.8m?
2660kg
4. What is the maximum capacity, in kg?
19,958kg
5. What is the minimum capacity, lbs?
2800lbs
6. How many lbs in a US Ton
2000
7. How many lbs in a UK Long Ton
2240
8. How many kg in metric tonne?
1000
9. How many lbs in a metric tonne?
2204
10. What is the weight of a steel cube measuring 1m x 1m x 1m?
7850 kg/m3

Load Chart Questionnaire – F002 – Answers
Question 1
a) What is the maximum radius in feet?
170 feet
b) What is the minimum radius in metres?
3 metres
c) What is the maximum (in kgs) that this crane can lift at a radius of 8 metres?
29,400kgs
d) Using the 140ft boom length, how much can the crane lift at 32 metres radius?
3,900kgs or 8,700lbs
Question 2
a) What is the boom angle when a 90ft boom is at a radius of 80ft?
30 degrees
b) With a 60ft boom at 30 degrees, what is the radius?
54 feet

Question 3
a) What is the maximum amount this crane can lift?
40 tonnes
b) On a platform lift, I , how far can the crane lift a load of 15te?

58 metres
c) If the SWH is 3.5m, how much can the crane lift at a radius of 58m?

7.4 tonnes
d) How many falls of rope are fitted to the crane when lifting 40te at a radius of 36m?
3 falls but crane cannot lift 40te at 36m
Question 4
1. With a boom length of 102ft, what is the crane capacity, in lbs, over the front at a radius
of 65ft?
13,500lbs
2. What is the boom angle at this boom length and radius?
47 degrees
3. What is the maximum capacity, in tonne?
25.5 tonne
4. With a boom length of 90ft, what is the 360-degree crane capacity, in lbs, at a radius of
75ft?
9,100lbs
5. Can the crane lift a load at 40ft radius, weighing 31,000lbs?
Yes but only over the front with a 90ft

Day 2

Day 1 Confirming Questionnaire – F003 – Answers
Instructor to hand out questionnaires and inform delegates that they have 10 minutes to
complete as many question as possible. After the allotted time gather in the questionnaires,
mark and discuss the answers with the delegates
1. What is the purpose of counterweights?
To counter act the weight of the boom and load
2. Which has the greater bearing pressure, firm clay or compact sand?
Compact sand
3. The only crane you have on site has a single fall capacity of 7 tonne; the load to be lifted
weighs 10 tonne. How can this lift be achieved using this crane?
Double reeve the hook block or break load into smaller lighter parts
4. Why is it important to set the crane up level?
To ensure stability
To enable the crane to work at its rated capacity
To reduce wear on the slew ring and associated parts
5. A load chart has a heavy black line drawn through it, what would this indicate?
Structural strength (above) and stability (below) lines
6. The crane load chart is unreadable, what action would need to be taken?
Do not proceed with lifting operations until a replacement chart is supplied
7. If the exact reading is not available on the load chart, what should you do?
Work to the safer lowest capacity
8. What is the operational condition of the crane deemed to be in when subjected to an

overturning moment, which cannot be increased by even a small amount?
Tipping
9. What should you always consult before making a lift?
Load chart

10. What is the recommended distance the outrigger should be positioned away from an
open excavation, if the evacuation is 3m (10ft) deep?
6m (20ft)

16. Hoists, Slew Ring and Sheaves
Hoists can be mechanically or hydraulically powered and consist of a drum, (plain or grooved)
side flanges, rope anchor, pawls and a brake / clutch.
Drums will provide a suitable first layer rope pitch diameter and have a sufficient rope capacity
to operate within the range of boom lengths, operating radii and vertical lifts. The drum end
of the rope shall be anchored to the drum, which is non-load bearing. No less than five full
wraps of rope should remain on the drum in any operating condition.
For proper spooling, and to prevent excessive wear on drum grooves, the angle at which the
rope leads to the drum, called the fleet angle, must be within controlled limits. The fleet angle
is measured between the first sheave and hoist drum centre line and a line from the centre of
the sheave to the inside edge (flange) of the hoist drum.
• For plain drums the fleet angle should not exceed: 1 1/2 degrees
• For grooved drums the fleet angle should not exceed: 2 1/2 degrees
If the fleet angle is too small, it will cause the rope to pile up
pulley
(nest) against the drum flange, damaging the rope. If the fleet
angle is too large, the rope will rub against the flanges of the
sheave or be crushed on the drum.
Drum flanges should extend a minimum distance of 1.5 times
Angle of fleet
the wire rope diameter past the top layer of rope unless an ideal distances =
12 x width of grooved drum
additional means of keeping the rope on the drum is supplied 20 x width of plain drum
(BS ISO 4308−1: 2003).
Brakes should be provided to prevent the drum from freely

rotating in the lowering direction and shall be capable
of holding the rated load indefinitely. Brakes shall be
automatically applied upon the return of the control lever to its
centre (neutral) position.
drum
Boom or load lowering shall be done only by engagement of
the power train. Free-fall lowering of the boom, or load, is not Width of
permitted. Drum
Fleet Angle
Pawls are fitted to the hoist, to allow a shaft or winch to rotate
in one direction only. They may be either automatic or manual in design.
The hoist manufacturer should approve boom and load hoists for man riding.

The slew ring allows the upper structure of the crane to rotate. Along with the slew drive
and brake being designed to give smooth starting and stopping with controllable rates of
acceleration and deceleration.
The type of slew ring assembly may be:
• Hook Roller
• Ball Bearing
• Roller Bearing
The specific type of slew brake / slew lock / parking mechanism, fitted to the crane should be
referenced in the manufacturers manual.
The brake should be controlled by the Operator at the Operator’s station. It should be
capable of remaining in the engaged position, without the attention of the Operator.
Periodically, the amount of clearance in the slew ring should be measured and compared
to the maximum clearance specified by the crane manufacturer. Clearances should be
measured at a minimum of four points around the slew ring (North, South, East and West). If
the clearance exceeds that specified by the manufacturer, the slew ring should be replaced.
In addition, backlash and teeth width in both the pinion drives and ring drive should be
measured and be within the crane manufacturer’s specification.
A percentage of slew bolts in accordance with the crane manufacturer’s instructions may also
require removing for periodic inspection along with grease samples.
The sheave groove contour should be smooth and free from defects harmful to the wire rope
and, in general, support one third of the ropes circumference, with the groove angle tapering
out and finishing in a rounded edge.
d
The sheave pitch diameter, D, in relation to the nominal wire
rope diameter, d, (D/d ratio) should be in accordance with
industry standards e.g. BS ISO 4308−1: 2003.
Sheave bearings should be routinely lubricated (some

modern cranes use sealed bearings) and guards fitted to
prevent the rope from coming out of the sheave groove.
The Crane Operator should always adhere to the specific D

tolerances specified by the crane manufacturer.
Sheave Dimension

17. Wire Ropes
Wire rope consists of a group of strands laid helically around a core. The strands consist of
a number of individual wires laid about a central wire. It should be thought of as a machine,
being composed of a number of moving parts, which requires periodic lubrication.
core
strands
wires
The majority of ropes are preformed by permanently applying a helical twist, mechanically to
each strand before assembly. This eliminates built-in stresses in the finished rope, resulting in
better performance and durability.
There are many types of wire rope construction, each having a purpose to suit a particular
application. Therefore, a wire rope of the wrong type will not give a satisfactory service and
deteriorate very quickly.
There are generally three types of rope used on cranes; single layer, multi-stranded (layered)
and compacted.
A single layered rope consists of one layer of outer strands (usually six
or eight) laid helically over a central core of steel or fibre.
This type has a certain amount of rope spin, which is natural during
use but should be kept to a minimum, with the aid of a swivel
because excessive rotation can cause serious fatigue in the rope.
A multi-stranded rope, which usually has two or three layers, is more

rotationally resistant than single layered rope, making it ideal as
hoist ropes, where strength, greater heights of lift and durability are
required.
A low-rotation multi-stranded wire rope consists of an inner layer

of strands laid in one direction covered by one or two further
layers of strands, laid in alternate directions. This has the effect
of counteracting torque (rotation) by reducing the tendency of the
finished rope to rotate. This type is ideal for whip (fast) line ropes.

A compacted rope, the outer strands are subjected to a compacting
process such as drawing, rolling, or swaging. They are generally,
significantly stronger than their non-compacted equivalents because
they have a greater cross sectional area in a given diameter. This
gives the rope a greater MBL (often more than 20% higher than
conventional products) combined with lower stress levels and a
greater bending fatigue resistance. This type is ideal for boom hoist
ropes.
Compacting also gives the rope a smooth external surface, which

results in a smoother wearing surface between adjacent wraps and
between the rope and the drum or sheaves.
There are two types of lay, which means the direction in which the wires and strands are
twisted around the core.
Ordinary / Regular lay rope, the wires in each strand lie opposite to the direction as the
strands.
Lang’s lay rope, the wires in each strand lie in the same direction as the strands.
Regular Lay Lang’s Lay
Of the two types, the ordinary / regular lay rope is easier to handle, more resistant to crushing
and distortion and is the more commonly used.
Note | Lang’s lay rope must not be used for slings or when one end is free to rotate
The direction of rope lay is important, to ensure the correct coiling and spooling of the rope.
The length of lay (or pitch) of a stranded rope is the distance, measured along the rope,
between the crown (highest point) of one strand and the next.
one rope lay length

When replacing a wire rope (replacement components should conform to the manufacturer’s
specification or an equivalent standard), give as much information as possible to the rope
supplier, which can usually be found on the previous certificate or on the previous reel.
All wire ropes should be supplied, from the manufacturer, with a certificate containing, for
example the following information:
Note | This will be recorded using an accepted coding system, consisting of numbers and
abbreviations.
• Application / intended use

• Rope length and tolerances
• Nominal diameter
• Construction, class or brand name (Dyform, Filler Wire, Warrington Seale, Seale Filler
Wire, Rotation Resistant, etc.)
• Type of core (FC, WSC, IWRC)
• Rope grade (1770; 1960; 2160)
• Wire finish (Bright, Galvanised)
• Lay type (Ordinary, Langs)
• Lay direction (left hand, right hand)
• Minimum Breaking Load / Force
• Termination requirements
• Special packaging requirements
• Special identification requirements
• Third party authority (LR, DNV, ABS etc.)
The Crane Operator, during the pre-start up and periodic checks, must examine all
accessible areas of the rope, paying particular attention to the main areas of deterioration,
which are:
• Areas of the rope, which pass over sheaves

• Areas of the rope that remain exposed to the elements for long periods of time
• Areas adjacent to terminations
• Drum terminations and cross over points
Whilst carrying this out, the Crane Operator must examine the wire rope for any signs of
deterioration or damage, which could affect the safe use or reduce the capacity of the rope.
These include:
• Broken wires
• Wear
• Internal / external corrosion
• Waviness / kinks
• Bird caging
• Strand / core protrusion
• Decrease in rope diameter
• Flattening / crushing
• Increase in lay length
• Thermal damage

Broken wires are a normal feature of service, resulting from bend fatigue and wear, usually
occurring towards the end of the ropes working life. Local wire breaks and rope distortion
may indicate a mechanical fault in the system. Broken wires may be removed by bending
backwards and forwards. If not removed, this may lead to further damage. Breaks that are
present on the crown of strands are an indication of abrasive wear and bend fatigue. Breaks
visible in the valley between strands are an indication of wear, fatigue or corrosion in the core.
Refer to applicable standards for specific discard criteria.
Every time a wire rope bends, each wire moves slightly in relation to its neighbour.
Wear is caused by normal use but excessive wear can be caused by incorrect rope tension,
large numbers of sheaves, acceleration and deceleration of the hoist, incorrect fleet angle,
rope to rope contact on the drum or a lack of lubrication.
Therefore, lubrication has two purposes, to provide corrosion protection and minimise internal
friction. The manufacturer carries out the lubrication of a wire rope initially, it should also
be carried out as soon as the rope is put into service and additionally at regular intervals to
extend the safe performance of the rope. Refer to applicable standards for specific wear
criteria.
Corrosion can be caused by a hostile environment or insufficient lubrication / dressing.

Internal corrosion may also be seen as a local increase in the diameter of the rope. If present,
then the rope should be discarded.
While not necessarily resulting in any immediate loss of strength, waviness in the rope, after
prolonged working, may result in wear and wire breaks. The wire rope should be discarded
if it affects the safe operation of the equipment. A bend or kink can cause excessive wear,
and in some cases reduce the strength of the rope. If severe, there is justification for the
immediate rejection of the rope.
Bird caging is when the outer layer of strands has become dislocated from the inner core
or when the outer strands become longer than the core. Such deformation of the rope may
occur as a result of shock loading of the rope from a slack position, incorrect installation or
incorrect termination. The rope should be discarded if this deformation is present.
Strand or core protrusion would be justification for the immediate rejection of the rope.
A decrease in the ropes diameter can indicate a collapse or fracture of the core. The area
near to terminations should be carefully inspected for such deformations. If this condition is
confirmed by internal inspection, the rope should be discarded.
Flattening or crushing can be caused by incorrect reeving, poor installation of the rope or
mechanical damage. If the condition is severe the rope should be discarded.
An increase in lay length can be attributed to stretch in the rope or core collapse / fracture.
Refer to rope manufacturers guidelines regarding stretch in the rope. If core collapse or
fracture is found to be the cause, the rope should be discarded.
The rope should be discarded if there is any evidence of thermal damage. Indicators are
dryness, loss of lubrication, bluing of the wire surfaces, fusion of wire surfaces or the
presence of weld splatter.
18. Wire Rope Terminations
Wedge sockets are suitable for most wire rope constructions and have an efficiency rating of
80% if correctly installed. Sockets can be installed onsite quickly and easily by a Competent
Person.
• To use with standard 6 or 8-strand wire rope the tail length of the dead end should
be a minimum of 6 rope diameters but not less than 6 inches.
• To use with rotation resistant wire ropes ensure that the dead end is seized before
inserting the wire rope into the wedge socket to prevent core slippage or loss of
rope lay. The tail length of the dead end should be a minimum of 20 rope diameters
but not less than 6 inches.
• Properly match socket, wedge and clip to wire rope size
• Align live end of rope, with centre line of the pin
• Secure dead end section of rope
• Tighten nuts on wire rope clip to recommended torque values
• Do not attach the dead end to the live end or install wedge backwards
• Apply a minimal load to fully seat the wedge and wire rope in the socket
• During use, do not strike the dead end section with any other elements of the rigging
(called two blocking)
Correct Installation Incorrect Installation
Wedge Tail clipped Rope

Backward to live line Backward

The fitting of a spelter socket is considered to result in the rope termination having an
efficiency of 100%. The most important factor to ensure a satisfactory termination is the
cleaning of the wire rope broom and socket. Sockets are assembled with either zinc or a two-
part resin material and are available as open or closed types. Spelter sockets can be installed
on site and can be reused if a magnetic particle test and visual inspection is carried out.
If possible, the poured socket termination should be proof load tested to verify it’s integrity
after fitting. However, this is not a mandatory requirement if personnel have been deemed
competent to fit the socket and have followed an approved procedure.
The recommended proof load applied should be 100% above the SWL / WLL, ensuring that
any overload applied does not exceed the maximum allowable overload of the appliance the
wire rope and socket are fitted to.
Note | Only trained and competent personnel should fit spelter sockets.
A mechanical or fold back termination is made when the wire rope is passed through an
oval shaped ferrule, formed into a loop and passed back through the ferrule where upon the
ferrule is compressed to a cylindrical shape.
The fitting of this type of termination is considered to result in a rope termination having an
efficiency of 90% to 95% (100% may be stated in some standards).
Before swaging
After swaging
“Dead end” of rope should
be flush or
slightly protruding.
Warning
There should be no deterioration in the vicinity of the termination and no broken wires within
6mm (1/4”) of the termination.

19. Spooling and Reeving
The most important objective when spooling a wire rope onto a winch drum is to ensure it is
wound on under tension and without trapping any twists in the rope. This can be achieved
with the use a back tensioning winch and ensuring the wire rope is fitted according to the
location of the drum termination and the lay of the rope.
Left Lay - Left Hand Right Lay - Right Hand
L R L R
Underwind Overwind Underwind Overwind

Left to Right Right to Left Right to Left Left to Right
Use Left Lay Use Left Lay Rope Use Right Lay Use Right Lay Rope
Rope Rope
Underwind Overwind Underwind Overwind

Fasten on Left Fasten on Right Fasten on Right Fasten on Left
In addition, wire rope when manufactured has a natural curve or memory. When spooling
wire rope from a storage drum onto the winch drum, to avoid reverse bending, which is
detrimental to the lay of the rope, always follow the guidelines shown below.
wrong wrong
Never reel from top to bottom or from bottom to top
right right
Always reel from top to top or bottom to bottom
It is essential, when spooling multiple layers, to get the first layer and future layers as secure
and well fitted as possible. The first layer will provide the grooving for upper layers and if not
carried out correctly, will allow upper layers to pull down between wraps and layers already
on the drum. This will cause damage and a reduced rope strength and service life.

Reeving is the passing of a wire rope around sheaves and pulleys to gain mechanical
advantage. The crane manufacturers guidelines, specific to the crane type, must be followed.
An example of a reeving configuration is shown below.
centre sheave for jib
boom head,
auxiliary main winch top sheave
winch
(optional)
boom head,
bottom sheaves
hook block
to dead end
anchor

20. Headache Balls and Sheave Blocks
A crane or sheave block is a frame that encloses one or more sheaves and is provided,
usually, with a hook that allows for the attachment of the load. The purpose of a block is
threefold. First, it is used to change the direction of the wire rope line. Second, used in
combination with the boom tip sheaves, to give mechanical advantage by allowing the use of
multiple parts of line and third to apply tension to the rope, to enable the correct spooling of
the wire on the winch drum.
The crane block is required to perform long lifts under continuous service conditions and is
characterised by multiple large diameter, long service life sheaves and the addition of cheek
plate weights. In addition they are typically fitted with a swiveling hook that allows the cargo
to rotate without fouling the multiple parts of reeving. Blocks can also be equipped with a
becket or mouse ear whereby the end of the rope line is affixed to the block.
An overhaul or headache ball is fitted to the fast line / whip line and typically consists of a
swivel hook, a weighted body and a wire rope connection point. The later being in the form
of a wedge socket or pinned clevis connection.
Its purpose is to allow for the attachment of loads,
retaining tension in the wire and have a sufficient
weight to unwind (overhaul) the wire rope from the
drum when the brake is released.
It is recommended that crane / sheave blocks and

headache balls are dismantled, inspected and
subjected to non-destructive testing examination at
intervals not exceeding five years. In addition, blocks
fitted with new or modified parts (in the primary load
path) should be proof load tested before use.
Headache Ball Crane Block

21. Controls, Gauges and Crane Motions
A crane not only has to lift loads, it must provide a comfortable work area and environmental
conditions suitable for a Crane Operator, who may be required to work over an extended
period of time. Therefore, controls, lockouts and indicators must all be within easy reach of
the Operator.
Furthermore, the controls, either in the form of levers, foot pedals, buttons or toggles, should
be designed to be intuitive and natural for the Operator to use. This means that if a control
is moved to the right, then the desired motion of the crane will follow in the same direction,
mimicking the motion of the Operator.
Each control should be marked to identify each motion controlled and the direction of
movement (example shown below). These markings should either be in the appropriate
language(s) or consist of internationally agreed symbols, which should be adequately
maintained. In addition, the crane’s computer, if fitted, shall also be compatible with these
requirements.
The six basic motions of a crane are:
• Hoist up
• Hoist down
• Boom up
• Boom down
• Swing / slew left
• Swing / slew right
Secondary
hoist control Primary hoist
lower lower
Boom control
Swing Swing control
left L.H. right Raise R.H. Lower
Raise Raise
Further movements may include travelling, spragging (the turning motion of a crawler crane
made by locking one set of tracks and turning the other set in order to pivot) and telescoping.

Additional controls may include, for example:
• Outrigger positioning
• Brakes and locks
• Emergency systems
• Over-rides
• Free-fall systems
• Horns
• Windscreen wipers
• Lighting and heating
• Counterweight controls / locks
Note | With newer models some of these systems (such as boom interlocks) are now being
controlled automatically by the cranes onboard computer systems.
To enable a Crane Operator to control the crane safely, they will require feedback from the
cranes gauges. These can be electronic, pressure or mechanical devices, which will provide
the Crane Operator with real time information relating to the cranes vital systems.
Examples would include, engine oil pressure, water temperature, wind speed, alarms
(shown below) and of course the Rated Capacity Indicator. Again, it is the duty of the Crane
Operator to be familiar with and understand the information given by the gauges and take any
appropriate action that may be required.
The Crane Operator should always be present at the controls when a load is suspended from
the crane. The crane should never be left unattended even for short periods, unless:
• All loads have been removed

• The crane and hook(s) have been left in a safe position
• The power supplies to all motions have been switched off or the engine has been
stopped
• Appropriate motion brakes and locks have been applied to put the machine in a safe
condition and;
• The ignition key and any other keys have been removed
For longer periods and for out-of-service conditions, switches should be locked off, fuel
supplies cut off and any doors giving access to machinery or control cabs locked to prevent
unauthorised access.
1 2 3 4 5 1. Visual Display Unit
2. Load Moment Indicator
3. Warning Light (Rear).
PAT DS 150 4. Warning Light (Side).
SYSTEM TEST 5. Warning Light (360˚).
REAR SIDE 360
MAX.LOAD 15.5T 6. Anti Two Block Warning Light.
ACT.LOAD 4.5T 7. Load Moment Pre Warning Light
RADIUS 9.05ft
8. Load Moment & Alarm Light
Button “Horn Off”
9. Boom Data Button
0 0 10. Tare Button
STOP
TARE H E 11. Outrigger Control / Light
12. Enter (E) Button.
13. Audible Alarm.
14. By Pass Switch.
15. Operating Code Switch.
6 7 8 9 10 11 12 13 14 15 16 16. Reeving Switch.

22. Initial, Pre-Start Up and Pre-Operational Checks
Initial Checks
The Crane Operator must carry out a series of initial, pre-start up and pre-operational checks
before the commencement of each work shift. The results of these checks must be entered
into a logbook and kept with the crane. Initial checks shall ensure that:
• All access ladders; walkways, gates and hatches are free from obstructions and
cleaned of any residual oils and greases
• Tracks, wheels and outriggers are fit for purpose
• All deck plates and gratings are secured and access hatches closed
• Service hoses, for example diesel, air, and water are neatly stowed
• Warning signs and barriers are prominently displayed
• Machinery spaces and cabs are in a clean and tidy condition
• All personal belongings or clothing are stored in such a manner that they do not
interfere with the safe operation of the crane during operations
• The operator’s cabin windows are clean, windscreen wipers are in a good condition
and that the screen wash system operates
• Cladding and panel work are secure
• The cranes structure is free from all loose material, which may have the potential to
result in dropped objects
• The ground conditions are suitable
• The stability of outriggers is correct if already extended
• The crane is set up level
• The area is clear of any slewing obstructions
• There are no hazards within the crane’s operating range, for example power lines
Pre-start Up Checks
This visual check is completed before the prime mover is started to determine the crane’s
suitability to carry out lifting operations safely. The Operator should use the pre-start checklist
supplied by the crane manufacturer and / or crane owner. The areas inspected during the
pre-start check should include:
• The boom, chords and lattices

• Security of connections and fittings
• Hook blocks
• Sheaves
• Wire ropes and pennants (including spooling on drums, rope terminations and any
anchorage points)
• Brake / clutch linings
• Oil levels
• Coolant levels
• Fuel levels
• Guards

Prior to start-up the Crane Operator shall ensure that all controls are in their neutral position
and that the main clutch (where fitted) is disengaged. On start-up of the prime mover, ensure
that all air and oil pressure gauges are within their safe operating range before carrying out a
function check of the crane controls.
Carry out a function check on all the crane’s controls. On friction clutch and brake type
cranes it is imperative that the efficiency of these components are ensured as there is
potential for ingress of foreign material which could cause slippage, for example water, grease
etc. Carry out a function check on:
• The boom minimum and maximum radius limits

• The hook blocks (main / auxiliary) over / lower hoist limits
• The Rated Capacity Indicator to ensure the correct configuration and reeving is
displayed
• The Rated Capacity Indicator’s visual and audible alarms
Note | The Operator must always approach limits with caution. During normal operations,
reliance must not be placed on limit switches or cutout devices to stop crane motions. Limit
switches should not normally be overridden. The relevant sections of the crane manufacturers
operations manual and company procedures must be referenced and complied with.
Ensure that appropriate load / radius charts are in good condition and posted at a strategic
point within the operator’s cabin.
If there is any doubt that a crane function cannot be carried out safely the Operator must
suspend operations until such time as control measures have been introduced and all
necessary precautions have been taken to ensure the crane can be operated safely.
Always ensure that the manually applied Emergency Load Release is secure and cannot be
inadvertently activated during normal operations. This type of system, where fitted, must be
function checked in controlled circumstances, generally with an unladen hook and only by a
Competent Person who is authorised to perform their activity.
The Crane Operator must also ensure that all available safety equipment is secure and in
good condition. In addition, that fire extinguishes are of the correct type and size as specified
by the Owner and that they are familiar with their application and use. Finally during the
operation of the crane, the operator should check:
• Gauges to ensure that all pressures and temperatures remain within their safe
operating range
• Listen for unusual engine and / or machinery noises
• Be aware of slight ‘shocks’ which could indicate bad spooling of hoist ropes or
imminent equipment / machinery failure
Any indication that systems are not functioning correctly or if anything out of the ordinary
occurs, stop and make the load safe. Investigate and report any defects or malfunctions to
the responsible person.

23. Principles of Operation
The crane should only be used for the specific purpose for which it has been designed
and not adapted for any other purpose without the approval from the manufacturer or a
Competent Person.
Before a load is attached, the Crane Operator must be aware of the weight of the load to be
lifted.
Access to the area of operation should be restricted to authorised personnel only.
Signs should be posted at strategic points, or the area policed, to ensure the laydown points
and adjacent areas have restricted access.
With ALL lifting operations the load should be lifted, under the direction from the Banksman,
a nominal distance only, in the first instance (trial lift).
Note | Ensure that the Banksman has correctly positioned the hook over the loads centre of
gravity, to remove any ‘drift’ in the load.
This “trial lift” allows load balance, stability and general security of the load while it is in a
relatively safe position to be assessed. If any discrepancies are found the load should be
lowered and the slinging revised. This sequence of trial lift and adjustment should be repeated
until the Operator is satisfied that the load is balanced, stable and secure.
As the load is lifted, the Operator should monitor the Rated Capacity Indicator for any
possible overload situation developing and check the operation of the hoist brake.
Prior planning of the route the load will be travelling will ensure any obstructions are cleared
away. If necessary, give a warning to personnel to clear the area prior to moving the load.
Avoid travelling the load over running machinery or critical equipment, never over personnel
and keep it as low as possible.
Before lifting any load, a check should be made to ensure that the lay-down point is of
adequate size and capable of taking the weight of the load. In addition, it may be necessary
to provide suitable landing packing, e.g. timber bearers, to enable the slings to be removed
from under the load. The load should never be lowered so as to trap the slings as this action
can cause severe damage to the slings.
When lowering the load, under direction from the Banksman, it should be brought to a halt
a short distance above the landing site to allow the Crane Operator to steady it, check the
position of the landing packing and ensure that all personnel have their fingers and feet clear
of the load. The load should then be inched down into position.
Before slackening off the slings, the load should be safe and stable. If not, it should be lifted
slightly, under direction from the Banksman, to allow the landing packing to be adjusted, and
then lowered again. This trial landing procedure is very similar to the trial lift procedure and
should be repeated until all those involved are satisfied that the load is safely landed.

During these operations, all movements should be carried out in a controlled manner. The
smooth operation of the crane reduces the possibility of the inherent risks involved with
undue shock loading to the structure and / or machinery caused by swinging loads.
Loads must always be kept within the specified radius of the crane with the hoist rope
retained in the vertical position. The crane motions must not be used to drag the load, as this
will impose severe side stresses on the crane boom.
Loads should not be lifted from baskets, half heights or containers until personnel have come
out of the unit to avoid them becoming trapped between the load and the unit.

24. Practical Crane Demonstration / Exercise
Equipment: Mobile crane and Competent Operator
Instructor: Using the supplied checklist (F004), identify to the delegates the crane’s
component parts and their function. Instruct delegates on common defects.
Delegates: Carry out a visual inspection of the crane and complete the supplied
checklist (F004).
Note | Prior to visual inspection the crane should be cleaned by appropriate means, e.g.
pressure washed, to remove all spoil / dirt that would otherwise conceal the structure or
mechanisms and prevent an effective examination.

25. Maintenance and Refuelling
The crane manufacturer will state within the maintenance manuals the items that SHOULD be
inspected / replaced / checked at specific intervals. When this is to be completed depends
upon the type of operations carried out and usage, which should be calculated by the owner
/ operator using calculations and guidelines supplied by the manufacturer.
Data loggers are not a legal requirement but if fitted certain systems are fitted with a modem,
enabling them to transmit “real time” data back to the crane manufacturer. Information
relayed back to the manufacturer, regarding crane overload, will have a direct affect on the
cranes warranty.
The crane owner should know the answers to the following questions:
1. Have the crane components been checked / replaced as per the manufacturers
recommendations based on duty / life cycle?
2. Is the crane’s life cycle monitored?
3. Is the crane still under warranty?
Failure to carry out appropriate planned inspections and preventative & reactive maintenance
can lead to structural or mechanical failure and collapse of the mobile crane.
Routine maintenance must be carried out in accordance with the crane manufacturer’s
instructions, which may be carried out weekly, monthly, quarterly and should include, for
example:
• Checks specified in the manufacturer’s handbook

• Functioning of controls for speed, smoothness of operation and limits of motion
• Checking of emergency and safety switches and interlocks, including limiting and
indicating devices
• Lubrication of all moving parts
• Inspection of filter elements and fluid levels
• Checking tyre pressures and for damage
• Visual inspection and measurements, as necessary, of structural members and
other critical components such as brakes, gears, fasteners, pins, shafts, wire ropes,
terminations, sheaves, locking devices and electrical contractors
• Signage, including warning signs and control markings
• Wear on components
• Checking of hooks and other load lifting attachments, safety catches and swivels for
damage
• Check for creep of hydraulic rams
All replacement parts should be identical or equivalent to the originals with a written report
supplied upon completion of the inspection.

A crane service record, such as a maintenance logbook, should be kept recording any
significant events concerning the safety and operation of the crane. These records should be
kept in a suitable, easily understood, format and should be transferred with ownership of the
crane. All entries in the maintenance logbook should:
• Clearly describe any work undertaken and list any parts that have been replaced
• Be dated
• Record the name of the person who carried out the work
• Be signed by the person who carried out the work
The maintenance history, especially that for a second-hand mobile crane, is essential. Before
a second-hand mobile crane can be operated for the first time, the owner / operator should
ensure the crane is subject to a thorough inspection.
During refuelling the Crane Operator must observe the following minimum safety guidelines:
• Refuelling must not take place whilst the engine is running

• Refuelling operations shall only to be carried out under the supervision of the Crane
Operator or the authorized Crane Mechanic
• An appropriate environmental assessment should be completed before refuelling
• Care must be taken to prevent the overflow or spillage of fuel onto the engine,
exhaust or electrical equipment
• Ensure that all isolation valves are closed when refuelling is complete
Note | Crane may required to be earthed while refuelling is being completed. Check and
adhere with site-specific procedures.

26. Periodic Inspection and Testing
Inspection is the act of examining and evaluating equipment or component parts, to

determine compliance with relevant regulations or standards. Testing is a process to
ascertain that design, workmanship, material integrity and the operating systems are fit for
purpose, i.e. the safe operation of the crane through all it’s operating parameters, which may
include overload testing.
Defects arising from the inspection or test should be reported to the Competent Person, who
will assess if the safe use of the crane is affected. If the safe use of the crane is affected, the
crane should be removed from operational service and caution notices displayed in key areas
and access points until the defect has been rectified.
Periodic inspection and testing must be carried out in accordance with relevant legislation,
regulations, standards and company procedures.
In the UK this is carried out in accordance with the requirements of the Lifting Operations and
Lifting Equipment Regulations. This stipulates that mobile cranes, defined as an appliance,
shall be inspection periodically every 12 months. If used for man-riding purposes then this
shall be carried out every 6 months. Testing requirements may be found in BS 7121 Part 3,
Code of practice for safe use of cranes.
BS 7121-3:2000, Code of practice for safe use of cranes Part 3 Mobile Cranes: The
examination scheme approach to thorough examinations, if used, should be based on regular
assessments of the crane in accordance with usage (this is usually known as condition
monitoring). Guidance on condition monitoring for cranes is given in ISO 12482-1.
Implementation of ISO 12482-1 requires co-operation of the crane supplier (manufacturer),
crane user (owner) and authorised Engineer (Competent Person). The crane supplier should
provide limiting criteria based on the crane design (e.g. the number of load cycles, load
spectrum, critical parts, exceptional circumstances). These criteria should not be based on
time alone.”
BS 7121-2:2003 Code of practice for safe use of cranes, Part 2: Inspection, testing and
examination: Mobile cranes with a rated capacity of less than 500t that are not thoroughly
examined in accordance with an examination scheme should be overload tested every 4
years”
BS 7121-2:2003 Code of practice for safe use of cranes, Part 2: Inspection, testing
and examination: On telescopic jib mobile cranes the jib should be dismantled at least
once every 4 years to examine any hidden mechanism parts, for example rope and rope
terminations, hydraulic cylinders.”
BS 7121-2:2003 Code of practice for safe use of cranes, Part 2: Inspection, testing
and examination: On lattice jib cranes all of the jib sections should be covered by a test
certificate.”
In the US this can be carried out in accordance with the requirements of, for example, OSHA
1910.180 Crawler Locomotive and Truck Cranes or ASME B30.5 Mobile and Locomotive
Cranes. These documents both stipulate periodic inspection at 1 to 12 month intervals,
depending on usage or as specifically recommended by the manufacturer.
27. Record Keeping
Records shall be maintained for each crane that are sufficient to enable the condition of the
crane to be determined and its fitness for further operation to be properly assessed.
The records should include the following:
• Technical information including maintenance instructions and performance data

provided by the manufacturer
• Records of reports of thorough examinations or tests certification, including ropes,
carried out on the crane
• Records of significant repairs and modifications to the crane including renewal of
major parts and confirmation of that they have been completed
• A record of daily and weekly checks
• Details of occurrences for example, shock loadings
Records shall be adequate to ensure that they allow a relevant and coherent history of the
crane to be readily retrieved. The records should be clearly identifiable with the crane to which
they refer.

Day 3

Day 2 Confirming Questionnaire – F005 – Answers
Instructor to hand out questionnaires and inform delegates that they have 10 minutes to
complete as many question as possible. After the allotted time gather in the questionnaires,
mark and discuss the answers with the delegates
1. What is the maximum fleet angle for a grooved drum?
2 ½ degrees
2. List the four main areas deterioration may be present on a wire rope fitted to a crane.
• Areas of the rope, which pass over sheaves

• Areas of the rope that remain exposed to the elements for long periods of time
• Areas adjacent to terminations
• Drum terminations and cross over points
3. What is the rated efficiency of an open wedge socket?
80%
4. When would a sheave become unsafe for use?
Excessive wear in a groove. Cracks or damage to a flange. Worn sheave pins. Damage
to cheek plate.
5. When a sheave groove is larger than the diameter of rope, what will happen to the rope?
It will cause the rope to flatten
6. What is the minimum dead end tail length from a wedge socket?
6 inches
7. If the crane slews too quickly when the load is near the maximum radius what might
happen?
Load can swing out and increase the radius resulting in crane overloaded
8. If the crane outrigger begins to sink into the ground, what action should the Crane
Operator take?
Slew crane smoothly away, returning load to the lift point if possible
9. What would a decrease in a ropes diameter indicate? (List two answers)
Wear and core collapse

10. At what intervals is it recommended that crane / sheave blocks and headache balls are
dismantled, inspected and subjected to non-destructive testing examination?
Five years

28. Man-Riding Operations
The raising and lowering of personnel by lifting equipment, which is not specifically designed
for that purpose, should only be undertaken in exceptional circumstances, when it is not
practicable to gain access by less hazardous means.
Although cranes are primarily designed for the purpose of handling materials, when they are
fitted with a suitably designed carrier or working platform they can provide a safer alternative
to for example, a ladder. However, it will not provide the same level of safety as purpose-built
equipment such as a mobile elevated work platform.
Therefore, if a crane is used, in exceptional circumstances, for lifting personnel adequate

precautions must be taken.
A second braking system must be provided for emergency use in case the normal braking
system fails. For cranes this should be fitted to both load and boom hoist systems and
be located as near to the hoist drums as possible. The brake should be strong enough to
hold indefinitely the weight of the carrier and the number of people carried. For hydraulic
transmission system cranes, the braking effect of the hydraulic system itself would be
considered as meeting the requirement for a secondary brake.
They should be equipped with hoist brakes that can be operated mechanically under all load
conditions.
The brakes should be automatically applied when the drive is in the ‘OFF’ or ‘NEUTRAL’
position, and on failure of the power supply to the motor or control device. The braking
operation should also be progressive, to avoid any shock loading of the hoisting system.
Clutches or other means of disengaging the drive train are prohibited, for man-riding
operations, unless there is a fail-safe interface making it impossible to disengage the clutch
when the drive train is in motion, or when there is a load on the hook. Free fall operation of
the load hoist or boom hoist systems is prohibited during man riding operations.
Any speed-change gearbox should be of a constant mesh type and designed so that it is not
possible to change the gear ratio while the hoist system is carrying any load.
The cranes limiting devices e.g. anti-two blocking, must function correctly and the crane fitted
with an emergency stop that arrests all motions of the crane.
In the event that the prime mover fails to re-start or in the case of a total power failure, it
should be possible to recover the carrier by manual means to a safe location.
In addition, the crane hook shall be designed to enable it to be closed and locked, with a
pinned or positive locking device.

When lifting personnel, in a man-riding basket, the Crane Operator must always:
• Have a clear view of the embarkation areas, load path and landing areas
• Check the prevailing weather conditions to ensure that they fall within the crane
manufacturer’s and owner / operators criteria
• When applicable, ensure that a secondary safety sling is attached between the
carrier and the crane hook block, and that a tag line of sufficient length is attached to
assist with controlling the carrier
• Establish radio communication with the Banksman prior to commencement of the
man-riding operation
• Ensure that all personnel involved in the operation have been briefed on the lift
procedure
• Ensure that the personnel carrier is kept clear of all obstructions and potential
snagging points
Note | An appropriate rescue plan should be produced before man-riding operations take
place and form an integral part of the sites emergency control procedures.
In the event of an emergency occurring the Operator must understand, prior to operating the
crane, their roles and responsibilities and the safe procedure to follow.
Personnel baskets and workbaskets must be inspected prior to each use and every six
months.
Note | Schlumberger define all man-riding operations as a high risk activity and therefore
must be approved through the exemption process.

29. Static and Dynamic Lifts
To ensure safe lifting operations, personnel must understand the terms static and dynamic in
relation to loads and conditions.
A “static” lift means that the load applied to the crane never becomes greater than the
weight of the load. If a load is lifted very slowly, gradually accelerated, then slowed down and
stopped, it will remain “static”.
A “ dynamic” lift means the load applied to the crane can be more than the weight of the
load.
This may be caused by, for example:
• Sudden acceleration in the hoist or boom systems

• Swinging loads
• Loads, which are lowered quickly and stopped abruptly
• Environmental conditions e.g. strong winds or gusts
• Sling slippage
• Lifting a load from a floating vessel
The crane load-radius charts for static and dynamic lifts shall be located in plain sight of the
Operator and used for each lift.

30. Tandem Lifts
Lifting a load with two cranes can be a hazardous operation and should be avoided if at all
possible. Where the physical dimensions, or weight of the load prevent it from being handled
by a single crane, then tandem lifting will be acceptable as long as the operation has been
carefully planned and is supervised and controlled by a Competent Person.
It is vitally important that an accurate assessment is made of the load liable to be imposed on
each crane. There should be a full appreciation of how and to what extent this load situation
can vary should the load come out of level or should one or both cranes require to boom up
or down, travel or slew, resulting in the hoist rope coming out of the vertical.
If any of these circumstances occur an additional load can be applied to either crane, or both
cranes, which may affect the stability or cause a structural collapse.
Where possible, cranes of equal capacity and similar characteristics should be used. The
cranes and rigging gear to be used should be selected to have a capacity margin greater
than that needed for the proportional load when handled as a single lift.
It is recommended that unless load sensors are being used, each crane, at the required
boom length and operating radius, should be capable of lifting 75% of the total load. If load
sensors are being used, each crane need only be capable of lifting 25% above its estimated
share of the load.
Tandem Overturning
Overturning a load (upending or tailing) is very similar to tandem lifting where two cranes lift
the load but once the load is clear of the ground, one crane lowers as the other one raises
and rotates the load through 90º.
In this type of operation, the total weight will be transferred to one crane therefore; each
crane must be capable of lifting the full weight of the load.

31. Acronyms, Definitions and Terminology
‘A’ Frame: An elevated structure which carries the boom / jib suspension ropes.
ASLI: Automatic Safe Load Indicator
Boom / Jib: Main structure from which a load is suspended.
CCU: Item of equipment lifted by slings, whose primary purpose is the transportation of
goods, materials, or equipment.
Chandelier: A motion-limiting device to prevent the hoisting of the hook block into the boom
tip sheaves.
Choke Hitch: The method of slinging a load by either, passing one eye through the other or
by passing both ends of a sling around the load and then through the looped end.
Colour Code: A method of marking equipment (normally with plastic tie-wraps or paint) to
give a visual indication of its certification status.
Competent Person: Someone who is considered to be experienced and knowledgeable in

the use of lifting equipment.
Counterweight: The weight or weights attached to the rear of the crane to keep the crane in
balance whilst lifting a rated load.
Derricking / Jibbing: Angular movement of the crane boom / jib in the vertical plane to
change the hook / operating radius.
Duties / Load Chart: A range of information, supplied by the crane manufacturer, on the
cranes safe abilities to lift a load at a given radius, in a given configuration.
Dynamometer: A component of certain crane types through which the hoist rope passes.
As weight is applied to the hoist rope, the dynamometer measures the deflection of the rope,
transmitting this information, as an indication of weight, to the load indicator.
Fly Jib: Detachable auxiliary jib fitted at the end of the main jib. On certain crane types may
be offset to various angles.
FOS: Factor of Safety / design factor. The relationship between the SWL and the breaking
load (MBL).
Gross Weight: The maximum allowable weight, which is equal to the Tare weight (weight of
empty) plus the Safe Working Load (weight of cargo).
Hook Block: The pulley block, which is attached / reeved to the hoist rope.
Lifting Appliance: Any lifting machine or appliance used for the purpose of raising, lowering
or suspending persons or materials.

Lifting Accessory: A device, such as a sling, hook, shackle or eyebolt, used to connect a
load to a lifting appliance.
LML: Load Moment Limiter
MBL: Minimum Breaking Load. This is the load specified in the relevant Standard from which
are derived other values such as the working load limit (WLL) / Safe Working Load (SWL).
MIPEG: Brand name (Micro Processor Engineering Group)
MLI: Moment Load Indicator
Moment: The force produced by a mass being exerted at a distance from the fulcrum.
NDT: Non-destructive Test. Any technique used to detect defects in a material without
subjecting it to physical stresses. These techniques include ultrasonics, dye penetrants,
magnetic particle inspection and radiography.
Outreach: The horizontal distance from the centre line of the lifting hook to the nearest point
of the crane i.e. the outrigger.
Outriggers: Extendable structural members on the crane mounting used to increase the
effective base on which the crane stands.
Overload: When the SWL at a given radius is exceeded.
Pendant Ropes: Wire ropes which support the boom / jib.
Proximity Hazard: Any hazard within or close to the radii of the crane.
Radius: The horizontal distance between the centre of rotation and the vertical centre-line
through the hook.
Reeving: The passing of wire ropes around sheaves and drums.
RCI: Rated Capacity Indicator
RCL: Rated Capacity Limiter
Slew: The rotary motion of the crane / load about the centre of rotation.
SWL: Safe Working Load. The maximum load as certified by a competent person that an
item of lifting equipment may raise, lower or suspend under particular service conditions.
Tare: The weight of the container without cargo. Tare weight shall include all fixtures normally
fixed to the container in service.
WLL: Working Load Limit. The maximum load that an item of lifting equipment is designed to
raise, lower or suspend.

32. Previous Incidents, Causes and Lessons Learned
Incident 1
• A 25T crane was hired from a contractor used on callout basis
• Once the first task was completed, the Job Supervisor left the Crane Driver
unattended to go and arrange the container, which was to be picked up in the
second area
• The Crane Driver rigged down the outriggers but did not retract the boom, length
(17m) and at a 62 degree angle
• The Crane Driver decided to drive to the second lifting area at low speed (ground
conditions – black top / tarmac surface not perfectly level)
• After driving 23m, the crane came into sight of the Job Supervisor who immediately
realized the danger and started to shout and waive at the Crane Driver to stop
• At this point, the crane’s superstructure (boom, cab, etc.) rotated, the crane toppled
and fell on top of a nearby parked logging truck and crushed the logging cabin
• A Field Engineer had been working in this cabin a few hours earlier.
Discuss with delegates causes and lessons learned
• The lifting chains and crane hook were not tied to the crane chassis and started
swinging side ways while the crane travelled
• The crane’s superstructure (boom, cab, etc.) had not been manually locked to
prevent it from rotating
Incident 2
• An electric spark was noticed while the crane raised it’s boom to stab out the pipe
from injector head. The boom was still 4ft to 6ft away from the overhead power
supply cables.

Incident 3
• While attempting to lower a rectangular FRAC silo onto its side from a standing
position (over turning), the crane lost control of the load, the slings attached to the
main block snapped.
• The load dropped hard to the ground.
• The whip (fast) line was attached to another sling that was threaded through the
handrails on the other side of the silo.
• After the main block slings broke, the whip (fast) line sling separated at the handrails.
• One “V” shaped section of handrail travelled approximately 80ft through the air and
struck a sleeping trailer about 4ft from where a man was standing.
• It also hit an electrical box, which then separated from the trailer shearing 6 screws
and made a hole in the trailer wall.
• The fast line had been used to rock the silo to get it to “break free” over towards the
crane. When it did break free, there was too much slack in the main block slings to
catch the falling silo.
Incident 4
• During rig up operations, while moving an ‘A’ Frame (weight 15 Ton) over to the rig
floor, the front outrigger and wooden mat of the 60 Ton crane began to sink into the
soft sand.
• As the outrigger continued to sink the crane toppled over towards the rig floor.
• The crane boom hit the shale shakers with the ‘A’ frame landing between the
substructure and the mud pits.

Incident 5
• Two cranes were used to offload a top mast section from a low boy truck
• Crane 1, telescopic boom, had a capacity of 90 Tons capacity
• Crane 2, telescopic boom, had a capacity of 50 Tons capacity
• Weight of the load, 20 Tons
• Both cranes were positioned
• Both Cranes Operators tensioned the lifting slings in order to position their booms
correctly
• Both Crane Operators lifted simultaneously, hoisting the mast section approximately
5” clear of the truck
• When the load stabilized, the low boy moved away; at this point, the mast section
was approximately +/- 3ft above the ground
• Number 1 Crane Operator started to lower the lift gently (lowering the block)
• Number 2 Crane Operator, instead of lowering the block, lowered the crane boom
• This caused the front of number 2 crane to lift approximately +/- 1.5ft off the ground
• At this point, the number 2 Crane Operator jumped out of the crane cab on to the
ground (approximately 6ft) leaving the crane in this position
• Number 1 Crane Operator lowered the mast section on to the ground. When
completed he went to the number 2 crane and lowered the other part of the mast on
to the ground
• The Crane Operator from number 2 crane fractured his left tibia below the knee
because of the jump from the crane

33. Roles and Responsibilities (Crane Operator, Banksman and Slingers)
All personnel involved in the lifting operation should be competent (or under supervision) and
familiar with the crane’s operational characteristics, parameters and the working environment.
Every lift should be subject to an appropriate level of risk assessment and planning.
While there is a shared responsibility for the safety of each lifting operation the Banksman
shall remain the person in charge of the activity and be easily identifiable from other personnel
by wearing a High-Visibility jacket or waistcoat, which is clearly marked to indicate that they
are the authorised Banksman.
The minimum number of personnel involved in each lifting team shall be three. They are:
• Crane Operator
• Banksman
• Slinger / Load Handler
Crane Operator roles and responsibilities:
• Observe lifting operations and learn from examples

• Work safely in accordance with regulations, company, procedures and lifting plans
• Be certified / authorized for the type of crane to be operated
• Carry out pre-operation / routine checks and maintenance in accordance with
manufacturer and company checklists
• Ensure that all safety devices fitted on the crane are operational
• Ensure that the crane is set up correctly, can function correctly and is fit to carry out
the required lifting operations
• Programme / correctly use load indication systems
• Ensure that the crane has current and appropriate certification
• Participate in lift planning, risk assessment and toolbox talks for each lift
• Identify / remove any potential hazards
• Account for the effects of wind and other environmental conditions
• Agree communications with the Banksman prior to undertaking a lift
• Understand hand signals, radio communications and the duties of the Banksman
and Slingers
• Verify the weight of each load before it is lifted
• Verify correct rigging arrangements
• Operate the crane under the direction of the Banksman
• Operate the crane so as to ensure the safety of personnel and plant
• Clearly communicate with the Banksman
• Respond to the emergency stop signal / command
• Take action to avoid a dangerous situation
• Report any faults immediately to your supervisor
• Resist pressure from others to carry out an unsafe act
• Stop and report any unsafe practices or actions
• Coach and mentor less experienced Crane Operators

Banksman roles and responsibilities:

• Ensure that all relevant requirements are implemented
• Participate in the planning and risk assessment of lifting operations
• Participate in pre-lift toolbox talks
• Be easily identified as the Banksman (high-visibility vest)
• Ensure that Slingers are correctly attired with the appropriate PPE
• Confirm that the lift is within the crane’s capacity and safe operating radius
• Never touch the load or lifting accessories while the load is suspended
• Restrict access to the area of operation to authorized personnel only
• Ascertain / confirm the weight of the load is within the capacity of the lifting
accessories
• Ensure the correct selection, set up and safe use of lifting equipment in accordance
with the lift plan
• Ensure lifting equipment and loads are properly inspected before use including
checks for potential dropped objects
• Ensure cargo is correctly packed and secure
• Ensure loads are slung correctly, accessories are securely attached, located correctly
and have freedom of movement
• Ensure that slings are not used at an angle in excess of the company stated
maximum
• Ensure the route to be travelled is clear and the landing area is suitable
• Identify / remove potential snagging points in the vicinity of the load
• Ensure the area around the load to be lifted is clear
• Ensure the load is free to lift
• Direct Slingers, ensuring they remain in a safe position
• Direct the Crane Operator using hand signals as the primary means of
communications or radio communications when applicable
• Be in a prominent safe position, away from the load, with a good view of the
complete lifting operation
• Continuously monitor the lifting operation
• Ensure tag lines are used correctly
• Remain in communication with the Slingers and Crane Operator at all times
• Ensure equipment is de-rigged, inspected, stored or quarantined correctly
• Coach and mentor Slingers and less experienced Banksmen
Note | Banksmen may assist Slingers in the preparation and checking of items to be
lifted e.g. laying out slings, etc., but only before assuming the role of the Banksman. The
connection and removal of loads to and from the crane hook or pennant shall only be carried
out by a Slinger.

Slinger roles and responsibilities:

• Ensure that all relevant requirements are met or exceeded
• Participate in the planning and risk assessment of lifting operations
• Participate in pre-lift toolbox talks
• Be distinct from the Banksman
• Restrict access to the area of operation to authorized personnel only
• Ascertain / confirm the weight of the load is within the capacity of the lifting
accessories
• Select, set up and safely use lifting equipment in accordance with the lift plan
• Ensure lifting equipment and loads are properly inspected before use including
checks for potential dropped objects
• Correctly pack and secure cargo
• Ensure loads are slung correctly, accessories are securely attached, located correctly
and have freedom of movement
• Ensure that slings are not used at an angle in excess of the company stated
maximum
• Ensure the route to be travelled is clear and the landing area is suitable
• Identify / remove potential snagging points in the vicinity of the load
• Ensure the area around the load to be lifted is clear
• Ensure the load is free to lift
• Correctly connect / disconnect loads to the lifting appliance
• Inform the Banksman when the load is connected to / disconnected from the lifting
appliance
• Confirm that the load is ready to lift
• Confirm you are standing clear whilst a load is lifted, landed or while slack is taken
up
• Assume a safe position during lifting operations and be aware of the position of
others
• Continuously monitor the lifting operation
• Use tag lines correctly
• Remain in communication with the Banksman at all times
• Ensure equipment is de-rigged, inspected, stored or quarantined correctly
• Coach and mentor less experienced Slingers

34. Communications (Hand Signals and Two-Way Radios)
A uniform continual communication system clearly understood by all personnel taking part in
the lifting operation shall be established before the lift commences.
Only the hand or radio signals given by the Authorised Banksman, should be responded to
unless an emergency situation clearly exists. Any person observing this type of situation may
give the emergency stop signal.
When hand signals are being used, visual contact with the Banksman must be maintained.
Lifting operations must cease if visual contact is lost. The operation can only re-start when a
clear line of vision has been re-established.
Note | Non-standard signals may be developed and used, when the situation requires it, but
all personnel must understand these signals before use.

When radios are being used the Crane Operator shall reach a clear understanding with the
Banksman before lifting operations begin. If there is any interruption to communications, such
as third party transmission, the lifting operation should cease and the load made safe, until
communications are restored.
When the load is being hoisted, lowered or suspended, initial instruction should be given
and the Crane Operator updated on a regular basis to assure the Operator that the line of
communication is still active and the Banksman is maintaining control of the lift.
During blind lifts communications shall be continuous.
In addition:
• During high winds ensure the area of the microphone is not exposed to direct
contact with the wind when speaking, as it may distort the transmission
• Always ensure that the transmission button is fully depressed before speaking into
the microphone
• Identify the station you are calling, speak slowly and clearly at all times and finish
your transmission with the word “OVER
• Do not release the button until a few seconds after completing your message
• The receiving Operator should indicate understanding of the message by saying
“ROGER”
• If the message is distorted or the instructions are unclear, the receiver must request
for it to be repeated
• The transmitting Operator should never assume that the message has been
understood until they hear the word “ROGER”
• At the close of communications, the transmitting operator must indicate the end of
the transmission by saying “OUT”
Note | Radio messages should only reflect work requirements and under no circumstances
should offensive language be used whilst transmitting.
When directing the crane, the following instructions may be used:
Pick up | Lift the load

Lower | Lower the load
Boom up | Raise the boom
Boom down | Lower the boom
Slew right | Slew to the right, from Crane Operators position
Slew left | Slew to the left, from Crane Operators position
All stop | Stop the movement immediately
Gently/Slowly | Slow movement
Slack off | Release tension to allow hook to be released
Hook free | Lift up releases hook

35. Lifting Planning (Schlumberger specific)
Instructor to explain to delegates the level of detail required in lifting plans and offer an
overview of the risk assessment process.
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36. Practical Crane Exercises
Delegates will use the lifting plans created during the planning exercises to carry out various
lifting operations using a mobile crane and lifting accessories.
Before commencement of the crane exercises the instructor shall explain the Schlumberger
Permit to Work system and offer guidance n the level of supervision for lifting operations.
A permit to work system is a formal written system used to control work, which may
adversely affect the safety of personnel, plant or the environment. It is also a form of
communication between management, supervisors, operators and those who carry out the
hazardous work.

All lifting operations need to be appropriately supervised. With ‘Appropriate supervision’
meaning that it should be proportionate to the risks involved and the competence of those
performing the work.
For example:
A routine lifting operation might appear to need intermediate or limited supervision but if
everyone on the lifting team is relatively new and have only completed initial training, then
direct supervision is required.
If the Banksman has been deemed competent after completing a workplace / skills
assessment, the Slingers have only completed initial training, and they are required to carry
out a lift that is difficult due to the nature of the load, e.g. has an awkward shape, has an
offset or high centre of gravity, is fragile, etc. then direct supervision by the Lifting Supervisor
would be required.
If however, the competent Banksman and Slingers, from above, were carrying out a simple
lift, only intermediate or limited supervision would be required.
Delegates to complete the mobile crane on-site pre-use checklist and all pre-operational
checks identified on the exercise lifting plans.
Crane Operations | Banksman and Slinger Duties
The following suggested lifting operations should be carried out. Each delegate should
complete at least two lifts, one taking the role of the Banksman and one completing the
duties of the Slinger.
Lifting Operations with:
• A Cargo Carrying Unit

• A Load that has an Offset Centre of Gravity
• A load that is slung with a choked single leg sling
• Single and Bundled Tubulars
• Restricted Access
• The Load unsighted by the Crane Operator


SLB Lifting

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3-Day SLB

Onshore Site Lifting Supervisor

Intellectual Ownership & Copyright of NSL Training Products & Materials.

All Images and Content © NSL 2009 3

1. Course Introduction and Registration

All Images and Content © NSL 2009 4

Day 1 Confirming Questionnaire Answers

Day 2 Confirming Questionnaire Answers

All Images and Content © NSL 2009 5

• Motivation and confidence for public speaking

• Country Specific Legislation / Regulations

ii. Training Course Requirements

• Classroom (size to suit number of delegates)

iii. Course Duration

iv. Successful Completion

All Images and Content © NSL 2009 6

vi. Instructor / Assessor Qualifications Experience

Assessors shall hold a recognized Skills Assessor’s award.

viii. Unsafe Acts

ix. Weather Conditions / Equipment Problems

Training shall be suspended if adverse weather conditions or equipment problems arise.

All Images and Content © NSL 2009 7

All Images and Content © NSL 2009 8

Management of Lifting Operations 15 minutes

Types of Cranes 15 minutes

All Images and Content © NSL 2009 9

All Images and Content © NSL 2009 10

All Images and Content © NSL 2009 11

All Images and Content © NSL 2009 12

Your introduction should include:

• Warm and understanding rather than cold and aloof

All Images and Content © NSL 2009 13

At the end of training, delegates will be able to:

All Images and Content © NSL 2009 14

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• Training and Competence

To simplify this process personnel should consider the following stages:

Prepare: Personnel roles and responsibilities

Categorize: Levels of competence

Risk Assess: Identify all the hazards

Plan: Method statement

Authorize: Approval and authorization

Execute: Safe operating procedures

Learn: Monitor and review

All Images and Content © NSL 2009 16

Truck mounted boom crane with lattice fly jib

Crawler mounted lattice boom crane

All Images and Content © NSL 2009 17

All Images and Content © NSL 2009 18

Truck Mounted Crane

All Images and Content © NSL 2009 19

Cranes Centre Tipping Axis Loads Centre

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real load radius

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The Crane Operator must always:

• Use the crane manufacturer’s load chart

All Images and Content © NSL 2009 23

• Sheaves with roller bearings - 4% per sheave

All Images and Content © NSL 2009 24

Crane mobility, in general, is either by means of wheels or crawler tracks.

• Retract and stow boom sections