Training Program on Crane Basic

Module No : CHSEE-TM-39-L2

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

OBJECTIVE
Know hazards associated with cranes Become familiar with common types of industrial and construction cranes Be familiar with methods of controlling crane hazards and preventing accidents
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 2

Hazards
Over 250,000 cranes in operation in USA 125,000 in construction 80,000 general and maritime 80 fatalities per year One death per thousand crane operators in their working lifetime (45 years) Risk to workers & citizens
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 3

 Major causes of crane accidents Contact with energized power lines (45% of accidents) Under hook lifting device Overturned cranes Dropped loads Boom collapse Crushing by the counter weight Improper outrigger use Falls Rigging failure
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 4

Industrial Cranes
Overhead Cranes
Common in industrial plants Supported by overhead rails Components
Bridge Trolley Hoist

Often pendant operated Easy to use, little training required

Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 5

Industrial Cranes
Gantry cranes
Mobile frame Trolley Hoist

Jib cranes

Pivot mounted boom Trolley Hoist

CHSEE-TM-39-L2 Rev 2, Oct 2006 6

Group Manufacturing Services Centre for HSE Excellence

Industrial Cranes
Power hoist
Usually electric or air operated

Chain hoist (or "chain fall")

Hand operated

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

Construction cranes

Tower cranes
Group Manufacturing Services Centre for HSE Excellence

Variable height climbing cranes Used for building construction

CHSEE-TM-39-L2 Rev 2, Oct 2006 8

Construction cranes
Mobile cranes
Crawler cranes Truck cranes Hydraulic cranes
Boom telescopes May have jib

Equipped with outriggers for stability

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

Construction Cranes

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

10

Construction Cranes

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

11

Construction cranes
Derricks
Boom angle can change Often used in shipyards, building construction, etc.

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

12

BASICS OF CRANES

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

13

Crane

Crane is a machine meant for lifting or lowering a load and moving it horizontally or slewing it to left or right and in which hoisting is an integral part of machine. It may be driven manually or by power and may be a fixed or mobile.
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 14

Basic Principle of a Crane

A Crane is designed on the Principle of load moment.

force X

force Y

O Fulcrum x Xx
Group Manufacturing Services Centre for HSE Excellence

Yy
CHSEE-TM-39-L2 Rev 2, Oct 2006 15

BOOM LENGTH

HEIGHT

LOAD

RADIUS
Group Manufacturing Services Centre for HSE Excellence

Fulcrum

AXIS OF ROTATION
16

CHSEE-TM-39-L2 Rev 2, Oct 2006

TYPES OF CRANES
CRANES
Mobile Stationary

Crawler Mounted Mechanical

(TFC 280)

Tyre Mounted

(EOT ,Gantry)

Overhead

Pedestal

Pole mounted (Jib Crane)

Lattice Boom

Telescopic Boom

Hydraulic
(AM.11320)

Rough terrain (TIL RT 740B)

All Terrain Truck Mounted (TIL 830 , AC 1600)

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

17

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

18

Boom Point Head

No. of falls Boom Top

Pendant Ropes Hook Block Boom Insert Boom Stoppers Outer Bail

Boom Hoist Rope

Inner Bail Boom Bottom

Gantry

Operator Cabin

Under Carriage
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006

Counterweights19
Crawler

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

20

Main Hoist Wire Rope

Telescopic Boom

Operator s Cabin

Winch (Main Hoist)

Boom Point Sheaves

Derrick Cylinder

Counter Weight

Hook Block

Slew Ring

Engine Out Rigger

Wheels

Components of Hydraulic Crane

Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 21

Definitions
Radius :Radius is the Horizontal distance at ground level, from the crane centerline of rotation to a vertical line through the centre of gravity of the suspended load on hook

Boom Length :Boom Angle :-

Boom Length of main boom measured from Boom Pivot to the Top Boom Point
Boom Angle is the angle of Boom to the horizontal
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 22

Boom Point Height :It is the vertical distance between Boom Point and Ground, measured perpendicular to the ground. It is also referred as Boom Point Elevation.

Load Chart :It is a chart representing rated capacities of crane at various radius w.r.t. various boom lengths,boom angle and configuration.

Rated Capacity :Rated capacity of a given radius is the maximum load permitted to be lifted by the crane at the particular radius. These are calculated on basis of various factors such as crane stability structural limitations etc. This also is called as Safe Working Load or SWL. Group Manufacturing Services CHSEE-TM-39-L2
Centre for HSE Excellence Rev 2, Oct 2006

23

Maximum capacity of Crane :This is the maximum capacity of a Crane and is obtained at minimum radius with basic minimum boom length of a crane. A crane is basically defined by the maximum capacity only. For example :- A 20 MT capacity crane can lift 20 MT load only at its minimum radius and that too, with its minimum or basic boom length only. Similarly a 500 MT crane can lift 500MT load at its minimum radius with minimum or basic boom length only.

Propel :The term Propel refers to marching /traveling of crawler Cranes

Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 24

O/R Width :
It is the distance between two opposite outriggers measured from centre to centre of O/R loads with outriggers in completely extended position.

Crane

O/R width

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

25

Hoisting/Lowering :Hoisting or lowering of hook block Swing (or slewing) :Slew of crane superstructure to either side along with his own axis. Boom Hoisting/Lowering :It is lowering or hoisting of boom with respect to its pivot essentially to increase or decrease radius. Marching (or Propelling) - in case of crawler cranes only Travel of a Crawler Crane forward or reverse. Telescopic boom extension/Retraction :Extending or Retracting of Telescopic Boom to increase or decrease Boom Length
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 26

Crane- Basic Operations

Schematic Of Power Train In Hyd. Crane (Tyre Mounted)

Winch Control Valve

Swing Unit Pump1

Swivel Unit

Engine

Torque Conv.

Transmissi on

Pump 2 & 3

Front Wheel
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006

RearWheel
27

Some Common Configuration Of Cranes

Crawler Crane
Main Boom Main Boom plus fixed Fly jib(at various offset angles) Main Boom plus Luffing fly jib Main Boom with Super lift or sky horse attachment Main Boom plus Luffing Jib/fly Jib + Super lift
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 28

Types of configuration in mobile cranes (a)Main boom (b)Main boom with Super Lift (c)Fixed Jib or Fly Jib (d)Fixed Jib with Super lift (e)Luffing Jib (f)Luffing Jib with Super Lift (g)Tower jib- Light load and better reach
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 29

Main Boom-Normal load

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

30

Main Boom with Super LiftHeavy load

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

31

Fly or fixed Jib- Better reach

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

32

Luffing Jib-Long reach

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

33

Luffing jib with Super lift- Heavy Load and long reach

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

34

General Safety Features Of Crane

1. A2B (Anti Two Block) OR Over Hoist Limit Switch :Gives alarm (and trips off further hoisting), in case of Hook Over Hoisting. 2. Boom Hoist Limit Switch (Crawler Cranes) :Generally a Shut Off valve which gives alarm in operators cabin (and cuts off further hoisting), when the boom has reached to a pre-set (maximum) angle during hoisting. 3. Overload Limit Switch (Hydra) :Gives a warning (alarm), in case the Hydra approaches Overload condition.
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 35

4. Safe Load Indicator (SLI) :SLI, when fitted on crane, measures and displays following data Radius of Hook Boom Length Boom Angle Actual Load Lifted by Crane Rated Capacity (SWL) SLI is also equipped to provide :A2B condition, indication & Tripping in case of Over Hoisting Analog indication of Load Moment, in terms of Green (Safe Zone), Yellow (Alert Zone) and Red (Danger & Cut Off zone) Indication, Alarm and Motion Cut Off, when an overload condition has reached.
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 36

SLI on Hyd. Crane General components (Kruger Mark 4 on Voltas 40 crane-as an example)
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 37

Controlled Load Lowering (CLL) is a mechanism provided on Crawler Cranes to achieve gradual lowering of Load (Hook) in a controlled manner.
This is achieved by providing special mechanisms,like planetary system or separate reduction achieved via chain and gears, in power train of Hoist Lowering . CLL is exactly opposite to the FREE FALL mechanism, possible on Cranes, wherein the Hook is allowed to come down freely with the aid of gravitational force. As the name free fall clearly suggests, it does not have control in lowering of Hook, except by applying brakes. And hence free fall, strictly, is not to be used on any crane. It is pertinent to mention here that lowering speed,also depends upon engine RPM and is in direct proportion of it.
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 38

Controlled Load Lowering In Crawler Crane

Chart data includes Structural capacity and tipping limits

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

39

Load Chart for 4040C on three axles

Over Rear

Over Side 39.8' Boom 22.8' Boom 55,880 * 45,650 42,660 * * 34,560 31' Boom 39.8' Boom 22.8' Boom

Over Front 31' Boom 39.8' Boom

Radiu s in Feet
6 8 10 12 15 18 20 25 30

22.8' Boom 55,880 *

31' Boom

55,880 * 45,650 42,660 * *

45,650 42,660 * * 39,380 36,350

39,380 36,350 34,560 39,380 36,350 34,560

34,790 31,800 30,000 34,790 31,800 30,000 34,790 31,800 30,000 27,450 27,080 25,320 29,950 27,080 25,320 29,950 27,080 25,320

20,030 20,160 20,210 22,690 22,870 22,100 25,010 23,820 22,100 16,870 17,000 17,050 18,250 18,430 18,510 18,760 19,010 19,140 12,050 9,150 12,100 9,220 7,340 12,170 12,240 8,860
CHSEE-TM-39-L2 Rev 2, Oct 2006

11,410 7,880

11,510 7,990 5,950

40

Group Manufacturing Services Centre 35 for HSE Excellence

8,950 6,920

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

41

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

42

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

43

CRAWLER CRANE

Use Hook latch to avoid slings from getting removed from hook
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 44

Tipping Axis

STABILITY OF CRANE
A is a point in the Tipping of Crane L1is Distance between Point A and CG of Counter Weight L2 is Distance between Point A and CG of Crane Assembly L3 is Distance between Point A and CG of Load W1 is weight of counter weight W2 is weight of Crane Assembly W3 is weight of Load To achieve the stability of Crane the following equation should be satisfied

Moment about point A

L2
Group ManufacturingL1 Services Centre for HSE Excellence

W1 X L1 + W2 X L2 >= W3 X L3
L3
CHSEE-TM-39-L2 Rev 2, Oct 2006 45

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

46

Mobile Cranes Importance of Outriggers

a) Tipping load when outriggers are to their full extension

Weight of crane =35MT. Weight of boom =2MT. B = Boom CG - 7.5mts. C = 2mts. - crane CG to tipping fulcrum L = 4mts. distance from load to tipping fulcrum

Stability relationship of above: a)Load x L + Boom weight x B =

Crane weight x C Tipping load= (35 x2-2 x 7.5) / 4 = 13.75 MT b)Tipping load when outriggers are 0.5mts. short of their full extension C = 1.5 = 2.0 - 1.5;B = 8.0 = 7.5 + 0.5 L = 4.5 = 4.0 + 0.5 Tip. load = (35 x 1.5 - 2 x 8) / 4.5 = 8.1 MT
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006

41% reduction of tipping load 47

IMPORTANCE OF QUADRANT
Front

Side

Y
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 48

SAFETY DEVICES IN CRANE

Over Hoist Limit switch

Boom Limit Switch

Hook Latch

Angle Plate Pointer

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

49

Unsafe Practices

Remedial Measures

Non-Use of Hook Latch

Use Hook latch to avoid slings from getting removed from hook

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

50

ABSENSE OF BOOM LIMIT SWITCH No Boom Limit Switch

Over Hoist Limit switch

Boom Limit Switch

Hook Latch

Angle Plate Pointer

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

51

ABSENCE OF OVER HOIST LIMIT SWITCH

No Limit Switch Limit Switch

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

52

 Soil Conditions must be sufficient. Blocking & Cribbing should be used.

VIOLATION
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 53

Spreads out the load so the supporting surface can support it.

Transmits the load without bending or breaking.

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

VIOLATION

54

Method 1
Area of float (in square feet) x 3 = Blocking area (in square feet) Method 2 Capacity of crane (in tons) / 5 = Blocking area (in square feet) Outrigger Beam

Float Pad Blocking/Cribbing

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

55

Transmitting the Load Properly placed with no gaps or spaces between pieces.

VIOLATION
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 56

Transmitting the Load; must always be level.

Wrong

RIGHT
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006

WRONG
57

Transmitting the Load; must always be stable and never block under outrigger beams inside the floats.

WRONG VIOLATION
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 58

 Usually made of hardwood. Through bolted together 8 12 inches thick.

If soil conditions are poor enough to require mats, the input of a soil engineer may be needed. Do not make any assumptions.
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 59

Recommended Safe Work Practice: Affected Zone

D x 1.5
D Be aware of existing underground utilities and backfill.
Group Manufacturing Services Centre for HSE Excellence

Affected Zone (Depth x 1.5) *Average Soil Only-To be used juditiashiasly

CHSEE-TM-39-L2 Rev 2, Oct 2006 60

 Follow all manufacturers recommendations and ensure crew is qualified and competent to make decisions.

ANSI requires that hook balls and blocks be lashed or secured during transit.
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 61

 Site allows for full extension of outriggers or crawlers. Minimum clearance of 2 feet from all objects for counterweight. Must be level within manufacturers specifications.
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 62

 Signs Barricades Trained Signal Persons

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

63

The following precautions shall be taken when necessary to dissipate induced voltages: Electrical ground directly to the upper rotating supporting the boom. Ground jumper cables. Combustible and flammable material shall be removed from the immediate area.
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 64

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

65

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

66

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

67

Rigging Safety Rules

Know the weight of the load Know the center of gravity of the load Make load attachment above center of gravity or stabilize Select hitch that will hold and control load Know rated capacities of slings and rigging hardware Select sling best suited for load Inspect all rigging gear prior to use Protect sling from sharp surfaces Protect load from rigging if necessary Allow for increased tension caused by sling angles Equalize loading on multiple leg sling Allow for reduction when using choker hitches Allow for sling angles when forcing choker Attach tag lines prior to lift if required
CHSEE-TM-39-L2 Rev 2, Oct 2006 68

Group Manufacturing Services Centre for HSE Excellence

Rigging Safety Rules

Keep personnel clear of lift area Lift load few inches and check rigging Know limitations of hoisting device Start and stop slowly Watch for obstruction and power lines Use proper hand signals Maintain load control Do not forget the law of gravity

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

69

If you over load the crane !

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

70

If you over load the crane !

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

71

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

72

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

73

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

74

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

75

Preventing Crane Accidents

Dropped loads
Anti-two block device (upper limit switch) Proper rigging Inspection Inspection Stable base No overloading No horizontal loading

Boom collapse

Crushing by the counter weight

Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 76

Preventing Crane Accidents

Proper outrigger use
Level Fully extended Stable base
Cribbing

Group Manufacturing Services Centre for HSE Excellence

CHSEE-TM-39-L2 Rev 2, Oct 2006

77

This presentation is prepared by Mr. Ashok Dashputre of Centre for HSE Excellence

Acknowledgement
We acknowledge the contributions of Safety Departments of Construction & Steady State of RIL Jamnagar

Thank You
Group Manufacturing Services Centre for HSE Excellence CHSEE-TM-39-L2 Rev 2, Oct 2006 78