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Crane Accidents and EmergenciesCauses, Repairs and Prevention
Presented by
Larry Lam Chairman
Soon Chong Tok Technical Director
Portek International Limited15 March 2007
For enquiries, please email: [email protected] contents of this document are copyrighted and proprietary, and may not be reproduced without the permission of Portek International Limited
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Definitions A Crane Accident is an unplanned and unintentionalevent involving a crane or cranes, or other objects that
result in damage or injury of some kind and normallyinvolves a strong human element in its causation.
A Crane Emergency situation is an unexpected andsudden event in which the crane is subject to damage,and where the cause is not immediately linked to theoperator.
A Crane Incident is a general term for either a craneaccident or emergency
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Crane Accidentscan happen in the following ways:
when a ship contacts a cranewhen a crane contacts a ship
when cranes contact each other due to strongwind gusts during operation, often resulting ina multiple chain collisionwhen a crane contacts another crane or anobject during operation
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Right seaside leg hitdiagonally by ship'sbow
(ship contacts crane)
Crane Accidents
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Crane boom struck ships funnel (crane contacts ship)
Crane Accidents
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Crane (blown by wind gusts) collapsed after collision
Crane Accidents
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Exceptional situation such as typhoons, hurricanes,
earthquakes resulting in crane collapse, derailment orsevere damageCrane failure as in
electrical fires in diesel generator or electrical roomcrane drive faults leading to free fall of loadmechanical faults as in brake failure, twist-locks
failures, etc resulting in uncontrolled fall of loadstructural damage as in fatigue failure, poor
workmanship or design.Heavy weather or inadequate lashing during ocean
transportation of cranes
Crane emergency situations can arise from
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Structural failure - A-frame pylon bent and tipped forward
Crane emergency situations
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Right tension rod broke from fatigue
Crane emergency situations
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Frequency of Crane IncidentsCrane Incidents are happening with increasingfrequencies, due to:
rapidly increasing population of cranesincreasing crane dimensions, hence decreasing visibilityand control
insufficient distance between fender face and seasiderail, and increasing flare of ships bow, as ships getbigger standards of crane maintenance not keeping up
standards of safety in crane operation and terminaloperation failing to keep upinsufficient understanding of risks involved, and lack ofprecautions takenadverse and unpredictable weather
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Typical Processes in a CraneIncident
Recovery phase comprising Survey andSalvage and StabilizationRepairs and Re-commissioning
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Typical damage
bending and buckling of the legs, sill beamsand portal beamsderailment seaside and landside bogiestearing apart of joints between equalizerbeam and sill beam
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Ship contacting
Crane boom
Typical damage
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Damage from Ship contacting crane
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Derailment at seaside
Typical damage
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No derailment landside,but severe damage toleg
Typical damage
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Severe bending oflandside leg
Typical damage
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Buckling of sill beam landside
Typical damage
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Joint at equalizer beam separated and twisted
Typical damage
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Total destruction of boom snagged by a departing ship
Typical damage
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Entire portal and boom twisted by ship pulling on boom
Typical damage
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Wind gusts causing crane collisions
Typical damage
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Damage from Collisions
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RepairsDesign and Analysis
Fatigue failure of an unloader & computer modeling of crane structure
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Simulation of failure & Redesign and Repairs
Repairs
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Crane Supports for Repairs
Computer simulation of crane support
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Crane Supports for Repairs
Robust support in place before cutting
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Repair Methodology
Damaged plate removed and replaced
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Repair Methodology
Replaced with new sill beam
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Repair Methodology
Heavy damage due to constraints to side way displacement
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Repair Methodology
Derailment allows displacement, therefore little or no damage
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Repair Methodology
Floating crane removing boom for repairs
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Repair Methodology
Re-installing repaired boom
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Repair Methodology
Boom hinge inspection and NDT checks
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Repair Methodology
Line boring of boom hinge
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Repair Methodology
Dimensional checksusing theodoliteequipment
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PreventionPrevention of crane incidents at
different levels:at crane design and engineering level,at crane operating level,at terminal operation level
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Double brake
machinery
Prevention at crane design level
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Caliper brakes on flanges of boom hoist drums
Prevention at crane design level
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Prevention at the terminal
operating levelBerthing and un-berthing - Vessels should comealongside quay as parallel as possible.Equipment maintenance not to be compromised infavour of operational expediency
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Risk Management Plan
Terminate the risk s not likely. Inherently
risky. Transfer the risks - InsurancePolicy. Consequential losses not covered
Tolerate the risks Accepting the risks. Selfinsurance
Treating the risks involves prevention, reducingthe likelihood of occurrence and severity of loss
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ConclusionRisks associated with container cranes willincrease, due to
Increasing probability of occurrenceGreater severity of loss.
Modern container quay cranes quantumleap in size, and complexity, not yet fullyunderstood as to risk factors
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Thank You