Pedestal Crane Training, Dock and Vessel Mounted seriestraining series dock and vessel mounted cranedock and vessel mounted crane pedestal mounted crane inspection ... dock and vessel

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TRAINING SERIES DOCK AND VESSEL MOUNTED CRANETRAINING SERIES DOCK AND VESSEL MOUNTED CRANE

PEDESTAL CRANE OPERATOR

SAFETY TRAINING

PEDESTAL CRANE PEDESTAL CRANE OPERATOROPERATOR

SAFETY SAFETY TRAININGTRAINING

DOCKAND

VESSELMOUNTED

DOCKDOCKANDAND

VESSELVESSELMOUNTEDMOUNTED

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“When anyone asks me how I can best describe my experience of nearly forty years at sea, I merely sayuneventful….(I)n all my experience I have never beenin any accident of any sort worth speaking about. Ihave seen but one vessel in distress in all my yearsat sea…I never saw a wreck and never have been wrecked, nor was I ever in any predicament thatthreatened to end in disaster of any sort.”

Captain E. J. Smith - 1907

“When anyone asks me how I can best describe my experience of nearly forty years at sea, I merely sayuneventful….(I)n all my experience I have never beenin any accident of any sort worth speaking about. Ihave seen but one vessel in distress in all my yearsat sea…I never saw a wreck and never have been wrecked, nor was I ever in any predicament thatthreatened to end in disaster of any sort.”

Captain E. J. Smith - 1907

Have someone read the following quote.

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Captain E. J. Smith became the captain of the Titanic in 1912

Captain E. J. Smith became the captain of the Titanic in 1912

5 years after that quote, Captain E. J. Smith sank.Ask the class what are some of the factors that contributed to the Titanic sinking. You will probably hear such comments as:•It was a “unsinkable” ship and they became overconfident•They were trying to break the record for trans-atlantic crossing•Because it was an unsinkable ship they did not need as many life boats•Icebergs were generally not spotted that far south that time of year

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TELESCOPING BOOM CRANETELESCOPING BOOM CRANE

OBJECTIVE: Familiarization of the components on a pedestal mounted crane.1. Point out each component and function.2. Note that this drawing is a cut away of the crane showing internal components.3. Note that certain components are the same on a boom truck and rough terrain crane.4. A more detailed explanation of each function will be discussed in a later slide.

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KNUCKLE BOOM CRANEKNUCKLE BOOM CRANE

OBJECTIVE: Familiarization of the basic components of a knuckle crane.1. Point out the differences between knuckle boom and straight boom cranes.2. Indicate how the knuckle hinge is particularly susceptible to side loading.

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SWINGING BOOM CRANESWINGING BOOM CRANE

The swinging boom type of crane is the simplest crane found on most docks.

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CRANE COMPONENTSCRANE COMPONENTS

PedestalPedestal

TurretTurret

Lift CylinderLift Cylinder

WinchWinchBoomBoom

HookHook

Boom TipBoom Tip

Wire RopeWire Rope

OBJECTIVE: Familiarization of the basic components of a knuckle crane.Whether the crane is the straight boom or knuckle boom type, the components are very similar.• The pedestal, which is mounted to the dock, is typically a cylindrical tube or a box. The height varies depending on the crane’s usage.• The turret is mounted on a bearing which is mounted to the pedestal. The boom, lift cylinder(s) and swing motor(s) are mounted on the turret.• The wire rope is wound on the winch which is normally mounted on top of the boom. • Lift cylinder(s) raise and lower the boom.• The boom tip houses the sheaves on which the wire rope runs.• The hook is attached to the end of the wire rope by various methods.

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SWINGING BOOM CRANE COMPONENTSSWINGING BOOM CRANE COMPONENTS

HookHook

Boom TipSheaveBoom TipSheave

WinchWinch

MastSheaveMastSheave

BoomBoom

Boom SupportBoom Support

Rotation BearingRotation Bearing Dock MountingDock Mounting

MastMast

OBJECTIVE: Familiarization of the basic components of a swing boom crane.

The swinging boom type of crane consists of a fixed length boom that is mounted on a vertical mast. The boom cannot be raised or lowered. This feature limits the movement of a load to a circular pattern at a fixed radius. The vertical mast is fixed in length as well and the base has a bearing of some type and is mounted to the dock. Crane rotation is typically manual, by means of bar or pipe which is pushed or pulled to rotate the crane. The winch used to hoist the load is often electrically powered, with the up / down control mounted on the end of an electrical cord.

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PEDESTAL MOUNTED CRANEInspection Check List

PEDESTAL MOUNTED CRANEInspection Check List

The operator is responsible for inspecting the crane prior to using it.The operator is responsible for inspecting the crane prior to using it.

INSPECTION AREA INSPECTION RESULTSSat. Unsat. N/A Comments

Supporting StructureWeldsBolts

Rotating System Bull & PinionGearSwing BrakesHydraulic Drive Motor

BoomWeldsStress & DistortionHinge PinBoom Cylinder & PinsWear PadsTelescopic OperationTip Section & SheavesAngle/Radius IndicatorAnti-Two Blocking Sys.

Winch SystemWire Rope ConditionRope ReevingMounting BoltsBrakesFunctional Operation

Hydraulic SystemPump PerformanceControl FunctionsControl MarkingsHydraulic Leaks Hose ConditionFluid Level

Load BlockSheavesPinsSwivelHook

OBJECTIVE: Review the parts of the crane that need to be inspected.1. Note similarities and differences between this crane and vehicle mounted cranes.2. Indicate who is responsible for performing these inspections.3. Indicate how the inspections are to be recorded.

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Pins & BossesPins & Bosses

BOOM & TURRET INSPECTIONBOOM & TURRET INSPECTION

Slide PadsSlide Pads

HeadHead

WinchWinch

WeldsWelds

OBJECTIVE: Point out specific areas of the crane to be inspected.1. This drawing can be used to show the general location of components for all three types of cranes.2. Refer back to slides 2 & 3 if necessary to point out additional inspection areas.

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TYPICAL DOCK MOUNTING METHODSTYPICAL DOCK MOUNTING METHODS

Check mounting methods to ensure that bolts are not loose and that no damage to the mounting or the dock is apparent.Check mounting methods to ensure that bolts are not loose and that no damage to the mounting or the dock is apparent.

OBJECTIVE: Swing boom crane mounting methods.

Check mounting methods to ensure that bolts are not loose and that no damage to the mounting or the dock is apparent.

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OBJECTIVE: Review operator’s responsibilities.

Prior to a crane being used, the crane operator is responsible for conducting a basic inspection of it. The operator is also responsible for investigating other deficiencies that may be apparent.

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OBJECTIVE: Review crane components to be inspected.

Look up inside the pedestal from time to time for leaks, lubrication and condition of hoses.

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INSPECT FOR LEAKING HYDRAULIC HOSES AND CYLINDERS

INSPECT FOR LEAKING HYDRAULIC HOSES AND CYLINDERS

LeakingCylindersLeakingCylinders

Chaffed, leaking,or damagedhoses

Chaffed, leaking,or damagedhoses

OBJECTIVE: Review crane components to be inspected.Hydraulic fluid coming from the end of the boom lift cylinder is normally a result of worn seals. All leaks need to be reported to whoever is responsible for the crane. Typically, minor weeping of hydraulic fluid does not render the crane inoperable, but if fluid is dripping heavily, the crane should not be used.Hydraulic hoses are often chafed when they move back and forth over metal edges. The edges do not necessarily need to be sharp to cause chafing and eventual hose failure. Report any damage to the responsible individual. If the wire mesh below the outer rubber jacket of the hose is exposed, the hose needs to be inspected and repaired by a competent person. Any hydraulic fluid found leaking from a hose compression fitting is a sign of potential serious failure and the crane should not be used until repairs are made.Leaking hydraulic fittings need to be repaired prior to a crane being used.

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Rotation gearRotation gearRotation ringRotation ring

Mounting holesMounting holes

SealSeal

Holes spaced for uniform loadHoles spaced for uniform load

Grease fittingGrease fitting

Bearing spacerBearing spacer

Ball bearingBall bearingBearing racewayBearing raceway

ROTATION BEARINGROTATION BEARING

OBJECTIVE: Familiarization of the design of the turret rotation bearing.1. Point out how the balls are what keeps the inner and outer races together.2. Allowable wear for most 3/4” balls is .055 inches. Need to check with the manufacturer for specific specifications.3. Note importance of proper lubrication.4. Wear can be identified by rocking the boom up and down when positioned in its most vertical position.

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WINCHWINCH

OBJECTIVE: Review causes of damaged wire rope.Before operating a crane and during operation, the winch should be inspected to ensure that the wire rope is smoothly wrapping onto the winch drum. If re-spooling is necessary, raise the boom up high and lower the hook until the improperly spooled area is cleared. Then raise the hook and monitor the winch to verify proper spooling. The primary cause of loose and uneven wraps of wire rope on a winch drum is continuing to unwind the winch after the load has been set down. When lowering a load, stop paying out the wire rope as soon as the line becomes slack. If the hook must be placed on the ground, lower the hook to the ground, stopping just before the hook touches it. Continue to lower the hook with a boom down function. Boom functions are not possible for swinging boom cranes.

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BOOMBOOM

OBJECTIVE: Use this slide to discuss the parts of the crane that have not been covered yet.1. All welds need to be checked for cracks.2. The boom needs to be extended and check for smoothness of operation. Any binding or difficulty in extending could be the result of damaged boom sections.3. Any hydraulic leaks need to be investigated and repaired. Check the hoses for chaffing and damage.4. The slide pads can be checked for proper alignment by extending the boom completely and lowering the tip toward the ground. Move the boom tip back and forth by pushing on it and observing how much the boom sections move inside each other. Excessive movement will require the slide pads to be adjusted or replaced.5. The boom tip needs to be checked to deformation and twisting.

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WORN GROVESWORN GROVES PROPER SIZE GROVEPROPER SIZE GROVE

CHECK FLANGES FORCHIPS, CRACKS, WEARCHECK FLANGES FORCHIPS, CRACKS, WEAR

CHECK BEARINGS FORWOBBLE, GREASE, EASEOF ROTATION

CHECK BEARINGS FORWOBBLE, GREASE, EASEOF ROTATION

MEASURE GROOVEMEASURE GROOVE

INSPECTING SHEAVESINSPECTING SHEAVES

CHECK GROOVE

WEAR

CHECK GROOVE

WEAR

150ºCONTACT

150ºCONTACT

OBJECTIVE: Review the inspection of the sheaves.

1. Check for bearing wear and lubrication.2. Check the flanges and treads.3. Show how to use a sheave gauge.4. Sheaves can only be repaired per manufacture’s procedures.

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HOOK INSPECTIONHOOK INSPECTIONWear & DeformationWear & Deformation

“Opening Up”“Opening Up”

Wear & CracksWear & Cracks

Cracks & TwistingCracks & Twisting

☯Wear☯ Deformation☯ Cracks & Sharp Nicks☯ Modifications☯ Safety Latches☯ Swivel Wear & Lubrication☯ Hook Shackle Mousing

☯Wear☯ Deformation☯ Cracks & Sharp Nicks☯ Modifications☯ Safety Latches☯ Swivel Wear & Lubrication☯ Hook Shackle Mousing

CHECK FOR:CHECK FOR:

Self-closinghookSelf-closinghook Standard safety latch hookStandard safety latch hook

OBJECTIVE: Review hook requirements.Most pedestal cranes are fitted with one of the above types of hooks.

The safety latch type of hook is equipped with a flapper that is spring loaded and keeps the latch closed. Latches are often damaged or missing. If a latch is missing or deformed, or the spring is missing, the hook is not to be used. The mouth of a hook should not be sprung open, deformed or bent.Any damage identified should be reported to the person responsible for the crane.

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• Wear• Deformation• Cracks & Sharp Nicks• Modifications• Safety Latches• Swivel Wear & Lubrication• Hook Shackle Mousing

• Wear• Deformation• Cracks & Sharp Nicks• Modifications• Safety Latches• Swivel Wear & Lubrication• Hook Shackle Mousing

HOOK INSPECTIONHOOK INSPECTION

Check for:Check for:

Self-closing hookSelf-closing hook

OBJECTIVE: Review hook requirements.

The self-closing type allows the hook to be opened with one hand. The spring loaded thumb latch should work freely, and the spring should lock the latch to prevent the hook from opening. Hooks with broken springs and latches should not be used. Worn hinge and latch components should not allow a hook to be opened more than a ¼ of an inch. A hook should not be used if it is bent, twisted or shows any other sign of damage.

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WIRE ROPE INSPECTIONWIRE ROPE INSPECTION

Heavy loads over small sheavesHeavy loads over small sheaves

Accentuated with heavy loadsAccentuated with heavy loads

STRAND KNICKINGSTRAND KNICKING

FATIGUE FAILUREFATIGUE FAILURE

Repeated bending, normal loadsRepeated bending, normal loads

FATIGUE BREAKSFATIGUE BREAKS

OBJECTIVES: How to identify different types of wire rope problems.1. Note the differences between fatigue “failures” and fatigue “breaks”.2. Kinked rope is common on small cranes because of over running the wire rope when

winching down.3. Refer to information sheet on this.

.

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Improper socketing, kinksImproper socketing, kinks

Sudden tension releaseSudden tension release

HIGH STRANDHIGH STRAND

BIRDCAGEBIRDCAGE

WIRE ROPE INSPECTIONWIRE ROPE INSPECTION

Crossed lines on drumCrossed lines on drum

KINKED WIRE ROPEKINKED WIRE ROPE

OBJECTIVES: How to identify different types of wire rope problems.Wire rope should be inspected for damage prior to operating a crane. Crushing is the primary cause of wire rope damage on cranes. The main cause of crushed wire rope is lifting loads when the rope is crossed over itself on the winch drum. This type of damage can be eliminated by keeping the wire rope spooled correctly at all times.Improper spooling can also cause broken wires in strands. Any broken wires found during inspection need to be reported to whoever is the responsible for the crane.Wire rope that has been kinked, crushed or shows other signs of damage needs to be evaluated by a competent person before it is used.

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CRANE CONTROLSCRANE CONTROLS

Crane controls need to function smoothly and without excessive play in the control linkage. All controls need to be properly labeled including function and direction of motion.

Crane controls need to function smoothly and without excessive play in the control linkage. All controls need to be properly labeled including function and direction of motion.

OBJECTIVES: Inspection of crane controls.

Before picking a load with a crane, test each of the crane controls to verify that all are operating correctly and smoothly. Each control is required to have a label indicating its function and the direction of motion for that function. When inspecting controls, make sure that all lever pins are securely fastened.

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ELECTRICAL CONTROLSELECTRICAL CONTROLS

OBJECTIVES: Inspection of crane controls.The electrical controls for a winch on a swinging boom crane need to be free of damage, and the up / down control labels need to be legible. The electrical cable entering the control housing needs to be free of chafing and properly sealed to prevent water from entering the unit

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STATIONARY

LOAD STOPPED

STATIC LOADSTATIC LOAD DYNAMIC LOADDYNAMIC LOAD

DIR

ECTI

ON

OF

MO

VEM

ENT

DIR

ECTI

ON

OF

MO

VEM

ENT

Total Load = Static Load + Dynamic LoadTotal Load = Static Load + Dynamic Load

DYNAMIC LOADDYNAMIC LOAD

OBJECTIVE: To show how the stress on the crane can increase by the movement of the load.How fast the load motion is started or stopped determines how much more dynamic loading will take place.When starting to lift a load, the crane must exert additional energy to put the load in motion. The amount of additional energy is dependent on how fast the load is accelerated. Fast acceleration will require a significant more effort than slow acceleration.Stopping a load that is in motion also requires additional energy. Sudden stops can place significant stresses on the crane which can result in structural failure.

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Net Load Net Load

RiggingRigging

Gross Load = Net Load + Rigging + AttachmentsGross Load = Net Load + Rigging + Attachments

GROSS LOADGROSS LOAD

OBJECTIVE: How to determine gross load.1. Include the weight of blocks, hook, overhaul weights.2. All rigging must be included.3.Load is considered to be anything below the tip of the boom.For all cranes, the gross load is considered to be anything hanging from the boom tip. This includes the weight of the wire rope, hook, slings, lifting hardware and the load itself. For most dock cranes, the weight of the hook and wire rope are not significant enough to affect the overall capacity of the crane. These can therefore be excluded from the gross load calculation. Other attachments used to lift the load should be included in determining the gross load.

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AVOID SIDE LOADING

AVOID SIDE LOADING

SIDE LOADINGSIDE LOADING

OBJECTIVES: Review improper uses of cranes.Cranes are designed to move loads vertically up and down. When a load is dragged by swinging the boom, extensive stress is applied to the boom, turret and swing drive components. This results in severe wear and eventual crane failure. At no time should the crane be used to drag any load in any direction.Side loading of a crane can also occur when lifting a large object in high winds. This practice should be avoided to prevent crane side loading and creating unsafe load handling conditions.

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SIDE LOADINGSIDE LOADINGThis practice puts tremendous strain on the pinion gear of the swing motor

This practice puts tremendous strain on the pinion gear of the swing motor

Dragging or yarding a load sideways could seriously damage the crane

Dragging or yarding a load sideways could seriously damage the crane

OBJECTIVES: Review improper uses of cranes.

Never intentionally side load the crane by yarding or dragging a load on the ground. This could seriously damage the boom or swing mechanisms on the crane. Knuckle booms are particularly susceptible to damage from this practice. This puts tremendous strain on the pinion gear of the swing motor which over time could fail.

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DETERMINING LIFTING CAPABILITYDETERMINING LIFTING CAPABILITY

• Calculate the gross load

• Determine the maximum radius

• Determine the maximum height

• Refer to load chart to determine if liftwill be within the crane’s capacity.

• Calculate the gross load

• Determine the maximum radius

• Determine the maximum height

• Refer to load chart to determine if liftwill be within the crane’s capacity.

OBJECTIVE: Review the steps in determining lift capability.The lift capacity of a crane is dependent on several factors. The maximum load that a crane can lift is often limited by the safe working capacity of its wire rope. Cranes used in maritime applications use a 5:1 safety factor for the wire rope. Therefore, a wire rope with breaking strength of 25,000 lbs. has a maximum safe working capacity of 5,000 lbs. Regardless of the lift capacity shown on a crane’s load chart, the maximum that the crane can safely pick will be the safe working capacity of the wire rope.

The radius, or distance a load is from the crane, also affects the crane’s lift capacity.With these pieces of information, the load chart can be consulted.

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LOAD CHARTSLOAD CHARTS

OBJECTIVES: Review the use of the load capacity chart.A load capacity chart is used to determine the maximum capacity of a crane for a given crane setup.Load capacity charts for telescopic cranes have two sections: One for boom retracted, and one for boom extended. When the boom is fully retracted, use the Boom Retracted portion of the load capacity chart. When the boom is extended, regardless of how far it is extended, use the portion of the chart titled, Boom Extended.Knowing either the boom angle as read from the boom angle indicator or knowing the distance from the crane to the load or radius, the maximum allowed lift capacity can be determined.If the measured boom angle or radius falls between given values on the load chart, the capacity is limited to the lower of the two given values.

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ASSESSING THE LIFTING REQUIREMENTS ASSESSING THE LIFTING REQUIREMENTS

The Big PictureThe Big Picture

Load

OBJECTIVE: To emphasize the importance in understanding all the elements of the lift.1. Note all obstructions.2. Need to limit access to the area of the lift and placement.3. Restrict the movement of vehicles and personnel through the lift area.4. Note location of the power lines.5. Evaluate the load.6. How long can the area be closed.

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ASSESSING THE LOADASSESSING THE LOAD

Need to Know:• Weight• Size• Center of Gravity

Need to Know:• Weight• Size• Center of Gravity

OBJECTIVE: To understand the importance of knowing the nature of load.1. Weights are often unknown or inaccurate.2. The size and shape of the load needs to be assessed to determine rigging and crane requirements.3. The center of gravity is often unknown but directly affects the stability of the load.4. Assessing the load will be covered in more detail further on during the training.

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RIGGING REQUIREMENTSRIGGING REQUIREMENTS

• Slings• Chains• Eyes• Special Hardware

• Slings• Chains• Eyes• Special Hardware

OBJECTIVE: To emphasize that the load needs to be properly rigged before attempting a lift.1. Determining how the load will be rigged is essential for a safe lift.2. The selection of the type of hardware is dependent on the load and were it is going.3. Rigging needs to be selected to prevent damage to the load and the lifting hardware.

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ASSESSING THE ‘PICK’ AREAASSESSING THE ‘PICK’ AREA

• Obstruction• Visibility• Personnel Safety• Pedestrians• Load Free to Pick• Height of Lift• Reach• Tag Line Required

• Obstruction• Visibility• Personnel Safety• Pedestrians• Load Free to Pick• Height of Lift• Reach• Tag Line Required

OBJECTIVE: To illustrate the importance in evaluating where the load will be picked.1. Everything needs to be considered prior to starting the lift.2. Allow sufficient time to preparing for and make the lift.3. The crane operator and the riggers need to confer on difficult lifts.

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ASSESSING THE ‘PLACEMENT’ AREAASSESSING THE ‘PLACEMENT’ AREA

• Obstruction• Visibility• Personnel Safety• Pedestrians• Load Support• Height of Lift• Reach• Accuracy of Placement

• Obstruction• Visibility• Personnel Safety• Pedestrians• Load Support• Height of Lift• Reach• Accuracy of Placement

OBJECTIVE: To emphasize the importance in checking out the placement area.1. Assess the placement area to assure that the load can be safety moved into place and set.2. Review each point on the slide and give examples as appropriate.

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HAND SIGNALSHAND SIGNALS

SWINGSWING STOPSTOP DOG EVERYTHINGDOG EVERYTHING

FLOAT INFLOAT IN KNUCKLEKNUCKLE FLOAT OUTFLOAT OUT

TELESCOPE INTELESCOPE INTELESCOPE OUTTELESCOPE OUTWIRE UPWIRE UPWIRE DOWNWIRE DOWNWIRE UPWIRE UPWIRE DOWNWIRE DOWN

BOOM UPBOOM UP BOOM DOWNBOOM DOWN TELESCOPE INTELESCOPE IN TELESCOPE OUTTELESCOPE OUT EMERGENCY STOPEMERGENCY STOP

SLOWLYSLOWLY ONE HANDONE HAND

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Wire Down Wire Down


The “wire down” signal is made by pointing your index finger down and moving it in a wide circular motion. Remember, the crane operator needs to be able to distinguish between all of the different hand signals. Often you will see a signal person point his hand down and rub his fingers together like he a chef season some some hot dish in the skillet. If he has a glove on and the lighting is not optimal it would be very difficult to know that he wanted you to wire down.

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Wire Down Slowly Wire Down Slowly


The “wire down slowly” signal is made by pointing your index finger down and moving it in a wide circular motion above the palm of your other hand.Again, the signal is clear and can be seen from a distance.

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Wire Up Wire Up


The “wire up” signal is made by pointing your index finger up and moving it in a wide circular motion.

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Wire Up Slowly Wire Up Slowly


The “wire up slowly” signal is made by pointing your index finger up and moving it in a wide circular motion below the palm of your other hand.

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Boom Up Boom Up


The “boom up” sign is given by extending your arm with the fingers in and the thumb pointing up.

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Boom Down Boom Down


The “boom down” sign is given by extending your arm with the fingers in and the thumb pointing down.

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Swing Boom Swing Boom


The sign for “swing” is given be pointing with one or both arms in the direction you want the load to travel. Be sure to keep your thumb tucked so as not to look like you want the operator to boom up.

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Knuckle Boom Knuckle Boom


On knuckle cranes, you may need to show which boom you want to have moved up.

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Telescope in Telescope in


The sign for “telescope in” is holding both hands out with thumbs pointing in. This sign can also be used on non-telescopic knuckle cranes for “knuckle in”.In essence it does the same thing. It moves the load toward the operator.

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Telescope Out Telescope Out


The sign for “telescope out” is holding both hands out with thumbs pointing out. This sign can also be used on non-telescopic knuckle cranes for “knuckle out”.In essence it does the same thing. It moves the load away from the operator.

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Telescope Out (One Hand) Telescope Out (One Hand) Telescope In (One Hand) Telescope In (One Hand)


This is the sign for signaling riggers that only have one hand free because they are active in controlling the load with the other hand. The sign is made by pointing the thumb in the direction you want the boom to telescope. To “telescope in” you would point your thumb toward the operator and to “telescope out” you would point your thumb toward yourself.

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Stop Stop


The stop is given by extending your arm and bringing it across your body in one quick motion. (It is not recommended that your use the common stop signal of clinching your hand and raising it above your head. This is not an easy signal to see a far distances or dim lighting.)

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Emergency Stop Emergency Stop


The “emergency stop” signal is given by crossing your arms in front of your and bringing them out to your sides. This can be done several times in succession until the operator does indeed stop. This signal is internationally know and can be given by anyone who might notice something amiss. Do not use this signal for your normal stop signal.

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Dog Everything Dog Everything


The ‘dog everything’ hand signal means for the operator to not perform any operation until the signal person gives the next signal.

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Boom Up, Wire Down (Float Load In) Boom Up, Wire Down (Float Load In)


This signal is a two-in-one signal basically telling the operator to float the load in or towards the operator. This can be done by booming up and wiring down at the same time. It can also be accomplished by telescoping in and wiring up.

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Boom Down, Wire Up (Float Load Out) Boom Down, Wire Up (Float Load Out)


This signal is a two-in-one signal basically telling the operator to float the load out or towards the signal giver. This can be done by booming down and wiring up at the simultaneously. It can also be accomplished by telescoping out and wiring down simultaneously.

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MAKING THE LIFTMAKING THE LIFT

Review the lift scenario with the operator, riggers and signal personAttach taglines when necessaryPosition signal person within visibility of the load and operatorBegin by lifting the load slowly Re-check the boom angle indicator to assess radius increase Keep load as low as possible when moving itSwing slowly to avoid swing out.Avoid erratic boomingFollow signal and stop operation when uncertainLower load slowly

Review the lift scenario with the operator, riggers and signal personAttach taglines when necessaryPosition signal person within visibility of the load and operatorBegin by lifting the load slowly Re-check the boom angle indicator to assess radius increase Keep load as low as possible when moving itSwing slowly to avoid swing out.Avoid erratic boomingFollow signal and stop operation when uncertainLower load slowly

OBJECTIVE: Review the basics of making a safe lift.1. Discuss each item with examples.2. Ask participants to add any additional items to the list.

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CRANE SAFETYCRANE SAFETY

Avoid two-blocking the craneDo not leave the crane with a suspended loadRig the crane with sufficient parts of line for the loadAlways have a minimum of three wraps of cable on the drumMonitor the winch to make sure the it is spooling correctingDo not lift loads over personnelLift one load at a time

Avoid two-blocking the craneDo not leave the crane with a suspended loadRig the crane with sufficient parts of line for the loadAlways have a minimum of three wraps of cable on the drumMonitor the winch to make sure the it is spooling correctingDo not lift loads over personnelLift one load at a time

OBJECTIVE: To review the basics of crane safety.1. Review each item and have the class comment on each.2. Ask participants for any additional items that could be added to the list.

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WIRE ROPE SLING INSPECTIONWIRE ROPE SLING INSPECTION

OBJECTIVE: To discuss the inspection of wire rope slings.1. The inspection criteria for wire rope applies to slings.2. Use a sling as an example to discuss the areas to inspect.

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Example of wire rope sling capacity tag

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CHAIN SLING INSPECTIONCHAIN SLING INSPECTION

OBJECTIVE: To discuss how to inspect chain slings.1. Chain length should be recorded when the chain is new and then subsequent measurements will disclosed stretch due to over loading.2. Review the various causes for chains being removed from service.

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SLING INSPECTIONSLING INSPECTION

CUTSLING

CUTSLING

CHAFFED SLINGCHAFFED SLING PUNCTURED SLINGPUNCTURED SLING

OBJECTIVES: Inspecting synthetic slings for damage.

This page and the next two pages show different types of damage for which synthetic flat slings should be removed from service. These slings need to be inspected prior to each use

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KNOTSIN

SLING

KNOTSIN

SLING

WELD SPLATTER DAMAGEWELD SPLATTER DAMAGE HEAT DAMAGEHEAT DAMAGE

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ILLEGIBLE DATA TAGILLEGIBLE DATA TAG

BROKEN STITCHESBROKEN STITCHES EXPOSED RED YARNSEXPOSED RED YARNS

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DEFORMATIONDEFORMATION BOLT SUBSTITUTIONBOLT SUBSTITUTION WEARWEAR

SHACKLESSHACKLES

PIN WITH COTTER(NOT LEGAL FOR LIFTING)

PIN WITH COTTER(NOT LEGAL FOR LIFTING)

ANCHOR BOLTANCHOR BOLTSCREW PINSCREW PIN

OBJECTIVE: Discuss basic design and inspection of shackles.1. Use only load rated shackles.2. Review the examples on the slide for inspecting the shackles.

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Side Loading Reduction ChartFor Screw Pin & Bolt Type Shackles Only†

Side Loading Reduction ChartFor Screw Pin & Bolt Type Shackles Only†

0° In-Line0° In-Line

45° from In-Line45° from In-Line

90° from In-Line90° from In-Line

100% of Rated Working Load Limit100% of Rated Working Load Limit



Angle of Side LoadAngle of Side Load Adjusted Working Load LimitAdjusted Working Load Limit

† DO NOT SIDE LOAD ROUND PIN SHACKLES† DO NOT SIDE LOAD ROUND PIN SHACKLES

SHACKLESSHACKLES

IN-LINEIN-LINE45 DEGREES45 DEGREES

90 DEGREES90 DEGREES

OBJECTIVE: Show the proper load attachment to shackles and reductions that need to be considered.1. Use a shackle to demonstrate the points made in the slide.2. Review the side loading reduction chart.3. Discuss where slings and hooks should be attached to the shackles.4. Point out the potential ways the pin can be unscrewed by the load and how to avoid it.

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LOAD

Shackles symmetrically loaded with two leg slings having a maximum included angle of 120 deg. can utilized to full Working Load Limit.

Shackles symmetrically loaded with two leg slings having a maximum included angle of 120 deg. can utilized to full Working Load Limit.

SHACKLESSHACKLES

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EYE BOLTSEYE BOLTS

DIRECTION OF PULLDIRECTION OF PULL ADJUSTED WORKING LOADADJUSTED WORKING LOAD

In-LineIn-Line

45 Degrees45 Degrees

60 Degrees60 Degrees

Full Rated Working LoadFull Rated Working Load

30% of Rated Working Load30% of Rated Working Load

25% of Rated Working Load25% of Rated Working Load

SHOULDEREDSHOULDERED

UNSHOULDEREDUNSHOULDERED

OBJECTIVE: Discuss the proper use of eyebolts.

Unshouldered eyebolts are to be used only for pulls inline with the shank of the bolt. They are not designed for angular pulls which could result in failure.Shouldered eyebolts may be used in angular pulls as long as the pull is in line with the plane of the eye. Angular pulls result in a significant reduction of the eyebolts capacity.Review the load reduction chart for shouldered eyebolts.Proper seating and the pull directions limits its capacity.

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SLING ANGLESSLING ANGLES

Stresses in the slings and the load increase as the sling angle decreasesStresses in the slings and the load increase as the sling angle decreases

OIBJECTIVE: To show how the stresses in the load and the slings increase as the sling angle decreases.When the sling angle decreases, the stress in the slings will increase. Also, the stress imposed on the load referred to as compression loading will increase significantly. The load has to be sufficiently strong enough to resist this loading or crushing may occur.

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1000 lbs10

00 lb

s

1000 lbs

500

lbs

500

lbs

1000 lbs

575

lbs 575 lbs

1000 lbs

705 l

bs

705 lbs

1000 lbs

1000 lbs 1000 lbs

1000 lbs

5735 lbs5735 lbs


5°

60°

45° 30°

OBJECTIVE: To demonstrate how the load in the slings increases as the sling angle decreases.Ideal sling angle is 60 degrees. This minimizes the stress on the slings and the load itself.A 60 degree sling angle exist if the distance between the pick points is equal to the length of the slings being used to make the lift.Note how the stress increases as the sling angle decreases. For each degree decrease in the sling angle, the stress increase much more rapidly.

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1000 lbs1000 lbs 1000 lbs1000 lbs 1000 lbs1000 lbs

500

lbs

500

lbs

500

lbs

500

lbs

AA

Factor ofAngle “A”Factor ofAngle “A”

Load in each slingleg = 500 x Load Angle Factor

Load in each slingleg = 500 x Load Angle Factor

HH

L

AA

Sling Angle Degree (A)Sling Angle Degree (A) Load Angle Factor = L/HLoad Angle Factor = L/H90906060505045453030

1.0001.0001.1551.1551.3051.3051.4141.4142.0002.000

Load On Each Leg Of Sling = (Load / 2) X Load Angle FactorLoad On Each Leg Of Sling = (Load / 2) X Load Angle Factor


OBJECTIVE: To show how the sling angle affects the stress on the sling.1. These formulas only work when the sling legs are the same length.2. Show how to do the calculations by completing a few examples.

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LOADING PALLETSLOADING PALLETS

SAFE TO MOVESAFE TO MOVEUNSAFE TO MOVEUNSAFE TO MOVE

OBJECTIVES: Review the importance of proper palletizing the load.

Loads that are to be lifted by a crane need to be properly prepared for the lift and lifted correctly.Prior to lifting a load, the operator is responsible for ensuring that the load is secure and will not fail during the lift.Cargo placed on pallets needs to be properly secured. Loose items need to be fastened to a pallet to prevent them from falling.Heavy items should be placed at the bottom of the load and as close to the center as possible.

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STACKING PRODUCTSTACKING PRODUCT

LOOSE PACKAGESNEED TO BE SECURED BEFOREMOVING.

LOOSE PACKAGESNEED TO BE SECURED BEFOREMOVING.

OBJECTIVES: Review proper handling of cargo.

Boxes of frozen product can become slippery, as frost forms on the boxes when exposed to warmer moist air. A stable load in the freezer hold may become unstable when it is hoisted onto a dock.

70


PROPER STACKING METHODSPROPER STACKING METHODS

For proper stacking of boxes, edges of

an upper layer should not be over the

lower edges.

For proper stacking of boxes, edges of

an upper layer should not be over the

lower edges.


Boxes stacked on pallets need to be placed so that upper boxes help to lock the lower ones in place. This is done by placing boxes so that the edges between the upper layers are not directly above the edges of boxes on lower layers. The above diagrams show various ways to properly stack boxes on pallets.

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UNSAFE STACKING METHODUNSAFE STACKING METHOD

Avoid having boxedges line up from layer to layer

Avoid having boxedges line up from layer to layer


Box edges from layer to layer should not line up. When they do line up as shown above, the layers are not locked together and the whole load can fall from the pallet when moved.

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CARGO NETSCARGO NETS


Cargo nets are used to handle loads of various sizes. Like other load handling equipment, these need to be load rated. The Safe Working Load needs to be on the cargo net indicating how much weight it can hold. Prior to use, the net needs to be inspected. If any defects are found, the net should be removed from service.

73


CARGO NETSCARGO NETS

PROPERLY LOADEDPROPERLY LOADED OVERLOADEDOVERLOADED


Cargo nets need to be properly loaded to avoid losing a load. The sides of the net should be higher than the cargo being lifted. When lifting a load, make sure that the net does not snag on anything.

74


PALLET BARSPALLET BARS

Inspect pallet bars for damagedbars, wire rope, synthetic rope, and hardware.

Inspect pallet bars for damagedbars, wire rope, synthetic rope, and hardware.


Pallet bars are used to lift pallets of cargo to and from vessels. Prior to use, these bars need to be inspected for damage. Any discrepancies found need to be corrected or the hardware removed from service. Pallet bars also need to be load rated and this load capacity designation needs to be on the pallet bar set.

75


LIFTING GAS CYLINDERSLIFTING GAS CYLINDERSNEVER lift gas cylinders bythe valve or valve protection housing. Cylinders should belashed onto a pallet or liftedby cylinder cages.

NEVER lift gas cylinders bythe valve or valve protection housing. Cylinders should belashed onto a pallet or liftedby cylinder cages.


Special care needs to be taken when handling gas cylinders. NEVER lift a gas cylinder by the valve or valve protection housing. Gas cylinders can be lashed to pallets or placed in cargo nets or there are special gas cylinder cages and bags designed for lifting cylinders.

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PLACING CARGO ON DECKPLACING CARGO ON DECK

Cramped spaceon vessel deckscan make cargo handling dangerous.

Cramped spaceon vessel deckscan make cargo handling dangerous.


When placing cargo on the deck of a vessel, the crane operator needs to be aware of where people are and stop an operation if any person gets himself into a dangerous place.No individual should attempt to stop cargo that is swinging. The crane operator is responsible for controlling the load and keeping it from swinging. Tag lines should be used to help control a load rather than any person coming in contact with the load.

77


HANDLING BULKY LOADSHANDLING BULKY LOADS

Bulky loads shouldbe broken down andlifted as individual items.

Bulky loads shouldbe broken down andlifted as individual items.


Lifting bulky loads should not be attempted, all at one time if there is any doubt about safety. Rather, break the load apart if necessary and lift the parts individually. This will ensure a safe lift.

Documents

Pedestal Crane Training, Dock and Vessel Mounted seriestraining series dock and vessel mounted cranedock and vessel mounted crane pedestal mounted crane inspection ... dock and vessel