MOBILE CRANE INSPECTION & SAFETY ASPECTS

MOBILE CRANE INSPECTION & SAFETY ASPECTS Speaker Introduction Name : Beniel R. Suresh Kumar Senior Inspection Engineer Consolidated Contractors Co. ...
Author: Martha Ball
8 downloads 2 Views 14MB Size
MOBILE CRANE INSPECTION & SAFETY ASPECTS

Speaker Introduction Name : Beniel R. Suresh Kumar Senior Inspection Engineer Consolidated Contractors Co. Heavy Lift Department [HLD] – Abu Dhabi – U.A.E. Bachelor of Engineering (Mechanical) Anna University - Chennai Tamil Nadu - India Industry work experience: 28 yrs.

Consolidated Contractors Company (www.ccc.gr)

2

Consolidated Contractors Company HEAVY LIFT DEPARTMENT [HLD]

Consolidated Contractors Company (www.ccc.gr)

3

HEAVY LIFT DEPARTMENT • CCC has been involved in the heavy lift business since 1980 empowered by a professional team consisting of Engineers, draftsmen, specialists and supervisors dedicated for this critical operation and following Company Safety and Quality standards. • The Heavy Lift Department provides the following services: • Heavy Lift Feed Study • Heavy Lift turnkey project • Heavy Lift Execution • Heavy Lift Consultation • Heavy Lift Management • Heavy Lift Engineering

• CCC owns over 875 cranes with a capacity ranging from 1600 to 8 tons.

Consolidated Contractors Company (www.ccc.gr)

HEAVY LIFT DEPARTMENT TYPE

CAPACITY

NO.

DEMAG CC 8800-1

Crawler

1,600 T

1

DEMAG CC 2500-1

Crawler

500 T

2

DEMAG CC 2200

Crawler

350 T

1

DEMAG CC 1800-1

Crawler

300 T

2

DEMAG AC 350

Truck Mounted

350 T

2

DEMAG CC 1500

Crawler

275 T

1

Consolidated Contractors Company (www.ccc.gr)

CCC Heavy Lift Department employ years of experience along with the latest software‘s for studying, designing, and creating all kinds of solutions through any phase of a project in order to execute the job in a safely and timed manner and provide the client with:

    

Constructability plan including any holdup required. Transportation Plans. Method statements and risk assessment plans. 3D / detailed lifting plans. Ground preparation requirement as per proposed cranes.

Consolidated Contractors Company (www.ccc.gr)

CCC records in Heavy Lifts ROP Project – K.S.A The Heaviest Lift Installation of 2 nos. Rectifiers 1,803T [73.99mtr length x 10.28mtr dia.] and 1,748T [72.2mtr length x 10.28mtr dia.] respectively utilizing MSG-80 as main crane and LR1800 as tail crane.

Consolidated Contractors Company (www.ccc.gr)

CCC records in Heavy Lifts QGX PROJECT – QATAR The Highest Flare Stack Erected 200mtr high Derrick Flare Stack 28-FL8401 using Demag CC8800.

Consolidated Contractors Company (www.ccc.gr)

Cranes

Consolidated Contractors Company (www.ccc.gr)

10

Contents 1. Introduction 2. International Standards and UAE Regulatory Compliance 3. Crane Accidents 4. Crane Types & Terminology 5. Crane Inspection and Importance 6. Mobile Crane Examination 7. Safe Operating Practices for Mobile Cranes 8. Conclusion

Consolidated Contractors Company (www.ccc.gr)

11

Introduction • To ensure protection of Environment, Health & Safety in the Construction sectors of United Arab Emirates and other countries in Middle East Region where Statutory examinations / Inspection of Mobile Cranes are carried out. “Lifting operations are inherently hazardous and require systematic management to avoid harm to people or damage to properties”. “Ensuring safe lifting operations with mobile cranes”.

“Any violation or gross negligence resulting in an injury to people or ending up in a fatal accident is a serious offence under the international rules and regulations”. “Since the greatest cost of a failure is the victim and their family”. Consolidated Contractors Company (www.ccc.gr)

12

Aim & Objective • To identify the hazards with regard to mobile cranes, their operations and general requirement for the safe use of cranes in accordance to international standards • To understand the basics of mobile crane, inspection, maintenance and pre-lift considerations. • To enhance the knowledge of inspection personnel through awareness and exchange of experience, to follow the best practice thus promoting a safety culture ultimately benefitting construction industry.

Consolidated Contractors Company (www.ccc.gr)

13

Our Goal • ‘’ZERO FATALITIES’’ • To achieve ‘’ZERO LOST TIME ACCIDENTS’’ • To minimize ‘’ALL DAMAGE TO PROPERTY’’ • To minimize ‘’DAMAGE TO THE ENVIRONMENT’’ AT ALL LOCATIONS • To promote AN ‘’ACCIDENT AND INJURY FREE’’ CULTURE

Consolidated Contractors Company (www.ccc.gr)

14

Compliance to International Standards & Legislations 1. 2. 3. 4.

BS 7121 DIN 15008 ASME B30.5 OSHA Construction Industry Standards (29CFR PART1926) 5. ESMA (U.A.E.)

Consolidated Contractors Company (www.ccc.gr)

15

Compliance to U.A.E. Legislations, Mandatory System requirement, Regulatory Instruments & Guidelines 1. UAE Ministerial Order No. (32) 1982 2. Abu Dhabi Emirate Environment, Health and Safety Management System, Abu Dhabi EHSMS Regulatory Framework, EHS Regulatory Instrument, Code of Practice, EHS RI –CoP 34.0 – Safe Use of Lifting Equipment and Lifting Accessories, Version 2.0, February 2012.

Consolidated Contractors Company (www.ccc.gr)

16

Compliance to U.A.E. Legislations & Standards U.A.E. Federal Accreditation Bodies: 1. ENAS = Emirates National Accreditation System, Department of Municipal Affairs, Abu Dhabi City Municipality - Emirates Authority for Standardization & Metrology Authority, ESMA 2. DAC = Dubai Accreditation Department – Dubai Municipality.

Consolidated Contractors Company (www.ccc.gr)

17

Role of Inspection personnel Competent Inspector / Examiner: a) A person appointed by the owner as required by the regulations to ensure that the test and examination is carried out. b) By reasons of his qualifications, training and experience, he is competent to carry out the test and examination;

Consolidated Contractors Company (www.ccc.gr)

18

Inspection personnel Category 1 - Engineer: a) B.Sc. Degree in Mechanical, Electrical or relevant engineering discipline from an institute of learning recognized by the relevant regulatory authority. b) Undergone appropriate training through a recognized training authority. c) Having minimum 3 years of working experience in inspection of lifting equipment.

Consolidated Contractors Company (www.ccc.gr)

19

Inspection personnel Category 2 – Engineering Technician: a) Diploma in Mechanical, Electrical or relevant engineering discipline from an institute of learning recognized by the relevant regulatory authority. b) Undergone appropriate training through a recognized training authority. c) Having minimum 5 years of working experience in the relevant engineering discipline at least 3 years of which must be related to lifting equipment.

Consolidated Contractors Company (www.ccc.gr)

20

Inspection personnel Category 3 – Others:

Personal with no formal education but with long experience in the field of inspections related to lifting equipment, subject to assessment of their competence by authorities.

Consolidated Contractors Company (www.ccc.gr)

21

Responsibilities of supervisory personnel Safety of Operation

Proceed

Lift is unsafe

Confirm safe condition

Report concerned to all associated

Correct Hazards

Consolidated Contractors Company (www.ccc.gr)

22

Safe operating practices for Mobile Cranes Cranes have the potential for accidents if safe operating practices are not followed. Safety is everyone’s concern and responsibility. It includes… 1. Operator’s responsibility 2. Signal man’s responsibility 3. Crew member’s responsibility 4. Management’s responsibility

Consolidated Contractors Company (www.ccc.gr)

23

Basic awareness 1. The characteristics, function & limitation of the model of the crane.

2. Information on the operating manual, load charts, all notes & warnings. 3. To determine the crane actual net capacity in every possible configuration. 4. Inspection & maintenance procedures to be followed in accordance with guidelines of manufacturer. 5. All the site conditions that may affect the safe operation of the crane including the presence of overhead power lines. Consolidated Contractors Company (www.ccc.gr)

24

Additional guidelines  Crane log book forms an effective tool in communicating the health of the equipment.  Log book reflects all inspection, maintenance and other work done on the crane at site.  Check whether site is properly prepared for crane operation.  Review work plan and requirement with site personnel.

 Find out the load and rigging weight and where the load is to be placed.  Check the number of parts of hoist line required is adequate or not.  Understand communication signals.  Ensure crane is operated in a smooth, controlled and safe manner.  Selection of the crane should always be based on the capacity, cost and adaptability to the site. Consolidated Contractors Company (www.ccc.gr)

25

Typical Construction site

Consolidated Contractors Company (www.ccc.gr)

26

Typical Construction site

Consolidated Contractors Company (www.ccc.gr)

27

Power Generation

Consolidated Contractors Company (www.ccc.gr)

28

Gas Turbine Generators

Consolidated Contractors Company (www.ccc.gr)

29

Utilities

Consolidated Contractors Company (www.ccc.gr)

30

WONDER !!!! HOW YOU CAN AVOID !!! “We operate the way we train “

Consolidated Contractors Company (www.ccc.gr)

31

WONDER !!!! HOW YOU CAN AVOID !!!

‘’ You don’t know what you don’t know until you find out you didn’t know it’’ Consolidated Contractors Company (www.ccc.gr)

32

Crane Accident

Consolidated Contractors Company (www.ccc.gr)

33

Crane Accident

Consolidated Contractors Company (www.ccc.gr)

34

Crane Accident

Consolidated Contractors Company (www.ccc.gr)

35

Crane Accident

Consolidated Contractors Company (www.ccc.gr)

36

Crane Accident

Consolidated Contractors Company (www.ccc.gr)

37

Crane Accident

Consolidated Contractors Company (www.ccc.gr)

38

Crane Accident

Consolidated Contractors Company (www.ccc.gr)

39

Crane Accident

Consolidated Contractors Company (www.ccc.gr)

40

Crane Accident

Consolidated Contractors Company (www.ccc.gr)

41

Crane – The Bird • Common name for a family of birds • Having long legs and long necks • Notable for their elaborate courtship dances

Consolidated Contractors Company (www.ccc.gr)

42

Crane - The Machine • It is an equipment designed to lift both vertically and horizontally , transport and position / land a load • Capacity ranges from few ton to several hundred tonnes • Motive power : Diesel/ Hydraulic / Electrical

Consolidated Contractors Company (www.ccc.gr)

43

Principles of Operation 1. 2. 3. 4. 5. 6. 7. 8.

Center Of Gravity Stability vs Instability Effects of location of tipping axis on stability & capacity Forward stability Backward stability Structure failure Wire rope safety factors Effects of overloading

Consolidated Contractors Company (www.ccc.gr)

44

The Lever and Fulcrum

All cranes use levers and fulcrums Consolidated Contractors Company (www.ccc.gr)

45

Cranes and Behaviour     

Don’t treat lifts casually Think and plan ahead Appoint one supervisor Standardize signals – given only by the supervisor Principles – right crane for the job – test certificates in date – safe load indicator working – competent operator – all hazards visible to operator

Consolidated Contractors Company (www.ccc.gr)

46

Safe Working Load (SWL) A calculated, design approved and certified maximum load, normally specified in Kilograms (kgs) or Tons, up to which, an item of “Lifting Equipment” is safe to operate.

Consolidated Contractors Company (www.ccc.gr)

47

Working Load Limit (WLL) The maximum load an item of “Lifting Equipment” is designed to raise, lower or suspend (determined by the manufacturer based on the properties of the equipment).

Consolidated Contractors Company (www.ccc.gr)

48

Center of Gravity STABLE

Hook is directly above Center of Gravity.

Consolidated Contractors Company (www.ccc.gr)

The center of gravity of an object is that point at which the object will balance. the entire weight may be considered as concentrated at this point. Any suspended object (load) will center itself directly under the hook.

49

Crane Selection The selection of the right crane for the lift, is determined by the factors listed below: 1. Length of crane boom required. 2. The maximum working radius of the crane. 3. Total load weight including the weight of the crane hook block and lifting tackle. 4. Levelness and compaction of the area where the crane is to be set up. 5. Availability of clearance for all swinging movement of the crane and the load. 6. Areas where the crane boom or load can be obstructed.

Consolidated Contractors Company (www.ccc.gr)

50

Crane Functions Telescope In & Out

Raise & Lower

Slew Left & Right Boom (Jib) Up & Down

Consolidated Contractors Company (www.ccc.gr)

51

Basic types & Configuration Rough Terrain (RT)

Truck Mounted (TM)

Crawler ( CC )

Consolidated Contractors Company (www.ccc.gr)

All Terrain (AT)

53

Rough Terrain Cranes

Consolidated Contractors Company (www.ccc.gr)

54

Rough Terrain Cranes • Suitable for off road applications in construction and industrial projects • Single cab construction • Good off road manoeuvrability in secondary roads • To be transported by means of trailers • Can not travel at highway speeds

Consolidated Contractors Company (www.ccc.gr)

55

All Terrain Cranes

Consolidated Contractors Company (www.ccc.gr)

56

All Terrain Cranes

Consolidated Contractors Company (www.ccc.gr)

57

All Terrain Cranes • Ideal for both on road and off road applications in construction and industrial projects • Double cab construction on purpose built chassis frame • Capable of travelling on both primary and secondary roads with good off road manoeuvrability • Self deployable • Can travel at highway speeds Consolidated Contractors Company (www.ccc.gr)

58

Truck Mounted Cranes

Consolidated Contractors Company (www.ccc.gr)

59

Truck Mounted Cranes • Ideal for on road applications in construction and industrial projects • Double cab construction built on truck chassis frame (for crane service ) • High capacity booms • Quick mobility and faster set up • Can travel at highway speeds Consolidated Contractors Company (www.ccc.gr)

60

Crawler Cranes

Consolidated Contractors Company (www.ccc.gr)

61

Crawler Cranes • Suitable for off road applications in construction

and industrial projects • Adjustable configurations • Ability to traverse with a load ( crawl ) if needed • Traverse at slow speed only

Consolidated Contractors Company (www.ccc.gr)

62

Crawler Mounted Telescopic Cranes

Consolidated Contractors Company (www.ccc.gr)

63

Heavy Lift Mobile Cranes

Consolidated Contractors Company (www.ccc.gr)

64

Industrial Cranes

Consolidated Contractors Company (www.ccc.gr)

65

Boom Trucks

Consolidated Contractors Company (www.ccc.gr)

66

Pick and Carry Cranes

Consolidated Contractors Company (www.ccc.gr)

67

Pick and Carry Cranes • All terrain general purpose cranes • No stabiliser required • Speedy traverse • Exceptional maneuverability in tight spaces • Normally flame proofed for use in mining industries

Consolidated Contractors Company (www.ccc.gr)

68

Cranes availability in Middle East region 1.

Industrial Cranes with telescopic boom.

2.

Rough terrain with telescopic boom.

3.

All terrain with telescopic boom.

4.

Truck mounted with telescopic boom.

5.

Crawler Lattice boom – Mechanical.

6.

Crawler Lattice boom – Hydraulic.

Consolidated Contractors Company (www.ccc.gr)

69

Crane Manufacturers

Consolidated Contractors Company (www.ccc.gr)

70

Identification of crane parts

Consolidated Contractors Company (www.ccc.gr)

71

Identification of crane parts

Consolidated Contractors Company (www.ccc.gr)

72

Crane components CAB

Boom Hoist drum Fuel tank Pump Engine

Consolidated Contractors Company (www.ccc.gr)

73

Identification of crane parts

Consolidated Contractors Company (www.ccc.gr)

74

Identification of crane parts 1. 2. 3. 4. 5. 6. 7.

Main Boom Luffing Cylinder Hoist Gear 1 Crane Operator’s Cab Crane Chassis Counterweight Hook Block and/or Hook Suspension Gear

Consolidated Contractors Company (www.ccc.gr)

75

Identification of crane parts

1. 2. 3.

Diesel Engine Hydraulic Pumps Hydraulic Oil Tank

Consolidated Contractors Company (www.ccc.gr)

76

Identification of crane parts

4. 5. 6. 7. 8. 9. 10.

Consolidated Contractors Company (www.ccc.gr)

77

Main Electrical Unit, Cab Superstructure frame Hydraulic control block Diesel tank Batteries Slew gear Roller bearing slewing rim

Types of Inspections 1.

Preventive

2.

Predictive

3.

Fluid analysis – hydraulic, engine & gear

Consolidated Contractors Company (www.ccc.gr)

78

Types of Inspections - Frequency

Annual Semi-Annual Monthly Weekly Daily

Consolidated Contractors Company (www.ccc.gr)

79

Monthly Safety Inspection of Cranes PROJECT:

INSPECTION REPORT

MONTHLY SAFETY INSPECTION OF CRANES THE FOLLOWING CRANES HAVE BEEN INSPECTED FROM THE SAFETY STANDPOINT, WITH SPECIFIC REFERENCE TO ALL WIRE ROPES, SHEAVES & ROLLERS, BOOM SECTIONS, HOOK BLOCK AND BRAKES; RESULT OF INSPECTION AND ACTION TAKEN ARE SUMMARISED BELOW PLANT NUMBER & DESCRIPTION

DATE INSPECTED

RESULT OF INSPECTION AND LIST OF DEFECTS NOTED

REMARKS:

MONTH:

PAGE ______ OF ______

ACTION TAKEN TO RECTIFY DEFECTS

SIGNED(PROJECT PLANT ENGINEER) _________________________________ DATE: ___________________________

Consolidated Contractors Company (www.ccc.gr)

80

Monthly Safety Inspection of Cranes PAGE........ REFERENCE

INSPECTION REPORT

OF

CRANE’S CRITICAL ITEMS FROM: Project Plant Engineer TO:

.......... DATE

PREPARED BY

DATE:.................................

Group Plant Manager - M.O.A.

FOLLOWING CRANES WERE CHECKED: PLANT NO.

DESCRIPTION

DATE OF INSP.

LMI



X

O

SHEAVES & ROLLERS

WIRE ROPES

*



X

O

*



X

O

*

BOOMS (INC. STOP & LACING



X

O

*

HOOK BLOCK



X

O

BRAKES

*



X

O

*

CONDITION:  = Satisfactory, X = Repair, O = Replace, * = Work Done   

Wire Ropes item to cover; main lifting rope, auxiliary lifting rope, third drum rope, boom hoist rope, pendant ropes & T.C. Trolley. Also Boom item to cover Mast Sections. Brakes item to include Swing brakes.

IN NO WAY CHECKING OF THE ABOVE MENTIONED CRITICAL ITEMS ON MONTHLY BASIS EXCLUDE THE DAILY WALK AROUND CHECKING

REMARKS: __________________________________________________________________________________

__________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ _______________________________________________________________ _________________________________ Project Plant Engineer

Consolidated Contractors Company (www.ccc.gr)

81

Monthly Safety Inspection of Cranes PLANT NO. MANUFACTURERS SERIAL NO.

INSPECTION REPORT HYDRAULIC CRANES

MAKE AND MODEL OF EQUIPMENT MAIN BOOM LENGTH /HOOK BLOCK / FALLS

CONDITION REF

PROJECT

INSPECTED BY

DATE OF INSPECTION FLY JIB LENGTH / HOOK BLOCK / FALLS

( = SATISFACTORY / X = REPAIR / O = REPLACE) COMPONENT O  X REF 

 = WORK DONE COMPONENT

1

UNDERFRAME / CHASSIS

21

OUTRIGGERS

2

ENGINE CARRIER

22

BOOM CONDITION & OPERATION

3

ENGINE SUPERSTRUCTURE

23

A-FRAME, SHEAVES & PINS

4

COOLING SYSTEM(S)

24

FLYJIB /

5

AIR INTAKE/EXHAUST SYSTEMS

25

HOOK BLOCKS

6

FUEL SYSTEM

26

HOIST DRUMS & MOTORS

7

TRANSMISSION AXLES /DIFFERENTIALS / FINAL DRIVE DRIVE SHAFTS/ PROPSHAFTS

27

ALL HOIST & WINCH CABLES

28

LMI SETTING & OPERATION

29

LMI LIMIT SWITCHES

10

SUSPENSION

30

A2B SWITCHES

11

AXLE LOCKOUTS

31

LOAD CHARTS IN CRANE

12

ROAD BRAKES

32

GREEN TAG

13

STEERING (FRONT & REAR)

33

EMERGENCY STOP CONTROL

14

UPPER FRAME / SUPERSTRUCTURE

34

15

CAB / GAUGES / CONTROLS

35

16

36 37

STATUS LIGHTS

18

GENERAL ELECTRIC SYSTEM ENGINE SAFETY / SHUT DOWN SYSTEM HYDRAULIC SYSTEM

EXTERNAL AUDIBLE ALARM SLING FOR HOOK BLOCK STOWAGE CONDITION OF CRANE LEVEL

38

FIRE EXTINGUISHERS

19

PNEUMATIC SYSTEM

39

CLEANLINESS & CONDITION

20

SWING & SWIVEL SYSTEM

40

ANY OTHER OBSERVATIONS

8 9

17

UNDERCARRIAGE / TYRES CONDITION REF

HOURS UW

LUFFER

LUBRICATION & STANDARD OF MAINTENANCE

DEFECTS FOUND

KMS

HOURS OW PROJECT PLANT ENGINEER’S INSTRUCTION

Consolidated Contractors Company (www.ccc.gr)

REF

PERCENT CONDITION PREREPAIR

POSTREPAIR

DEFECTS FOUND

DATE REPAIRS COMPLETED

GPM / FIELD SERVICES’ USE

82



X

O



Inspection requirement 1.

Visual examination

2.

Dimensional examination

3.

Functional/operational test, Overload test

4.

Open-up examination

5.

Electrical test and examination

6.

Non-destructive test

7.

Inspection methods and procedures

8.

Check list

9.

Reporting

Consolidated Contractors Company (www.ccc.gr)

83

Crane Inspection 1.

Upper machinery structure

2.

Lower machinery structure

3.

Operating controls

4.

Attachments

Consolidated Contractors Company (www.ccc.gr)

84

Upper machinery structure

Consolidated Contractors Company (www.ccc.gr)

85

Lower Structure Crawler shoe

Swing bearing

Carbody weight

Swivel joint Carbody

Adjustment link

Crawler cylinder Upper roller

Idler roller

Shoe guide

Crawler frame

Propel motor & Propel reduction unit

Lower roller

Consolidated Contractors Company (www.ccc.gr)

86

Lower machinery structure

Consolidated Contractors Company (www.ccc.gr)

87

Crane components critical items for inspection 1.

Wire ropes – hoist, boom & pendants

2.

Sheaves and rollers

3.

Boom sections and lacings

4.

Hook blocks

5.

Load moment indicators

6.

Brakes

Consolidated Contractors Company (www.ccc.gr)

88

Crane components – Wire Ropes

Consolidated Contractors Company (www.ccc.gr)

89

Crane components – Winch drive & lubrication

Consolidated Contractors Company (www.ccc.gr)

90

Crane components – Hydraulics / Filters

Consolidated Contractors Company (www.ccc.gr)

91

NDT-Non-destructive testing a) Whenever, the need for NDT examination is

identified, the inspection personnel has to ensure conductance of examination through review of the NDT reports and records. b) NDT shall be carried out by level II inspector

using one or more of the following NDT methods as deemed necessary.

Consolidated Contractors Company (www.ccc.gr)

92

NDT-Non-destructive testing methods a) Radiographic testing b) Ultrasonic testing c) Magnetic particle testing d) Liquid penetrant testing

e) Eddy current testing

Consolidated Contractors Company (www.ccc.gr)

93

Crane Assembly - Reeving Mechanical Advantage

Wrong

Consolidated Contractors Company (www.ccc.gr)

94

Correct

Crane Assembly – Reeving Mechanical Advantage

Consolidated Contractors Company (www.ccc.gr)

95

Crane assembly – Rope terminations Wedge Sockets

Right Consolidated Contractors Company (www.ccc.gr)

Wrong 96

Crane Assembly – Rope Terminations

WRONG

Consolidated Contractors Company (www.ccc.gr)

97

Crane Assembly - Hooks

Consolidated Contractors Company (www.ccc.gr)

98

Crane Assembly - Hooks Always ensure that the hook has got a Safety Latch

Consolidated Contractors Company (www.ccc.gr)

99

Swivel Hooks with Safety Latches These allow the load to be moved round without twisting and possibly endangering slings, wire ropes and chains. The safety latch ensures that the rope or chain does not slip off the hook. Consolidated Contractors Company (www.ccc.gr)

100

Crane Assembly - Sheaves

Consolidated Contractors Company (www.ccc.gr)

101

Crane Assembly – Sheaves Sheave Groove Profile Wrong

Consolidated Contractors Company (www.ccc.gr)

Wrong

102

Safety devices

Boom over hoist L/S (Final stop)

Hook over hoist L/S

Load detector Aux.

Main

Boom angle sensor

Consolidated Contractors Company (www.ccc.gr)

103

Crane Safety devices - Anti Two Blocks

Two Block Cutout

Consolidated Contractors Company (www.ccc.gr)

104

Safety Devices High Level Cut - Out: • Designed to prevent the Hook Block Assembly coming into contact with the Jib Head (ATB) Low level Cut - Out: • Normally sensed from the Winch. Stops the Winch with a Minimum of 3 Wraps (turns) of Wire remaining on the Winch Drum

Consolidated Contractors Company (www.ccc.gr)

105

Safety Devices

Consolidated Contractors Company (www.ccc.gr)

106

MANUFACTURER MAXIMUM ALLOWED WIND SPEED TEREX DEMAG AC350

UP TO 20 BOOM

15.0 M/SEC

20 - 35 BOOM

12.5 M/SEC

ABOVE 35 M BOOM

9.8 M/SEC

GROVE RT 500 SERIES UP TO 8.8 M/SEC

NO RESTRICTION

UP TO 13.3 M/SEC

USE MINIMUM BOOM LENGTH GROVE RT 700 SERIES

MIN BOOM

MAX BOOM

LIEBHER LTM 1030

14.3 M/SEC MIN BOOM 9 M/SEC MAX BOOM

LIEBHER LTM 1055

14.3 M/SEC MIN BOOM 9 M/SEC MAX BOOM

LIEBHER LTM 1100

14.3 M/SEC MIN BOOM 9 M/SEC MAX BOOM

LIEBHER LTM 1200

14.3 M/SEC MIN BOOM 9 M/SEC MAX BOOM

XUZHOU QAY 25

MAX 12.4 M/SEC

UP TO 8.8 M/SEC

NO RESTRICTION

UP TO 13.3 M/SEC

USE MINIMUM BOOM LENGTH

XUZHOU QAY 100

MAX 10.8 M/SEC

HITACHI SCX 1200

10 M/SEC

XUZHOU QAY 50

MAX 10.8 M/SEC

HITACHI SCX 700

10 M/SEC

SENEBORGEN 630M

MAX 15 M/SEC

KOBELCO CKE 1350

10 M/SEC

SENEBORGEN 583M

MAX 14 M/SEC

KOBELCO CKE 1800

10 M/SEC

TADANO GR 300 EX

MAX 10 M/SEC

KOBELCO CKE 600

10 M/SEC

TADANO TR 500 EX

MAX 10 M/SEC

TEREX DEMAG AC100

MAX 9.8 M/SEC

Consolidated Contractors Company (www.ccc.gr)

107

Crane Maintenance - Inspection failures 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Manufacturer recommendation Replacement standards Maintenance standards Lubrication Fuel Inspection schedule Genuine spare parts Inspection procedure Repair procedure Welding procedure Treatment of industrial discharges Weather conditions

Consolidated Contractors Company (www.ccc.gr)

108

Load Charts

Ensure Handbook and Chart are Ensure Handbook and Chart are with Crane with Crane Consolidated Contractors Company (www.ccc.gr)

109

Load Charts •Basic Terms and Conditions

 Boom Length and Angle  Load Radius  Range Diagram  Value of Boom Angle, Boom Length

• Determining Main Boom Capacities

• Determining Main Boom Capacities with Jibs or Boom Extensions

Consolidated Contractors Company (www.ccc.gr)

110

Crane capacities are dependent on 2 Factors

Consolidated Contractors Company (www.ccc.gr)

111

The distance from the center of rotation to the center of the load or hoist line

Radius Consolidated Contractors Company (www.ccc.gr)

112

The distance from the center pivot of the boom base to the top boom nose sheave

Consolidated Contractors Company (www.ccc.gr)

113

The angle in degrees between the boom base section and horizontal

Boom Angle

Consolidated Contractors Company (www.ccc.gr)

114

Load Charts

Consolidated Contractors Company (www.ccc.gr)

115

Load Charts

Consolidated Contractors Company (www.ccc.gr)

116

LOAD WEIGHT Do not exceed the crane rated capacity

Take the weight of the Hook block and lifting Tackles into consideration.

Consolidated Contractors Company (www.ccc.gr)

117

Load Moment Indicators

Consolidated Contractors Company (www.ccc.gr)

118

Safe Load Indicators

Consolidated Contractors Company (www.ccc.gr)

119

Crane Set-Up The machine: When travelling, the boom should be fully retracted, lowered & stowed in its travelling position. (Boom angle between 00 - 300)

Consolidated Contractors Company (www.ccc.gr)

120

Crane Set-Up

Consolidated Contractors Company (www.ccc.gr)

121

Crane Set Up

Consolidated Contractors Company (www.ccc.gr)

122

Crane Set Up • Blocking / Cribbing

Method 1: Area of Float (Outrigger Pad) M² x 3 = Blocking Area M² Method 2: Capacity of Crane (in Tonne)/50 = Blocking Area M²

Consolidated Contractors Company (www.ccc.gr)

123

Crane Set Up Do not set up too close to trenches etc., as the machine vibration can cause the walls to collapse.

Consolidated Contractors Company (www.ccc.gr)

124

Crane Set Up

Consolidated Contractors Company (www.ccc.gr)

125

Levelling the Crane

Check that Cranes are Level Consolidated Contractors Company (www.ccc.gr)

126

Failure to Level the Crane is a Common Accident Cause What can happen when you swing over the side!

Just a little side tilt when lifting a load over the rear can become dangerous when swung over the side.

Consolidated Contractors Company (www.ccc.gr)

Load radius increases swung over the side.

127

when

Levelling the Crane Possible cap. loss due to crane being out of level Capacity Lost When out of Level

Boom Length and Radius 1°





Short Boom, Minimum Radius

20 %

20 %

30 %

Short Boom, Maximum Radius

8%

15 %

20 %

Long Boom, Minimum Radius

30 %

41 %

50 %

Long Boom, Maximum radius

5%

10 %

15 %

Accurate Calculations are available from the specific, applicable Crane Manufacturers

Consolidated Contractors Company (www.ccc.gr)

128

Levelling the Crane

Crane Mats Consolidated Contractors Company (www.ccc.gr)

129

Hand Signals

Consolidated Contractors Company (www.ccc.gr)

130

The principal The principalfailures failuresofofcranes cranes Overturning

Caused by weak support, operating outside the crane’s capabilities, by striking obstructions or strong winds

Overloading

By exceeding the operating capacity or operating radii or by failure of safety devices

Collision

With other cranes, overhead cables or structures;

Support failure

Can occur due to placing of crane over cellars and drains outriggers not extended, made-up or not solid ground or failure of structural components of the crane

Operator errors

Errors from impaired or restricted visibility, poor eyesight, inadequate training

Loss of load

From failure of lifting equipment, lifting accessories or slinging procedure

Consolidated Contractors Company (www.ccc.gr)

131

Unsafe Operating Condition

Poor ground conditions are a factor in many accidents

Consolidated Contractors Company (www.ccc.gr)

132

Unsafe Operating Condition

Many Crane Accidents are Caused by Poor Blocking Under Floats

Consolidated Contractors Company (www.ccc.gr)

133

Unsafe operating condition

WRONG

Consolidated Contractors Company (www.ccc.gr)

134

Unsafe operating condition Tinted Glass

Consolidated Contractors Company (www.ccc.gr)

135

Unsafe operating condition

Consolidated Contractors Company (www.ccc.gr)

136

Unsafe Operating Condition

Consolidated Contractors Company (www.ccc.gr)

137

Failures will result in

Consolidated Contractors Company (www.ccc.gr)

138

Comparison of benefits Crane - Simulators

Consolidated Contractors Company (www.ccc.gr)

139