1.0 PURPOSE
The purpose of this procedure is to provide guidelines for Nitro Construction Services in the safe operation of floor cranes (in-house overhead cranes) during maintenance work in customer facilities.
2.0 RESPONSIBILITY
It is the responsibility of the Site Manager/Superintendent to implement the requirements of this procedure.
3.0 REFERENCES
29 CFR 1910.179
4.0 DEFINITIONS
4.1 Automatic Crane – a crane which when activated operates through a preset cycle or cycles.
4.2 Brake – a device used for retarding or stopping motion by friction or power means.
4.3 Bridge – that part of a crane consisting of girders, trucks, end ties, footwalks, and drive mechanism which carries the trolley or trolleys.
4.4 Clearance – the distance from any part of the crane to a point of the nearest obstruction.
4.5 Crane – a machine for lifting and lowering a load and moving it horizontally, with the hoisting mechanism an integral part of the machine. Cranes whether fixed or mobile are driven manually or by power.
4.6 Drum – the cylindrical member around which the ropes are wound for raising and lowering the load.
4.6 Emergency stop switch – a manually or automatically operated electric switch to cut off electric power independently of the regular operating controls.
4.7 Fail-safe – a provision designed to automatically stop or safely control any motion in which a malfunction occurs.
4.8 Floor-operated crane – a crane which is a pendant or nonconductive rope controlled by an operator on the floor or an independent platform.
4.9 Gantry Crane – a crane like an overhead crane except that the bridge for carrying the trolley is rigidly supported on two or more legs running on fixed rails or other runways.
4.10 Hoist – an apparatus which may be a part of a crane, exerting a force for lifting or lowering.
4.11 Hoist chain – the load-bearing chain in a hoist.
NOTE: Chain properties do not conform to those shown in ANSI B30.9-1971, Safety Code for Slings.
4.12 Holding brake – a brake that automatically prevents motion when power is off.
4.13 Limit switch – a switch that is operated by some part or motion of a power-driven machine or equipment to alter the electric circuit associated with the machine or equipment.
4.14 Load – the total superimposed weight on the load block or hook.
4.15 Load block – the assembly of hook or shackle, swivel, bearing, sheaves, pins, and frame suspended by the hoisting rope.
4.16 Main switch – a switch controlling the entire power supply to the crane.
4.17 Master switch – a switch which dominates the operation of contactors, relays, or other remotely operated devices.
4.18 Overhead crane – a crane with a movable bridge carrying a movable or fixed hoisting mechanism and traveling on an overhead fixed runway structure.
4.19 Power-Operated Crane – a crane whose mechanism is driven by electrical, air, hydraulic or internal combustion means.
4.20 Rated load – the maximum load for which a crane or individual hoist is designed and built by the manufacturer and shown on the equipment nameplate(s).
4.21 Rope – refers to wire rope, unless otherwise specified.
4.22 Stop – a device to limit the travel of a trolley or crane bridge. This device normally is attached to a fixed structure and normally does not have energy-absorbing ability.
4.23 Switch – a device for making, breaking, or for changing the connections in an electric circuit.
4.24 Trolley – the unit which travels on the bridge rails and carries the hoisting mechanism.
4.25 Trolley travel – the trolley movement at right angles to the crane runway.
4.26 Wall crane – a crane having a jib with or without trolley and supported from a side wall or line of columns of a building. It is a traveling type and operates on a runway attached to the sidewall or columns.
5.0 PROCEDURE
5.1 General Requirements
5.1.1 Rated load markings
5.1.1.1 The rated load of the crane shall be marked on each side of the crane, and if the crane has more than one hoisting unit, each hoist shall have its rated load marked on it or its load block and this marking shall be legible from the ground or floor.
5.1.2 Clearance from obstruction
5.1.2.1 Minimum clearance of 3 inches overhead and 2 inches laterally shall be provided and maintained between crane and obstructions.
5.1.2.2 Where passageways or walkways are provided obstructions shall not be placed so that the safety of personnel will be jeopardized by movements of the crane.
5.1.2.3 Whenever a crane is in transit with no load and boom lowered, the clearance must be a minimum of 10’ plus 0.4 inches for each kV over 50kV for energized power lines.
5.1.3 Designated personnel
5.1.3.1 Only designated personnel shall be permitted to operate a crane covered by this section.
5.2 Crane Inspections
5.2.1 Inspection procedure for cranes in regular service is divided into two general classifications based upon the intervals at which the inspection should be performed. Any deficiencies shall be carefully examined and determination made by the Supervisor as to whether they constitute a safety hazard.
5.2.1.1 Frequent inspections – Daily to monthly intervals. The following items shall be inspected for defects at intervals defined:
5.2.1.1.1 All functional operating mechanisms for maladjustment interfering with proper operation. Daily.
5.2.1.1.2 Deterioration or leakage in lines, tanks, valves, drain pumps, and other parts of air or hydraulic systems. Daily.
5.2.1.1.3 Hooks with deformation or cracks. Visual inspection daily; monthly inspection with a certification record which includes the date of inspection, the signature of the person who performed the inspection, and the serial number of the hook inspected.
5.2.1.1.4 Hoist chains, including end connections, for excessive wear, twist, distorted links interfering with proper function, or stretch beyond manufacturer’s recommendations. Visual inspection daily; monthly inspection with a certification record which includes the date of inspection, the signature of the person who performed the inspection, and an identifier of the chain which was inspected.
5.2.1.1.5 All functional operating mechanisms for excessive wear of components.
5.2.1.2 Periodic inspections – 1 to 12-month intervals. Complete inspections of the crane shall be performed at intervals defined in 5.2.1.3. These inspections shall include requirements from 5.2.1.1 above and, the following items.
5.2.1.2.1 Deformed, cracked, or corroded members.
5.2.1.2.2 Loose bolts or rivets.
5.2.1.2.3 Cracked or worn sheaves and drums.
5.2.1.2.4 Worn, cracked or distorted parts such as pins, bearings, shafts, gears, rollers, locking, and clamping devices.
5.2.1.2.5 Excessive wear on brake system parts, linings, pawls, and ratchets.
5.2.1.2.6 Load, wind, and other indicators over their full range, for any significant inaccuracies.
5.2.1.2.7 Gasoline, diesel, electric, or other powerplants for improper performance or noncompliance with applicable safety requirements.
5.2.1.2.8 Excessive wear of chain drive sprockets and excessive chain stretch.
5.2.1.2.9 Electrical apparatus, for signs of pitting or any deterioration of controller contactors, limit switches and pushbutton stations.
5.2.2 Cranes not in regular use
5.2.2.1 A crane which has been idle for one (1) month or more, but less than 6 months, shall be given an inspection conforming with the requirements of Sections 5.2.1.1 and 5.2.2.3 of this procedure.
5.2.2.2 A crane which has been idle for over 6 months shall be given a complete inspection conforming with Sections 5.2.1.1, 5.2.1.2 and 5.2.2.3 of this procedure.
5.2.2.3 All rope which has been idle for a month or more due to shut down or storage of a crane on which it is installed shall be given a thorough inspection before it is used.
5.2.2.3.1 This inspection shall be for all types of deterioration and shall be performed by an appointed person whose approval shall be required for further use of the rope.
5.2.2.3.2 A certification record shall be available for inspection which includes the date of inspection, the signature of the person who performed the inspection, and an identifier for the rope which was inspected.
5.3 Prior to Crane Access
5.3.1 The Nitro Construction Services supervisor shall check with the floor crane supervisor for any specific crane particulars; i.e. brakes, extra travel, etc.
5.3.2 Before manning the crane, all personnel shall receive instructions on this procedure, the specific job tasks, and any related hazards.
5.3.2.1 Documentation of specific job tasks and related hazards shall be accomplished through the use of the Job Safety Analysis form.
5.3.3 The crane shall be certified as safe for use as defined in Section 5.2.1 above.
5.3.4 When the crane is to be operated remotely, the Nitro Construction Services supervisor shall designate one competent person per shift as the control operator and one competent person per shift as the on-crane contact and ensure effective communications between the two (radios when possible).
5.3.5 Any malfunctions of the crane shall be reported immediately. In the event of a malfunction, the crane shall be Locked Out and tagged “Do Not Operate.”
5.4 Crane Movement
5.4.1 Prior to movement of the crane, the operator shall assure that the crane and rail have been inspected for objects and/or debris that could potentially fall off during movement of the crane.
5.4.2 Prior to crane movement the operator shall remove all non-essential personnel and assure that all essential personnel on the crane are ready to move and are protected against falls and other hazards. Other hazards may include moving components such as gears, shafts, etc.
5.4.3 Do not hoist, lower, swing, or travel while any person is on any part of the load, load line, or headache ball.
5.4.4 Personnel must be notified and removed when loads are to be traversed overhead unless other safety precautions are taken.
5.4.5 A radio will be used when it is not possible to ensure adequate signals between the signal person and the crane operator. Under normal circumstances, crane operator will only take signals from one individual.
5.5 Additional Safety Precautions
5.5.1 Always run crane at low speed.
5.5.2 Stop before you reach the end of the crane rail, as this may drop debris, etc.
5.5.3 Ensure written approval from the facility owner before any crane modifications.
5.5.4 Ensure fire extinguishers are available and fully charged on the crane.
5.5.5 When using the controls on the operating floor, make sure controls are tagged-out if left unattended.
5.5.6 Stay alert for developing hazards related to equipment build-up, loose tools, or any other component that may fall from the crane.
5.5.7 Never disconnect any safety device associated with the operation of the crane.
5.5.8 Exposed moving parts such as gears, set screws, projecting keys, chains, chain sprockets, and reciprocating components that might constitute a hazard under normal operating conditions shall be guarded.
5.5.8.1 Guards shall be securely fastened.
5.5.8.2 Each guard shall be capable of supporting without permanent distortion the weight of a 200-pound person unless the guard is located where it is impossible for a person to stop on it.
6.0 APPENDICES
6.1 NCS Form 027 – Critical Lift Permit Verification
6.2 NCS Form 028 – Overhead Crane Inspection Form
6.3 NCS Form 029 – Critical Lift Permit