Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 1 f 11 Purpse Overhead cranes, hists, and rigging equipment are used by HOUSTON, INC emplyees fr lifting and mving materials. In rder t maintain a safe wrkplace fr its emplyees, nly qualified individuals shall perate these devices. This prgram utlines the prcedures fr safe peratins and the training requirements regarding verhead cranes, hists and rigging equipment. Scpe Applies t all HOUSTON, INC emplyees wh perate verhead cranes, hists, and rigging equipment in the scpe f their jb duties and assignments. When wrk is perfrmed n a nn-wned r perated site, the peratr s prgram shall take precedence, hwever, this dcument cvers HOUSTON, INC emplyees and shall be used n wned premises, r when an peratr s prgram desn t exist r is less stringent. Definitins ANSI - the American Natinal Standards Institute. Appinted - assigned specific respnsibilities by the emplyer r the emplyer's representative. Auxiliary hist - a supplemental histing unit f lighter capacity and usually higher speed than prvided fr the main hist. Brake - a device used fr retarding r stpping mtin by frictin r pwer means. Bridge - that part f a crane cnsisting f girders, trucks, end ties, ft-walks, and drive mechanism that carries the trlley r trlleys. Bridge travel - the crane mvement in a directin parallel t the crane runway. Bumper [buffer] - an energy absrbing device fr reducing impact when a mving crane r trlley reaches the end f its permitted travel; r when tw mving cranes r trlleys cme in cntact. Crane - a machine fr lifting and lwering a lad and mving it hrizntally, with the histing mechanism an integral part f the machine. Cranes, whether fixed r mbile, are driven manually r by pwer. Designated - selected r assigned by the emplyer r the emplyer's representative as being qualified t perfrm specific duties. Drum - the cylindrical member arund which the rpes are wund fr raising r lwering the lad. Emergency stp switch - a manually r autmatically perated electric switch t cut ff electric pwer independently f the regular perating cntrls.
Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 2 f 11 Flr-perated crane - a crane which is pendant r nncnductive rpe cntrlled by an peratr n the flr r an independent platfrm. Hist - an apparatus that may be a part f a crane, exerting a frce fr lifting r lwering. Hlding brake - a brake that autmatically prevents mtin when pwer is ff. Limit switch - a switch that is perated by sme part r mtin f a pwer-driven machine r equipment t alter the electric circuit assciated with the machine r equipment. Lad - the ttal superimpsed weight n the lad blck r hk. Lad blck - the assembly f hk r shackle, swivel, bearing, sheaves, pins, and frame suspended by the histing rpe. Main hist - the hist mechanism prvided fr lifting the maximum rated lad. Main switch - a switch cntrlling the entire pwer supply t the crane. Overhead crane - a crane with a mvable bridge carrying a mvable r fixed histing mechanism and traveling n an verhead fixed runway structure. Rated lad - the maximum lad fr which a crane r individual hist is designed and built by the manufacturer and shwn n the equipment nameplate(s). Rpe - refers t wire rpe, unless therwise specified. Runway - an assembly f rails, beams, girders, brackets, and framewrk n which the crane r trlley travels. Side pull - that prtin f the hist pull acting hrizntally when the hist lines are nt perated vertically. Span - the hrizntal distance center t center f runway rails. Standby crane - a crane which is nt in regular service but which is used ccasinally r intermittently as required. Stp - a device t limit travel f a trlley r crane bridge. This device nrmally is attached t a fixed structure and nrmally des nt have energy absrbing ability. Trlley - the unit that travels n the bridge rails and carries the histing mechanism. Trlley travel - the trlley mvement at right angles t the crane runway. Wall crane - a crane having a jib with r withut trlley and supprted frm a sidewall r line f clumns f a building. It is a traveling type and perates n a runway attached t the sidewall r clumns.
Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 3 f 11 Key Respnsibilities Managers and Supervisrs Are respnsible t ensure that emplyees and cntractrs are trained and qualified n the prper peratins and have been trained in crane and hist safety. Mdificatins r additins which affect the safe peratin f the equipment may nly be made with the manufacturer s written apprval. Are respnsible t see that all prvisins f this prgram are fllwed and that crane inspectins are perfrmed and the equipment is in safe perating cnditin. Emplyees Emplyee peratrs are respnsible t fllw the requirements f this prgram and reprt any damage r needed repairs immediately t their supervisr. Operatrs must meet the physical qualificatins, pass a physical, a written examinatin, understand and be able t use a lad chart as well as calculate lads fr the crane type perated. Emplyees designated as crane peratrs are respnsible fr the entire lift. In additin, crane peratrs are respnsible t: Make the required inspectins, Ensure that the crane is maintained, Ensure that all persnnel wrking in the area arund the crane are kept clear f all hazards related t crane peratins. Determine the weights, and crrect rigging required fr lads t be lifted. Prcedure General HOUSTON, INC shall cmply with the manufacturer s specificatins and limitatins applicable t the peratin f any and all cranes. Where manufacturer s specificatins are nt available, the limitatins assigned t the equipment shall be based n the determinatin f a qualified engineer cmpetent in this field and such determinatins will be apprpriately dcumented and recrded. Attachments used with cranes shall nt exceed the capacity, rating, r scpe recmmended by the manufacturer. This prgram applies t all cranes including verhead cranes, wall cranes, (jib cranes) and thers having the same fundamental characteristics. HOUSTON, INC shall permit nly thse emplyees qualified by training r experience t perate equipment and machinery. Manufacturer rated lad capacities and perating speeds shall be fllwed.
Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 4 f 11 All cranes in service and utilized by HOUSTON, INC shall meet, as a minimum, the design specificatins f the American Natinal Standard Safety Cde fr Overhead and Gantry Cranes, ANSI B30.2.0-1967. Each crane shall have the lad rating plainly marked n each side f the crane. Rated lad capacities, and recmmended perating speeds, special hazard warnings, r instructin, shall be cnspicuusly psted n all equipment. Instructins r warnings shall be visible t the peratr while he is at the cntrl statin. If the crane has mre than ne histing unit, each hist shall have its rated lad marked n it r its lad blck and this marking shall be clearly legible frm the grund flr. All cranes shall be lcked and tagged ut while repairs are in prgress t them r any ther equipment r building structure that may have persnnel r equipment in their path. Whenever internal cmbustin engine pwered equipment exhausts in enclsed spaces, test shall be made and recrded t see that emplyees are nt expsed t unsafe cncentratins f txic gases r xygen deficient atmspheres. Inspectins Onshre/Offshre Cranes and hists that have been verladed shall be inspected prir t being returned t service. The inspectin and testing requirements are included. Initial inspectin and test shall be perfrmed by a qualified third party. Prir t initial use all new and altered cranes shall be inspected and tested t ensure cmpliance with the prvisins f 29 CFR1910.179 and ABSI B30.2. Only after determining, by this inspectin, testing and prper dcumentatin, that the crane is in safe perating cnditin, shall it be put int service. HOUSTON, INC shall designate a cmpetent persn wh shall inspect all machinery and equipment prir t each use, and during use, t make sure it is in safe perating cnditin. Any deficiencies shall be repaired, r defective parts replaced, befre cntinued use. Daily pre-use inspectins shall be perfrmed by the crane peratr (designated as HOUSTON, INC s designated cmpetent persn) prir t beginning shift and thrugh bservatin during nrmal peratin. Daily inspectins shall include: Any deficiencies shall be repaired, r defective parts replaced, befre cntinued use. All functinal perating mechanisms fr maladjustment interfering with prper peratin. Deteriratin r leakage in lines, tanks, valves, drain pumps, and ther parts f air r hydraulic systems. Hks, if defrmatins r cracks are fund the hk shall be tagged ut f service until repaired and tested by qualified persnnel. Hist chains, including end cnnectins, fr excessive wear, twist, distrted links interfering with prper functin, r stretch beynd manufacturer's recmmendatins. Quarterly and annual inspectins shall be dcumented with a certificatin recrd which includes the signature f the qualified third party (persn r agency) wh perfrmed the inspectin, the date, and identifier (serial number, unit number, etc.) fr each piece f equipment. If safety hazards are fund during inspectins, the equipment in questin shall be tagged ut and nt used until repairs are made. Any deficiencies cnstituting a safety hazard shall cause the equipment t be tagged ut f service until repairs are made.
Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 5 f 11 A thrugh, annual inspectin f the histing machinery shall be made by a cmpetent persn, r by a gvernment r private agency recgnized by the U.S. Department f Labr. HOUSTON, INC shall maintain a recrd f the dates and results f inspectins fr each histing machine and piece f equipment. All crawler, truck, r lcmtive cranes in use shall meet the applicable requirements fr design, inspectin, cnstructin, testing, maintenance and peratin as prescribed in the ANSI B30.5-1968, Safety Cde fr Crawler, Lcmtive and Truck Cranes. Hwever, the written, dated, and signed inspectin reprts and recrds f the mnthly inspectin f critical item prescribed in sectin 5-2.1.5 f the ANSI B30 5-1968 standard are nt required. Instead, HOUSTON, INC shall prepare a certificatin recrd which includes the date the crane items were inspected; the signature f the persn wh inspected the crane items; and a serial number, r ther identifier, fr the crane inspected. Operatinal Prcedures Only qualified persnnel shall perate cranes and equipment cvered by this prgram. Operatrs shall cmply with the fllwing safety rules while perating cranes and hists: Emplyees shall nt be expsed t unsafe cncentratins f txic gases r xygen deficient atmspheres when internal cmbustin engine pwered equipment is used. Tests shall be cnducted and dcumented. D nt engage in any practice that will divert yur attentin while perating the crane. Respnd t signals nly frm the persn wh is directing the lift r any appinted signal persn. Obey a stp signal at all times, n matter wh gives it. D nt mve a lad ver peple. Peple shall nt be placed in jepardy by being under a suspended lad. D nt wrk under a suspended lad unless the lad is supprted by blcks, jacks, r a slid fting that will safely supprt the entire weight. Have a crane r hist peratr remain at the cntrls r lck pen and tag the main electrical discnnect switch. Ensure that the rated lad capacity f a crane's bridge, individual hist, r any sling r fitting is nt exceeded. Knw the weight f the bject being lifted. Check that all cntrls are in the OFF psitin befre clsing the main line discnnect switch. If spring-laded reels are prvided t lift pendants clear ff the wrk area, ease the pendant up int the stp t prevent damaging the wire. Avid side pulls. These can cause the hist rpe t slip ut f the drum grve, damaging the rpe r destabilizing the crane r hist. T prevent shck lading, avid sudden stps r starts. Shck lading can ccur when a suspended lad is accelerated r decelerated, and can verlad the crane r hist. When cmpleting an upward r dwnward mtin, ease the lad slwly t a stp. At the start f each wrk shift, the designated cmpetent persn peratr shall d the fllwing steps befre making lifts with any crane r hist:
Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 6 f 11 Test the upper-limit switch and slwly raise the unladed hk blck until the limit switch trips. Visually inspect the hk, lad lines, trlley, and bridge as much as pssible frm the peratr's statin; in mst instances, this will be the flr f the building. If prvided, test the lwer-limit switch. Test all directin and speed cntrls fr bth bridge and trlley travel. Test all bridge and trlley limit switches, where prvided, if peratin will bring the equipment in clse prximity t the limit switches Test the pendant emergency stp. Test the hist brake t verify there is n drift withut a lad. If prvided, test the bridge mvement alarm. Lck ut and tag fr repair any crane r hist that fails any f the abve tests. Any deficiencies shall be repaired, r defective parts replaced, befre cntinued use. Mving a Lad Center the hk ver the lad t keep the cables frm slipping ut f the drum grves and verlapping, and t prevent the lad frm swinging when it is lifted. Inspect the drum t verify that the cable is in the grves. Use a tag line when lads must traverse lng distances r must therwise be cntrlled. Manila rpe may be used fr tag lines. Plan and check the travel path t avid persnnel and bstructins. Lift the lad nly high enugh t clear the tallest bstructin in the travel path. Start and stp slwly. Land the lad when the mve is finished. Chse a safe landing area. Never leave suspended lads unattended In an emergency where the crane r hist has becme inperative, if a lad must be left suspended, barricade and pst signs in the surrunding area, under the lad, and n all fur sides. Lck pen and tag the crane r hist's main electrical discnnect switch. Parking a Crane r Hist Remve all slings and accessries frm the hk. Return the rigging device t the designated strage racks. Place the emergency stp switch (r push buttn) in the OFF psitin. Rigging and Sling Inspectins and Safety Requirements Only select rigging equipment that is in gd cnditin. All rigging equipment shall be inspected annually; defective equipment is t be remved frm service and destryed t prevent inadvertent reuse. The lad capacity limits shall be stamped r affixed t all rigging cmpnents.
Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 7 f 11 All devices shall be visually inspected prir t use and remved frm service fr any f the fllwing cnditins: Nyln slings with: Abnrmal wear. Trn stitching. Brken r cut fibers. Disclratin r deteriratin. Wire rpe slings with: Kinking, crushing, bird caging, r ther distrtins. Evidence f heat damage. Cracks, defrmatin, r wrn end attachments. Six randmly brken wires in a single rpe lay. Three brken wires in ne strand f rpe. Hks pened mre than 15% at the thrat. Hks twisted sideways mre than 10 degrees frm the plane f the unbent hk. Ally steel chain slings with: Cracked, bent, r elngated links r cmpnents. Cracked hks. Shackles, eye blts, turnbuckles, r ther cmpnents that are damaged r defrmed. Rigging a Lad Determine the weight f the lad - d nt guess. Determine the prper size fr slings and cmpnents. D nt use manila rpe fr rigging. Ensure that shackle pins and shuldered eyeblts are installed in accrdance with the manufacturer's recmmendatins. Ensure that rdinary (shulderless) eyeblts are threaded in at least 1.5 times the blt diameter. Use safety hist rings (swivel eyes) as a preferred substitute fr eye blts wherever pssible. Pad sharp edges t prtect slings. Remember that machinery fundatins r angle-irn edges may nt feel sharp t the tuch but culd cut int rigging when under several tns f lad. Wd, tire rubber, r ther pliable materials may be suitable fr padding. D nt use slings, eyeblts, shackles, r hks that have been cut, welded, r brazed. Install wire-rpe clips with the base nly n the live end and the U-blt nly n the dead end. Fllw the manufacturer's recmmendatins fr the spacing fr each specific wire size. Determine the center f gravity and balance the lad befre mving it. Initially lift the lad nly a few inches t test the rigging and balance. Cranes r hists shall nt be laded beynd their rated capacity fr nrmal peratins.
Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 8 f 11 Any crane r hist suspected f having been verladed shall be remved frm service by lcking pen and tagging the main discnnect switch. Overladed cranes shall be inspected, repaired, lad tested, and apprved fr use befre being returned t service. Wrking at heights n cranes r hists: Anyne cnducting maintenance r repair n cranes r hists at heights greater than 6 ft (1.8 m) shall use fall prtectin. Fall prtectin includes safety harnesses that are fitted with a lifeline and securely attached t a structural member f the crane r building. Prperly secured safety nets are anther ptin fr fall prtectin. Use, f a crane, as a wrk platfrm shuld nly be cnsidered when cnventinal means f reaching an elevated wrksite are hazardus r nt pssible. Wrkers shall nt ride a mving bridge crane. Persnnel shall nt bard any bridge crane unless the main discnnect switch is lcked and tagged ut f service. Signals t the peratr shall be in accrdance with the standard hand signals prescribed by the applicable ANSI standard fr the type f crane in use unless vice cmmunicatins equipment (telephne, radi, r equivalent) is used. Signals shall be discernible r audible at all times. Sme special peratins may require additin t r mdificatin f the basic signals. Fr all such cases, these special signals shall be agreed upn and thrughly understd by bth the persn giving the signals and the peratr, and shall nt be in cnflict with the standard signals. All maintenance, tests and inspectins shall be cnducted in accrdance with the manufacturer s recmmendatins. All recrds f annual and lad testing shall be retained at the facility where each crane, hist r ther equipment cvered by this prgram is lcated. All maintenance and repair recrds shall be retained fr the life f the equipment. The use and peratin f client wned cranes, hists and rigging equipment by qualified HOUSTON, INC persnnel will ccur nly at the express permissin f the designated client representative. An accessible fire extinguisher f 5BC rating, r higher, shall be available at all peratr statins r cabs f equipment. When perating cranes near pwer lines rated 50 KV r belw, minimum clearance between the pwer line and any part f the crane r lad shall be 10 feet.
Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 9 f 11 Offshre Crane peratrs will be designated wh have apprpriate ffshre experience and training which must cmprise f minimum amunts f classrm sessins and hands-n training which will cver lubricating pints, adjustments, principles f crane peratins, lad charts, hand signals and inspectins. Refresher training is required every fur years. Training shall include the use f fire extinguishers. Offshre physical qualificatins include: the API 2D physical requirements - visin f at least 20/30 Snellen in ne eye and 20/50 in the ther eye with r withut glasses, and have depth perceptin; be able t distinguish between red, yellw, and green; hearing, with r withut a hearing aid, adequate fr the specific peratin; and n histry f disabling medical cnditin which may be sufficient reasn fr disqualificatin. A fllw-up evaluatin is required every 4 years. Lad test recrds will be furnished shwing prcedures utlined in Appendix E f API2D, 4.2. Training: Training shall include: Dcumentatin f emplyee, date f training and subject matter, including methd used t test knwledge f material. N emplyee shall perate cranes r equipment cvered by this prgram until training has been cmplete and management has apprved and designated him r her as a qualified peratr.
Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 10 f 11 OVERHEAD CRANE AND HOIST INSPECTION PROCEDURES Inspectins can be classified as either "frequent" r "peridic" based upn the intervals at which the inspectins must be perfrmed. Frequent Frequent inspectin daily: The fllwing shall be inspected fr defects as nted. All functinal perating mechanisms fr maladjustment interfering with prper peratin. Daily must be perfrmed by peratr. (n dcumentatin required) Deteriratin r leakage in lines, tanks, valves, drain pumps, and ther parts f air r hydraulic systems. Hks with defrmatin r cracks. Hks with cracks r having mre than 15% in excess f nrmal thrat pening r mre than 10 degrees twist frm the plane f the unbent hk shuld be discarded. Wire rpe and nyln sling inspectin Daily inspectins are t be cnducted by the equipment peratr. These inspectins are visual inspectins made daily when the verhead crane is used and recrd keeping is nt required. Peridic inspectin Annual: The annual inspectin shall be perfrmed and dcumented by a qualified third party. Recrds shall be kept at the lcatin f the cmpleted inspectin.
Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 11 f 11 DAILY GUIDE FOR OVERHEAD CRANE INSPECTIONS N All functinal perating mechanisms fr maladjustment interfering with prper peratin N Leakage in lines, tanks, valves, drain pumps, and ther parts f air r hydraulic systems N N Hks fr defrmatin, chemical damage, r cracks. Hks having mre than 15% in excess f nrmal thrat pening r mre than 10 degrees twist frm the plane f the unbent hk. Hks. Dye penetrant, magnetic particle, r ther suitable crack-detecting inspectin perfrmed at least nce a year. N All functinal perating mechanisms fr excessive wear f cmpnents N Rpe reeving fr nncmpliance with manufacturer's recmmendatins N Cnditin f wire rpe. N Defrmed, cracked, r crrded members N Cracked r wrn sheaves r drums. N Lse blts, nuts, r rivets N Wrn, cracked, r distrted parts such as pins, bearings, shafts, gears, rllers, lcking and clamping devices N Excessive wear in brake system parts, linings, pawls, and ratchets N Lad, wind and ther indicatrs ver their full range, fr any significant inaccuracies N N Gasline, diesel, electric, r ther pwer plants fr imprper perfrmance r nncmpliance with applicable safety requirements. Electrical apparatus, fr signs f pitting r any deteriratin f cntrller, masterswitches, and push buttn statins. N Required warning labels absent r illegible. N Supprting structure, trlley and bridge fr alignment and cntinued ability t supprt the impsed lads.