Overhead Crane Safety Training for third party especially in uae, contains all the safety aspects for the operation of over head cranes

Overhead Crane Safety Training

1. Safe Use & Operations of EOT Cranes

2. Company Introduction TUV SW  is a  leading organization in quality, safety, and sustainability solutions provider that specializes in testing, inspection, auditing, certification and training. By delivering objective solutions to its customers and the environment. TUV SW adds tangible value to businesses, consumers and the environment. The company caters clients across a wide range of sectors that include aviation, automotive, marine, oil & gas, food & safety, power & utilities, consumer products, electrical & electronics, construction & real estate, transport & infrastructures, industrial & manufacturing, and government.

3. We Deals in:- Testing Inspection Auditing Certification Training

4. Out Objective The purpose of our Safety Awareness Training course is to equip the learner with the knowledge, skill and competence to recognize and maintain good health and safety practices in a familiar supervised environment. Participants should be familiar and have a good knowledge of their work environment & able to make a safer work place.

5. Personal Introduction Name Job Experience

6. Don’t Disturb Others

7. Objective Objectives Learn standard operating procedures applicable to Electric Overhead Traveling Crane Local Regulation / DAC or OSHAD Provide an Introduction to Crane and Lifting Safety. Establish Crane and Lifting Safety in Today’s Industry. Introduce Basic Safety Concepts and Techniques to use EOT Cranes. Provide Skills for Operators, Maintenance Workers and Supervisors etc. Raise Safety Awareness.

8. Legal Requirements Employer shall ensure to provide training to their employees before commencing any job with lifting equipment or lifting accessories as per OSHAD CoP 34 V3-2016 (Safe Use of Lifting Equipment and Lifting Accessories.)

9. Introduction/ CoP EOT Crane (electric overhead traveling crane) This COP Code of Practice covers general requirements like inspection, maintenance and safe operations. OSHAD COP 34.0 Safe Use of Lifting Equipment and Lifting Accessories V 3.0 July 2016

10. Definition & types of Crane What is Crane? A crane is a type of machine, generally equipped with a hoist rope, wire ropes or chains, and sheaves, that can be used both to lift and lower materials and to move them horizontally. It is mainly used for lifting heavy things and transporting them to other places . Types of Crane

11. Overhead Cranes Overhead cranes are used in many industries To move heavy and oversized objects that other material handling methods cannot. These cranes have a railed support structure, also known as a bridge, and a wheeled trolley that travels across the bridge horizontally. Several varieties of overhead cranes exist including gantry, semi-gantry, cantilever gantry, storage bridge and wall cranes.

12. Introduction/ Definition EOT Crane (electric overhead traveling crane) What is EOT crane? Electrical overhead travelling crane What Is Its Capacity? Its SWL- safe working load Eg . 5t, 2t, 32t, etc. Testing requirements? It is tested annually by competent person. It is compulsory by Local & International law.

13. Introduction Lifting Overview The lifting of objects generally occurs on construction sites, in factories, Plant and other industrial situations. Correct lifting can move large objects efficiently and reduce manual handling operations. However, Incorrect lifting can lead to disastrous accidents. Every year, incorrect lifting procedures cause injuries, loss of work time and property. People, machinery, loads, methods and the work environment, are all important factors for correct lifting. Provided that enough safety measures are fully implemented, lifting accidents can be reduced.

14. A rigging or lifting  plan  is developed every time a heavy load is being lifted. The basic idea behind a rigging  plan  is to have control and establish safety precautions. It is an important  planning  process that will identify all hazardous situations that might be encountered during  lifting . Basics of Lifting What is Rigging/ Lifting Plan?

15. A  permit-to-work system  is a formal written  system used to control certain types of  work  that are potentially hazardous. A  permit-to-work  is a document which specifies the  work  to be done and the precautions to be taken.  Permits-to-work  form an essential part of safe  systems  of  work  for many maintenance activities. Basics of Lifting What is permit to work system?

16. SWPs (Safe working procedure) are also referred to using other terms, such as Standard  Operating Procedure . A SOP ( Safe Work Procedure)  is a step by step description of a process when deviation may cause a loss. This risk control document created by teams within the company describes the safest and most efficient way to perform a task. Basics of Lifting What is SWP and SOP?

17. PPE is equipment that will protect the user against health or safety risks at work. It can include items such as safety helmets, gloves, eye protection, high-visibility clothing, safety footwear and safety harnesses. It also includes respiratory protective equipment also Basics of Lifting What are PPEs?

18. Making the workplace safe includes providing instructions, procedures, training and supervision to encourage people to work safely and responsibly . Even where engineering controls and safe systems of work have been applied, some hazards might remain. These include injuries to: the lungs, eg from breathing in contaminated air the head and feet, eg from falling materials the eyes, eg from flying particles or splashes of corrosive liquids the skin, eg from contact with corrosive materials the body, eg from extremes of heat or cold PPE is needed in these cases to reduce the risk. Basics of Lifting Why PPEs are important?

19. According to the survey of accident  Statistics ' & Census of Fatal Occupational  Injuries , Several fatal occupational  injuries found  were related to cranes, derricks, hoists, and hoisting accessories in history. OSHA's analysis of  crane accidents  in general industry and construction identified an average of 71 fatalities each year USA. Basics of Lifting Crane Accident Statistics worldwide

20. Accidents related to cranes? While you are working around the crane you must know that 20 % to 25 % of all construction & Industrial fatalities are related to cranes Basics of Lifting

21. Crane accidents are one of the leading causes of construction workers’ deaths. Causes of these accidents include: Cranes buckling or collapsing.  Weight exceed the capacity,, Balance of rigging , Balance of Out riggers, Unstable Ground Conditions. Improper employee training.  Training. Improper coordination of rigging team, Understanding and Identification of hazards, safe distance between the crane operation and work performed by other workers. Mechanical failures.  Poor Maintenance of lifting equipment mechanical failures. Lack of Lubrication. Contact with electrical Power lines.  Electrocution, Inspections.  Lack of thorough Examination and inspection from a competent person. Basics of Lifting Six basic things attributes the Crane Accidents

22. Overhead Crane by Parts

23. Overhead Crane by Parts Winch/ Hoist with Crab Trolley

24. Cranes covered in the Training Electric Power Overhead Travelling Crane/ Jib Crane / Hoist Operations

25. Pre-Operational Checks & Inspections INSPECTION CHECKLIST FOR EOT CRANE 1. Identify items that were inspected. 2. Show the status of the inspected items. 3. Provide the signature of the inspector. 4. Show the date. 5. File it and maintain it! Review the manufacturers specified inspection requirements! Basic inspection before prior to use

26. Pre-Operational Checks Inspection before use Visually inspect the runway system. Are all bolts in place? Are there any obstructions on the runway? Visually inspect bridge, trolley and hoist connections. Does everything appear normal? Visually inspect the mainline conductor bar system. Are the conductors aligned properly? Are all joint covers in place? Are there any broken or loose support brackets?

27. Hazard Crane Inspection activities are always hazardous Exposure to moving parts Under the Machinery Directive 2006 All moving parts must be covered Never touch moving part

28. Pre-Operational Checks Inspection before use Check for any loose or missing parts. Check end stops. End stops prevent the trolley from running off the beam. Know the location of disconnect switch that will cut the power off only to the hoist or crane. Be sure it is readily accessible and not blocked. Make sure wire rope is properly seated in its drum and sheave grooves without any slack or overlapping.

29. Electric Shock Hazard DANGER HIGH VOLTAGE Always Ensure Energy Sources Are Dissipated Before Initiating Any Maintenance Activity. 2 TON ACME CRANE Pre-Operational Checks Inspection before use

30. Pre-Operational Checks Inspection the system condition Inspect the control device to make sure all warning labels are in place and there are no cracks or missing bolts in the case .

31. Operational Inspection Does the “E” stop function correctly? Do all the directional buttons and motions function correctly? Test the hoist limit switches and any travel limit switches, if present, to ensure they are operating correctly. This should be done without load. If there are any horns or lights present, do they function properly? Do all motions of travel run smoothly with no unusual sounds present? Check the ground for any signs of oil leakage. Pick up a load and make sure the brakes are functioning properly. Operational Checks

32. Inspection Findings Do not Operate Tag out system If any damage or malfunctions are noted during the daily inspection, the operator shall immediately advise the appointed person so corrective action can be taken. If a malfunction occurs during operation , the operator shall immediately advise the appointed person so corrective action can be taken. If corrective action has not been completed by the end of the shift, the operator will advise the operator or operators of the next shift that corrective action is required and verify the crane is tagged out with an out of order sign or Do not Operate.

33. Operations Operational Instructions Associates in the direction of travel should be warned to move and remain clear of a lifted load at all times. Loads should not be suspended over personnel below. Under no circumstances may anyone ride the hook or load. Directional movement should be made smoothly and deliberately. Avoid rapid movements in any direction.

34. Operations Operational Instructions Under no circumstances may anyone ride the hook or load.

35. Falling and Failing the Load Never Position yourself under the load or between a fixed object and load Always use taglines for Load Movement 2 TON Operations Rigging, Slinging and lifting activities are always hazardous Never Position yourself or any person under the load or between a fixed object and load & never operate from the wheeled or movable place. Always use taglines for Load Movement

36. Operations Do not exceed the rated load capacity of the crane, hoist, chain, cable, slings, or other component. Slings, load chains and other lifting devices must be fully and securely seated in the hook before moving a load. Remove slack from the sling, chain, or cable before lifting a load. Operational Instructions

37. Operations Use the following Practices to avoid swinging the load Locate the hoist directly above the lifting point of the load before lifting. Lower loads directly below the hoist. Keep hoisting ropes vertical. Do not pull or push the load. Maintain two full wraps of cable on the hoisting drum.

38. Operations Use the following Practice to check the brakes When lifting loads at or near capacity, test the hoist brakes by returning the master switch or push button to the “OFF” position after raising the load a few inches off the floor. If the brakes do not hold, lower the load to the floor slowly and do not operate the crane. Report the situation immediately and DO NOT USE until repaired.

39. Operations Use the following Practice to raise the load Ensure that all loads are lifted high enough to clear obstructions before moving the bridge or trolley. Whenever possible, maintain a minimum clearance of one foot above loads and to the sides. Raise the load only to the height necessary to clear lower objects. Never pull a hoist by the pendant cable.

40. Operations Cautions Never leave the controls unattended while a load is suspended. If it becomes necessary to leave the controls, lower the load to the floor. Familiarize yourself with the location of the disconnect switch. If loss of electrical power occurs, place controls in the “OFF” position to prevent unexpected startup upon restoration of power.

41. Operations Use the following practice in power failure Disconnect power to a EOT Crane/ hoist that is unsafe or in need of repair. Arrange to have the disconnect switch locked and the control panel tagged with and “Out of Order” or “Do Not Operate” tag . Never operate a EOT Crane/ hoist that has been tagged with an “Out of Order” or “Do Not Operate” tag,

42. Hazard Rigging failure hazard Rigging  is a critical part of lifting operations.... Improper  rigging  practices to lift the load can cause  rigging failure. Rigging failure  can expose riggers and other workers nearby to a variety of potential hazards and material or property loses.

43. Hazard Struck by hazard Struck by injuries produced by forcible contact or impact between the injured person and an object or piece of equipment.  Struck-by hazards  in construction cause accidents such as the following: A construction worker was hoisting bricks in a bucket to the top of a building.

44. Never Position yourself or any person under the load or between a fixed object and load & never operate from the wheeled or movable place. Always use taglines for Load Movement

45. Basics of Rigging Tools Lifting & Rigging Tools Shackles Webbing Slings Wire Rope Slings Chain Slings Hooks Wire Rope Clips Eyebolts Spreader Beams Lifting Clamps Specially Designed Lifting Devices

46. Shackle is very useful lifting Accessory Shackle Necessary Marking on Shackles WLL (Working Load Limit) Size CE Mark Serial No ( Punched By User) Manufacturer Name **A CE mark applied to products to indicate that they conform with relevant EU directives regarding health and safety or environmental protection.

47. Proper Use of Shackle Shackle Use only the proper pin, never replace with a bolt. Never use a screw pin shackle if the pin can roll under load.

48. Shackle Inspection Shackle

49. Synthetic slings are also very useful lifting accessory Synthetic Sling Types Of Polyester Webbing Slings Flat webbing Sling Round Sling/ Endless Sling Polyester Grommet Sling

50. Necessary Marking on Synthetic Slings Synthetic Slings Name Of Material WLL (In Different lifting positions) Safety Factor Size Reference Standard CE Mark Name Of Manufacturer Serial No

51. Safe Use of Synthetic Slings Synthetic Slings Always use softeners to avoid from sharp edges Additional piece of polyester can be used in summer season to avoid from direct metal contact in heat. Protect slings against sharp edges

52. Reject The slings in such cases Synthetic Slings

53. Reject The slings in such cases Synthetic Slings

54. Necessary Marking on Wire Rope Slings Wire Rope Slings WLL/SWL (with angle if multi legs) Length Thickness/ Diameter CE Mark Serial No

55. Inspection of Wire Rope Sling (as per BS EN 13414) Wire Rope Slings Cracking and pitting Bird Caging Kinking Deformation Rust Heat stress Severe Corrosion, Localized Wear Broken wires (10 in 1 lay, 5 in one strand) Damaged fittings

56. Reject the slings in such cases Wire Rope Slings

57. Safe Use of Wire Rope Clips Wire Rope Slings

58. Components of Chain Slings Chain Slings Four Leg Chain Slings b a Master Link Coupling Link Connecting Link Chain Connecting Link Lower End Fittings Reach = a + b Single Leg Slings Reach Upper End Fitting Connecting Link Chain Connecting Link Lower End Fitting

59. Inspection of Chain Slings Chain Slings Chain Size Manufacturers Grade Rated load and angle Reach Number of legs Manufacturers trademark Identification Tag

60. Inspection of Chain Sling Chain Slings Twists or bends Nicks or gouges Excessive wear at bearing points Sign of weld or over heated Grade Mark of chain Stretch due to overloading Distorted or damaged links Jaw opening of Hooks Safety Latch/Trigger Kit

61. Hooks

62. Inspection of Chain Slings Hooks

63. Inspection of Chain Slings Hooks

64. Inspection of Chain Slings Hooks

65. Eye Bolts Eye Bolts Vertical Shouldered eyebolts may be loaded vertically and 90 degrees. Shoulder less eyebolts may be loaded in this direction only. 90 Degrees

66. Eye Bolts Eye Bolts Result Load Load Correct Orientation – Load is in the plane of the eye. Incorrect Orientation – When the load is applied to the eye in this direction it will bend. Always load an eyebolt in the plane of the eye. Load

67. Eye Bolts are also very useful lifting Accessory Eye Bolts Necessary Marking on Eye Bolts WLL (Working Load Limit) Size CE Mark Serial No ( Punched By User) Manufacturer Name **A CE mark applied to products to indicate that they conform with relevant EU directives regarding health and safety or environmental protection.

68. A spreader beam is used to support long loads during lifts and to prevent the load from tipping, sliding, or bending. Lifting Beams It must be marked with minimum Serial No. & Safe working Load. Rigger must inspect physical condition of eyes, beam all welded part before and after use. Never overload more than capacity Always follow manufacturers instructions

69. There are various kind s of lifting clamps which are designed as per profile user. Lifting Clamps All lifting clamps must be marked with below details WLL/SWL Serial No Name of Manufacturer Date of Manufacture Size or Range of use CE mark Batch No

70. Before Lifting any object a rigger must know Lifting The Load Know the Weight Know the Capacity Retain the Load Control the Load

71. Types of hitches Slinging

72. Slinging

73. Center of Gravity Slinging Capture the Center-of-Gravity When the object is in suspended condition it always center itself under the lifting point Always center the lift above the center of gravity, not the physical center of the object

74. Center of Gravity Slinging

75. Center of Gravity Slinging The sling must not be attached to the load at a point lower than the loads center of gravity Exception to this rule when lifting loads on pallets or skids Then apex of sling must be above the center of gravity

76. Knowing the Gravity Center Slinging Marked on the load by manufacturer Located in catalogs or blueprints Some objects have lifting lugs Calculate or estimate it

77. Sling Angle Factor Slinging

78. Crane Hand Signals

79. Lifting Safety Exercise What will you use to lift this tank Would it be matter if the tank will be full or half…??

80. Lifting Safety Exercise 2 TON What is the Risk in this photo..?

81. Lifting Safety What is major mistake in this accident…?? 5 TON 2 TON 10 TON LOAD Exercise

82. Lifting Safety Exercise What’s wrong with these shackles?

83. Lifting Safety Exercise What could be the possible reason for this injury as Rigger..??

84. Cautions Check Your Permit! Do Proper Planning Always Follow Lifting Plans Always do Tool Box Talks Prior to start

85. Have you got any question..?

86. 92 Thank you for your kind attention