1. The Basics of Overhead Crane Pre-op Inspections
Safety Team presents
The Basics of Overhead Crane Pre-op Inspections
Like to start out showing the Centrale rotor drop video after initial introductions

2. Disclaimer The following information is for informational use only.
This is not intended to replace or add on to the state/federal regulations or guidelines.

3. Introduction

4. Presentation Objectives
The proper names of various types of overhead cranes and hoists.
Daily operator inspection procedures and corresponding components.

5. During This Study Students Will Learn:
The different types of crane duty cycles and their applications.
Safe operating practices for overhead cranes and hoists.

6. During This Study Students Will Learn:
Reviewed and Adopted in to law (Consensus) by:
OSHA – Occupational Safety & Health Administration
DOSH – Division of Occupational Safety & Health (Department of Labor & Industries – L&I WA state)

7. Overhead Crane and Hoist Types, Terminology and Classifications

8. Applicable Regulations
Cranes used in industry are regulated by
29CFR (Code of Federal Regulations) Industry Consensus Standards
Industry Consensus Standards
ASME B30.2 Overhead and Gantry Cranes
ASME B30.9 Slings
ASME B Rigging Hardware

9. Overhead Bridge Crane
End stops are designed to stop the crane at about 30% of its maximum speed.

10. Overhead Gantry Crane What makes it a gantry crane is that it has legs
Semi-gantry = a one legged crane

11. Duty Cycles
The Duty Cycle rating of crane determines the amount of work a particular crane can perform in a specified time frame.
For an overhead crane or hoist, there are 6 general overhead crane and hoist duty cycles classifications.
These are based on; the amount it can lift, the vertical and horizontal distance traveled, the number of times per hour it will lift, and the work environment.
The duty cycle of a crane is a concern of the purchaser and the manufacture.

12. Duty Cycles
In the left image the Alliance Ingot crane runs many hours per day transporting ingots over a distance of several hundred feet. (a heavy or sever duty cycle rated crane) (this bay is about 90 feet wide)
The crane in the right hand image was used in the early 1980’s to install the motor in the background and has not been used since that time. (an infrequent or stand by crane) (this building is about 30 wide)
The Alliance ingot crane operates many hours per day transporting ingots over a distance of several hundred feet between soaking pits and rolling mill, the is an example of a “HEAVY USE” crane, ton capacity.
132 drive motor, service crane, used in the early 1980’s to install the motor in the background and has been on “STANDBY” ever since that time, 85 ton capacity.

13. Machine Condition
Look at combining sections 3 and 4 into something more manageable. Having 2 repeating sections is redundant, minus a few variations (things that production does not even do).

14. Repairs/Modifications
Only repairs approved by the manufacturer
Maintenance manual will provide info on approved repairs and procedures.
Strictly prohibited unless approved by manufacturer or a qualified engineer.
Mods/repairs to any:
Load bearing
Load supporting
Load controlling

15. Electrical Systems Mechanical Systems
Check for:
Bridge girder cracks
Loose or missing mounting bolts
Lack of lubrication where needed
Loose couplings
Worn brake linings
Check for: Moisture
Proper closure and latching of doors
Damaged electrical disconnects
Resistors must be:
Tight, no loose connections
Clean and show no signs of overheating
Remove the majority of this slide?

16. Control Functions Check all: Control functions prior to use
Run each controller through its step
This is the speed and functions (up/down, north/south, etc…)

17. Safety Devices Numerous devices installed (operator check)
Fire extinguishers (BC 10lb min. cab crane only)
Emergency descent device Rescumatic, (cab crane only), this device will allow a person of up 300 lbs. to safely decent from a crane cab at a rate of 3 feet per second.
Travel limiters (i.e. end stops)
Can be mechanical or electrical
Load limiters
Travel alarms
Warning lights
The most important safety device is the:
Upper limit switch (A.K.A - Youngstown)
Stops upward travel of the hook block before contacting the bridge or hoist drum

18. Load Line Condition Inspected once a month – end to end (crane crew)
Broken Wires
Crushing
Bird caging
High stranding
Heat damage
Chemical damage
Kinking
Crushed Rope
Broken Strands

19. Load Line Condition Wire Rope - broken wires
Hoist Rope: 12 – 4 – 1 criteria
12 broken wires in one rope lay
4 broken wires in one strand
1 broken wire at the end fitting
Wire Rope Slings: 10 – 5 – 1

20. Load Line Condition Chains - look for any:
Flat spots caused by abrasion
Cracked/broken welds
Twisting
Elongation
Bowl wear
Corrosion
Heat damage
Weld spatter
Grade (must be 8 or 10)
Chain designed for lifting will be marked with a grade number of 8 or 10
Grade 8 chain may also be represented as 80 or 800
Grade 10 chain may also be represented as 100 or 1000