1. TENNESSEE VALLEY AUTHORITY TRAINING MATERIALS COVERSHEET
SAFETY TRAINING
TRAINING MATERIALS COVERSHEET
Safety Training
TRAINING PROGRAM
Crane Safety (Pendant)
COURSE TITLE
COURSE NO.
The above signatures indicate that this lesson plan has been reviewed and accepted by affected organizations through the Safety Training Peer Team and the Safety & Health Organization. It is approved for standardized deployment throughout TVA.
An archive of signed copies of lesson plan coversheets is maintained by the Technical Training Organization. The latest copy of this lesson plan and other standard safety training lesson plans are posted on the Technical Training sharepoint site:

2. SAFETY TRAINING
REVISION/USAGE LOG

3. I. PROGRAM: SAFETY TRAINING
II. COURSE: PENDANT CRANE SAFETY INITIAL
III. LESSON TITLE: CRANE SAFETY (PENDANT)
IV. LENGTH OF LESSON/COURSE: 4 HOURS
V. TRAINING OBJECTIVES
Terminal Objective
Upon completion of training, each participant will demonstrate the ability to safely operate a pendant-controlled crane. Successful completion requires a score of 80% on a written exam. Participant’s will also be required to complete a performance exam (with a score of 100%) using the Pendant-Controlled Crane Performance Evaluation in Appendix C. The evaluation requires the participant to perform a pre-operational inspection and safely operate a floor operated pendant-controlled crane in accordance with TVA procedures.
Note: Prerequisites for this course are Rigging Program Requirements ( ), Safe Rigging Principles and Requirements ( ), MTS (NPG), MTS (NPG)
Enabling Objectives
Identify certification and recertification requirements for pendant-controlled crane operators.
Define the following crane terms: runway, bridge, trolley, hoist, hoist drum, hoist block, safety latch, and pendant control.
State the frequency that pre-operational inspections should be performed.
Identify unacceptable conditions that might be discovered during an annual or pre-operational inspection.
Given an unacceptable condition discovered during an annual or pre-operational inspection, state the actions that should be taken.
Identify proper rigging and load handling techniques and restrictions.
Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set a load.
State how to properly store a pendant-controlled crane when it is not used.
Describe operator responsibilities and potential hazards when operating a pendant-controlled crane.
Hand signal review.
Using Appendix C, complete performance evaluation by conducting a pre-operational inspection and safely operating pendant-controlled crane to lift, move, and set a load.

4. Training & Development
Pendant Crane Safety
Safety Training
Training & Development
VI. TRAINING AIDS:
Computer with projector for Power Point Presentation or overhead projector for transparencies
Whiteboards or flipchart and markers
VII. TOOLS AND EQUIPMENT
Overhead pendant-controlled crane
Object to be lifted (such as motor, pump, etc.)
Appropriate rigging hardware (slings, eyebolts, shackles, etc.) needed to lift object
VIII. TRAINING MATERIALS:
Lesson Plan 59112, Pendant Crane Safety: one copy of lesson plan appendices and attachments for each participant
Appendices:
Appendix A, Industry Experience
Appendix B, Fossil and Hydro Power Safety Meeting Topic, “What Should You Know about Using Synthetic Web Slings”
Appendix C, Pendant-Controlled Crane Performance Evaluation
Appendix D, Slide Narration for CBT
Attachments:
Attachment 1, NUREG-0612, Control of Heavy Loads at Nuclear Power Plants
Attachment 2, Hand Signals for Controlling Crane Operations
Attachment 3, Pendant-Controlled Crane Operating Experience Packet
IX. REFERENCES
TVA Safety Procedure, “Requirements for the Safe Operation of Cranes”
TVA Safety Procedure, “Rigging”
SDP-MMDP-2, “Safe Practices for Operation of Overhead Handling Equipment”
29 CFR , “Overhead and Gantry Cranes”
29 CFR , “Cranes and Derricks”
ASME B , “Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)”
ASME B “Overhead Hoists (Underhung)”
NUREG 0612, “Control of Heavy Loads at Nuclear Power Plants”

5. CRANE SAFETY (PENDANT) 00059112
X. Introduction
A. Each year, equipment accidents take a heavy toll in lives, crippled bodies, and property damage. As a result, it is easy to see the benefits of having a well-trained crane operator.
B. Operating a pendant-controlled crane takes skill and concentration. Your safety and your co-workers’ safety depend on your ability to safely control movement of loads you lift and move.
C. As the person who operates a pendant- controlled crane, it is important that you know:
1. How the crane works.
2. The crane’s limitations.
3. The weight of the load you are lifting.
4. The area in which you are operating.
5. Where your co-workers are during a lift.
6. Potential hazards that could affect your safety.
Instructor Notes
Project slide 5 on to screen while students are entering classroom and during introduction.
This section is covered in the Summit video entitled “Pendant Controlled Crane Safety”

6. Terminal Objective
Upon completion of this course, the participants will be able to safely operate a pendant-controlled crane.
Successful completion requires:
A score of at least 80% on a written exam
100% on a performance evaluation requiring you to:
Perform pre-operational inspection.
Operate floor operated pendant-controlled crane.
XI. Lesson Body
Terminal Objective
Upon completion of this course, the participants will be able to safely operate a pendant-controlled crane.
Successful completion requires:
A score of at least 80% on a written exam
100% on a performance exam requiring you to:
Perform pre-operational inspection.
Operate floor operated pendant-controlled crane.
Instructor Notes
Review Terminal Objective with class.

7. Course Objectives
Identify certification and recertification requirements for pendant-controlled crane operators.
Define the following crane terms: runway, bridge, trolley, hoist, hoist drum, hoist block, safety latch, and pendant control.
3. State the frequency that pre-operational inspections should be performed.
4. Identify unacceptable conditions that might be discovered during an annual or pre-operational inspection.
Lesson Body
Enabling Objectives
Instructor Notes
Review objectives with class.

8. Course Objectives
Given an unacceptable condition discovered during an annual or pre-operational inspection, state the actions that should be taken.
6. Identify proper rigging and load handling techniques and restrictions.
7. Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set a load.
8. State how to properly store a pendant- controlled crane when not in use.
XI. Lesson Body
Enabling Objectives
Instructor Notes
Review objectives with class.

9. Course Objectives
Describe operator responsibilities and potential hazards when operating a pendant- controlled crane.
Review ANSI Hand Signals Related to Pendant Cranes
11. Using Appendix C, complete a performance evaluation by conducting a pre-operational inspection and safely operating a pendant- operated crane to lift, move, and set a load.
XI. Lesson Body
Enabling Objectives
Instructor Notes
Review objectives with class.

10. Objective 1
Identify certification and recertification requirements for pendant-controlled crane operators.
XI. Lesson Body
Instructor Notes
Objective 1, Identify certification and recertification requirements for pendant-controlled crane operators.

11. Certification Requirements for Pendant Crane Operators
Prior to operating pendant crane:
Training ( )
Knowledge eval (80%)
Performance eval (100%)
Retraining required every 3 years.
XI. Lesson Body
A. Certification Requirements
1. This lesson (59112) required prior to operating any pendant-type crane or hoist
a. Knowledge evaluation – 80%
b. Performance evaluation - 100%
2. Retraining is required every 3 years
Instructor Notes
Objective 1, Identify certification and recertification requirements for pendant-controlled crane operators.

12. Objective 2
Define the following crane terms: runway, bridge, trolley, hoist, hoist drum, hoist block, safety latch, and pendant control.
XI. Lesson Plan
Instructor Notes
Objective 2, Define the following crane terms: runway, bridge, trolley, hoist, hoist drum, hoist block, safety latch, and pendant control.

13. Main Parts of Pendant-Controlled Crane
XI. Lesson Body
B. Parts of a Pendant-Controlled Crane
1. Runway – rails upon which bridge moves forward and back.
2. Bridge - main structure or girders that span crane’s work area and supports trolley and hoist.
3. Trolley – unit that contains hoist mechanism and travels along bridge from end to end.
4. Hoist – mechanism used to raise or lower load.
5. Hoist drum – spool that winds or unwinds hoist cable.
6. Pendant control – controls all movement: forward and back, left to right, up and down, and stopping.
Instructor Notes
Objective 2, Define the following crane terms: runway, bridge, trolley, hoist, hoist drum, hoist block, safety latch, and pendant control.
Pendant-controller consists of electric controls suspended by flexible cable, so it can be operated from ground.
All buttons have spring returns so they move automatically to OFF if operator releases pendant.

14. More Pendant Crane Definitions
XI. Lesson Body
B. Parts of a Pendant-Controlled Crane (cont)
7. Load (hoist) block – located at end of hoist cable with load hook attached:
a. Load – total superimposed weight on load block or hook.
b. Side Pull – that portion of hoist pull acting horizontally when hoist lines are not operated vertically.
8. Safety Latch – secures load onto hook.
9. Limit switch – a switch operated by motion of power driven machine to alter associated electrical circuit Main Switch – a switch which controls entire power supply to crane.
11. Master Switch – a switch which dominates operation of contactors, relays, or other remotely operated devices.
Instructor Notes
Objective 2, Define the following crane terms: runway, bridge, trolley, hoist, hoist drum, hoist block, safety latch, and pendant control.
Block assembly includes hook or shackle, swivel, bearing, sleeves, pins, and frame.

15. Objective 3
State the frequency that pre-operational inspections should be performed.
XI. Lesson Plan
Instructor Notes
Objective 3, State the frequency that pre-operational inspections should be performed.

16. Required Inspections
All cranes SHALL be inspected annually by qualified personnel (ASME B30.16).
Pre-operational inspection SHALL be performed by operator at beginning of shift.
Move crane to area where block will not hurt anyone or damage equipment if it fails during inspection.
XI. Lesson Body
C. Required Inspections
1. All pendant-controlled cranes shall be inspected annually by qualified personnel, in accordance with ASME B30.16.
2. A pre-operational inspection shall be performed by operator at beginning of shift, in accordance with ASME B30.16.
3. Move crane to area where block will not hurt anyone or damage equipment if it fails during inspection.
4. At completion of inspection, log all results in accordance with site procedures.
Instructor Notes
Emphasize importance of procedural adherence.
Objective 3, state the frequency that pre-operational inspections should be performed.

17. Objective 4
Identify unacceptable conditions that might be discovered during an annual or pre-operational inspections.
XI. Lesson Plan
Instructor Notes
Objective 4, Identify unacceptable conditions that might be discovered during an annual or pre-operational inspection.

18. Check Hooks
No more than 5% and not to exceed ¼ inch increase in throat opening.
(Dimension A)
Measurement taken from punch marks.
XI. Lesson Body
D. Required Inspections (cont)
1. Inspect hooks
a. Throat opening is to be no more than 5%, not to exceed ¼ inch, of the normal throat opening.
Instructor Notes
Objective 4, Identify unacceptable conditions that might be discovered during an annual or pre-operational inspection.

19. Check Hooks
No visibly apparent bend or twist from the plane of the unbent hook.
No visible cracks.
No excessive wear.
Safety latch in place.
XI. Lesson Body
D. Required Inspections (cont)
1. Inspect hooks (cont)
b. No visibly apparent bend or twist from the plane of the unbent hook.
c. No visible cracks.
d. No excessive wear.
e. Safety latch in place.
Instructor Notes
Objective 4, Identify unacceptable conditions that might be discovered during an annual or pre-operational inspection.
Do not use a hook without a safety latch.

20. Check Hoist Ropes Watch for broken wires in this area
Check for broken wires
XI. Lesson Body
D. Required Inspections (cont)
2. Inspect hoist ropes and end connections:
a. Reeved properly.
b. No excessive wear.
c. Not twisted or distorted.
d. Not stretched.
Instructor Notes
Objective 4, Identify unacceptable conditions that might be discovered during an annual or pre-operational inspection.
Hoist chain or rope shall be free from kinks or twists.

21. Check Bridge and Trolley
All covers and attachments secure
No loose objects lodged on crane or hoist
Trolley and bridge alignment correct
XI. Lesson Body
D. Required Inspections (cont)
3. Inspect bridge and trolley:
a. All covers and attachments secure.
b. No loose objects lodged on crane/hoist.
c. Trolley and/or bridge alignment correct.
Instructor Notes
Objective 4, Identify unacceptable conditions that might be discovered during an annual or pre-operational inspection.

22. Check Wall-Mounted Attachments
Cracks
Loose bolts
Broken or cracked welds
End stops properly attached
XI. Lesson Body
D. Required Inspections (cont)
4. Inspect wall-mounted attachments or crane/hoist supporting devices:
a. Cracks.
b. Loose bolts.
c. Broken or cracked welds.
d. End stops are properly attached.
Instructor Notes
Objective 4, Identify unacceptable conditions that might be discovered during an annual or pre-operational inspection.

23. Check Trolley and Bridge Rails
XI. Lesson Body
D. Required Inspections (cont)
5. Inspect trolley and bridge rails:
a. No cracks or broken places.
b. No signs of overloading.
c. Trolley stops securely attached.
d. Bridge stops and bumpers securely attached.
Instructor Notes
Objective 4, Identify unacceptable conditions that might be discovered during an annual or pre-operational inspection.

24. Check Pendant Control Press STOP button Verify control buttons:
Properly labeled
Free of damage
Verify control cable:
Securely attached and not damaged
Not putting strain on electrical cable
Verify ASME-required warnings in place.
XI. Lesson Body
D. Required Inspections (cont)
6. Check the Pendant Control Station:
a. Press STOP button to ensure crane not energized.
b. Verify all control buttons labeled and free of physical damage.
c. Verify control cable securely attached and not damaged.
d. Ensure pendant control is adequately supported by steel cable or chain and not just by electric control cable.
e. Warnings placed on floor-operated hoist shall conform to ASME B30.16.
Instructor Notes
Objective 4, Identify unacceptable conditions that might be discovered during an annual or pre-operational inspection.
Review Warning Flag-3, Maintenance Facilities, Tools and Equipment
Discuss Industrial Safety Bulletin in which movement of pendant cable caused electrical cable to move and permitted two wire lug ferrules to make contact. This contact caused hoist to move up, even though operator was pushing down button.
Warning Label on back or side of control

25. Check Crane Functions
Move bridge and trolley, looking and listening for signs of defects.
Raise and lower hoist.
Check cable wrapping on spool.
Check operation of limit switches.
XI. Lesson Body
D. Required Inspections (cont)
7. Check each function of crane:
a. Move bridge and trolley, looking or listening for signs of defects (screeching or squealing).
b. Raise and lower hoist.
c. Check cable wrapping on spool.
d. Check operation of limit switches.
Instructor Notes
Objective 4, Identify unacceptable conditions that might be discovered during an annual or pre-operational inspection.

26. Check Upper Limit Switches
XI. Lesson Body
D. Required Inspections (cont)
8. Inspect hoist upper limit switches:
a. Raise hoist hook to check upper limit of travel.
b. Hook should be traveling at minimum speed when contact with upper limit switch is made.
c. Take care to avoid two-blocking hoist.
d. If limit switch fails to operate, do NOT operate crane/hoist; contact maintenance to have problem investigated and corrected.
Instructor Notes
Objective 4, Identify unacceptable conditions that might be discovered during an annual or pre-operational inspection.
Refer to Appendix A for OE 14316, Failure of Upper Limit Switch Causes Fuel Cask Auxiliary Hook and Block to Fall 70 Feet.
CAUTION: When testing upper limit switch, ensure that no personnel or vital plant equipment is below the hook and load block assembly.
Discuss BFN OER , Fatality Caused by a Crane Accident (9/26/86) to reinforce need to ensure that area beneath crane is cleared of any personnel during any crane testing, diagnostics, troubleshooting, or maintenance.
Review Industry Event

27. Objective 5
Given an unacceptable condition discovered during an annual or pre-operational inspection, state the actions that should be taken.
XI. Lesson Plan
Instructor Notes
Objective 5, Given an unacceptable condition discovered during an annual or pre-operational inspection, state the actions that should be taken.

28. Reporting Deficiencies
Move crane to less traveled area.
Turn all controllers OFF.
De-energize main switch.
Place warning signs on crane..
Barricade crane or station watchman.
XI. Lesson Body
E. Deficiencies
1. Any deficiencies discovered should be reported to supervisor immediately and problems resolved prior to operating crane:
a. Warnings or “out-of-order” signs shall be placed on crane.
b. All controllers placed in OFF.
c. Main switch de-energized and locked, tagged, or flagged in de- energized position when electrical power not required.
d. Move crane to area not frequently traveled by personnel.
e. Secure area below crane with barricades, tape, rope, or by posting a watchman.
Instructor Notes
Objective 5, Given an unacceptable condition discovered during an inspection, state the actions that should be taken.
Preferred that signs be put on control panel.
Remind students to ensure that area beneath crane is cleared of any personnel during any crane testing, diagnostics, troubleshooting, or maintenance.
Discuss BFN OER , Fatality Caused by a Crane Accident (9/26/86).

29. Correcting Deficiencies
Deficiencies must be corrected.
Engineering evaluation required if repairing load bearing members.
Appropriate tests should be performed after maintenance.
Pre-operational inspection shall be done prior to operating crane.
XI. Lesson Body
E. Deficiencies (cont)
2. Hazardous conditions shall be corrected before normal operation of crane.
3. Repairs to load bearing members should be evaluated by engineering.
4. Appropriate tests should be performed at completion of maintenance, prior to crane operation.
5. When maintenance completed, pre- operational inspection shall be done to prove operability. .
Instructor Notes
Objective 5, Given an unacceptable condition discovered during an inspection, state the actions that should be taken.
Adjustments and repairs shall be done by designated personnel.
Discuss SQN PER , Pendant Controlled Crane Operated prior to completion of required Post Maintenance Test.
Post maintenance testing required by ASME B

30. Identify proper rigging and load handling techniques and restrictions.
Objective 6
Identify proper rigging and load handling techniques and restrictions.
XI. Lesson Plan
Instructor Notes
Objective 6, Identify proper rigging and load handling techniques and restrictions.

31. Preparing for Lift Crane operator shall perform the pre-plan lift.
Use good housekeeping practices.
Select and use proper rigging.
XI. Lesson Body
F. Preparing for a Lift
1. Before lifting a load, be sure to:
a. Crane operator shall perform the pre-plan lift.
b. Use good housekeeping practices.
c. Select and use proper rigging.
Instructor Notes
Objective 6, Identify proper rigging and load handling techniques and restrictions.
Show Summit video entitled “Pendant Controlled Crane Safety.”
Note: Objectives 6 – 8 are covered by the video.

32. Pre-plan the Lift Check weight capacity of crane and sling.
Plan where to set load.
Check intended route.
Identify potential hazards.
XI. Lesson Body
F. Preparing for a Lift (cont)
2. Pre-plan the lift:
a. Check weight capacity marking on crane and load tag on sling to ensure load within capacity of crane and sling devices being used.
b. Know where you plan to set the load.
c. Be aware of the environment.
1) Always check intended route.
2) Identify co-workers, equipment, or other objects in the area.
d. Identify potential hazards before performing lift.
Instructor Notes
Objective 6, Identify proper rigging and load handling techniques and restrictions.
Cranes SHALL NOT be loaded beyond their rated load except for special heavy lifts approved by plant manager in writing after appropriate reviews of ASME B Each site has a procedure controlling these heavy loads.

33. Use Good Housekeeping Ensure adequate clearance to nearby equipment.
Ensure aisles clean.
Keep tools, cords, and other objects off floor so you can move freely.
XI. Lesson Body
F. Preparing for a Lift (cont)
3. Use good housekeeping practices:
a. Ensure adequate clearance to nearby equipment.
b. Ensure aisles are clean.
c. Keep tools, cords, and other objects off floor so you can move freely.
Instructor Notes
Objective 6, Identify proper rigging and load handling techniques and restrictions.

34. Select and Inspect Rigging
Select proper rigging.
Check load tag.
Inspect rigging.
Inspect sockets, slings, handles, and connections.
Remove rigging from service if defective.
XI. Lesson Body
F. Preparing for a Lift (cont)
4. Select and Inspect Rigging:
a. Select type of rigging based on object being lifted and its weight.
b. Check load tag on rigging to be sure it exceeds load.
c. Before use, inspect all rigging for defects that could affect capacity.
d. Inspect all sockets, chokers, handles, and other connections.
e. All defective slings must be tagged and removed from service.
Instructor Notes
Objective 6, Identify proper rigging and load handling techniques and restrictions.
Look for signs of wear, tear, kinks, bird caging, cuts, fatigue, rot, aging, deterioration, holes, etc.
Refer to Appendix B, Fossil and Hydro Power Safety Meeting Topic entitled “Materials Handling Synthetic Web Slings”

35. Objective 7
Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set a load.
XI. Lesson Plan
Instructor Notes
Objective 7, Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set a load.

36. Position Crane & Attach Sling
Position bridge and trolley directly over load.
Ensure hoist line vertical.
Lower hook to attach sling.
Ensure sling properly balanced and controlling load.
Do NOT tie knots in sling.
XI. Lesson Body
G. Lifting a Load
1. Position Crane and Attach Sling:
a. Position bridge directly over load.
b. Position trolley directly over load.
c. Ensure hoist line vertical when lifting.
d. Attach load to load block hook with slings by lowering hook so sling can be easily attached with safety clasp engaged.
e. Sling should be attached so as to provide control of load.
f Sling should be properly balanced so that it will lift load without damaging it.
g. All hooks, rings, and sockets used as sling connections should develop full rated capacity of sling.
h. Do not tie knots in sling; this will reduce sling’s load capacity.
Instructor Notes
Objective 7, Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set a load.
Ensure hoist line free of kinks or twists and not wrapped around load.
Never use hammer or force to attach sling to hook.
Ensure that slings are clear of all obstacles.
Discuss side pull and illustrate on board if necessary.

37. 3 Factors Affecting Capacity
Load Balance
Unbalanced load creates greater force on sling than actual weight of load.
Angle
Angle of sling reduces capacity.
Load Movement
Rapid, sudden movements result in increased forces due to dynamic loading.
XI. Lesson Body
G. Lifting a Load (cont)
2. Three factors can negatively impact sling and affect capacity:
a. Load Balance – unbalanced load can create greater force on sling than actual weight of load.
b. Angle – angle of sling also reduces capacity.
1) If 10 degree angle, capacity = lbs.
2) If 30 degree angle, capacity = lbs.
3) If 70 degree angle, capacity = lbs. c. Load Movement – rapid, sudden movements result in increased forces due to dynamic loading.
Instructor Notes
Objective 7, Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set a load.
Resulting dynamic loading can be as much as 3 times normal load force.

38. Hand Signals Flagman and crane operator must understand each other.
Operator responds only to signals from designated flagman.
Flagman must be in constant communication with operator.
When a flagman is not required, the operator is responsible for movement of crane.
XI. Lesson Body
G. Lifting a Load (cont)
3. Hand signals:
a. It is critical that flagman and crane operator understand each other completely.
b. Operator shall respond only to signals from the designated flagman.
c. Flagman must be in constant communication with operator.
d. If crane operator loses sight of flagman, operator must stop all crane operations.
e. When flagman not required, crane operator is responsible for movement of crane.
f. Crane operator should obey all STOP signals, no matter who gives them.
Instructor Notes
Objective 7, Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set a load.
Flagman shall wear orange reflective vest. At some sites, orange reflective gloves are also required.
Hand signals are taught in Rigging training which is a prerequisite for this course.
Refer to Attachment 1, “Hand Signals for Controlling Crane Operations”
Stop and think when each signal is given. Never make assumptions or move crane until clear signal given and understood.

39. Raising Hook & Inspecting Load
Once sling in place, slowly raise hook to remove slack.
Make final inspection.
Ensure sling in center of hook.
NEVER pull sling from under load while load resting on sling.
XI. Lesson Body
G. Lifting a Load (cont)
4. Raising Hook and Inspecting Sling:
a. After slings in place, slowly raise hook until there is no slack in sling; then stop.
b. Make final inspection of sling.
1) Ensure load is secured, balanced, and positioned in sling.
2) Sling is sitting in center of hook.
3) Hoist rope is not kinked.
4) Multiple part lines are not twisted around each other.
c. Never pull sling from under load while load is resting on sling.
Instructor Notes
Objective 7, Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set load.
Hook and hoist ropes and chains are properly reeved and aligned.

40. Lifting Heavy Loads
When heavy loads lifted in critical areas, such as:
Fuel pits
Reactor building
Intake pumping station
Special precautions must be taken:
Equipment readiness
Load movement path
In accordance with NUREG 0612.
XI. Lesson Body
G. Lifting a Load (cont)
4. Raising Hook and Inspecting Sling (cont)
d. When heavy loads are to be lifted in critical areas (around fuel pits, reactor building, intake pumping station, etc.) special precautions must be taken as to equipment readiness and load movement path, per NUREG 0612.
Instructor Notes
Objective 7, Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set load.
Mention plant-specific procedure controlling heavy and critical lifts.

41. Notifying Others & Positioning Self
Notify co-workers before lifting and moving load.
Operator must be positioned so that:
Load is in view.
There are no potential pinch points.
STOP if any concern about safety.
XI. Lesson Body
G. Lifting a Load (cont)
5. Notifying Others and Positioning Self:
a. Notify all co-workers in area before lifting and moving load.
b. Position self so you have best view of load without putting self in potential pinch points.
c. Whenever there is any doubt as to safety, operator shall stop operation and consult with supervisor before handling load.
Instructor Notes
Objective 7, Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set load.

42. Using Pendant Control Keep both hands on pendant control.
Use pendant to control all movement:
Forward and back.
Left and right.
Up and down.
Electric brake will set if release control button.
XI. Lesson Body
G. Lifting a Load (cont)
6. Using the Pendant Control:
a. Keep both hands on pendant control.
b. Remember the pendant control is used to move the load in three directions.
1) Forward and back
2) From side to side
3) Up and down
c. When you release control button, electric brake will automatically set.
Instructor Notes
Objective 7, Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set load.
Discuss in detail how directions are given at your site: i.e., north, south, east, west.
Emphasize attention to detail when using pendant control to ensure pressing correct button.

43. Lifting Load Always lift straight up.
Raise load high enough to clear obstacles.
NEVER put hands between load and sling.
Ensure co-workers properly positioned.
Check intended path.
XI. Lesson Body
G. Lifting a Load (cont)
7. Lifting the Load:
a. Always lift load straight up.
b. Raise load high enough to clear obstacles before traveling with it.
c. Never place hands between load and sling while load is being lifted.
d. Ensure you and co-workers are properly positioned when lifting or moving load to avoid being struck by load or snapped sling.
e. Tag line should be used on most loads.
f. Check intended path before moving load since operator attention will be focused on load during move.
Instructor Notes
Objective 7, Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set load.
Cranes are not used for side pulls unless authorized by qualified person who has determined that stability of crane not endangered and that various parts of crane will not be over-stressed. No operational manual for any type crane permits side pulls.
Emphasize importance of good housekeeping.

44. Lifting Loads near Rated Load
If load being handled is close to rated load.
Check hoist brakes once per shift:
Raise load short distance.
Apply brakes.
Observe load for slippage.
Observe drum for turning.
XI. Lesson Body
G. Lifting a Load (cont)
7. Lifting the Load (cont)
g. Operator shall check hoist brakes at least once each shift if load being handled is approaching rated load capacity.
1) Raise load short distance.
2) Apply brakes.
3) Observe load for slippage.
4) Observe drum for turning.
Instructor Notes
Objective 7, Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set load.

45. If Two Cranes Used to Lift Load
If 2 or more cranes used to lift load:
One qualified person is in charge:
Analyze operation.
Instruct all personnel.
Positioning.
Rigging of load.
Movements to be made.
XI. Lesson Body
G. Lifting a Load (cont)
7. Lifting the Load (cont)
h. When two or more cranes are used to lift a load, one qualified person shall be in charge of operation and is responsible for:
1) Analyzing the operation.
2) Instructing all personnel involved in the proper positioning, rigging of the load, and movements to be made.
Instructor Notes
Objective 7, Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set load.
NOTE: IF MORE THAN ONE HOOK OR CRANE IS USED, IT IS A HIGH HAZARD LIFT, PERSONNEL SHALL REFER TO SAFETY PROCEDURE ON “REQUIREMENTS FOR SAFE OPERATION OF CRANES” FOR GUIDANCE.

46. Moving Load Avoid sudden starts and stops:
Causes load to swing.
Places extra stress on crane and slings.
Maintain smooth steady pace.
Slow down gradually.
Avoid swinging load.
XI. Lesson Body
H. Moving the Load
1. Avoid sudden starts and stops:
a) May cause load to swing.
b) Places extra stress on slings and crane.
c) Could cause injuries, property damage, and increased maintenance for crane.
2. When traveling, maintain smooth, steady pace, anticipate your stops, and slow down gradually.
3. Avoid swinging load:
1) Increases amount of load force.
2) More rapid or sudden movement is, greater force will be.
3) Force can be as much as 3 times normal load force.
Instructor Notes
Objective 7, Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set load.
Slow starts and stops minimize swinging of hooks and loads.

47. Moving Load Check intended path Watch for traffic.
NEVER carry load over co-workers.
Keep both hands firmly on pendant.
Face load when traveling.
Ensure pendant control wire not tangled with hoist lines.
Use tag line if needed to control load.
XI. Lesson Body
H. Moving the Load (cont)
4. Check intended path before moving load.
5. Watch for traffic.
6. Do NOT lift, lower, or travel with anyone on the hook.
7. NEVER carry load over co-workers; let them move out of way.
8. Keep both hands firmly on pendant control.
a. Deadman’s switch will stop energy to bridge and trolley if pendant slips out of your hands.
b. But, load can still drift and may harm co-workers or damage equipment.
9. Always face load when traveling.
10. Ensure pendant control wire does not get caught or tangled with hoist lines or on objects.
Instructor Notes
Objective 7, Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set load.
Use tag line if needed to control load.
Operator SHALL not leave controls while load is suspended in area accessible to people.

48. Setting Load Place bridge and trolley directly over landing position.
Do NOT swing load into place.
Slowly set load.
Lower hook so slings can be removed.
XI. Lesson Body
I. Setting the Load
1. Place bridge and trolley directly over landing position.
2. Do not swing load into place.
3. Slowly set load.
4. Lower hook so slings can be safely and easily removed from hook.
5. Ensure that no load is attached, stow the hook, and open the master switch.
Instructor Notes
Objective 7, Describe safe work practices to be used when operating a pendant-controlled crane to lift, move, and set load.
Load shall not be lowered below point where less than 2 wraps of rope remain on each anchorage of hoisting drum unless lower limit device is provided, in which case not less than 1 wrap shall remain.

49. Objective 8
State how to properly store a pendant-controlled crane when not in use.
XI. Lesson Plan
Instructor Notes
Objective 8, State how to properly store a pendant-controlled crane when it is not used.

50. Securing Crane Set load. Walk pendant back under bridge.
Store all slings; do not drag them.
Move crane to designated area.
Raise hook to intermediate position.
Place controls OFF.
XI. Lesson Body
J. Securing Crane when not in use
1. Before leaving crane unattended, operator SHALL land any load, place controllers in OFF position, and open master switch.
2. When storing the crane after work is completed:
a. Do not swing or toss pendant control out of way when finished.
b. Walk pendant control back directly under bridge.
c. Properly store all slings
d. Avoid dragging slings on floor or abrasive surfaces.
e. Move crane to designated area, safely out of way.
f. Raise all hooks to intermediate position.
g. Place all controls in OFF position.
Instructor Notes
Objective 8, State how to properly store a pendant-controlled crane when it is not used.
Be sure that all controllers are in OFF position before opening the master or emergency switches so that the crane will not start unexpectedly.

51. Objective 9
Describe operator responsibilities and potential hazards when operating a pendant-controlled crane.
XI. Lesson Plan
Instructor Notes
Objective 9, Describe operator responsibilities when operating a pendant-controlled crane.

52. Operator Responsibilities
Do NOT operate if physically or mentally unfit.
Do NOT engage in anything that will divert attention.
Understand hazards.
Inspect crane & slings.
Carefully plan each lift.
Respond to signals.
Notify co-workers.
Smoothly perform lift.
Avoid sudden starts and stops.
Place bridge & trolley directly over load.
Properly store crane and rigging.
XI. Lesson Plan
K. Operator Responsibilities
1. As a pendant-controlled crane operator, you are responsible for safely moving thousands of pounds in close proximity of co-workers and equipment.
2. Operator must understand responsibilities:
a. Understand & respect potential hazards.
b. Know capabilities & limitations of crane.
c. Inspect crane and slings before use.
d. Carefully plan each lift and perform it smoothly.
e. If flagman used, respond to signals.
f. Obey all STOP signals, no matter who gives them.
g. Avoid sudden starts and stops.
h. Notify all co-workers when making lift.
i. Always place bridge and trolley directly over load when lifting or lowering it.
j. Properly store crane and rigging.
Instructor Notes
Objective 9, Describe operator responsibilities when operating a pendant-controlled crane.
When operating crane, don’t engage in any activity which will divert attention and don’t operate crane if physically or mentally impaired.
Never make assumptions or move crane until clear signal given and understood.
Refer to Attachment 1, “Hand Signals for Controlling Crane Operations.”

53. Potential Hazards Tripping over items on floor. Tripping on cable.
Hitting someone.
Hitting plant equipment.
XI. Lesson Plan
K. Operator Responsibilities (cont)
3. Potential Hazards
a. Tripping over items on floor.
b. Tripping on crane cable.
c. Hitting someone.
d. Hitting plant equipment.
Instructor Notes
Objective 9, Identify potential hazards when operating a pendant-controlled overhead crane.

54. Review ANSI Hand Signals Related to Pendant Cranes
Objective 10
Review ANSI Hand Signals Related to Pendant Cranes
XI. Lesson Plan
Instructor Notes
Objective 17, Under the direction of an examiner, inspect a cab-operated overhead crane, conduct a pre-operational function test, and safely move a load through a marked obstacle course.

55. Necessity of Hand Signals
Provide for safety
Universal signals
Verbal signals not always possible

56. Rules Governing Hand Signals
Only one signal person should signal operator (except for emergency stop)
Hand signals should be in accordance with ASME standards (unless voice communication is used)
Signals should be discernible or audible at all times
Special operations may require modifications of, or addition to, standard signals
Special signals should be agreed upon and understood by both signal person and operator
Hand signals shall be posted conspicuously

57. Use Main Hoist
Tap fist on head, then use regular hand signals

58. Use Whipline (Auxiliary Hoist)
Tap elbow with one hand, then use regular hand signals

59. Raise Load
Move hand in small horizontal circle with forearm vertical and forefinger pointing up

60. Emergency Stop
Extend arms outward slightly down and move hands rapidly right and left

61. Move Slowly
Along with any movement signal, place other hand motionless in front of hand giving motion signal
Example means “hoist the load slowly”

62. Trolley Travel
Point thumb in desired direction of travel with palm up, fingers closed

63. With arm extended, palm down, move arm back and forth horizontally
Stop
With arm extended, palm down, move arm back and forth horizontally

64. Bridge Travel
Make a pushing motion in direction of travel with arm extended forward and hand open and slightly raised

65. Lower
Move hand in small horizontal circle with arm extended downward and forefinger pointing down

66. Dog Everything Clasp hands in front of body
The signal “Dog Everything” means stop and shut down all lifting operations

67. Objective 11
Using Appendix C, complete a performance evaluation by conducting a pre-operational inspection and by safely operating a pendant-controlled crane to lift, move and set a load.
XI. Lesson Plan
Instructor Notes
Objective 10, Using Appendix C, complete a performance evaluation by conducting a pre-operational inspection and by safely operating a pendant-controlled crane to lift, move, and set a load.

68. Performance Evaluation
Instructor demonstration.
Time for student practice.
Students may perform inspection in pairs but must independently lift, move, and land load.
While one student operates crane, another student attaches load and gives hand signals to operator.
Students then reverse roles.
Each student must independently complete Appendix C.
XI. Lesson Plan
L. Performance Evaluation
Instructor demonstrates proper inspection and operation of crane.
Students practice.
Students divide into pairs (optional).
Students may perform crane inspection in pairs but must independently lift, move, and set load.
While one student operates crane, other student attaches load and gives hand signals to operator to move load to designated area.
Students then reverse roles.
Instructor completes Appendix B for each student.
Instructor Notes
Objective 10, Using Appendix C, complete performance exam by conducting a pre-operational inspection and safely operating pendant-controlled crane.
Safety Precautions:
All personnel in immediate area will wear hard hat and safety glasses.
Students will wear gloves to protect hands.
All rigging hardware must be approved and have current inspection visible, if required.
Lay down area will be marked for student to set load.

69. Click Here Return to Course
Industry Event
Click Here Return to Course
Appendix A, Operating Experience
OE14316, Failure of Upper Limit Switch Causes Fuel Cask Auxiliary Hook and Block to Fall 70 Feet
Summary:
On June 4, 2002, with Salem Unit 1 at 100 percent power and following crane activities in the fuel building, a crane operator performed activities to stow the pendant operated 3-ton rated auxiliary hook on the fuel cask crane. The crane operator raised the hook, relying on the anti two-block switch to stop the auxiliary hoist movement. The switch failed and the hook continued to rise, snapping the cable. The block and hook fell 70 feet to the floor.
The cause of the event was a failure of the hoist upper limit switch. Follow-up testing indicated the switch would intermittently fail.
Human performance deficiencies contributed to the event in that the crane operator did not inch the hoist into the upper limit switch at a very slow speed as directed by training and procedure and he relied on the upper limit switch as a stop control during normal operation.
Corrective actions include adjusting the hoist brake, inspecting the block and hook, load testing hoist after reassembly, testing Unit 2 crane's limit switch, and inspecting other cranes limit switches.
Future corrective actions include replacing the hoist cable, revising training lesson plans to emphasize not to rely on the limit switches to stop, and evaluating the installing an additional limit switch to both unit's cask handling cranes.
This event is not significant because there was no damage to other equipment or personnel injury. This event is NOTEWORTHY because of the potential for serious personnel injury and equipment damage.

70. Appendix B What should you know about using synthetic web slings?
1. Synthetic web slings are easily cut and have poor abrasion resistance when compared with chain and wire rope slings.
2. Nylon slings are damaged by acids, but resist caustics.
3. Polyester slings are damaged by caustics but resist acids.
4. Sunlight, moisture, and temperatures above 90°C (194°F) damage both nylon and polyester slings.
5. Use slings made of the right material for the job.
6. Check the manufacturers' slings for code number and rated capacity. Reference charts showing slings and hitch rated capacities are available from manufacturers.
7. Inspect slings before using them.
8. Keep an inspection record for each sling.
What should you check when selecting slings?
1. Refer to the manufacturer's reference chart for the capacity rating.
2. Check a sling before using it.
3. Determine the weight of the load.
4. Prevent loading more than the rated capacity by considering sling angle.
5. Protect webbing from sharp corners, protrusions, or abrasive surfaces.
6. Ensure that the sling choking action is on the webbing, not the hardware.
7. Have slings repaired by a sling manufacturer only.
What should you avoid when using slings?
1. Do not drag slings across floors or other abrasive surfaces.
2. Do not drop slings with metal fittings.
3. Do not set loads down on top of slings.
4. Do not pull slings from under loads when the load is resting on the sling.
5. Do not weld anything hung from a sling.
6. Do not lengthen or shorten slings by tying knots.
7. Do not place stitch patterns (laps) on hooks, sharp corners, or choker bearing points.
What kinds of damage make a synthetic web-sling unusable?
1. Increased stiffness of sling material.
2. Acid or caustic burns.
3. Melted, burned or weld spatter damage.
4. Holes, tears, cuts, snags.
5. Broke or worn stitching.
Appendix B
What should you know about using synthetic web slings?
1. Synthetic web slings are easily cut and have poor abrasion resistance when compared with chain and wire rope slings.
2. Nylon slings are damaged by acids, but resist caustics.
3. Polyester slings are damaged by caustics but resist acids.
4. Sunlight, moisture, and temperatures above 90°C (194°F) damage both nylon and polyester slings.
5. Use slings made of the right material for the job.
6. Check the manufacturers' slings for code number and rated capacity. Reference charts showing slings and hitch rated capacities are available from manufacturers.
7. Inspect slings before using them.
8. Keep an inspection record for each sling.
What should you check when selecting slings?
1. Refer to the manufacturer's reference chart for the capacity rating.
2. Check a sling before using it.
3. Determine the weight of the load.
4. Prevent loading more than the rated capacity by considering sling angle.
5. Protect webbing from sharp corners, protrusions, or abrasive surfaces.
6. Ensure that the sling choking action is on the webbing, not the hardware.
7. Have slings repaired by a sling manufacturer only.
What should you avoid when using slings?
1. Do not drag slings across floors or other abrasive surfaces.
2. Do not drop slings with metal fittings.
3. Do not set loads down on top of slings.
4. Do not pull slings from under loads when the load is resting on the sling.
5. Do not weld anything hung from a sling.
6. Do not lengthen or shorten slings by tying knots.
7. Do not place stitch patterns (laps) on hooks, sharp corners, or choker bearing points.
What kinds of damage make a synthetic web-sling unusable?
1. Increased stiffness of sling material.
2. Acid or caustic burns.
3. Melted, burned or weld spatter damage.
4. Holes, tears, cuts, snags.
5. Broke or worn stitching.

71. Appendix C –Pendant-Controlled Crane Performance Evaluation
Student Name _________________________________ Student SSN ___________________
Instructor Signature____________________________ Date ________________
Student Signature_____________________________
Appendix C –Pendant-Controlled Crane Performance Evaluation
Student Name _________________________________ Student SSN ___________________
Instructor Signature____________________________ Date ________________
Student Signature_____________________________
Performance Step
Pass
Fail
1. Inspect crane control station to ensure control power switch is in off position, control station suspended by chain or aircraft cable, and controls not damaged.
2. From floor, inspect bridge and trolley area, checking for obstructions, loose or damaged equipment, and hoist rope reeved properly on drum.
NOTE: When performing steps 3 – 11, ensure that no personnel or vital equipment under hook.
3. Turn on control power switch and move hoist to clear area, if necessary.
4. Check upper hoist limit switch and down control of hoist for proper operation.
5. Check trolley for proper control response.
6. Check bridge for proper control response.
7. Lower hoist and check lifting block, hook, and hoist rope for damage.
8. Following flag person’s signals, center hook over load.
9. Attach hook and move load, maintaining sight of load or flag person, and not contacting obstacles.
10. Land load gently.
11. Secure crane by storing hook and turning off control power.
Performance Step
Pass
Fail
1. Inspect crane control station to ensure control power switch is in off position, control station suspended by chain or aircraft cable, and controls not damaged.
2. From floor, inspect bridge and trolley area, checking for obstructions, loose or damaged equipment, and hoist rope reeved properly on drum.
NOTE: When performing steps 3 – 11, ensure that no personnel or vital equipment under hook.
3. Turn on control power switch and move hoist to clear area, if necessary.
4. Check upper hoist limit switch and down control of hoist for proper operation.
5. Check trolley for proper control response.
6. Check bridge for proper control response.
7. Lower hoist and check lifting block, hook, and hoist rope for damage.
8. Following flag person’s signals, center hook over load.
9. Attach hook and move load, maintaining sight of load or flag person, and not contacting obstacles.
10. Land load gently.
11. Secure crane by storing hook and turning off control power.