1. External Operations Experience Update: Cranes, Slings and Things that Go Drop
Department of Energy
Operating Experience Work Group
February 24, 2015
Larry Stirling,
Office of Analysis (AU-23)

2. Many Kinds of Cranes

3. Many Kinds of Cranes

4. Many Kinds of Cranes

5. Many Kinds of Cranes

6. Crane Safety Program Elements
Site Safety Rules.
Periodic Training.
Inspection Program.
Maintenance Program.
Operating Safety Rules.
Operator Prequalification.
Control of Hazardous Energy Sources.

7. Implementation Dedication Personal Interest Management Commitment
Understanding and Support from the work force

8. Inspection, Testing & Maintenance
Start of Each Shift
1. Visually Inspect all units for integrity, leaks etc.
2. Check the operation of the crane; controls & movement.
3. Operate empty hook till it actuates the upper limit switch.
4. Operate hoist and trolley brakes, ensure no excessive coasting.
5. Check for twisted, broken or kinked cables or chains.
6. Observe correct drum spooling as the hook is raised.
7. Inspect for deformed, cracked, or stretched hooks.
8. Inspect for serviceable safety latches.
9. Check for air or hydraulic fluid leakage.
10. Check for load capacity stenciling on both sides of unit.
11. Review the manufacturers inspection requirement

9. Inspection, Testing & Maintenance
Monthly 1. Visually Inspect all critical items. 2. Measure hooks for deformation or stretching. 3. Inspect hooks for cracks, missing or broken parts. 4. Measure lifting chains for excessive stretch, twisting etc. 5. Inspect for twisted, broken or kinked cables or chains. 6. Follow any additional recommendations of the manufacturer.

10. Inspection, Testing & Maintenance
Periodic Inspections (1 to 12 months)
1. Interval dependent on
Type of activity
Severity of service
Environmental conditions

11. Inspection, Testing & Maintenance
Inspection should cover:
Chain or cables
Electrification
Brakes
Warning devices
Reeving
Hoist drives
Limit switches
Balance
End stops

12. Inspection, Testing and Maintenance
Hook conditions
Travel drives
Couplings
Controls
Signage

13. CMAA Periodic Inspection Recommendations
Standby or infrequent – Annual
Light service (2-5 lifts hr) – Annual
Moderate service (50% capacity, 5-10 lifts hr.) Annual
Heavy service (50% capacity, lift hr.) Semiannually

14. CMAA Periodic Inspection Recommendations
Severe service (near capacity, 20+ lifts hr.) Quarterly
Continuous severe service (near capacity and continuous service through day) Bi-monthly
Different conditions may suggest different intervals. Review the manufacturers specific inspection requirements.

15. Load Testing Requirements
Vary according to type of crane and usage
New cranes
Used cranes
Idle cranes
Altered cranes
Review manufacturers specific inspection requirements

16. Preventative Maintenance
1. Cleaning and lubricating the wire rope (cable) and load chain. 2. Adjusting the brakes. 3. Checking and filling gear cases 4. Replacing contaminated oil 5. Lubricating bearings, gears, pinions, linkages, shafts… 6. Adjusting operation of limit switched 7. Cleaning or replacing pitted or burned electrical contacts 8. Cleaning or replacing air and fluid filters 9. Inspecting all controls and warning systems

17. Preoperational Tests 1. Ensure all emergency disconnects are known
2. Get help if you are not familiar with cranes’ operation
3. Follow manufacturers recommendations
4. Use your checklist
5. Inspect electrical controls
6. Check for obstructions in travel path

18. Preoperational Tests
7. Test all controls to determine proper operation
8. Observer for smooth operation of components
9. Never unwind the spool completely
10. Check upper and lower limit switches

19. Preoperational Tests Hooks 1. Replace if deformed or cracked
2. Check functioning of safety latch
3. Twists from the plane of unbent hook
4. Check for proper swivel
5.Hook repair generally not recommended
6. Emergency hook repair only under competent supervision
7. Load test hook after repair

20. Preoperational Tests Rope 1. Replace if reduction in diameter is found
2. Broken or worn outside wires
3. Corroded or broken wires at end of connections
4. Sever kinking, crushing, cutting or unstranding
5. Corroded, cracked, bent , worn, improperly applied end connections

21. References
ASME B30.1, “Jacks, Industrial Rollers, Air Casters, and Hydraulic Gantries”
ASME B30.2, “Overhead and Gantry Cranes (Top-Running Bridge, Single or
Multiple Girder, Top-Running Trolley Hoist)”
ASME B30.3, “Tower Cranes”
ASME B30.4, “Portal and Pedestal Cranes”
ASME B30.5, “Mobile and Locomotive Cranes”

22. References ASME B30.6, “Derricks”
ASME B30.7, “Base-Mounted Drum Hoists”
ASME B30.8, “Floating Cranes and Floating Derricks”
ASME B30.9, “Slings”
ASME B30.10, “Hooks”

23. References ASME B30.11, “Monorail Systems and Underhung Cranes”
ASME B30.12, “Handling Loads Suspended from Rotorcraft”
ASME B30.13, “Storage and Retrieval Machines”
ASME B30.14, “Side Boom Tractors”
ASME B30.16, “Overhead Hoists (Underhung)”

24. References
ASME B30.17, “Overhead and Gantry Cranes (Top Running Bridge, Single Girder,
Underhung Hoist)”
ASME B30.20, “Below-The-Hook Lifting Devices”
ASME B30.21, “Manually Lever Operated Hoists”
ASME B30.22, “Articulating Boom Cranes”

25. References ASME B30.23, “Personnel Lifting Systems”
ASME B 30.24, “Container Cranes”
ASME B30.25, “Scrap and Material Handlers“
ASME B30.26, “Rigging Hardware”
ASME B30.27, “Material Placement Systems”
ASME B30.28, “Balance Lifting Units”
ASME BTH-1, “Design of Below-the-Hook Lifting Devices”

26. References
ASME HST-1, “Performance Standard for Electric Chain Hoists”
ASME HST-2, “Performance Standard for Hand Chain Manually Operated Chain
Hoists”
ASME HST-3, “Performance Standard for Manually Lever Operated Chain Hoists”
ASME HST-4, “Performance Standard for Electric Wire Rope Hoists”
ASME HST-5, “Performance Standard for Air Chain Hoists”
ASME HST-6, “Performance Standard for Air Wire Rope Hoists”
ASME NQA-1, “Quality Assurance Program Requirements for Nuclear Facilities”

27. References ASME Cranes for Nuclear Facilities
ASME NUM-1, “Rules for Construction of Cranes, Monorails, and Hoists (With
Bridge or Trolley or Hoist of the Underhung Type)”
ASME NOG-1, “Rules for Construction of Overhead and Gantry Cranes
(Top running Bridge, Multiple Girder)”

28. References Crane Manufacturers Association of America
CMAA Specification 70, “Specifications for Top Running Bridge & Gantry Type”
Multiple Girder Electric Overhead Traveling Cranes
CMAA Specification 74, “Specifications for Top Running and Under Running”
Single Girder Electric Overhead Traveling Cranes Utilizing Under Running Trolley
Hoist

29. References Department of Labor
29 CFR 1910, “Occupational Safety and Health Standards for General Industry”
29 CFR 1926, “Occupational Safety and Health Regulations for Construction”

30. References
Industrial Truck Standards Development Foundation (ITSDF):ITSDF B56.1, “Safety Standard for Powered Industrial Trucks – Low Lift and High
Lift Trucks”
ITSDF B56.5, “Guided Industrial Vehicles”
ITSDF B56.6, “Rough Terrain Fork Lift Trucks”
ITSDF B56.10, “Safety Standard for Manually Propelled High Lift Industrial
Trucks”
ITSDF B , “Hook-Type Forks and Fork Carriers for Powered Industrial
Forklift Trucks”
ITSDF B , “Liquid Propane Gas (LPG) Fuel Cylinders (Horizontal or
Vertical) Mounting - Liquid Withdrawal - For Powered Industrial Trucks”

31. References Material Handling Industry of America
ANSI, MH29.1, “Safety Standard for Industrial Scissor Lifts”

32. References
“NIOSH Alert: Preventing Worker Injuries and Deaths from Mobile Crane Tip-Over, Boom Collapse, and Uncontrolled Hoisted Loads” DHHS (NIOSH) Publication :
A Guide to Cranes and Derricks: North Carolina Department of Labor

33. References
M_009 Overhead Crane Safety Lecture, Milton J. Shoup, III, University of Rochester:
Navy Crane Center, “NAVFAC P-307 Web-Based Training:”

34. References Crane and Sling Safety (USMRA):
UC Berkeley, Environment, Health and Safety, Crane/Hoist Safety Program:
University of Michigan: Crane – Job Safety Analysis Form:
Occupational Safety and Health Administration: Sling Safety,

35. Contact Information:
Larry Stirling
Office of Analysis (AU-23)