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    57 views36 pages

    Overhead Crane Inspection Handout

    Uploaded by

    Walidbenrhouma

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 36
    LLOYDS BRITISH Training LLOYDS BRITISH TRAINING SERVICES ATLAS HOUSE 4-6 BELWELL LANI FOUR OAKS SUTTON COLDFIELD WEST MIDLANDS B74 4AB DEFINITION OF Inspection ‘A visual inspection carried out by a competent person looking carefully and critically for anything which may impair the safe and efficient working of an appliance. Examination ‘A visual examination by a competent person carried out carefully and critically, and supplemented by other means, ie. measurement, non destructive testing or parts of the appliance are to be dismantled in order that the competent person shall arrive at a reliable conclusion as to the condition and safety of the appliance. REPORTING DEFECTS AND WITHDRAWALS FROM SERVICE When an inspection or examination reveals excessive wear or any other defect in a lifting appliance which is such as to render the appliance unsafe, it shall immediately be withdrawn from service and the management notified. COMPETENT PERSON Although the expression "competent person" is widely used in the Factory Act and Regulations when referring to the examination of various kinds of plant, there is no legal definition of the term. Itis generally accepted that a competent person is one who has the necessary knowledge and experience, both theoretical and practical, of the type of equipment under examination, to certify with confidence that it is free from patent defect and suitable in every way for the duty for which it is required. This general statement was confirmed in the approved code of practice to the Docks Regulations 1988 and Guidance, which also stated the competent person should be over 18 years of age. Further the Pressure Systems and Transportable Gas Containers Regulations 1989 establishes that "competent persons" refers not to the individual employee who carries out the duty but to the which employs him. ‘The Lifting Equipment Engineers Association expands on these general comments with the following observations of the qualifications of a competent person: = He must have adequate practical experience in examining and testing lifting equipment. He must have a questioning mind and not take anything for granted. He must point out faults or errors in the work being examined, also give reasons for his criticisms, remembering always that upon his inspection will depend the users life. He must also take responsibility for accepting material which, in his opinion, is safe. He must have imagination to visualise conditions under which particular types of equipment will be used and take every opportunity of extending his knowledge and experience. He must have a knowledge of materials used in the manufacture of lifting equipment and understand how they perform under load conditions. It is not considered necessary that the said knowledge and experience shall be vested in any ‘one or same individual, but that such qualifications may be held jointly within several members of staff of a Company. (CRANE MAINTENANCE (GENERAL NOTES) 1 INTRODUCTION ‘The installation of cranes and lifting equipment in any organisation requires special attention with regard to basic rules and procedures for operators, maintenance and inspection personnel, It is essential that these rules and procedures are understood at all levels and are ‘common throughout the organisation. It should also be clearly stated who is authorised to carry out the respective tasks. Cranes, lifting machines, chains, ropes and lifting tackle are subject to statutory requirements and regulations in most countries, and in the U.K. the principal references are the Factories ‘Act 1961, The Health and Safety at Work etc Act 1974 and the British Standards Institute BS 7121 1989, Code of Practice for the Safe Use of Cranes. Persons carrying out testing, examination and inspection under these provisions should be appointed competent persons, and the particulars required by law should be recorded. 2 SAFETY 2:1 ACCESS and EGRESS ‘Access to an overhead crane is usually by stairs, steps or ladders. Stairs are preferable to ladders and, where vertical ladders are provided, these should be hooped and rest platforms provided where necessary. Particular attention should be paid to the safe access to an Electric Overhead Travelling Crane (E.0.T.C.) and the gantries. Adequate precautions should be taken to avoid placing hands on crane rails and live conductor wires or conductor bars. Notice should be taken of any other cranes on the same gantry or on adjacent gantries, Dust allowed to collect on access platforms can also create hazards and any oil or grease patches should be cleaned up immediately. ‘As with any confined space, head damage can occur, and it is recommended that all persons gaining access to an overhead crane should wear head protection. At all points of access to overhead gantries or to positions where a person may be struck by an overhead crane, a notice should be displayed restricting access to authorised persons only. 2.2. GUARDS and FENCING Persons using access and maintenance platforms should be protected from injury by adequate guarding and fencing of moving parts of the crane and hoist gear, and from coming into contact with live electrical equipment. Particular things to look out for are traverse shafts and couplings, conductor bars or wires. These should be suitably guarded or fenced (Fig.1). ‘Adequate clearance should also be provided between festoon cables and outer fencing (Fig.2). Guards and fencing may have to be removed when servicing and maintenance operations are carried out, and should therefore be as light and convenient to handle as possible, consistent with strength of construction. If possible, storage provision should be made for repair work being carried out, so as not to create a hazard, either by obstruction or by falling from the crane on to workers below. Exposed moving parts associated with prime movers must be securely guarded at all times, regardless of their position. Positional safety should not be relied on unless access is effectively prevented when the parts are in motion. 2:3. FIRE Some of the common causes of fire are:- a) overheating of electrical motors, with breakdown of insulation or overheating of bearings. b) cables shorting to frame. ©) ignition of oil and grease. 4) ignition of waste materials. Regular inspection and planned maintenance will effectively reduce fire risk, and should include the inspection and maintenance of fire-fighting equipment, alarm and escape apparatus. Additionally, all persons liable to work on overhead cranes should be trained in aspects of fire prevention, means of escape, alarm systems and the operation of fire-fighting equipment. The latter should be used as a first-aid measure only, as the prime concem of the operator should be to escape from the situation as quickly as possible. Various types of escape apparatus can be supplied with overhead cranes, and the type chosen will depend upon the environment and/or personal preferences (Figs.344). These should only be used as a last resort, but practice and familiarisation with their use is an essential part of the training process. General housekeeping and cleanliness play an important role in reducing the risks and hazards likely to occur on overhead cranes, and should be the subject of regular monitoring to maintain standards. 3. WORKING ON OR NEAR OVERHEAD CRANES 3:1 Potential Hazards ‘Working on or near overhead cranes requires the consideration of certain hazards:- a) _persons working on the wheel track may be struck by a crane on the same or on an adjacent track. b) _ persons working on a moving crane may be trapped in places of limited clearance. ©) persons working above floor level may be struck by the crane or its load. 4) loose tools and equipment may fall from the crane on to people working below. ) persons may fall from the crane to floor level. f) persons may come into contact with live electrical conductors Some of these hazards are subject to statutory provisions under Section 27 of the Factories ‘Act 1961. Compliance is not always easy in works engaged on a continuous process, or where several cranes operate on the same or adjacent tracks. 3:2 Safety Precautions All persons required to work on or near overhead cranes should be made aware of the hazards and precautions to be taken. Particular attention should be drawn to the dangers of gaining access to a crane or gantry where other cranes are in operation on the same or adjacent gantry tracks. If it is necessary to inspect or test a crane whilst in motion, then the crane driver should come under the direction of the inspecting or maintenance staff. Only one person should be allowed to give instructions to the driver and the driver should be instructed to ignore all other instructions, with the exception of "emergency stop", whilst the work is being carried out. Portable electric tools and lighting should preferably be low-voltage. The use of long flexible leads should be avoided wherever possible by provision of a suitable convenient supply Provision should also be made to “lock off” the main isolators when necessary, and written procedures drawn up to prevent the supply being switched on whilst work is still in progress (see Appendix 1). Effective procedures should be drawn up for ensuring that all personnel concerned are notified of any maintenance or repair work being carried out, and suitable precautions are taken to prevent accident or injury. Such rules and procedures should be rigidly enforced and controlled. It is essential that other service engineers and contractors are made aware of these rules and procedures, and carry out their duties in accordance with them. Particularly, “effective measures” must be taken to prevent any crane from approaching within 20ft (6.096m) anyone working at or near the track of an overhead travelling crane, where he may be struck by the crane. 4 MAINTENANCE ‘The purpose of these guidelines is to outline maintenance procedures which, when properly applied, will assist in maintaining a high degree of reliability and safety. Generally the guidelines lay a particular emphasis on the daily or shift checks carried out by the crane driver. Through experience, he will notice any unusual signs or sounds whilst carrying out a routine check, These checks are in addition to the examination by maintcuance personnel. Effective inspections are dependent on:- a reliable system for the selection and issue of inspection reports. a positive form of feedback and follow up. a continuous up-dating of records. a facility for identifying hazards and failures which are repetitive or common to other plant within a works group. CRANE TEST PROCEDURES ‘After carrying out any major maintenance it is essential that the following test procedure is carried out prior to returning the crane into service:- a) b) ©) 4) °) D) run all motions light. check operation of electrical equipment. check direction of motor rotation on all functions. set and check limit switches and brakes. lift Safe Working Load. functionally test and check any magnets, grabs etc, for correct operation. YE Action in Case of Fire The crane drivers action will be dictated by:- (@) The position of the crane in relation to the hazards. (b) The nature of the operation on which he/she is engaged. (©) The proximity of the crane to a safe means of escape. (d) The lovation and the severity of the fire. Isolation of the crane should be carried out as soon as it is considered practicable to do so. Specific instruction in emergency procedures should be included in the crane drivers training. Emergency escape apparatus suitable for use with Electric Overhead Cranes. Various types of controled lowering devices are avaiable. Figure 3 Figure 4 A folding stairway which can be permanently attached 1 the erane structure APPENDIX I ELECTRICAL PERMIT TO WORK In order to ensure an effective permit t0 work system the following basic steps should be taken, the correct sequence is of vital importance. ‘Isolate from ALL sources of supply. 'b Test to ensure equipment is ‘DEAD’. ¢ Attach “danger” boards or labels to all points of isolation. Attach suitable lead to shorting clamps across conductors and to suitable earth. 1b Attach “danger” label to shorting and earth clamps, 3 Issue “Permit to Work” in accordance with Works’ Rules, 4 : 2 Carry out work. bb Remove all tools and equipment. € Ensure that all personnel ae with=

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