Crane Operations and Safety Tips

Crane
Operations
and Associates
CONFIDENTIAL AND PROPRIETARY

Any use of this material without specific permission of PT PERTAMINA (Persero) is strictly prohibited (Date of Presentation Here)
Crane Types
The lifting Golden Rules

Crane Types
Basic Functions
The most common cranes consist of a swiveling machinery deck and control cab.
Cranes have 2 winches, one to facilitate luffing or jibbing up & down and one for hoisting & lowering.
The main Six motions of the Cranes:
1. Luff or Jib Up (to decrease the working radius)
2. Luff or Jib Down (to increase the working radius)
3. Hoist Raise
4. Hoist Lower
5. Slew Left
6. Slew Right
Where relevant (e.g. crawler cranes) there are an additional two motions which are Travel Forwards &
Backwards
Safety Features
In the interest of safety and to assist the crane operator, the crane has various limiting devices for
the six motions to prevent damaging the crane, they are as follows:
1) When Jibbing up, there are a limits to prevent the jib coming into contact with the back-stops
2) When jibbing down, there are limits the jib angle becoming less than approx 15 degrees to
the horizontal. (this limit can be over-ridden to allow parking of the jib in the rest)
3) When hoisting, there is a limit trip to prevent the hook block being pulled through the sheaves
4) When lowering, there is a limit trip to prevent running the hoist rope completely off the winch
drum thus losing the rope, hook block and possibly the load.
5) When slewing, there is a limit to prevent the jib striking against obstructions.
Restriction to Crane Operations
The most common restriction to cranes operations is bad weather, specifically high wind speed which
Can blow the load out of the safe operating radius possibly resulting in an overload situation.
In offshore environment as a result of high winds, the sea state must be considered. If supply vessel
is pitching up and down in a heavy swell, snatching the load will take place and this is increase the
Dynamic loading on the crane.
On land, if there has been prolonged heavy rain, the ground may be softer than normal. This would
obviously cause stability problems when trying to set up and level a crane.
When working onshore in close proximity to overhead electric lines, no parts of crane must come
within 15 meters of the cables.
Special care has to be taken when working near the edges of excavations or even quay sides.
When the load is transferred through to an outrigger, it could be disastrous if the edge collapsed.
When working close to ditch or excavation job,
The position of crane must also ensure as far as

possible any underground facilities like drains,
gas
main, or water pipes that might collapse under
the loading
How inspect a crane ?
 Check Colour code, ID number, SWL
 Pre use check to be done daily (GS EP EXP 311)
1°/ Check the rated load indicator is correctly set and appropriate to:
- Jib length
- Number of falls
- Ballast weight
- Outrigger position
- Hook capacity
2°/ Check that the correct load radius scale appropriate to the jib
length is fitted on the visual indicator
9
 Daily Pre use checks

3°/ Check the security of counterweights:
4°/ Check the oil level, fuel level and lubrification.
5°/ Check the ropes and ropes terminal fittings and anchorage for
obvious damages and wear Oil level too
low!
Bulldog clip on Bad spooling !

live rope !
The lifting Golden Rules 10

6°/ Check the condition and inflation pressure:
7°/ Check all water is drained from any reservoir.
8°/ Check the crane structure for damages
9°/ Check condition of spreader plates and no leak on outrigger

cylinder
Structural damages Corrosion
11
10°/ In the interest of safety and fire prevention, check
that crane cabin is in tidy condition
10°/ Check the operating pressure in any air and / or hydraulic

No fire extinguisher
system.
11°/ Check the operation of the crane through all motion with
particular attention to brakes
12°/ Check the operation of all limit switches or cut out
Anti two block devices

Test boom limit switch Boom stop

How read a crane chart ?
Boom length
Load
THE LOADS INDICATED EXCLUDE
THE WEIGHT OF THE HOOK BLOCK
Radius
→ Never exceed crane capacity !!!

Particular care when reaching 80 % of capacity (including DAF)
13
JIKA LOADCHART NYA SEPERTI INI BAGAIMANA CARA MEMBACANYA?
NAH YANG INI APA LAGI
The bold line shown in this table

indicates the limit:
• Above the line: Damage to the
equipment
• Below the line: The equipment
will overturn
KOK LOAD CHART

NYA ADA 2 INI
MAKSUDNYA APA?
BE CAREFUL TO UNITS
Charts could be in Pound / feet
1 T (metric ton) = 2204 lbs

1 lbs = 0.45 kg
1 m = 3.28 ft
1 ft = 0.30 m

Presentat
ion title -
Place and
15 Country -
Date
APAKAH BOLEH MOBIL CRANE MENGANGKAT BEBAN TANPA
MENGELUARKAN OUT RIGGER??
1. APAKAH BOLEH OUT RIGGERNYA HANYA KELUAR “SETENGAHNYA” SAJA?
2. APAKAH BOLEH “MOBILE CRANE” MENGANGKAT BEBAN SAMBIL JALAN?

3. BAGAIMANA JIKA FLY JIB NYA DI PASANG BERAPAKAH SUDUTNYA??
4. APAKAH..???
5. APAKAH..??? REVING LINE NYA BOLEH DI KURANGAI ATAU DI TAMBAH?
GO TO CHART
Presentat
ion title -
Place and
16 Country -
Date
Safe use of cranes
 First rule:
Having a lifting plan (even generic) to know at least:
- Cargo weight
- Cargo Centre Of Gravity
- Start and end position
- Crane use ratio during operation
- Ground bearing pressure
→ See on next slide an example of lifting drawing for a complex operation

Safe use of cranes Load to be lifted Ground
with 5%bearing
Crane
cont radius
use
pressure
ratio
Start position
End position
18
Safe use of cranes
 Always make sure outriggers are deployed and are positioned on spreader plate
OK NO
→ Spreader plate size depends of ground condition and of applied load

Safe use of cranes
 Make sure there are no underground facilities under crane foot.
Gas main, water main,..
NO
→ Underground facilities position to be marked on the soil or on the

quay !!
Marking on quay.
20
Safe use of cranes
 When working next to an excavation, make sure safe distance are respected
Distance a
a=b
depth
b
NO
OK
Make sure a ≥ 2 x b
Make sure d ≥ 2m

Safe use of cranes
 When working next quay side respect the minimal distance between quay side and crane
foot.
Minimal distance to quay border
OK
→ Minimal distance crane foot / crawler to quay to be given by quay designer (generally
around 2 m)
Safe use of cranes
 Make sure the quay / Jetty are strong enough to withstand the crane loads
Observation of Jetty supporting plate Jetty structural inspection !!!!

generated a ....
→ Quay and jetty to be regularly structurally inspected.

Safe use of cranes
 Check that the type of ground can withstand the bearing pressure transmitted via the
outriggers when the crane is lifting the heaviest load.
SOIL - Presumed bearing pressure Maximal bearing pressure
Non cohesive soils (T/m²) Lbs/in²
Dense gravel or dense sand and gravel > 60 >87

Medium dense gravel or medium dense sand and gravel < 20 to 60 <29 to 87
Loose gravel, or lose sand and gravel < 20 <29
Compact sand > 30 >43,5
Medium dense sand 10 to 30 14,5 to 43,5
Loose sand < 10 <14,5
Cohesive soil (T/m²) Lbs/in²
very stiff bolder clays and hard clays 30 to 60 43,5 to 87
Stiff clays 15 to 30 21,5 to 43,5 Tragic accident probably due to soil
Firm clays 7,5 to 15 10,5 to 21,5 collapse
Soft clays and silts <7,5 <10,5
Very soft clay NA NA
Peat NA NA
Made ground NA NA
→ Presumed bearing pressure of soils: for information only.

Proper values to be determined by geotechnical CPY.

Safe use of cranes
 Make sure there are no side loads when performing an operation
→ Main risk of side load is to

create boom collapse or crane
overturning
NO NO OK

Safe use of cranes
 Make sure there are no tilt forward or backward when performing an operation
Risk of tilt forwards

Risk of tilt
backwards
NO NO
NO NO
OK
Level ground: Normal operation Uphill: Radius reduces Downhill: Radius increase
Safe use of cranes
 Dragging the load is strictly forbidden !!!
RISKS OF CRANE OVERTURNING
NO

Safe use of cranes
 Make sure the minimal distance are respected when working next to electrical lines.
Distance to be ≥ 15m
OK
NO

Safe use of cranes
 Make sure the weather conditions allows the operations to be carried out
 Wind limitation to be given by crane manufacturer (can be reduced if decided by affiliate)
EXTRACT OF LIEBHERR LR 1350 DATA SHEET
Max permissible wind speed on Liebherr LR 1350 is 9m/s
Crane collapse that happened to lifting operation carried out with

excessive wind

Safe use of cranes
 Crane signal (recommended in BS7121)

Safe use of cranes
 Crane signal (recommended in BS7121)

BASIC PRINCIPLE
LIFTING OPERATION Compliant sling
Factor in plant in the vicinity

and weather conditions Compulsory temporary
barriers suited to the
environment
Tag line to
guide the load
The signaler* equipped

with high visible jacket
Outrigger pads
Nobody under
the load
Crane operator* Portable gas monitor in

Daily check list process areas

*Qualified and competent personnel
QUIZZ

 What are the following ? Boom end sheave
Expandable sections Anti two block device
Boom base
Lifting wire rope

Counterweight
Hook block
Lifting hook
Turntable Boom raising cylinder
Outrigger pad
Outrigger extendable beams

QUIZZ
 What are the following ?
Anti two block
Jib stop
Angle indicator

QUIZZ
 What is wrong here ?
Correct method for wedge socket termination
Bulldog clip on live rope

QUIZZ
 How
Is it possible
many 5ato
Considering lift a load
T2counterweight
T hook of 73
block T@
are
and T3,5m
1mounted with
on 21m
of rigging the boom
crane?
weight, ? maximal
which
load
NO can
5 !! !!!
This be lifted
What about
crane @hook
chart 9m
is radius
block
given ?25 Trigging
forand weight ?
counterweight!
34,6 T (34,6 T + 2 T + 1T = 37,6 T) with 16,8 m boom length

QUIZZ
 What does it mean (according to BS 7121) ?
Hoist Travel to me Emergency stop

QUIZZ
Most probably exceed of Outriggers are not deployed !!!

capacity at radius

QUIZZ
Not enough
clearance !!
Always at least 1 m of
clearance between any
part of the crane and
fixed parts

QUIZZ
 Is the crane correctly positioned?
a = 10 m a=7m
1m 3m
b=5m b=4m
No !! Minimal distance foot plate – No !! Following condition to be

top of talus to be at least 2 m respected: a ≥ 2b
So distance to be a ≥ 8m

QUIZZ  What is wrong here ?
Too close from electrical lines !! 1 - Never walk under a suspended load
2 - Bad rigging
Minimal distance is 15 m 3 - No safety cash on hook
4 - No appropriate EPI
5 - No safety barriers

Lifting Operation Plan

• Lifting Golden rule: A lifting plan has been established prior any
lifting operation. WHY ?

 To control all the parameters of an operation and to avoid :
• And
Clashes
Soil problems
manysituation
Overload others ...
Bad positioning Minimal distance to electrical

lines
 Which operations have to be covered by a lifting plan ?
ALL !!!! Routine and non Routine

 Generic lifting plan for routine lift

 Specific lifting plan for non routine lift
Use of Spreader bar Lifting points under COG Lift by 2 or more cranes
And many others ….
High monetary Roll up operation
value
Crane use ratio >80 %

 What has to be covered in a lift plan ?
1°/ The operation brief description
1 - What has to be lifted ?

2 – Departure point
3 – Arrival point
4 – Lifting mean
5 – Trajectory
4
1
2
 2°/ The operation categorization
An operation can be : Complex
In CR EP HSE 043 list of criteria to define the criticality of operation :
- The lift will use downgraded equipment
- Use of two or more cranes
- The load has a centre of gravity above lifting points
- The crane use ratio is > 80%
- And many others ...(surface acting as a sail, near to live lines, etc..)
50 T crane downgraded to 10 Tandem lift Lift point under COG

T

3°/ The site data
When onshore, among others
- Maximal site allowable bearing pressure

- Minimal distance to quay
- Excavation location
- Presence of underground facilities
- And others (site slope, adjacent building presence ...)
Make sure a ≥ 2 x b
Make sure d ≥ 2m

3°/ The site data
When offshore or marine, among others :
- Maximal laydown area allowable bearing pressure
- Minimal boat approach distance
- Maximal wave height
- DP limitation (for marine lift)
- Others ( Max wind speed, unprotected process area,..)

4°/ The cargo data
We have to know:
- The cargo description

- The overall dimensions
REDUCTOR XXX
- The weight
- The COG position
450 KG Z
Y cog
W cog
X cog

4°/ The cargo data
We have to also know :
- The lifting point details if any
Eye bolt
450 KG
Padeyes Trunnions Hoist ring

5°/ The equipment data
EQUIPMENT HAVE TO BE DESCRIBED !
APPLIANCES ACCESSORIES

FOR APPLIANCES – cranes and others (crane illustrated here)
- Crane type (crawler, mobile, gantry, ..) and manufacturer
- Model (LRX 999,...)
- Crane SWL (if downgraded it must be specified)
- Crane chart
- Last inspection certificate
- Maintenance record on demand
Liebherr mobile crane

LTM 1030
SWL 35 T
Crane chart
Inspection certificate
For Accessories
- Accessories identification on drawing
- Quantity of each type
- ID number and description
- Length and weight of items
- SWL
- Last inspection certificate (on demand)
Length Weight
Item QTY ID Number Description SWL (T)
(m) (Kg)
1 2 HLM 1234 Wire rope sling Ø 36 mm 8 60 35 T
2 4 HLM 1528 to 1531 Shackle crosby G2130 61,6 25 T
3 1 HLM 1489 Spreader bar SWL 25 T 4 150 25 T
4 2 HLM 1589 Soft sling swl 20 T 10 70 20 T

6°/ The load determination method
Some safety factor are applied on the load to be lifted
TOTAL WEIGHT 90229 Kg
10
5 %%when
3 whenthe
theload
weight
weight isisgiven
calculated
is weighed (by manufacturer or on manifest)
6°/ The load determination method
Some DAF (Dynamic Amplication Factor) are applied on the load to be lifted
10
5 %%for
when moving
static (case of crawler cranes)
operation
7°/ The operation step by step
The operation must be described in a detailed and precise way
- Starting position of cargo and lifting appliance
- Connection details of rigging equipment
- Step by step between starting position and end position
- Lifting radius of each position
- End position
- Who do which operation
5Example:
- When all crew member have moved away from cargo,
1 - DP supply
Banksman vessel
to give thetosignal
be positioned at 10 m from
to crane operator the
for lifting
6platform
- Lift the load of vertically of around 15 m
72--Reduce
Bring the
thecrane
craneatradius
a radius of 25
to 18 m m on top of cargo to be
8lifted
- Slew by 180 ° clockwise
93--Lower
Lowerthe
theload
hookon ondedicated
top of cargo
area
4 --Crane
10 hook
Slingers to be connected
to disconnect to preinstalled rigging by
the load
boat crew
18 m
25 m
10 m
8°/ The drawings
The drawings should content at least:
- View of the starting and end position (top view and side view)
- View of the rigging
- Accessories description (can be the same than section 5 with ratio
check in addition)
Top view of start and end position Side view of start position Side view of end position

8°/ The drawings
The drawings should also content :
- Crane table: Very important to check the crane use parameters

9°/ The working team..... must be identified
Must be at least mentioned (for non routine lift only):
- Name of each person involved in the operation
- It’s function on the operation
- It’s training certificate

7
How To Create LOP
1
2
63
Lifting Categorization
64
Lifting Categorization
Q1 Internal Training 2013. 65

Location/ area
Dimana ini…? Powerhouse nomer berapa?
Selalu berusaha memberikan informasi lokasi dan area yg komplit & jelas dimana akan
dilakukan lifting operasi..!!!

Diagram/ Sketch/ mooring plan/ Gambar/ foto
• Berikan informasi yang relevant untuk membantu reviewer.

• Akan lebih mudah untuk memberikan informasi lewat gambar dari pada memberikan
gambaran dengan kata-kata saja.
• Masukkan gambar sederhana, foto ataupun gambar teknik jika memungkinkan..
• Jika LOP menggunakan crane barge atau kapal, MOP juga di butuhkan pada saat pengajuan
permit.
• ***REMEMBER……1 PICTURE  1000 WORDS***

Menggunakan visio, autocad dan program menggambar lainnya.

Presentation title - Place and Country - Date
68
Month Day Year
Menggunakan drawing menu di ms word, exel

ataupun power point.

69
Month Day Year
Manual drawing / sketch
70
Beam clamp 2T
Chain block 2T
Load 500 Kg
Kombinasi foto, menu drawing ataupun manual sketch.
71
72
Diskripsi / gambaran dari Lifting operasi
• Di bagian ini, uraikan dengan singkat dan jelas tentang lifting operasi yang dimaksud:
• Catatan penting:
1. Apa yang akan diangkat?
2. Dari mana mulai proses pengangkatan?
3. Kemana akan di angkat atau diletakkan?

Weight of load / berat beban
Contoh / example:
• (a) Xmas Tree. Data dari manufactur 2.4 Ton.

•  2.4 x CF(1.05) = 2.52 Ton. 
• (b) 16” Pipe Spool. Calculated / dihitung 1.8 Ton.
• 1.8 x CF(1.1) = 1.98 Ton.
• (c) Dredging bucket. Estimated / diperkirakan 4 Ton.
•  4 x CF(1.2) = 4.8 Ton.
• (d) CF(1.03) = Weighed / ditimbang.
• NOTE – Sangat direkomendasi untuk menggunakan data yang paling mendekati berat
beban yang sesungguhnya (ditimbang, manufactur, dihitung). Memperkirakan berat
beban sering mengakibatkan kesalahan perhitungan. “Perkiraan / Estimated” sebagai
pilihan terahir. Jika ragu, selalu lebihkan perkiraan berat yang akan di angkat.
74
Lifting equipment & accessories yang akan digunakan
• Dibagian ini masukkan diskripsi singkat alat yang harus digunakan, contoh:
• Crawler crane, forklift, swing jib, chain block dll.
• Wire rope slings, webslings, Crane penant, shackles, beam clamp, hooks etc.
• NOTE – Jangan hanya menulis ‘Slings dengan SWL yg cukup’.
Seluruh SWL/WLL harus disebutkan di LOP.
Color Code juga harus di sebutkan di bagian ini.
75
Contoh / example:
76
Step by step / langkah kerja
Contoh / example:
77
Contoh / example:
78
Contoh / example:

79
Month Day Year
Planned, reviewed & Approved
Contoh / example:
80
THANKS FOR YOUR ATTENTION
Don’t Forget, if any doubt...
!!! STOP THE OPERATION AND ASK !!!
81
Praktek membuat LOP
1. Lifting 10ft container dari kapal ke rig V.V
82
Praktek membuat LOP
2. Lifting coil tubing well head injector
83
Praktek membuat LOP
3. Lifting coil tubing dari jetty ke kapal.
84
Praktek membuat LOP
4. Loading offloading general CCU / baket di jetty.
85
END OF SLIDE

Crane Operations and Safety Tips

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Crane Operations and Safety Tips

Uploaded by

Copyright:

Available Formats

Crane

CONFIDENTIAL AND PROPRIETARY

The lifting Golden Rules

The position of crane must also ensure as far as

 Check Colour code, ID number, SWL

 Pre use check to be done daily (GS EP EXP 311)

 Daily Pre use checks

4°/ Check the oil level, fuel level and lubrification.

Bulldog clip on Bad spooling !

The lifting Golden Rules 10

 Daily Pre use checks

6°/ Check the condition and inflation pressure:

7°/ Check all water is drained from any reservoir.

8°/ Check the crane structure for damages

9°/ Check condition of spreader plates and no leak on outrigger

Structural damages Corrosion

10°/ Check the operating pressure in any air and / or hydraulic

12°/ Check the operation of all limit switches or cut out

Anti two block devices

The lifting Golden Rules 12

→ Never exceed crane capacity !!!

The bold line shown in this table

KOK LOAD CHART

1 T (metric ton) = 2204 lbs

The lifting Golden Rules 14

2. APAKAH BOLEH “MOBILE CRANE” MENGANGKAT BEBAN SAMBIL JALAN?

Having a lifting plan (even generic) to know at least:

- Cargo Centre Of Gravity

- Start and end position

- Crane use ratio during operation

- Ground bearing pressure

→ See on next slide an example of lifting drawing for a complex operation

The lifting Golden Rules 17

The lifting Golden Rules 19

Gas main, water main,..

→ Underground facilities position to be marked on the soil or on the

The lifting Golden Rules 21

Minimal distance to quay border

Observation of Jetty supporting plate Jetty structural inspection !!!!

→ Quay and jetty to be regularly structurally inspected.

The lifting Golden Rules 23

Non cohesive soils (T/m²) Lbs/in²

Dense gravel or dense sand and gravel > 60 >87

→ Presumed bearing pressure of soils: for information only.

The lifting Golden Rules 24

→ Main risk of side load is to

The lifting Golden Rules 25

Risk of tilt forwards

 Dragging the load is strictly forbidden !!!

RISKS OF CRANE OVERTURNING

The lifting Golden Rules 27

The lifting Golden Rules 28

 Wind limitation to be given by crane manufacturer (can be reduced if decided by affiliate)

EXTRACT OF LIEBHERR LR 1350 DATA SHEET

Max permissible wind speed on Liebherr LR 1350 is 9m/s

Crane collapse that happened to lifting operation carried out with

The lifting Golden Rules 29

The lifting Golden Rules 30

The lifting Golden Rules 31

Factor in plant in the vicinity

The signaler* equipped

Crane operator* Portable gas monitor in

• REMEMBER……1 PICTURE  1000 WORDS