S.M. No.

: SNTI / EGS / SM /
Rev. No. :
Effective Date :

(An ISO 9001 Organisation)

Let us learn and lead

Study Material

On

EOT Crane Operation

Cabin Control
SEGS92
 EOT CRANE OPERATION

EOT Cranes are major material handling machine used in steel industry. EOT
Crane is used to lift and shift material from one place to another place. It has better
performance, reliable, efficiency and can carry higher loads. It uses clean energy i.e.
electrical energy and requires no extra ground space to perform its operation. In
steel industry Production and productivity are very much dependent on operation of
EOT crane.

This study material focuses on the subject “EOT Crane Operation”. EOT
Crane Operation with best skills and information are the main issue now days
especially with new operators. This study material will help to know what are the
information and skills required to operate EOT crane.

This study material includes information about Steel wire rope, rejection
criteria of steel wire rope, selection of Hoisting equipment and the effect of sling
angle on load carrying capacity of steel sling which are needed for any EOT Crane
Operator to know well. Our employees will be certainly benefited by this study
material.

Prepared by Approved by
Ashwani Sharma Mr. P.K.Das
Junior Engineer-II Senior Manager
Electrical EEI

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 EOT CRANE OPERATION

Sl. No. Topics Page No.

1 Introduction to EOT crane 03

2 EOT Crane and its construction 03-17

3 Requirement of EOT crane in steel plant 18

4 EOT crane checklist 19-20

5 EOT crane hand signal 21-22

6 Steel rope and accessories 23-27

7 Safe Hoisting 28-30

8 Selection of hoisting equipment 31-33

9 Effect of apical angle on load carrying capacity 34-36

of steel sling

10 Do’s and Don’ts for EOT crane operator 37-42

11 Questionnaire for self evaluation 43-45

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 EOT CRANE OPERATION

1. Introduction to Crane
A crane is a type of machine, generally equipped with a wire ropes or chains, and
sheaves, that can be used both to lift and lower materials and to move them
horizontally. It is mainly used for lifting heavy materials and transporting them to
other places.

For different types of load and circumstances in which load needs to be moved,
many different types of crane have been developed, such as:

 Gantry Crane
 Overhead Crane
 Building crane (Rotary/stationary )
 Mobile crane
 Crawler mounted crane.
 Jib crane.

In this book we shall confine ourselves to the Electric overhead travelling (EOT)
cranes.

2. EOT Crane and Its construction

What is an EOT crane?

An EOT crane is a material handling device or machine which can transport material
from one place to another place in horizontal as well as in vertical direction. It can
move load in 3 dimensional spaces in 6 directions.

An EOT crane runs on two overhead gantries which are mounted up on the columns
in the both sides of the bay. The floor area which is covered by EOT crane is called
Bay. An EOT crane mainly consists of a crane car, Trolley and Hoist mechanism.
Crane car travels on runway rails which are mounted up on two overhead gantries.
The crane car travels longitudinally to the bay and its motion is called longitudinal
travel, commonly abbreviated as LT. Trolley travels on the rails provided on Crane
car. Trolley travels cross the bay and its motion is called Cross travel, generally
abbreviated as CT. Hoist mechanism is used to either hoist or lower crane hook in
the bay. Hoist motion of the crane is generally abbreviated as HT.

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Buffers are fitted at all the four corners of crane car. Its function is to absorb vibration
produced due to collision.

Stoppers are provided at the end of rails. Its function is to prevent falling of crane car
from gantry.

Similarly, wheel stopper is provided at end of trolley rails. Its function is to prevent fall
of trolley from crane girder.

Electrical Supply:

Electrical Power is fed to the EOT crane by DSL. DSL

stands for down shop lead. For AC crane it consists of 4
power rails of colour Red, yellow, Blue and Green out of
which Red, Yellow and Blue carries 3 Phase AC power
and green is used for earth.

To ensure availability of power in DSL, DSL Indicator is used with

DSL. It consists of red, yellow and blue lamp. When electrical supply
is available in DSL it glows.

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Controllers for EOT crane operation

EOT crane operations can be controlled from cabin and ground. There are three
types of controls available:
1. Control by means of Master Controller
2. Control by means of push button – Pendant controller
3. Control by means of radio frequency signal- Radio remote controller
Out of these controls, master controllers are available in crane operator’s cabin. The
pendant controller and radio remote controller is used to control crane from ground.

Master Controller:

For cabin-operated cranes, operator control switches are

called master controller. At least three master controllers
are provided in crane cabin to control LT, CT and HT
motion of the crane, one for each motion.

The Master controller lever centre position is Zero or

Neutral. At this position of master controller crane will not
move and brakes will remain applied. For movement of
crane in any motion direction (LT, CT & HT), move the lever of the respective master
controller from zero position to higher notch position. As the lever notch position
increases crane speed increases. To apply brakes move the lever to zero position.

Pendant controller:

A pendant controller is a box with push buttons. It is

connected to crane by means of an electric cable and
a supporting steel chain or sling. On pendant
controller, pushbuttons are provided for movement of
crane hoist, Crane Bridge and trolley. These
pushbuttons are usually marked by directional arrows.
At the top of pendant controller a red coloured
emergency push button is also provided.

In some cranes pendant controller have provision for two different speeds for the
crane movements. For every motion there are two buttons, one for slow speed and
other for fast speed.

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Remote controller:

An EOT crane can be controlled from the

distant place by using a wireless remote
controller. The remote control of crane
takes place through a transmitter unit
(remote controller) and a receiver unit. A
remote controller is a hand held device
and receiver is mounted on Crane Bridge. Remote controller transmits radio
frequency signal and receiver unit receives that signal and move crane according to
the given signal. To move crane, operator gives command from ground.

When remote controller is switched ON, a beep sound will produced, when the beep
stops, the crane can be operated. The remote controller unit is powered by means of
a battery, which is located at the bottom of the controller. When the battery is low,
remote controller will produce short pulsating beeps. At that moment, first press the
emergency stop push button and then change the battery. Don’t forget to recharges
the empty battery.

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Crane Car

It is the main traveling structure of the crane which spans the width of the bay and
travels in a direction longitudinal to the bay, generally abbreviated as LT. The crane
car is usually constructed of two longitudinal girders called Bridge, which are
connected by cross girders Called End Truck.

The crane car drive is installed on Crane car. The crane car drive consists of Motor,
Gear Box, brake and crane wheel. Wheel cases are constructed in cross girders.
Crane wheels are fitted in wheel cases. The crane car also supports the trolley,
hoisting mechanism for hoisting and lowering of hook, crane operator cabin and
electrical panels.

Motor: Slip ring or squirrel cage induction motor is used to drive crane car. It is
coupled to input shaft of the crane car gear box.

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Gear Box:
A gearbox is a mechanical device utilized to increase the
output torque or change the speed (RPM) of a motor. In
the crane car drive mechanism speed reduction gear box
is used to drive crane wheels. Input shaft of the gear box is
connected to motor and the output shaft is connected to
the driving wheels. Since output shaft of reduction gear
box rotates at slower speed than Input shaft therefore Speed of the wheel is
comparatively lower than speed of motor.

Brake:
An electromechanical brake is installed on crane car
drive motor. When controller position is switched to
start Crane car travel then respective brake is pulled
electrically to open and then motor drives the driving
wheel through gearbox. When controller position is
switched to stop crane car travel then the respective
brakes closes mechanically by the spring pressure
and stops Crane Car.

The brake closes when:-

1. LT controller is switched to zero position.

2. The emergency stop Push Button is pressed.
3. The Emergency Switch is switched OFF.
4. Power failure occurs.
5. End limit switch is operated.

Crane Wheel:
Crane wheels are made of cast steel and
Crane Wheel
run on rails which are mounted on the
crane gantry. Flange provided on the crane
wheel guides wheel on runway rail. Wheel collar
or Flange
There are two types of crane wheels
Crane Rail
1. Driving wheels
2. Trailing wheels

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The function of driving wheel is to receive drive from motor and move crane freely on
rail. It also carries the weight of the crane.

The function of a trailing wheel is only to carry the weight of the crane.

Resistance Box
Resistance boxes are located on the crane car at one of the longitudinal girder. It is
connected to rotor circuit of slip ring induction motor. It is used for Starting and speed
control of Slip Ring induction motor.

By changing the resistance in the Rotor Circuit in various steps, the torque and
speed of the motor can be controlled to the desired value.

At the beginning of motion maximum resistance is included to the rotor circuit to

produce necessary high starting torque. At this condition crane will start running at
slower speed. To run at higher speed, resistance is cut out in steps by controllers.

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Crane Cabin:
Crane cabin is fitted on crane car. It is the place from where EOT crane operator
operates crane. In crane cabin master controllers, emergency switch, emergency
push button, bell and communication system, etc. are available, this supports crane
operator to operate crane safely.

Outside the cabin a pilot lamp is mounted. The pilot lamp consists of red and green
coloured lamp. When crane is ON green coloured lamp will glow, it signifies that
crane will not move. It is safest condition to board on crane. When crane is start, red
lamp glows, it signifies that crane can move according to the given command. Never
board on crane when pilot lamp is glowing red. When pilot lamp remains dark, it
signifies that crane is off.

Trolley Rail:

On crane car trolley rail is mounted on longitudinal girder. Crane trolley travels on
this rail.

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TROLLEY

Trolley is situated on the Crane car. It has four wheels through which it travels on
trolley rails.

The structure of the trolley is similar to that of the crane car. It comprises of trolley
floor, 2 longitudinal girders, 2 cross girders, 2 driving wheel, 2 trailing wheels and
trolley drive mechanism.

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 EOT CRANE OPERATION

Trolley Floor:
Trolley floor is the space where trolley drive mechanism and hoist drive mechanism
are installed. On trolley other necessary accessories are also fitted which are
required to operate and control them.

Trolley drive mechanism:

Trolley drive mechanism consists of motor, gear box, brake and drive shaft.

Motor:

Slip ring or squirrel cage induction motor is used to drive crane Trolley. It is coupled
to input shaft of the trolley gear box.

Gear Box:
In the trolley drive mechanism speed reduction
gear box is used to drive trolley wheels. Input
shaft of the gear box is connected to motor and
the output shaft is connected to the driving
wheels. Since output shaft of reduction gear box
rotates at slower speed than Input shaft
therefore Speed of the wheel is comparatively
lower than speed of motor.

Drive Shaft:
The drive shaft is used to connect output shaft of the gearbox to driving wheels. It is
used to transfer mechanical power developed by motor to driving wheels through
gear box.

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Brake:
An electromechanical brake is installed on trolley motor.
When controller position is switched to start trolley travel
then respective brake is pulled electrically to open and
then motor drives the driving wheel through gearbox.
When controller position is switched to stop trolley travel
then the respective brakes closes mechanically by the
spring pressure and stops trolley travel.

The brake closes when:-

1. CT controller is switched to zero position.

2. The emergency stop Push Button is pressed.
3. The Emergency Switch is switched OFF.
4. Power failure occurs.
5. End limit switch is operated.

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 EOT CRANE OPERATION

HOISTING INSTALLATION
The hoisting installation is mounted on the trolley. It consists of motor, gearbox, rope
drum and brake. The function of hoist installation is to hoist or lower crane hook. The
function of hoist installation is controlled by the controllers provided in crane.

Motor: Slip ring Induction motor is used to drive crane Hoist. It is coupled to input
shaft of the hoist gear box.

Gear Box:

A gearbox is a mechanical device utilized to increase

the output torque or change the speed (RPM) of a
motor. In hoist mechanism speed reduction gear box is
used to drive rope drum. Input shaft of the gear box is
connected to motor and the output shaft is connected
to the rope drum. Since output shaft of reduction gear
box rotates at slower speed than Input shaft therefore
Speed of the rope drum is always lower than speed of motor.

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Brake:
An electromechanical brake is installed on hoist gear
box. When controller position is switched to start hoist
travel then respective brake is pulled electrically to
open and rope drum start rotating. When controller
position is switched to stop hoist travel then the
respective brakes closes mechanically by the spring
pressure and rope drum stops rotating.

The brake closes when:-

 HT controller is switched to zero position.

 The emergency stop Push Button is pressed.
 The Emergency Switch is OFF.
 A power failure occurs.
 Rotary Limit switch is operated.
 Counter weight limit switch is operated.

Rope Drum:
The Rope drum is coupled with the
output shaft of hoist gear box. The rope
drum is provided with grooves on its
outer periphery. These grooves guide
the steel wire rope when they are
wound-up and wound-off.

Care should be taken that:

1. When the sheave block reaches

its highest position, there should
be at least one full turn groove
should be left vacant on rope drum.
2. When the sheave block is at its lowest position, there should be at least 2 full
turns of rope wrapped on drum.

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 EOT CRANE OPERATION

Rotary limit switch-

Rotary limit switch is an electric switch, which is operated mechanically. Rotary limit
switch is coupled to the shaft of the hoist drum through coupling. It is used to limit the
highest and lowest position for hoist travel. During hoisting, rotary limit switch
operates for stopping over-hoisting of hook block before reaching counter weight
limit switch. Similarly, during lowering, rotary limit switch operates before reaching 6
inches above ground to stop over-lowering of hook block.

Thus rotary limit switch allows crane hoist to operate within highest and lowest point
of Hoist travel.

Counter weight limit switch-

Counter weight limit switch is an electric
switch, which is operated mechanically. It is
also called block limit switch. Counter weight
limit switch is fitted on the crane trolley. Its
function is to prevent over- hoisting of hook
block. It consists of a lever arm, camshaft
and electrical contacts. On one end of the lever arm a weight is suspended by sling
and on other end counter weight block is fixed. Suspended weight is slightly heavier
than counter weight. Cam shaft is present at the centre of lever arm. When rotary
limit switch gets failed then over-hoisting occurs and then hook block lifts the
suspended weight due to which counter weight rotates the cam shaft and actuates
electrical contacts to stop hoisting motion.

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3. Requirement of EOT crane in Steel Plant

EOT crane is critical equipment in Steel production plant. It is used in almost all the
departments for the following purposes

 Hot metal movement

 Hot roll and cold roll coil handling
 Slab handling
 Billet handling
 Removing scale from scale pit
 Scrap handling
 Loading/Unloading products on/from wagon or trucks
 Lifting roll
 Placement of big motor on foundation and its alignment
 Plate Handling, Etc.

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4. EOT Crane checklist

Before Starting EOT crane Ensure following

1. DSL Light.
2. SWL of crane.
3. Green lamp is glowing near cabin.
4. Condition of wire rope.
5. Any groove, wear, twist, crack and deformation in crane hook.
6. Wire rope is properly winding on drum.
7. Condition of tackles, Steel Sling, and chain
8. Proper balancing of hook block and beams (whether tilted in one side)
9. Oil Leakage from gear box.
10. Cabin glass panes – to ensure clear and unobstructed view
11. Cabin light and fan is working.
12. Floor light is glowing.
13. Fire extinguisher – Physical observation
14. Emergency switch is working or not
15. Gong bell or any other equivalent device
16. Controller Handle should be at zero position
17. Functioning of Communication system
18. Crane load display.

After crane start check following Ensure Following

1. All Controller operation
2. Emergency Push button operation
3. Over hoist limit switch
4. Hoist brake
5. Anti-collision device
6. Foot Switch
7. Load attachment
8. Close circuit camera
9. Magnet operation
10. All clearances if taken over from maintenance
11. Any written instruction in the operator’s cabin
12. Area in which crane will operate

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 EOT CRANE OPERATION

13. Position of people on the ground

14. Anybody working on track line
15. Any abnormal sound coming from crane.

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5. CRANE HAND SIGNALS

Hoist: Lower:
With forearm vertical, forefinger With arm extended downward,
pointing up, move hand in small forefinger pointing down, move hand in
horizontal circle. small horizontal circles.

Trolley Travel:
Bridge Travel:
Palm up, fingers closed, thumb
Arm extended forward, hand open and
pointing in direction of motion, jerk
slightly raised, make pushing motion in
hand horizontally.
direction of travel.

Emergency Stop:
Stop:
 Both arms extended, palms
Arm extended, palm down, move arm
down, move arms back and
back and forth horizontally.
forth horizontally.
 Operator should obey the
emergency stop signal given by
any one in shop floor.

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 EOT CRANE OPERATION

Multiple Trolleys or Hook: Hoist Slowly:

Hold up one finger for block marked Use one hand to give any motion
"1" and two fingers for block marked signal and place other hand
"2." Regular signals follow. motionless in front of hand giving the
motion signal.

Magnet Disconnect:
Crane operator spreads both hands
apart-palms up.

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 EOT CRANE OPERATION

6. STEEL ROPE AND ACCESSORIES

STEEL ROPE
It is a flexible force transmission device , which has numbers of strands laid helically
around a core .

Wire material is - Carbon steel

Parts of steel rope

1. Wire
2. Strands
3. Core

Type of core

1. Fiber or Hemp core

 This rope is popular.

 It provides soft bed for strands.
 Reduces internal wear.
 It contains Lubrication.

2. Steel core

It is used, where rope is subjected to heat and shock load.

Specification of EOT CRANE Rope

As per IS – 2266 –1977

 Rope construction – 6 x 36
 Hemp core
 Tensile strength 180 Kg/mm²
 Un-galvanised
 Right hand
 Regular lay

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6x36 FC RH OL FSWR

6 - Number of strands

36 - Number of wires in each strand

FC - Fibre Core

RH - Right Handed Strand

OL - Ordinary Lay

FSWR - Flexible Steel Wire Rope

ROPE REJECTION CRITERIA

1. Maximum permissible reduction in steel rope diameter is 7 % for general

purpose rope and 3 % for critical application.
2. Maximum number of visible broken wire at or near rope termination is 3
3. Maximum permissible reduction in diameter of the outer wires of the rope is
40%.
4. Maximum permissible number of visible broken wire over a length of the rope-

Ordinary lay Lang lay

Construction
6D 30D 6D 30D
6/19 10 19 5 10
6/36 14 29 7 14

5. Maximum permissible envelop diameter of a wavy rope is 4/3 x rope diameter

6. There should be no bird cage formation
7. There should not be significant local increase or decrease of rope diameter.
8. There should no kink
9. There should be no evidence of plastic wear, corrosion, and core collapse.
10. Lay length of steel rope should not be more than 2.5%.

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OTHER TYPES OF ROPE

Nylon Rope:
Nylon rope have superior strength and remarkable stretching capabilities. It is
stronger than both manila and polypropylene rope, Nylon rope commonly finds its
application for pulling the heaviest loads and bearing the most weight.

With having superior strength, nylon rope have smooth outer surface and its
resistance to abrasion makes it ideal for pulley systems or winches. Also, different
fall protection systems or rescue line assemblies are constructed from nylon rope.
Nylon rope is resistant to UV, chemical exposure or any other form of rot.

Pros & Cons:

Positives: Strong, smooth, abrasion resistant, UV resistant.
Negatives: Absorbs water, weakens in water.
Most Common Uses: Towing lines, anchor lines, pulleys, winches, tie-downs, fall-
protection systems.

Manila Rope:
Manila rope consists of natural hemp
fibers. The natural strength and easy
availability makes manila rope a
standard quality rope.
Because of susceptibility to liquid
absorption and UV decay, care should
be taken of sustained tension on the
rope. For purposes such as climbing
and stage rigging, manila rope absorbs perspiration providing better grip. This rope
will not hazardously snap back when broken as other synthetic ropes.

Pros & Cons

Positives: Visually appealing, snap-resistant, low-cost.
Negatives: Not UV or water resistant may harden or rot over long periods of time.
Most Common Uses: Pulling, landscaping, rigging.

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Belt or Synthetic Web Slings

Web slings are available in two materials – nylon and polyester (Dacron). Nylon is
resistant to many alkalis whereas polyester is resistant to many acids. Nylon slings
are more common but polyester slings are often recommended where headroom is
limited since they stretch only half as much as nylon slings.

Synthetic web slings offer a number of advantages for rigging purposes.

 Their relative softness and width create much less

tendency to mar or scratch finely machined, highly polished
or painted surfaces and less tendency to crush fragile
objects than fibre rope,

 Because of their flexibility, they tend to mold

themselves to the shape of the load.

 They do not rust and thus will not stain ornamental precast concrete or stone.
 They are non-sparking and can be used safely in explosive atmospheres.
 They minimize twisting and spinning during lifting.
 Their light weight permits ease of rigging, their softness precludes hand cuts,
and the danger of harm from a free-swinging sling is minimal.

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Shackle

Shackle is used to join the slings or where there is no place to connect the sling
directly to load.

Types:
 Bow type: Recognisable by their BOW shape, bow shackles
are commonly used when working with more than one sling or
chain. Ideal for jobs such as rigging, bow shackles provide an
easy way of fastening chains and slings securely. These
shackles come with a variety of weight limits.

 Dee type: Most commonly used when working with single sling
or chain. Dee shackles - as the name suggests - are shaped
like the letter D. This type of shackle looks like loop of a chain,
so sometimes it is also referred to as 'chain shackles'.

Clamp: It is used to create temporary eye in a Rope.

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7. SAFE HOISTING
It is important to know the followings things before transporting a material from one
place to another
1. Weight of the load
2. Shape size and construction of load
3. Slinging of hoisting devices
4. Road map
5. Destination

Regarding shape size and construction of the load

1. Where is the centre of gravity?
2. Does the load have any part that is susceptible to damage?
3. Does environment needs to be cleared?
4. Will the shape of the load pose any extra problem with respect to its transport
and such?

Regarding slinging of load with hoisting devices.

1. Does the load have any crane hook?
2. Can the load be slung on by means of slings alone?
3. Are there any protective devices required?
4. Are there any special devices required, such as a hoisting yoke?

Regarding road that must be travelled with load.

1. Can the shortest way be travelled with the load?
2. Must the load be transported at a special height?
3. Are the dimensions of the load such that any passage may be too narrow?

Regarding destination of the load

1. Where and how are the circumstances for placement of the load?
2. Must any space be cleared?
3. In what position must the load be placed?
4. Are there any chocks require?

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As per norms, the weight must be indicated in a clearly legible manner on every load
weighing more than 1000 kg.
If this is not the case, the mass can be deduced:
1. By weighing the load
2. By calculating the load
3. By estimating the load.
4. By comparing the load to a load whose weight is known
5. By looking up the data about the load.

Weight calculation
For calculation of weight of an object two
things needs to know
 Volume
 Density
For rectangular object volume is obtained
by multiplying the length, width, and height.
Density is a fixed datum and is different for
each material
The density is expressed mostly in tons/m³
Density of Steel = 8 ton /meter³
Mass = Volume x Density

Example: Calculate the weight of the object

shown in figure.
Solution:
Volume = Length X Width X Height
= 4 x 1 x 2 = 8 m³
Density – 8 ton / m³
Weight = 8 x 8 = 32 ton.

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Lifting a load
Before lifting a load ensure
1. Crane hook is just above the center of gravity of load.
2. Before lifting a load make sure that proper and healthy hoisting device is
selected.
3. Before lifting the load, make sure that the load is tied properly.
4. Before lifting a load make sure hook is engaged properly with the slinging or
hoisting device.
5. Do not lift a load with jerk.
6. If the dimension of load is uniform cuboid, the center of gravity can be found
by drawing imaginary line across from the four corner of the load. The
intersection point of those lines denotes the center of gravity.
7. If the dimension of load is not uniform approximately slung at center of gravity
and then it is lifted about 6 inches from floor level. If the load is tilting one side
then load must be settle down on floor and hook must be sifted to tilting side
to achieve the center of gravity.

Landing a load
Before landing a load crane should reach the designated place and following points
should be considered.
1. Place must be clean.
2. While landing the load there should be no swing in crane.
3. Load should be placed at designated place.
4. Load should not fall to the ground.
5. Load should be stacked properly depending upon shape and size.
6. Load should not be placed in pathway.
7. Place must not be wet.
8. Packing should be provided under load when the load is to be placed in a
sloping place.
9. Before placing the load, a wooden block should be placed under it.
10. While placing the load there should be no jerk.

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8. Selection of hoisting Equipment

Choice of hoisting equipment is determined largely by the
 Shape
 Size
 Material of the load
A load with sharp edges requires extra attention.
If load is fitted with crane hook or hoisting point, a multiple chain with hook is the
appropriate hoisting device.
If the load has no hoisting point, one may decide on steel slings.

Hoisting Application Advantage Disadvantages

Device
Chain For Coarse work  Less sensitive to Heavy
damage
 More flexible
Steel Sling General hoisting  Relatively lighter than  Rigidness
device used chain  Can prick in
everywhere  Available in many hand
sizes
Nylon sling For loads that  Simple  Big elongation
must not be  Flexible  Temperature
damaged  Soft Sensitive
 Light weight
Hoisting Belt For load that must  Big load bearing area  Sensitive
not be damaged  Flexible  Can cuts easily
 Light weight
Special For hoisting long Time saving High purchase
hoisting load Cost
equipment

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Special Hoisting Equipment

C-Hook: Grab Bucket:

Magnet: Pallet:

Scissor tong Drum Clamp:

Plate Clamp:

Hoisting Yoke

Spreader Beam:

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LOAD LIFTING CAPACITY OF STEEL ROPE

Approximate Working load of steel rope can be determined by the formula

Safe Working load in Kg = D2 x 10

= D x D x10

Where, D is Diameter in millimetre

Safe Working load in Kg = Diameter x Diameter x 10

A steel rope of 20 mm diameter will lift a load of 4000 kg.

Safe Working load in Kg = Diameter x Diameter x 10

= 20 x 20 x 10

= 4000 kg

= 4 ton

LOAD LIFTING CAPACITY OF NYLON ROPE

Approximate Working load of nylon rope can be determined by the formula

Safe Working load in Kg = D2 x 1.5

= D x D x1.5

Where, D is Diameter in millimetre

Safe Working load in Kg = Diameter x Diameter x 1.5

A nylon rope of 20 mm diameter will lift a load of 600 kg or 0.6 ton

Safe Working load in Kg = Diameter x Diameter x 1.5

= 20 x 20 x 1.5

= 600 kg

= 0.6 ton

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9. Effect of Apical angle on load carrying capacity sling

Working Load table (Calculation from the hoisting equipment)

2 Part 2 Part
1 Part 2 Part vertical Apical angle upto
Apical angle upto
90° 90°- 120°

Load = Load = Load = Load =

1 x capacity of 1.5 x capacity of 2 x capacity of 1 x capacity of single
sling single sling single sling sling

Choker or Run 3 or 4 Part Apical Angle 3 or 4 Part Apical Angle

through upto 90° 90°-120°

Load = 0.5 x capacity Load = 2 x capacity of Load = 1.5 x capacity of

of sling single sling single sling

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Example 1: How heavy may load be at the most when a steel

sling of 4 tons is used and it is slung on as in fig. shown?

Solution: Load = 1 x capacity of sling

=1x4

= 4 Ton

Example 2: How heavy may load be at the most when a steel

sling of 4 tons is used and it is slung on as in fig. shown?

Solution: Load = 0.5 x capacity of sling

= 0.5 x 4

= 2 Ton

Example 3: How heavy may load be at the most when two

steel slings of 4 tons are used at 600 and it is slung on as in
fig. shown?
0
60
Solution: Load = 1.5 x capacity of single sling

= 1.5 x 4

= 2 Ton

Example 3: How heavy may load be at the most when

two steel slings of 4 tons are used at 1100 and it is slung
on as in fig. shown?

Solution: Load = 1 x capacity of single sling 0

110
=1x4

= 4 Ton

Example 4: How much load, Two 10 ton capacity sling will

lift?

Solution: Load = 2 x capacity of single sling

= 2 x 10

= 20 ton

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Example 5: How much load, Three 10 ton capacity sling

will lift at 300 ?

Solution: Load = 2 x capacity of single sling

= 2 x 10

= 20 ton

Example 6: How much load, four 9 ton capacity sling will

lift at 120 ° ?

Solution: Load = 1.5 x capacity of single sling

= 1.5 x 9

= 13.5 ton

Example 7: In this figure, how much load can be

lifted by two 4 ton capacity slings?

Solution:

Load lifted by single sling = 1.5 x capacity of sling

= 1.5 x 4

= 6 ton

Total load lifted by both sling = 2 x load lifted by single sling

= 2 x 6 ton

= 12 ton

Example 8: To lift a load of 6 ton what will be the capacity of

required sling?
Load
Solution: Capacity of single sling = 2

6
=2

= 3 ton

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10. Do’s and Don’ts for EOT crane operator

Do’s
1. Always use PPE while operating crane such as helmet, goggles, safety shoe,
and hand gloves.

2. Check the lifting devices for its fitness for use.

3. Use hand rail while moving on crane

4. Ensure the cleanliness of cabin glass for

proper visibility.

5. Ensure apical angle between two steel slings

should not be more than 120°

6. Ensure apical angle between two chain slings should not be more than 900.

7. Check hoist brake by lifting a load upto six inches above ground.

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 EOT CRANE OPERATION

8. Remove work gloves before operating the pendant control of a crane.

9. Use proper tackle which is designed to lift that particular load.

10. Lift the load above man height clearances before moving the crane

11. Remove the load / tackle from hook after completion of job.

12. Follow crane hand signal, given by authorized person only

13. Ensure crane hook is settled above the centre gravity of the load.
14. Keep the trolley at the middle of longitudinal girder as far as possible while
carrying a load.
15. Switched off emergency switch, before leaving the crane cabin
16. Put off the main isolating switch if crane is not used for more than an hour
17. If LT brake fails during movement reverse the crane just sufficient to stop.
18. If CT brake fails reverse the CT motion of crane just sufficient to stop.
19. Swing angle should not be more than 100 from horizontal plane.
20. Ensure that hook block is well lifted above man height clearance after
completion of job.
21. At the beginning of shift a qualified crane operator should always perform a
daily crane inspection prior to operating his or her crane, no matter how much
of a hurry he or she is in.
22. If a crane is not stopping with controller press emergency push button.
23. Attachments should be always placed in the attachment stand.
24. Before operating the Crane operator should check the Warning lights and
sirens mounted on crane. These are used to warn other employees in the
area of crane movement and shall be maintained in good operating condition.
25. While reaching end point of LT, CT and Hoist motion, crane speed should be
Slow.
26. Before start of every motion bell should be rang.
27. Before using spreader beam it should be checked for its balance by lifting it
the in air.
28. Ensure the proper reeling of magnet cable

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29. Check the magnet chain properly engaged with crane hook
30. If you find that hoist brake fails while moving load don’t put off the emergency
switch. Keep on moving load with a hoisting and lowering combination and put
load at safe place.
31. If SWL of EOT crane is not known ask your supervisor.
32. Bell should be ringed before operating crane.
33. When there is sudden power cut during moving a load at first Position all
controller at zero position.
34. After completing the job park the crane at designated parking place.
35. Counter weight limit switch should be checked by crane maintenance
personnel.

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Don’ts
1. Don’t lift the load while swinging

2. Don’t keep the load on the ground while swinging

3. Don’t lift the load with jerk

4. Don’t put down the load with jerk on the ground

5. Don’t move load over the man working on shop floor or control room

6. Don’t Lift telescopic coil by tong, use C-Hook.

7. A load should not hoisted up as high off the ground as possible, and as close
to the upper limit switch as possible, prior to traveling with the crane.

8. Don’t use lifting tackle which is unfit for use.

9. Don’t use lifting tackle which is unfit for use.

10. Don’t use crane hook if its mouth opening has increased
by 15° or wear of hook is more than 10%.

11. Don’t switch off the magnet when it is holding load much
above ground level.

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12. Never perform side pulling of load by EOT crane.

13. Do not use mobile while operating the crane.

14. Don’t use Pan, Pan parag , Gutka, Tobacoo in the cabin and shop floor.

15. Don’t lift a load if you are not satisfied with slinging.

16. Don’t hold damage steel slings without gloves.

17. Don’t operate crane when too many persons start giving
signal

18. Don’t drag Load/ wagon from the crane.

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19. Don’t carry a person on a crane hook

20. Don’t lift a load more than SWL of crane.

21. Don’t stay over a furnace for longer period.

22. Never operate a crane that has been tagged out of service, if you will only be
using it for a short period of time.

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11. Questionnaire for self-evaluation:

Select most suitable answer Full Marks: 4x25 = 100

1. What a crane operator should do when SWL of crane is not known?

a) Ask your superior c) Guess
b) Go to such crane whose d) Refuse to work
SWL is known
2. A 1ton load is to be lifted with single part steel sling, what should be its
diameter.
a) 10 c) 25
b) 15 d) 30
3. What should be maximum apical angle between two leg steel slings?
a) 60º c) 120º
b) 90º d) 150º
4. Two 4 T capacity steel slings, whose apical angle is 120 º are applied to lift a
load. How much load would be lifted safely?
a) 2 T c) 6T
b) 4T d) 8
5. Which attachment is required to lift a hot metal bucket?
a) C – Hook c) Tong
b) Spreader Beam d) Grab Bucket
6. What does this crane hand signal stands for?
a) Stop
b) Emergency stop
c) Hoist
d) Bridge travel
7. What shall be maximum angle of swinging load from horizontal?
a) 05 º c) 15 º
b) 10 º d) 20 º
8. After completion of job, what you do?
a) Disengaged hook from c) Press emergency button
load d) All of above
b) Lift crane hook above
man height

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9. What will be the weight of a 12 meter steel slab width is 1meter and height is
0.5 meter? considering density of steel 8 Ton/meter3
a) 12 ton c) 8 ton
b) 48 ton d) 6 ton
10. Which limit switch is operated first during hoisting?
a) End c) Rotary
b) Block d) Position
11. During transporting a load if you notice that load is slipping down, what you
will do?
a) Press emergency switch c) Load will be settle down
b) Switch off main switch by hoisting and lowering
combination.
d) Left crane unattended
12. What should be avoided during lifting a load
a) Swing c) Lift
b) Jerk d) Vibration
13. Which safety device prevents collision between two cranes?
a) Collision preventer c) Anti-collision device
b) Buffer and stopper d) Electromagnetic brake

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Subjective Questions

Que1. What is an EOT crane?

Que2. What are the constructional features of an EOT crane?
Que3. What are the various attachments of EOT crane?
Que4. What are the uses of EOT crane?
Que5. What are the various types of EOT crane?
Que6. What care should be taken for safe operation of EOT crane?
Que7. What are the 5 things a crane operator should know before transporting
a load?
Que8. What are the rejection criteria of wire rope slings?
Que9. What parts needs to be inspected before starting an EOT crane?
Que10. Draw rough sketch of LT, CT and hoist drive.
Que11. What safety precaution will you take while landing a heavy load?
Que12. Write do’s and don’t while operating EOT crane.

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