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Crane Safety (Pendant) - 00059112Safety Training
Technical TrainingPendant Crane Safety - 00059112
Safety TrainingTraining & Development
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CRANE SAFETY(PENDANT)
00059112
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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.
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Course Objectives1. Identify certification and recertification
requirements for pendant-controlled crane operators.
2. 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.
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Course Objectives5. 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.
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Course Objectives
9. Describe operator responsibilities and potential hazards when operating a pendant-controlled crane.
10.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.
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Identify certification and recertification requirements for pendant-controlled crane
operators.
Objective 1
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• Prior to operating pendant crane:– Training (00059112)– Knowledge eval (80%)– Performance eval (100%)
• Retraining required every 3 years.
Certification Requirements for Pendant Crane Operators
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Define the following crane terms: runway, bridge, trolley, hoist, hoist drum, hoist block,
safety latch, and pendant control.
Objective 2
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Main Parts of Pendant-Controlled Crane
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More Pendant Crane Definitions
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State the frequency that pre-operational inspections should be performed.
Objective 3
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• 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.
Required Inspections
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Identify unacceptable conditions that might be discovered during an annual or pre-operational
inspections.
Objective 4
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Check Hooks
No more than 5% and not to exceed ¼ inch increase in throat opening.(Dimension A)
Measurement taken from punch marks.
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• No visibly apparent bend or twist from the plane of the unbent hook.
• No visible cracks.
• No excessive wear.
• Safety latch in place.
Check Hooks
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Check Hoist Ropes
Watch for broken wires in this area
Check for broken wires
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• All covers and attachments secure
• No loose objects lodged on crane or hoist
• Trolley and bridge alignment correct
Check Bridge and Trolley
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• Cracks
• Loose bolts
• Broken or cracked welds
• End stops properly attached
Check Wall-Mounted Attachments
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Check Trolley and Bridge Rails
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• 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.
Check Pendant Control
Warning Label on back or side of control
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• 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.
Check Crane Functions
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Check Upper Limit Switches
Review Industry Event
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Objective 5
Given an unacceptable condition discovered during an annual or pre-operational inspection,
state the actions that should be taken.
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• Move crane to less traveled area.
• Turn all controllers OFF.
• De-energize main switch.
• Place warning signs on crane..
• Barricade crane or station watchman.
Reporting Deficiencies
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• 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.
Correcting Deficiencies
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Identify proper rigging and load handling techniques and restrictions.
Objective 6
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• Crane operator shall perform the pre-plan lift.
• Use good housekeeping practices.
• Select and use proper rigging.
Preparing for Lift
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• Check weight capacity of crane and sling.
• Plan where to set load.
• Check intended route.
• Identify potential hazards.
Pre-plan the Lift
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• Ensure adequate clearance to nearby equipment.
• Ensure aisles clean.
• Keep tools, cords, and other objects off floor so you can move freely.
Use Good Housekeeping
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• Select proper rigging.
• Check load tag.
• Inspect rigging.
• Inspect sockets, slings, handles, and connections.
• Remove rigging from service if defective.
Select and Inspect Rigging
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Describe safe work practices to be used when operating a pendant-controlled crane to lift,
move, and set a load.
Objective 7
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• 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.
Position Crane & Attach Sling
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• Load BalanceUnbalanced load creates greater force on sling than actual weight of load.
• AngleAngle of sling reduces capacity.
• Load MovementRapid, sudden movements result in increased forces due to dynamic loading.
3 Factors Affecting Capacity
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• 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.
Hand Signals
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• 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.
Raising Hook & Inspecting Load
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• 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.
Lifting Heavy Loads
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• 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.
Notifying Others & Positioning Self
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• 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.
Using Pendant Control
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• 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.
Lifting Load
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• 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.
Lifting Loads near Rated Load
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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.
If Two Cranes Used to Lift 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.
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• 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.
Moving Load
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• 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.
Moving Load
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• Place bridge and trolley directly over landing position.
• Do NOT swing load into place.
• Slowly set load.
• Lower hook so slings
can be removed.
Setting Load
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State how to properly store a pendant-controlled crane when not in use.
Objective 8
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• 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.
Securing Crane
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Describe operator responsibilities and potential hazards when operating a pendant-controlled
crane.
Objective 9
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• 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.
Operator Responsibilities
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• Tripping over items on floor.
• Tripping on cable.
• Hitting someone.
• Hitting plant equipment.
Potential Hazards
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Review ANSI Hand Signals Related to Pendant Cranes
Objective 10
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Necessity of Hand Signals• Provide for safety
• Universal signals
• Verbal signals not always possible
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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
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Use Main Hoist
Tap fist on head, then use regular hand signals
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Use Whipline (Auxiliary Hoist)
Tap elbow with one hand, then use
regular hand signals
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Raise Load
Move hand in small horizontal circle with forearm vertical and forefinger pointing up
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Emergency Stop
Extend arms outward slightly down and move
hands rapidly right and left
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Move Slowly
• Along with any movement signal, place other hand motionless in front of hand giving motion signal
• Example means “hoist the load slowly”
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Trolley Travel
Point thumb in desired direction of travel with palm up,
fingers closed
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Stop
With arm extended, palm
down, move arm back and forth
horizontally
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Bridge Travel
Make a pushing motion in direction of travel with arm extended forward
and hand open and slightly raised
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Lower
Move hand in small horizontal circle with arm
extended downward and
forefinger pointing down
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Dog Everything
• Clasp hands in front of body
• The signal “Dog Everything” means stop and shut down all lifting operations
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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.
Objective 11
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• 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.
Performance Evaluation
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Industry Event
Appendix A, Operating Experience
OE14316, Failure of Upper Limit Switch Causes Fuel Cask Auxiliary Hook and Block to Fall 70 FeetSummary: 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.
Click Here Return to Course
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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. 70
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Crane Safety (Pendant) - 00059112Safety Training
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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.
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