Safe Work Procedure for Overhead Crane

SAFE WORK PROCEDURE

FOR OVERHEAD CRANE
Safe Work Procedure for Overhead Crane

1. Introduction
 Purpose: To outline the procedures for the safe operation of overhead cranes and ensure
compliance with HSE rules & regulations.

 Scope: Applicable to all operators, maintenance personnel, and workers involved in

overhead crane operations.

 Responsibilities: Clearly assign roles, including Crane Operators, Riggers, Supervisors,

and Safety Engineer.

2. Operator, Rigger & Signal Qualifications

 Certification: Operators, rigger & signalman must be trained, certified, and competent in the
operation of overhead cranes.

 Refresher Training: Regular training sessions and assessments should be conducted to

maintain operator competency.

 Understanding of Procedures: Operators must fully understand and comply with the SWP
and manufacturer’s instructions.

3. Pre-Operation Procedures
 Daily Inspection Checklist:

o Visual Inspection:

 Inspect the crane for any visible damage or wear, including the hook, wire
ropes, chains, and slings.

 Check the integrity of structural components like the bridge, runway, and
hoist.

 Inspect all controls and buttons for functionality.

o Operational Inspection:

 Test the crane’s controls, including lifting, lowering, and movement in all
directions.

 Verify that limit switches, emergency stops, and brakes are functioning
correctly.

 Check the load chain for lubrication and ensure no links are twisted.

 Confirm that all safety devices, such as overload limiters, are operational.

o Environmental Check:

 Ensure the work area is clear of obstructions, with adequate lighting and no
overhead hazards.

 Confirm that the area beneath the crane is clear of personnel and obstacles.

 Assess the work environment for any potential hazards like poor weather
conditions.

 Ensure that beneath the crane run way is free from potential hazard.
Safe Work Procedure for Overhead Crane

4. Load Handling Procedures

 Preparing the Load:

o Ensure the load is within the rated capacity of the crane.

o Use appropriate lifting gear, ensuring slings, hooks, and chains are in good condition.

o Secure the load properly using the correct rigging techniques.

 Lifting the Load:

o Position the crane directly over the load to prevent side loading.

o Lift the load slowly and steadily to avoid sudden movements or swings.

o Check the balance of the load after lifting it slightly off the ground.

 Moving the Load:

o Move the crane and load slowly, avoiding sudden starts or stops.

o Ensure that the load is as close to the ground as possible during transit.

o Use clear hand signals or radio communication between the operator and ground
personnel.

 Lowering the Load:

o Lower the load slowly to its destination.

o Ensure the load is stable and secured before detaching the rigging.

o Avoid placing the load in a position that could cause it to topple or create a hazard.

5. Operational Safety Procedure

 General Safety Rules:

 Never exceed the crane’s rated load capacity.

 Do not use the crane to lift people unless specifically designed and certified for this
purpose.

 Avoid carrying loads over personnel or workstations.

 Do not leave a suspended load unattended.

 Emergency Stop Procedures:

 Operators must be familiar with the location and operation of emergency stop
controls.

 In case of an emergency, immediately stop all operations and assess the situation.

 Communication:
Safe Work Procedure for Overhead Crane

 Ensure effective communication between the crane operator and ground personnel.

 Use standardized hand signals and communication devices when necessary.

 Establish a clear line of sight or use a spotter if the operator’s view is obstructed.

6. Post-Operation Procedures

 Securing the Crane:

 Lower the hook to a safe position when not in use.

 Turn off the power supply and lock out/tag out the crane if maintenance is required.

 Secure the crane and prevent unauthorized use.

 Post-Use Inspection:

 Conduct a visual inspection of the crane and lifting equipment for any signs of wear or
damage.
 Report any defects or issues to the supervisor immediately.
 Record the inspection findings and any actions taken.
7. Maintenance and Inspection

Routine Maintenance:

 Follow the manufacturer’s maintenance schedule for routine checks and

servicing.
 Lubricate moving parts, inspect electrical systems, and replace worn components
as necessary.

Periodic Inspections:

 Conduct comprehensive inspections at intervals specified by the manufacturer or

manual guideline

 Engage qualified personnel for detailed inspections, including non-destructive

testing if required.

 Maintain detailed records of all maintenance and inspection activities.

Corrective Actions:

 Immediately address any defects or issues identified during inspections.

 Do not operate the crane until repairs or replacements have been completed and
verified.

8. Emergency Procedures
 Equipment Failure:

 If the crane malfunctions during operation, stop immediately and lower the load if
possible.

 Do not attempt to repair the crane without proper authorization and training.

 Report the failure to the supervisor and follow the company’s incident management
procedures.

 Accident Response:

 In case of an accident, activate the emergency stop and provide first aid if needed.
Safe Work Procedure for Overhead Crane

 Notify emergency services and follow the company’s emergency response plan.

 Secure the area and prevent further operations until the situation is resolved.

9. Compliance and Documentation

Record Keeping:

 Maintain records of all training, certifications, inspections, maintenance, and

incidents.

 Ensure records are readily available for review by HSE Engineer and regulatory
bodies.

Regulatory Compliance:

 Regularly review and update the SWP to ensure ongoing compliance with HSE
regulations.

 Conduct audits and safety reviews to identify areas for improvement.

Review and Continuous Improvement:

 Periodically review the SWP for updates based on changes in regulations,

equipment, or work practices.

 Incorporate feedback from Operators and HSE Engineer to improve procedures.

10. Acknowledgment and Sign-Off

 Operator and Supervisor Sign-Off:

 Ensure that all personnel involved in crane operations have read,
understood, and signed the SWP.

 Keep signed copies on file for reference and compliance purposes.

11. Additional Safety Considerations

Fatigue Management:

 Implement measures to manage operator fatigue, such as regular breaks and shift
rotations.

Personal Protective Equipment (PPE):

 Ensure all personnel wear appropriate PPE, including hard hats, safety boots, and high-
visibility vests.

This comprehensive SWP should be tailored to fit the specific crane model, work environment, and
operational needs. Regular training and strict adherence to these guidelines will help ensure safe
crane operations and compliance with HSE Regulations.

Lifting Categories
Lifting operations are divided into 3 categories: Standard lift, heavy lifts,
critical lifts.
Standard/Routine Lift

Routine lifts are those involving known or evaluated weight, shape

and center of gravity under normal environmental conditions, using
standard rigging arrangements and carried out by competent
Safe Work Procedure for Overhead Crane

personnel.
A Risk Assessment is adequate to determine hazards and suitable control
measures.

Heavy Lift
Heavy lifts are defined as those where:
 The lifted item weighs > 10t, load length > 14 meters and/or
large dimension or tandem lifts shall be considered as (Critical
lift) (unless otherwise stated in contractual documents) .The
lifted item's weight exceeds 75% of the maximum rated load
for the lifting equipment
 Any multiple crane lift where two or more cranes are used, not
including tailing crane
 Any lift where the crane load line will not be vertical
 Any lift with concerns on access, clearances, and ground bearing
pressure
 Any lift which poses concerns on safety, such as lifting over
new or existing installation
 Any lift that requires special handling because of location
and/or configuration as required by engineering or vendor

Critical Lifts (Lifted load 75%-100% of chart)

A critical lift shall be any time where two (2) cranes or more are required
for setting vertical equipment, or, will exceed 75%, or more, of the load
chart.

Types of Work Requiring a Permit to Work

 Any lifting operations, Lift > 10 Tons
 Tandem lifts
 Lifts over existing plant
 Lifts exceeding 75% of the load capacity of the crane
 Lifts adjacent to live overhead power lines
 Use of Crane Suspended Man Basket

Documents Requirements for Lifting Operation (If Necessary)

Work Method of Statements & Risk Assessments

Work Method Statement for the lifting and erection of all equipment’s,
structures, or materials and in case of lifting methods shall be
prepared. The Work Method Statement should include the following
minimum information from a Safety viewpoint:
 Scope of Work
Safe Work Procedure for Overhead Crane

 Job Checklist
 References
 Location
 Work Procedures
 Schedule
 Key personnel
 Coordination
 Equipment, Materials and Resources
 Step by step sequencing of works.

Lifting Gear

Lifting gear is any piece of equipment below the hook used to attach
the load and includes:
 Chains
 Slings (wire rope slings, synthetic webbing slings, etc.)
 Shackles
 Hooks
 Chain sling adjusters
 Spreader beams
 Lifting frames

All lifting equipment must be inspected by Line Supervisor/Leader,

Operator, HSE Engineer and shall have valid third-party test
certificate and documents available at the site. It shall also be
inspected by qualified person on a quarterly basis for color coding
purpose. This specific quarterly inspection comes in addition to all
daily inspections performed by competent person. Check list shall be
used for all inspections and records shall be made available for
verification and audit.
Any lifting gear that is not produced by a recognized and competent
manufacturer and lifting gears fabricated from rebar, metal plates,
etc. are not permitted. Any field modified gear must be re-certified
before use.

Wire ropes shall never be used if:

1. 5 or more wires are broken in a strand in a lay length, or;

2. 10 or more wires are broken anywhere in a lay length, or;

3. it is “bird-caged” or kinked, or;

4. it has excessive corrosion, or;

Safe Work Procedure for Overhead Crane

5. An electric current flow has passed through the rope