Material handling by Crane
What is a Crane?
A large, tall machine used for moving heavy
objects by suspending them from a
projecting arm or beam; equipped with a
hoist rope, 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 things and transporting them to
other places. The device uses one or more
simple machines to create mechanical
advantage and thus move loads beyond the
normal capability of a human.
Basic Terminology
• Consists of a rotating structure for lifting and lowering horizontally on
Crane rubber tires or crawler treads
Hoist • Used to lift and lower load.
• An inclined spar, strut, or other long member supporting the
Boom hoisting tackle
Boom stops • A device used to limit the angle of the boom at its highest position
Block • Sheaves or grooved pulleys in a frame with hook, eye and strap
Brake • To slow or stop motion by friction or power
• Extension attached to the boom point to provide added boom
Jib length for lifting specified loads
Types of Material Handling Equipment
Hydra Cranes
New Generation Cranes Types of Cranes used in Tata Power - DDL
Lorry mounted cranes
Truck Mounted Cranes
Fixed Tower Cranes
Crawler Cranes
New Generation
Mobile Tower Cranes Hydra Cranes Cranes
Safety features available on cranes
1. Over Hoist hyd. system cut-Off & warning alarm for operator.
2. Over Load hyd. system cut-off & warning alarm for operator.
3. Safe load indicator system fitted on machine for protection fro accidents
4. Flow control valve is fitted in derrick in line to lift & lower the boom in controlled speed .
5. Reverse gear buzzer is connected with reverse gear.
6. Side view mirror fitted on the window rod
7. Back light ,brake lights and traficators light fitted for indication to other
8. Hand brake is a mechanical brake
9. Wire rope tensioner fitted on hydraulic winch assembly for proper reaving of wire rope on winch cable drum
10. Air assisted hydraulic operated brakes on front wheels
11. Hydraulic operated mechanical disc brakes on rear wheels
12. Mechanical disc brake are hand brake
13. Ropes cabin ergonomically designed cabin for operators protection.
Basic crane safety guidelines
1. Cranes must be operated only by qualified and trained personnel
2. Crane must be duly inspected before using
3. Be sure to follow signals, and the manufacturer instructions, while operating a crane.
4. Cranes must be on a firm, stable surface and must be level.
5. Watch for overhead electric power lines. Maintain at least a 10-foot safe working clearance from all power lines
6. Be sure to use the correct load chart for the crane’s configuration and setup
7. Everyone around must be aware of the lift being made
8. There is no high wind condition
9. Barricade all accessible areas inside the crane’s swing radius.
10. Raise a load a few inches, hold, verify capacity and balance, and test the brake system before delivering load.
Hazard Identification
Injury from
Collapsing slipping, tripping
and falling
Stuck by or
Property crushed by
Damage falling loads due
to rigging failure
Injury from Crane Electrocution
due to power
falling material
Hazards line
Crane hand signals
Note: Only a Qualified Rigger will give hand signals
Crane Checklist Performa
The crane being deployed at
site must be checked in
accordance to crane checklist
and the same to be sent to
concerned Project officer or
engineer in-charge.
Work using crane must not be
started until the clearance is
given by the concerned Project
officer or engineer in-charge.
The crane must be
accompanied with a competent
driver and helper.
PPE (PERSONAL PROTECTIVE EQUIPMENT)
Any person is working with MHE (Material handling equipment) or RCE (Road construction equipment), then
personal safety is first priority to all concern staff. For personal safety , work carefully on machine and follow
the safety rules & systems and adopt PPE (Safety Equipment)
1. Always wear Safety Helmet
2. Always wear Mask on nose during working in chemical industry and in dusty condition
3. Always wear Safety Shoes
4. Always wear tight dress or uniform
5. Always use safety belt , while working more then two maters height
6. If you are working on machine then , you must be familiar with machine's all operating & safety systems
7. Always wear hand gloves while working on machine
Five Steps of Safety
• Planning of work
1.
• If you are doing any work, that means hazards are involved. Identify the
2. hazards
• Precautions to be taken to prevent hazards.
3.
• Familiarize the team with the work and precautions to prevent hazards
4.
• Think for other unexpected hazards and guide working team accordingly &
5. watch
Safety Precautions “Prior to Lift”
1. Place the crane on level round with proper working position
2. Crane working area must be barricaded properly to avoid entry of unauthorised
persons
3. All unwanted persons will be moved out from barricaded area.
4. Check Over Head Electrical lines or any other obstructions, before marching &
placing the crane for work
5. The load chart of crane is built to lift weight in crane straight position.
6. Check the SLI (Safe load indicator) system of crane before start work
7. If crane is working on road side, HSE person to be deputed to clear the traffic
How do accidents occur?
Instability Lack of
unsecured load, communication
load capacity
the point of operation is
exceeded, or a distance from the crane
ground not level operator or not in full
or too soft view of the operator
Unskilled
crane Inadequate
operator or maintenance or
Lack of inspection
training
Life saving principles of lifting operation
Dos: Don’ts :
1. Do follow the lift plan, considering, load, location and lifting team. 1. Do not allow yourself or any one
2. Do perform and use JSA Checklist for inspection of crane and lifting tools & else below the suspended load.
tackles. 2. Do not hold the suspended load
3. Do check the load is within safe working limit of lifting equipment. by hands as it may swing & hit
4. Deploy trained manpower and ensure competent supervision. back.
5. Ensure anchoring of lifting tackles at designated lifting points/lugs with
3. Do not use damaged lifting
suitable sling.
equipment or accessories.
6. Do ensure only authorized person /Competent supervisor is engaged for
signalling activity.
7. Do ensure inspection of ground condition for stability of crane during lifting.
Note : - As an employee you are
8. Do ensure proper placing of lifting tackles in crane hook with availability of
hook latch. authorized and expected to stop
9. Do Ensure checking of over head power line and other obstruction in swing any task or operation which you
radius of crane. believe that the risk to people or
10. Do Ensure placing of lifting tools and tackles at pre defined CG point for safe assets is not being properly
lifting. controlled.
11. Do ensure inspection of wire rope and belt slings for damages.
12. Do ensure proper working of limit switches , reverse horn and clearance of
swing area.
Important points to note
1. As per our safety process, all crane operators must undergo crane handling
training provided by DOSEC
2. Only trained crane operator are authorized and can operate crane at Tata Power-
DDL site
3. Crane can be operated only in the presence of HOG/ZM/ZSO/ZRDMO/primary
tagging authorization holder
Thank You
