Tom CarpenterCrane Maintenance Technician

• OSHA 29 CFR 1910.179 – Overhead and Gantry Cranes1910.179 (b)(2) – All new overhead and gantry cranes constructed and i ll d f A 31 1971 h ll h d i ifi i f installed on or after August 31, 1971, shall meet the design specifications of ASME B30.2

• www.osha.govASME B30 2 O h d d G C• ASME B30.2 – Overhead and Gantry Cranes

• CMAA 70 – Spec for Top Running Bridge & Gantry Type Multiple Girder Electric Overhead Traveling Cranes

• CMAA 78 – Standards & Guidelines for Professional Services Performed on Overhead Cranes

• Nucor Steel Berkeley Overhead Crane Program• Nucor Steel Berkeley – Overhead Crane Program

• Understand why an overhead crane preventative maintenance program is important.

• Discuss various procedures used for maintenance and inspection team safetyteam safety.

• Methods used for maintenance & inspection tracking, daily operator reports, and logbook entries.

• Review engineered solutions used to reduce hazards involving overhead and gantry cranes.

• OSHA 29CFR1910.179 (l)(1) States:A preventive maintenance program based on the crane manufacturer’s recommendations shall be establishedrecommendations shall be established.

• Preventive maintenance programs reduce overall maintenance costs and prevent serious shutdowns by forewarning serious potential problems, therefore maintaining safe and reliable crane operations.

• Job Safety Analysis (JSA)• Job Safety Analysis (JSA)By reviewing the JSA for the crane to be inspected, the inspection team will be able to easily identify:

- Required PPE, Tools, and Equipment- Job steps to complete the inspection

Area specific hazards and controls by hazard analysis- Area specific hazards and controls by hazard analysis- Lock out points for the crane being inspected- Any additional procedures needed to complete the inspection

Crane Boarding ProcedureBoarding:

1. Identify the crane, by crane number and ask permission to board. If no response, do not board the crane, call the operator again. (i.e. 603 crane operator this is ___________, can I board your crane?)board your crane?)2. Once approval is granted from the crane operator, push the red bridge stop button and confirm the red light comes on, and board the crane.3. Outside employers performing service and/or maintenance on overhead cranes at Nucor Steel Berkeley must comply with lockout / tag out standards for overhead bridge cranes.

Unboarding:

1. Identify the crane, by crane number and ask permission to unboard. If no response, do not attempt to exit the crane, call the operator again. (i.e. 603 crane operator this is ___________, can I exit your crane?)2. Once approval is granted from the crane operator, push the red bridge stop button, confirm red light comes on, and unboard the crane.3 After unboarding push green bridge stop button and confirm green light comes on 3. After unboarding, push green bridge stop button and confirm green light comes on. 4. Advise the crane operator that you are off the crane and it is clear to operate.

Bridge Stop Circuit

• Ensures personnel safety when boarding / unboarding crane• Pushbutton station are wired in series for multiple access locations• When actuated, the circuit removes control power from the bridge

drives preventing crane movement while accessing the crane.p g g

• References: OSHA 29CFR1910.179 (l)(2)(i)(e) – Where other cranes are in operation on the same runway, rail stops or other suitable means shall be provided to prevent interference with the idle crane.

ASME B30.2 Section 2-2.3.2.a.6 – If the runway remains energized, stops or a signalperson(s) shall be provided to prohibit contact by the active crane(s) with the idle crane, with persons performing maintenance, and with equipment used in

f i th i tperforming the maintenance.

Rail Stop Installation Procedure• P T id th f i t ll ti d l f b id il • Purpose: To provide the safe installation and removal of crane bridge rail

stops to prevent the contact of active cranes with the crane being serviced, maintenance personnel, and associated equipment.

• Responsibilities: Any personnel servicing overhead cranes.

R il St I t ll ti P dRail Stop Installation ProcedureNOTE: When possible, the crane hot rail will be locked out to prevent interference from active cranes.

1. Position the crane to be serviced in the desired location. If other cranes are being operated in the same bay, verify that rail stop location will not interfere with other crane operations.

2. Notify the area supervisor, operator(s) of crane to be serviced, and active cranes of intent to install rail stops. Identify the crane, by crane number and ask permission to install rail stops. If no response, do not p y , y p p p ,continue with the installation, call the operator again. (ie: 603 crane operator this is ___________, can I install rail stops?)

3. Install a tag on the active crane controls that states: “CAUTION Crane bridge rail stops installed.”

NOTE: If rail stops are stored on the crane, retrieve the rail stops using the Crane Boarding Procedure.

4. Position both rail stops with the curved edge facing away from the stationary crane no less than 15 feet from the edge of the crane bumper.

5. Rail stops must be installed by hammering wedge into place so that the rail stop is clamped onto the rail.

6. Rail stops, once installed, will be marked at the rail stop with a red flashing light.

7. Notify crane operators and supervisor in the affected area of the existence and location of the rail stops in place.

Rail Stop Installation Procedure

Crane Interference Procedure

• If it becomes necessary to perform work of any kind that would placepersonnel or equipment into the crane-way or high enough as topersonnel or equipment into the crane-way or high enough as topotentially interfere with the movement of the crane an “OverheadCrane-Way Equipment Interference Permit” must be filled out.

• The purpose is to make all parties involved aware of the work beingperformed. Once work is completed a copy must be turned in to thesafety office for retention purposessafety office for retention purposes.

• This excludes fork lift operation unless a basket is being used with thefork lift to lift personnel Anytime a piece of equipment is at thefork lift to lift personnel. Anytime a piece of equipment is at theelevation of the electric overhead crane rails, the lockout procedureor rail stops MUST be utilized.

Crane Interference ProcedureProcedure

Crane Interference Procedure

Inspection & Maintenance Reports

• ASME B30.2 Section 2-2.1.5 States: Dated inspection reports of comparable records shall be made on critical items such as hoisting machinery, sheaves, hooks, chains, ropes, and other lifting devices. Records shall be placed on file.hooks, chains, ropes, and other lifting devices. Records shall be placed on file.

• CMAA 78 Section 4.5.4 States: Inspection reports shall be given to the Purchaser’s responsible person in a specific and legible format. Inspection

d h ll b k t fil b th / h d if li bl th records shall be kept on file by the owner/purchaser and, if applicable, the service provider for a period of three (3) years from the date of the actual inspection.

• CMAA 78 Section 4.6.4.1 States: Maintenance records shall be kept on file evidencing adjustments, maintenance, and repairs that have been performed. Maintenance records should be retained for the life of the equipment.

Inspection Reports:

Daily Operator Inspection

Inspection Reports:Logbook Maintenance Entries

Inspection Reports:Preventative Maintenance Tracking

Inspection Reports:

Crane PM Inspection Checklist

Inspection Reports

• The SafeSide™ voltage portals (part numbers R-1A003 and R-T3) reduce arc

Non-Contact Voltage Detection

• The SafeSide voltage portals (part numbers R-1A003 and R-T3) reduce arc flash risks and increases electrical safety by providing maintenance personnel a no-touch voltage portal on the outside of grounded metallic electrical enclosures.

• VoltageVision® (R 3W) flashes whenever hazardous voltage is present in any • VoltageVision® (R-3W) flashes whenever hazardous voltage is present in any individual phase. After disconnecting power to an enclosure, electricians can pre-verify voltage isolation while the enclosure door is safely closed. The risk of arc flash is reduced because electricians know if there is power inside the enclosure before re-verifying isolation with a meter.y g

• Thru-door voltage detection if used in a safety program must be written into the LOTO procedure to meet requirements of NFPA 70E 120.(C)(2).

• For additional information visit www.Graceport.com

Non-Contact Voltage Detection

VoltageVision®

SafeSide™SafeSide

Electrified Rail Conductor System – Collector Shoe Mod.

• Mill-wide reporting of arc flashes from crane collector systems

• Most flashing was a result of rail shaving buildup on the collector shoes

Electrified Rail Conductor System – Collector Shoe Mod.

Worked with Transtech Power Transfer Systems to develop graphite plug insert built into the collector shoes for lubrication

What is a Gantry Crane?

Gantry Crane Safety Circuit

A crane similar to an overhead crane except that the bridge for carrying the trolley is rigidly supported on two or more legs running on fixed rails or other runwaylegs running on fixed rails or other runway.

Semi Gantry Crane

Gantry Crane Safety Circuit

yA crane with one end of the bridge rigidly supported on one or more legs that run on a fixed rail or runway, the other end of the bridge being supported by an end truck running on an elevated rail or runway.pp y g y

• Gantry cranes have been equipped with bumper

Gantry Crane Safety Circuit

Gantry cranes have been equipped with bumper safety switches to prevent personnel injury and equipment damage during crane operations.

• The gantry safety circuit is active at all times The gantry safety circuit is active at all times.

• Each switch requires only 4lbs of actuation force.

• The following events will occur once contact has been made with the bumper safety switches:

Bridge travel will stop.g pHorn will sound for 10 seconds.Red light on gantry leg will flash.

• For additional information visit: • For additional information visit: www.tapeswitch.com

• Points have been added to both the trolley and bridge on all overhead cranes to

Personnel Tie-Off Points

Points have been added to both the trolley and bridge on all overhead cranes to provide personnel a secure location to attach harness lanyards. This allows personnel to move freely when performing maintenance or inspections.

• Develop a better understanding of why an overhead crane preventative maintenance program is important.

• Discussed various procedures used for maintenance and inspection team safety such as Crane Boarding, Rail Stop Installation, and Crane InterferenceCrane Interference.

• Examples of maintenance & inspection tracking, daily operator reports, and logbook entries.

• Reviewed several engineered solutions used to reduce hazards involving overhead and gantry cranes.

Have A Safe Day!y