Overhead Crane Session

Overhead Crane General Use & Inspection Criteria • The Selection Process For Both Overhead Cranes & Underhung Hoists, Should Not Be Taken Lightly. • A Significant Amount Of Pre-planning Is Needed To Place The Proper Crane Or Hoist Into The Proper Environment. • The Key To Equipment Longevity Is Complete And Through Inspections

Different Equipment Types • Overhead Cranes • Gantry, Semi-gantry, Bridge, Cantilever etc • Underhung Hoist • Monorail, Underhung Bridge, Wall jib, Floor jib, etc • Electric, Air (pneumatic), Manual powered

Duty Cycle Classes • There Differences Between Overhead and Underhung Crane Classifications

Duty Cycles - Overhead Cranes • CMAA spec 70 • ASME B30.2

Duty Cycles - Overhead Cranes There are six Service Class designations for the Overhead Cranes based on their Load Class and Load Cycles. • Class A – F • Class A – Standby or Infrequent Service • Class B – Light Service • Class C – Moderate Usage • Class D – Heavy Service • Class E – Severe Service • Class F – Continuous Severe Usage

Duty Cycles - Underhung Hoists • CMAA spec 74 • ASME B30.16

Duty Cycles – Underhung Hoists

There are four Service Class designations for the Overhead Cranes based on there Load Class and Load Cycles. • Class A – D • Class A – Standby or Infrequent Service • Class B – Light Service • Class C – Moderate Usage • Class D – Heavy Service

Duty Cycle & Maintenance Cost • Placing Class B Crane Into A Class C Environment is Tantamount to ….

Flushing Your Maintenance Dollars Down The Toilet!

Overhead Crane Inspections

There Are Two Reasons For The Correct And Timely Performance Of Inspections, And Testing On Overhead Cranes.

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Overhead Crane Inspections Humanitarian • Decrease The Probability For Equipment Failures That Result In Personnel Injuries/Death. • Provide A Safer Working Environment For All Workers.

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Overhead Crane Inspections Economic • Increased Productivity. • Decrease Repair & Replacement Cost.

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LOCKOUT/TAGOUT  29 CFR 1910.147  Procedures Designed To Save Lives And Prevent Injuries Prior To Maintenance And Inspection Procedures

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TYPES OF STANDARDS Regulatory Standards  Federal OSHA  State OSHA • Must Be “At Least As Effective” As Federal OSHA • 25 States & Two Territories

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TYPES OF STANDARDS Regulatory Standards (cont.)  Local Requirements  Employer Practices  Manufacturer Specifications/ Recommendations

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TYPES OF STANDARDS Consensus Standards • ASME (American Society of Mechanical) • CMAA (Crane Manufacturers Association of America) • NEC (National Electric Code)

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INSPECTION REQUIREMENTS Federal - General Industry

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Initial (29 CFR 1910.179 (j) (1))

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Regular (29 CFR 1910.179 (j) (2))

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Frequent: 29 CFR 1910.179 (j) (2) and ASME B30.2

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Periodic: 29 CFR 1910.179 (j) (3) and ASME B30.2

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INSPECTION REQUIREMENTS

Federal – Construction • Permanently Installed Cranes Exempted 1926.1438

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INSPECTION REQUIREMENTS Federal – Construction • Non-Permanently Installed Overhead Cranes Used in Construction Must comply with the following: • • • • • • • •

Modified Equipment (1926.1412 (a)) Repaired/Adjusted Equipment (1926.1412 (b)) Post-assembly (1926.1412 (c)) Each Shift (1926.1412 (d)) Monthly (1926.1412 (e)) Annual/Comprehensive (1926.1412 (f)) Severe Service (1926.1412 (g)) Equipment Not In Regular Use (1926.1412 (h)) 18

INSPECTION PROCESS Inspections may be broken down into systems, i.e. • Mechanical – Brakes (not including the actuators) – Brake lining – Gear Box(s) – Drive (End) Trucks – Drive Shafts, etc.

• Structural – Runway – Rails – Bridge Girders, etc.

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INSPECTION PROCESS Inspections may be broken down into systems, i.e. • Electrical – Motors – Controllers – Brake actuators – Buss Bars – Electrical Cabinets, etc.

• Hydraulic/Pneumatic – Brake Actuators – Master Cylinder, etc.

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Mechanical Inspection

INSPECTION PROCESS •

Drive Wheel, Gearbox & Driveshaft

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Mechanical Inspection

INSPECTION PROCESS •

Brake Lining, Drums & Components

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Mechanical Inspection

INSPECTION PROCESS •

Catwalk & Driveshaft Alignment & Mounting

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Mechanical Inspection

INSPECTION PROCESS •

Gear Box Inspection

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Structural Inspection

INSPECTION PROCESS •

Runway & Rails

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Structural Inspection

INSPECTION PROCESS •

Support Column Alignment & Missing Hardware

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Structural Inspection

INSPECTION PROCESS •

Bumpers & End Stops

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Structural Inspection

INSPECTION PROCESS •

Confirm Square of Bumpers &Rails

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Electrical Inspection

INSPECTION PROCESS •

Wiring and Wire Terminations

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Electrical Inspection

INSPECTION PROCESS •

Hoist Motor

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Electrical Inspection

INSPECTION PROCESS •

Collectors & Conductors

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Hydraulic/Pneumatic Inspection

INSPECTION PROCESS •

Hydraulic Brake for Leakage

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REQUIREMENTS FOR LOAD TESTING Operational Tests and Rated Load Tests:  Initial Installation (NEW)  After Alterations, Repairs Or Modifications  29 CFR 1910.179 (K) (1)  ASME B30.2-2.1 And 2-2.2.2  Some State OSHA’s Require Load Testing

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DOCUMENTATION  Required  Annual  Monthly On Critical Items And Running Rope

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DOCUMENTATION  Recommended Documentation And Retention Time • Daily (Current And Previous Month) • Weekly (Latest Plus Previous 4) • Monthly/Quarterly (Latest Plus Previous Year) • Semi-annual/Annual (Latest Plus Previous Year) • Others (Latest Plus Previous Year)

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DOCUMENTATION • Required Documentation And Retention Time Per 29 CFR 1926 Subpart CC • Monthly (29 CFR 1926.1412 (e)(3) (document must be retained for a minimum of three months) • Annual (29 CFR 1926.1412 (f)(7) (document must be maintained and retained for a minimum of 12 months)

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DOCUMENTATION • • •

Maintains A Complete Inspection, Maintenance, And Testing History Of The Equipment. Allows End User To Establish Life Cycle Cost. Assist In Establishing Trend Analysis.

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DOCUMENTATION  Can Establish Requirements For On-hand Spare Parts To Decrease Replacement Lead Time  Provides Statistical Data To Predict Mean Time Between Failure (MTBF)  Provides Statistical Data To Predict Mean Time To Repair (MTTR)  To Defend Against Liability 38

STORAGE OF DOCUMENTATION

Documents should be stored in a place where they are readily available. All workers, most importantly the operator, should know where these papers are. 39

SUMMARY The Inspection And Testing Of Overhead Cranes And Hoists Is Crucial To Safe Workplace Conditions. Any Kind Of Equipment Begins Depreciating After Its First Use. A Defect In Equipment Can Bring A Quick End To The Day, In A Best-case Scenario.

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