STATISTICS OF THE DANGEROUS OCCURENCES RELATED TO CRANE

IN TPCIL SINCE 2011

S.NO DATE Time Description Result

1 09.01.2012 5:25 PM While lifting the chipped pile with help of crane, the

chipped pile fall loose on the ground. D O Item a.

2

24.02.2012 12:15 PM Worker run over by hydra. Fatality

3

27.04.2012 4:15 PM Hook drop off while lifting the steel bar cage D O Item a.

4

02.06.2012 3:45 AM Crane swing the steel cage and hit the mouth of worker. M T

5

10.06.2012 1:00 PM Crane boom collapsed due to overloading D O Item g.

6

28.06.2012 2:15 AM Crane counter weigh swing and hit stationery vehicle. D O Item g.

7

14.08.2012 9:00 PM Crane boom collapsed due to dragging of load. D O Item a.

S.NO DATE Time Description Result

8

28.11.2012 12:35 PM Hydra touched the 11 KV line D.O

9

02.06.2013 3:40 PMWhile reversing the Hydra, the hydra's boom got contacted with the

over head barrier's scaffold pipe, then the pipe hits the cable(11 KV Cable), results the DTR got tripped

Do

10

18.06.2013 3:45 PM The boom of the crane hit and damaged the Y Phase of the 11 kV cable and causing a trip to BTG areas. DO

11

31.07.2013 4:30 PMwhile lifting a pipe of 24 Ton using a 150T crawler crane and the

belts capacity of 10T x 2 Numbers, one belt snapped and the pipe dropped to the ground.

DO

12

29.07.2013 3:40 PMwhile lifting a beam of 1.5 Ton using 150 ton crawler crane, the

winch drum air pressure hose burst resulting in winch brake failure. The beam was dropped from 30 m to the ground.

13

25.01.2013 7:30 AM hydra tilting during tandem lifting D.O

14

26.01.2013 10:30 AM hydra tilting during tandem lifting D.O

S.NO DATE Time Description Result

1526.07.2013 11:30 AM While hydra is shifting a coil at Boiler #2, it toppled due to uneven

ground. There is no injury to person. DO

16

22.08.2013

05.38 PM

While a Hydra was shifting a rectangular duct at the material yard, it moved into an uneven soft depression (due to rain) and toppled

on its leftDO

17

14.11.2013 8:45 AM

The tube supporting pipes stored behind the MPH #1 was to be shifted to TG#1 maintenance bay with the help of 150T crane, but the team of M/s MECH Engineering used two hydras bearing reg. no. KA 35 xxxx and MH 35 xxxx to perform the shifting of TSP by

tandem lifting. The hydra bearing reg. no. MH 35 xxxx front tyre got stuck in the wet soil which tilted the hydra partially, as a immediate action the hydra operator lowered the load but due the poor road

condition and wet soil the hydra toppled.

DO

WHY CRANES?

The crane is the primary machine used for the vertical movement of construction materials.

MATERIALS HANDLING EQUIPMENT

1. Eot Cranes

2. Gantry Cranes

3. Semi Gantry

4. Pillar Type

5. Fork Lifts

6. Jambos

7. Mobile Cranes

8. Loco

9. Front End Loader

• Lorries, Trailors.

SAFE OPERATION OF CRANE DEPENDS ON

Rigger

Crane Operator

Maintenance Persons

Competent persons

Statutory Authority

TYPES OF CRANES MOSTLY USED IN CONSTRUCTION INDUSTRY

1) Crawler Cranes:

2)Wheel-Mount Cranes:

STATUES

FACTORIES ACT 1948 – SECTION 29.

Lifting machines, chains, ropes, lifting tackles to be tested by competent person.

Register to be maintained with all particulars.

OPERATOR AND DRIVERS

Qualified & Licensed operators

Experienced Person

Physically Fit

Case Study Videos:

1) Video 12) Video 23) Video 34) Video 45) Video 5

5 TONALWAYS ENSURE THE

LIFTING DEVICE AND ALL SUPPORTING

COMPONENTS ARE RATED FOR THE LOAD TO

BE LIFTED!

2TON

10 TON LOAD

KNOW THE RATED LOAD OF THE CRANE

Factors to be considered before lifting with crane

Soil ConditionAccessWeight of the loadHeight of the load to be liftedMaximum angle of the boom to lift the load.Sling heightHook block height

SAFETY DEVICES IN CRANE

Angle Plate

Pointer

Boom Limit Switch

Over Hoist Limit switch

Hook Latch

SAFETY DEVICES IN CRANEBOOM ANGLE INDICATOR

DESCRIPTION OF LOAD INDICATOR

GENERAL SAFETY INSTRUCTION

1. When not in use crane should be parked with load hook raised, control switches to neutral & main switch open.

2. No crane shall be used for the purpose of transportation of passengers.

3. Cranes on same runways should be avoided from collision.

4. The Crane Operator should ensure the availability & serviceable condition of fire extinguishers.

5. Crane should not be used for dragging & pulling.

6. Impact load should be avoided.

7. The condition of ropes, slings are to be checked before loading.

8. Notify the shift in charge for and special lifts.

9. Spreader beam to be used for lengthy objects.

10.Operator should follow signal from only one person. But he should respond for stop signal from any persons.

11.For any maintenance work on crane, runway “Permit to work” system to be followed.

Lifting OperationsPossible causes for failure while lifting

Poor machine condition

Machine configuration not to specification

Improper revving

Improper use of outriggers

Soft footing

Crane not in level

Lifting OperationsPossible causes for failure while lifting

Side loading

Increase of load radius

Unsafe rigging practice, Rapid swing rate

Impact loading - rapid acceleration/deceleration

High wind speeds

TANDEM LIFTING

MIRRORS LOCATED ON EITHER SIDE FOR OPERATOR VIEW OF HOOK

MIRROR LOCATED ON RIGHT SIDE

OF OPERATOR CABIN TO VIEW HOOK MIRROR LOCATED ON LEFT SIDE OF OPERATOR CABIN TO VIEW

HOOK

VIEW OF MAN STANDING AT HOOK FROM OPERATOR SEAT., PHOTO TAKEN FROM OPERATOR’S SEAT.THRU RIGHT SIDE MIRROR.

VIEW OF SAME MAN STANDING AT HOOK FROM OPERATOR SEAT., PHOTO TAKEN FROM OPERATOR’S SEAT.THRU LEFT SIDE MIRROR

Hand signals shall be post on the equipment or conspicuously at the jobsite.

ANSI B30.5 – Hand Signal Chart

Do's After the training1) Reflecting jacket should be wore by signal man.2) Communication between Signal Man and Operator.(Walky-Talky or

Whistle).3) Before Performing the activity ask for the permit(Load > 20 T) and

Permit for tandem lifting.4) No Unauthorized operator is entertained.5) Only Authorized operators of that particular crane only should

operate it.6) No unsafe act will be performed.7) If anyone forces you to do unsafe act turn–off the ignition and come

to fire-station along with key.

8) Give a call at 8978681139 - M N Murthy to provide any information regarding your crane operating conditions or anyone forcing to do an unsafe act.

ANY QUERIES??

Signalperson: Signals shall be Discernible or audible at all times. No response shall be made unless signals are clearly understood.

Hand Signals

Hoist: With the forearm vertical, forefinger pointing up, move hand in small horizontal circle.

Hand Signals - Hoist

Lower: With the arm extended downward, forefinger pointing down move hand in small horizontal circle

Hand Signals - Lower

Use Main Hoist: Tap fist on top of head then use regular signals.

Hand Signals – Main Hoist

Use Whip-Line: (Auxiliary Hoist) Tap elbow with one hand, then use regular signals.

Hand Signals – Whip-line

Raise Boom: Arm extended fingers closed with thumb pointing upward.

Hand Signals – Raise Boom

Lower Boom: Arm extended fingers closed with thumb pointing downward.

Hand Signals – Lower Boom

Move Slowly: Use one hand to give any motion signal and place the other hand motionless in front of hand giving the motion signal (Hoist slowly shown as example).

Hand Signals – Move Slowly

Raise the Boom & Lower the Load: With arm extended, thumb pointing up, flex fingers in and out as long as load movement is desired.

Hand Signals – Raise Boom & Lower the Load

Lower the Boom & Raise the Load: With arm extended, thumb pointing down, flex fingers in and out as long as load movement is desired.

Hand Signals – Lower the Boom& Raise the Load

Swing: Arm extended, point with finger in direction of swing of boom.

Hand Signals - Swing

Stop: Arm extended, palm down, move arm back and forth horizontally.

Hand Signals - Stop

Emergency Stop: Both arms extended, palms down, move arms back and forth horizontally.

Hand Signals – Emergency Stop

Travel: Arm extended forward hand open and slightly raised make a pushing motion in direction of travel

Hand Signals - Travel

Dog Everything: Clasp hands in front of body.

Hand Signals Dog Everything

Travel Both Tracks: Use both fists in front of body, making a circular motion about each other, indicating direction of travel, forward or backward. (For land cranes only)

Hand Signals – Travel Both Tracks

Travel One Track: Lock the track on side indicated by raising fist. Travel opposite direction indicated by circular motion of other fist, rotated vertically in front of body. (For land cranes only)

Hand Signals – Travel One Track

Extend Boom: (Hydraulic cranes) Both fists in front of body with thumbs pointing outward.

Hand Signals – Extend Boom

Retract Boom: (Hydraulic cranes) Both fists in front of body with thumbs pointing towards each other.

Hand Signals – Retract Boom

Extend Boom – One Hand Signal: (Hydraulic cranes) One fist in front of chest with thumb tapping on chest.

Hand Signals – Extend BoomOne Hand

Retract Boom – One Hand Signal: (Hydraulic cranes) One fist in front of chest with thumb pointing outward and heel of fist tapping on chest.

Hand Signals – Retract BoomOne Hand