Worldwide S&ES Manual Database Policy 2.

21:Use of Mobile Cranes

Equipment lifts on a customer's property are made by a hoisting contractor and contractor crew.
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NOTE: If a Praxair location has the proper equipment and employees trained and experienced in
equipment lifting, then the employees may make equipment lifts on a customer's property as long as
written procedures and written authorization from management exists. Such written authorization must
be reviewed and reissued periodically.
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If conditions are hazardous, an employee authorized to issue Hazardous Work Permits (HWPs) for use of mobile
cranes is present to protect Praxair's interests; this rule applies whether the crane is being used at a Praxair or
customer location.
It is important to adequately describe the load and area for the lift to the crane vendor.
Praxair personnel do not assist in crane operations with contractor crews. If a location has trained and
experienced personnel, they may perform rigging operations with contractor crew on sensitive lift
operations (e.g., lifting bullgears, compressor covers, and rotors).

When Praxair owns the mobile crane, and our employees do lifting on a customer's property, safe procedures to
protect personnel are followed.
Worldwide S&ES Manual Database Policy 2.21:Use of Mobile Cranes

Minimum Precautions
The following basic safety rules are the minimum precautions taken when using mobile cranes:
When working near power lines, position the crane safely by performing the following activities:
Before the start of operations near electrical lines, notify the owners of the lines or their authorized
representatives, and provide them with all pertinent information. The power in the lines should be shut off
where possible or insulating sleeves installed.
Assign a safety observer to watch the movements of the mobile crane on any Praxair-supervised job. The
observer's sole responsibility is to watch the clearance to lines and to ensure that people are out from
under suspended loads and clear of crane movements.
Prior to making the lift, set the crane and boom in the fixed lifting position. Maintain a minimum clearance of
12 ft (3.7 m) in a horizontal plane between any electrical power lines and the crane or any part of the lift (e.g.,
boom, cable, hook, or load) See Mandatory Clearances Between Crane and Power Lines. Never make a crane
lift where the boom is directly above or below an energized power line.
Install a marker 12 ft (3.7 m) from the crane to indicate the area in which personnel are not allowed during the
lift. Markers may include a safety rope, barricades, signs, or any device clearly visible to the crane signaler.
Install them approximately 3 ft to 4 ft (1 m to 1.2 m) above ground level.
When the marker has been installed, the lift can be made. The crane with the boom in the lifting position must
not violate the 12-ft (3.7-m) clearance.
The 12-ft (3.7-m) clearance rule also applies to transformers or other exposed conductors
Worldwide S&ES Manual Database Policy 2.21:Use of Mobile Cranes
Minimum Precautions.Continued.
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NOTE: Under certain extreme circumstances, area office management may authorize plant supervision to
allow the crane, wire rope, slings, chains, etc., to intrude upon the 12-ft (3.7-m) safety clearance. PLANTS
DO NOT HAVE AUTHORITY TO WAIVE OR DECREASE THIS SAFETY SPACING POLICY. The Area S&ES
Manager must be informed of these exceptional cases beforehand and of planned precautionary safeguards.
The Praxair Safety and Environmental Services (S&ES) Department is available for consultation and is
interested in these unusual occurrences.
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Never overload a crane. Do not exceed the crane manufacturer's specified load limits for various positions of
the boom.
Use proper size and strength slings, wire ropes, cables, chains, hooks, etc. Closely inspect these devices
before use. (See Sling Inspection Guidelines in the Safety & Health Manual database.)
Do not use makeshift boom extensions.
Ensure that the crane is level before it is put into operation. Do not operate it on soft or sloping ground. Set
outriggers before the lift is started. Outriggers give reliable stability only on solid ground. Make sure crane
placement provides adequate clearance from plant equipment.
Ensure that the crane operator regularly inspects the brakes, cables, and other vital parts of the crane. The
HWP signer should check with the crane operator to be sure that this has been done.
Before lifting a load, make sure riggers and other personnel are out of harm's way. Caution all personnel in the
area to keep clear of the boom and cab or be excluded by means of barriers.
Use standard crane hand signals.
Ensure that all crane signals are given by one assigned signaler, and the signals are clearly understood by the
operator before setting the crane in motion.
Worldwide S&ES Manual Database Policy 2.21:Use of Mobile Cranes

Power Line Safety Rules Remarks

1. Exposed Power Line
1A. Power Transmission Lines (15kv and 23' 1" for each kv Area or Tonawanda management
above) over 15 kv approval needed to obtain
variance from 12' rule.
1B. Typical above 600v overhead electrical 12'1" for each kv
lines (uninsulated, insulated no ground, over 15 kv
shield no tray, integrity not known)
2. Power Line in Trays and Conduit
2A. High voltage (600v or above) cable, Crane can approach U/A required between operator,
insulated, shielded, and grounded in closer than 12' to work crew, and
metallic or nonmetallic cable tray or power lines. supervision on work
conduit (metallic tray and conduit must Use safe crane op. procedures.
be grounded). procedures.
2B. Low voltage (less than 600v), insulated Same as above (2A). Same as above (2A).
cable in metallic or nonmetallic cable
tray or conduit (metallic tray and
conduit must be grounded). In
nonmetallic cable tray and conduit the
insulated cable must have separate
ground conductor run along with or in
the insulated cable.
Worldwide S&ES Manual Database Policy 2.21:Use of Mobile Cranes

Other Recommendations to Consider

Only conduct crane work during daylight hours and fair weather
conditions.

Position the crane to minimize the need for changes in the boom angle
and extension or contraction of the hydraulic sections.

Evaluate the use of planks, beams, or other outrigger supports for added
stability in soft or rough terrain to minimize unanticipated crane
movement.

Use insulation blankets or sleeves when the crane is near energized high
voltage lines.
STANDARD HAND SIGNALS

Click to View Standard Hand Signals.ppt

 Common Cranes We Use.

1
TRUCK MOUNTED CRANE
WITH TELESCOPIC BOOM.
(COLES HUSKY, VOLTAS OMEGA)

CRAWLER CRANE WITH ARTICULATED HYDRAULIC MOBILE CRANE.

LATTICE BOOM. (ACE RHINO, ESCORTS HYDRA)
(TATA 955alc, TFC 280, TATA 320)
SAFETY DEVICES IN A CRAWLER CRANES
-HOOK LATCH- Prevent the sling from slipping out of
Hook.
-BOOM LIMIT SWITCH and BOOM CLUTCH KICK OUT
ASSEMBLY Prevent Over-hoisting and collapse of the
Boom backward.
-BOOM ANGLE INDICATOR- Indicate the operating angle
of the Boom.
-OVER HOIST LIMIT SWITCH- Alarm the Operator, If Over-
hoisting of the Hook takes place.
- LOAD CHART Shows the crane capacity at various
operating radius and boom length.
 SAFETY DEVICES IN CRANE
Over Hoist Limit switch

Boom Limit Switch Hook Latch

Boom Angle Indicator

Angle Plate
Pointer
 SAFETY DEVICES IN A
TRUCK MOUNTED CRANES
-HOOK LATCH- Prevent the sling from slipping out of
Hook.
-STABILITY ALARM (Only in High Cap. Cranes)- Prevent
unstable condition of the crane.
-LOAD MOMENT INDICATOR Indicate capacity at all
operating radius and boom length. Lock all operation
under unsafe state.
-OVER HOIST LIMIT SWITCH- Alarm the Operator, If Over-
hoisting of the Hook takes place.
 COMMON ACCIDENTS DUE TO
NON AVAILABILITY OF SAFETY SYSTEMS

Non-Use of Hook Latch. Fall of Load

Due to disengagement of sling from
Hook.
 COMMON ACCIDENTS DUE TO
NON AVAILABILITY OF SAFETY SYSTEMS
Limit Switch

Absence of Over
hoist Limit Switch
 COMMON ACCIDENTS DUE TO
NON AVAILABILITY OF SAFETY SYSTEMS
Over Hoist
No Boom Limit Switch Limit
switch

Boom Limit Switch Hook Latch

Angle Plate
Pointer
 BOOM EXTENSION /DISMANTLING.

- Improper /unstable support of the boom/jib during

erection or dismantling can cause collapse.
- Px personnel should not participate in these activities.
- Keep away when such activity takes place.
 Tippin
g Axis STABILITY OF CRANE
A is a point in the Tipping of
Crane
L1is Distance between Point A
and CG of Counter Weight
L2 is Distance between Point A
and CG of Crane Assembly
L3 is Distance between Point A
and CG of Load
W1 is weight of counter weight
W2 is weight of Crane Assembly
W3 is weight of Load
A To achieve the stability of Crane
the following equation should be
satisfied
L2
Moment about point A
L1 L3 W1 X L1 + W2 X L2 >= W3 X
L3
 OVERTURNING OF CRANES
A>> OVERLOADING
When Load is more than the Rated Load Lifting Capacity of the crane at a particular
Operating Radius and Boom Length. Toppling / overturning occurs.
Always check the Load Chart of the Crane and ensure the Lifting Capacity at the
required Boom length and Op. Radius. Remember: More the Op. Radius, Lesser
the Capacity. Capacity is less on the sides.
Toppling Occurs When: W1 X L1 + W2 X L2 < W3 X L3

A 50 MT crane does not necessarily

mean that the capacity is always 50 T.
At a particular Op. Rad the Cap may be
as less as 5 MT only.
 OVERTURNING OF CRANES

B>> Tyre Pressure

Inadequate Tyre pressure causes

crane to become unstable.
Deflated Tyre on one side cause
cranes to topple on the same side.
Possibility of toppling increases
while Loaded or with swinging
load.

Check Tyre condition while using

truck mounted or Hydra cranes.
 OVERTURNING OF CRANES

C>> Sudden Load, Jerk Load, Unstable Load

Sudden lifting of Heavy Load or sudden release of load that is stuck on ground
or beneath other load.
Sudden braking on rapidly descending load.
Abrupt swinging of Load to the side.

Lift of Load smoothly, control

Hoisting .
Ensure proper signals are used and
given by experianced Signal Man.
Ensure that Overloading on the Side
will not occur before swinging.
Practice Slow swing.
 OVERTURNING OF CRANES
D>> Failure of Outrigger while lifting load
(in Tyre Mounted Hydraulic Cranes)
If Outrigger fails with load, toppling of a crane is almost inevitable.

Out Rigger

Check for any hydraulic leakage/damage in the outrigger systems .

Never use with any of the outrigger partially extended.
Keep an eye on the outriggers on all sides during operation and lifting.
Never operate outrigger with load.
 OVERTURNING OF CRANES

E>> Loose Soil, poor Ground condition

Bad / poor Ground condition means
loose soil which will subside under the
load of the crane causing instability.
Sinking of Outrigger, wheels , crawler
in mud, sand or unstable ground.
Road edges, excavation, trenches etc.
cause this kind of accidents..

Check Ground condition where the crane is working.

Place sleepers, concrete/steel pads below Outriggers/ crawlers
Do not operate / lift load on loose, sand, muddy ground condition.
Do not operate very close to trench, excavation edges.
Do not march closely along road edge.
 OVERTURNING OF CRANES
F>> Tandem Lifts
Tandem operations require high level of synchronization between two cranes.
Calculation of the Load distribution of Two cranes taking part in the operation
should be accurate.
Adequate Factor of Safety to be kept for both the units.

NEVER march cranes with load in

Tandem !!
Never Do a Tandem operation
without adequate planning and expert
erection crew.
Make sure no wrong signal is given to
the operators.
Use service of Signal man experianced
in Tandem Operations.
 OTHER ACCIDENT CAUSES
A>> Electrical Over Head Lines

- Make sure that the Crane is not required to

march below O/h lines.
- The boom should not come close to power
lines during hoisting/ Swinging. CRANE BOOM
TOUCHING
OVER-HEAD
TRANSMISSION LINE
 Scheme and Methodology for Handling and Erection of VIST.
Step 01>> Unloading of VIST from Truck/ Trailer.

Lifting Lug

- Make sure the tank is stable before mounting on the trailer or and carry out Rigging activities.
- Check the Lifting Lugs and ensure they are not damaged, worn.
-Mount safely on the truck and attach the Dee Shackles or Lifting Hooks to the Lugs.
- Select Dee Shackle with adequate capacity. They should be tested and certified and in good
physical condition. Attach with Two Lifting hooks on top and one on the Leg (As Shown).
Dee Shackles Comes in 1,2,3,5,10,15 MT capacity.
-Next, Attach the Slings to the Dee Shackes and the Hook of the Crane.
- Slings should be tested and certified, in good physical condition. Calculate the Lifting angle
to deduce the load on the sling. Sling Cap should be > than the Load on it.
..Selction of Sling Cont.
 T=WxL
HxN
T = TENSION
W = WEIGHT OF THE LOAD(15 MT
say)
L = LENGTH OF SLING
L
N = NO. OF SLING LEGS (03) H
TL Length of the Tank (4m Say)
H Vertical Clearance (TL/2 x Tan)

- Base angle of the Sling
TL / 2

What You Need to Find Out? TL

a) Length Of the Slings Required (L). b) Capacity of the Sling to be selected.

Lesser the Critical Angle, greater the T = W x L = 15 x 4

Tension on the sling. HxN 3.46 x 3
Considering this we shall Safely
maintain the Base angle () 60deg. T = 5.78 MT.
L = TL /2 / Cos 60 = 4/2 / 0.5 =4 m. Hence the Capacity of each sling must
be > 5.78 MT. Say Safely 10 MT,
So, Length of Slings = 4 Considering a Factor of Safety
meters.(Each) (Approx)1.5.
 Scheme and Methodology for Handling and Erection of VIST.
Step 02>> Place tank on sleepers on ground before erection.

Guy Rope to control

the equipment from
safe Distance

- Tie the Guy rope ( As shown ) before lifting the tank. Guy rope is used to control swing,
movement of the tank manually during handling.
- Unload the tank Horizontally on sleepers equally spaced and kept on hard ground.
- Prevent rolling of the tank by proving suitable stopper at the base.
- Unload the crane, only when you are sure that the tank is stable on the ground.
- Disengage the Slings and Dee shackles.
 Scheme and Methodology for Handling and Erection of VIST.
Step 03>> Erection of Tank from Horizontal Position.

- Select suitable slings for erection of the tank. (Use

calculation as in Step 1)
- Attach Both slings using Dee Shackles of adequate
cap.
- Attach slings with the crane hook.
- Place adequate stopper below the tank leg to
F
prevent sliding while hoisting the load.
Stopper - Attach guy rope from opposite end to control
movement.
- The crane should operate slowly synchronizing
both hoist and swing. This synchronized operation
to continue until the orientation of the tank is
vertical.
- Next proceed to lift the tank and place the same on
its pedestal / foundation.
- Make sure that adequate Vertical Clearance is
available for safe Erection. We need to calculate for
the vertical clearance prior to attempting the
erection. (See calculation in next slide)
Boom Length Calculation:
Boom Length Bl (To be calculated)
Vertical Hook Clearance-Vc (Safely 6ft)
Sling Height Sh-Say 6 ft
Tank Height Th Say15 ft.
Vc=6 ft (Say) Foundation Fh Say 2 ft.
Boom Pin Ht Bh Say 4 ft.
Say Boom Angle = 60 Deg.
()
Sh=6 ft (Say)

Bl = (Vc+Sh+Th+Fh Bh)
Sin 60
= 25ft / 0.866
Th=15 ft (Say)
= 28.8 ft.
Therefore , The required
q
Boom Length = 30 ft
Bh=4 ft

Fh=2 ft
Scheme and Methodology for Handling and Erection of VIST.
Step 04>> Alignment and positioning of Tank.

- Lowering of the tank on the foundation to be done slowly to prevent any

damage to the Foundation / Tank or personnel injury.
- Use the guy rope to control movement of the tank.
- Lower the tank smoothly such that the foundation bolts insert easily in the
pockets.
- Careful and well coordinated operation is required to prevent injury. Hand
injury is most probable during such operation.
- Check alignment and grout the pocket.
Scheme and Methodology for Handling and Erection of VIST.
Step 05>> Dis-engaging Sling and Crane.

- A 14 mm polyamide rope system for the ascender device

Ascender Device. will be attached to the crane prior to erection and leave it
freely.
-Once the tank is erected, fix the ascender device and seat
with the suspended rope properly.
-Lower the crane hook a bit to allow slackness in the sling.
- Seat in the chair and Use the hand operated automatic
ascending gear for safe vertical hoist of the personnel
seated in the Chair.
-Disengage manually the Dee shackle and Sling from the
tank lifting lugs.
- Make sure the crane does not move till the person lowers
himself to the GL.
-Descend down slowly the same way using the manual
gear.
- Detach the device and lower the crane hook to remove
sling and rope.
One 20 KL capacity liquid storage tank was being
unloaded from trailer using 02 no. s of Hydra type cranes
at one CSG site, under the supervision by our CSG
Engineer.
After unloading the tank under HWP, Customer wanted
to shift the tank to another location which is
perpendicular to the location where tank is unloaded.
While shifting the tank by using 2 Hydras from one place
to another place, one Hydra crane toppled side ways by
90 degree.
There was no injury to any person. There is a minor
damage to storage tank plumbing.
- Job was carried out without a plan.
- Rigging plan or a Work procedure was not developed earlier to
carry out the job safely.
- Shifting of the tank was not initially planned. Hence, evaluation of
the Safety Aspect of the job was not done.
- Inadequate / incompetent supervision which allowed use of two
cranes in shifting the tank.

- Articulated Hydraulic cranes (Hydra). Are not meant for marching

with load in tandem. (Two cranes at a time).
- A slight jerk load or un-syncronized operation would overload /
unstabilize any one or both of the units.

On attempting to carry out a tandem operation to shift the tank, one

of the crane was overloaded beyond its SWL and got toppled.