1. PURPOSE
1.1 This global engineering specification defines the minimum standards and responsibilities for the safe control and operation of Air Products owned overhead gantry and jib cranes at all Air Products work activities worldwide.
2. SCOPE
2.1 This specification shall supplement all national, provincial, or local codes and external standards in force within the country where this specification is being applied. Examples of some standards are indicated in paragraphs 3.2 through 3.6. If there are any conflicts between this specification and the applicable codes and standards, the Air Products representative shall be notified immediately.
2.2 This specification shall supplement any instruction notes on the erection and lifting instructions, drawings and any attached appendixes. If there are any conflicts among these documents, the Air Products representative shall be notified immediately.
3. RELATED DOCUMENTS
Note: The latest revision of applicable related documents in force at the date of contract award shall apply.
3.1 Air Products Engineering Documents 4WCE-600501 Personnel Lifting System (Manbasket)
3.2 American Society of Mechanical Engineers (ASME) B30.2 Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist) B30.9 Slings B30.10 Hooks Safety Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings B30.11 Monorails and Underhung Cranes B30.16 Overhead Hoists (Underhung) B30.17 Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung Hoist) B30.20 Below the Hook Lifting Devices
3.3 American Society for Testing and Materials A 391/A 391M Standard Specification for Grade 80 Alloy Steel Chain
3.4 British Standards Institution (BSI) BS 7121 Code of practice for safe use of cranes British Legislation Lifting Operations and Lifting Equipment Regulations 1998 L113 – Safe Use of Lifting Equipment – Approved Code of Practice and Guidance
3.5 CSA International (CSA) CSA B167 Safety Standard for Maintenance and Inspection of Overhead Cranes, Gantry Cranes, Monorails, Hoists and Trolleys
3.6 International Organization for Standardization (ISO) 9926-1 Cranes – Training of Drivers-Part 1 12480-1 Cranes – Safe Use: General 15513 Cranes – Competency requirements for crane drivers, slingers, signalers, and assessors
4. DEFINITIONS
4.1 Air Products representative is any qualified Air Products site or plant manager or designated employee who has responsibility for organizing and managing lifting operations in a specific location.
4.2 Approval, unless specified otherwise, shall mean approval by Air Products in writing or by e-mail.
4.3 Authorization: The approval or permission from the appropriate entity for another individual to act in a defined role for a specific period.
4.4 Certification: A statement attesting authoritatively that a specified standard or condition has been met.
4.5 Competent: Capable of identifying existing and predictable hazards in the operation, conditions, or surroundings that are hazardous, dangerous, or can initiate such a condition or situation, has the ability to take the necessary steps to abate the hazards identified, and has the knowledge to differentiate between minor and major hazards.
4.6 Crane operator is the qualified person who is authorized by Air Products to operate the controls of the crane and meets all the requirements of federal, provincial, and local regulations. Only personnel qualified by training, experience, medical evaluation (where appropriate) and formal written and practical testing shall operate overhead gantry or jib cranes. (Note: In the United States mandatory substance abuse testing is required.)
4.7 Designation: The selection or assignment to perform a prescribed task or function. Designation to perform a function shall only be given to “qualified” persons.
4.8 Ground: Includes soil and improved surfaces such as aggregate paving, asphalt, and concrete.
4.9 Hazardous operating area: An area in the work site that contains physical conditions that, if not protected against, might create an unsafe lifting operation.
4.10 Lift supervisor is the delegated person who fulfills the responsibility for progressing the work activities that involve the use of the crane(s) (in the UK this individual fulfills the role of the Appointed Person). In some instances the lift supervisor might be the person who acts in one or all of the functions as the signalperson/banksman and rigger/slinger.
4.11 Qualified: Has the training, experience, or instruction to be deemed “competent.” Has demonstrated the ability to perform all assigned duties and do so in a safe manner. When required, has met the appropriate “license,” “certification,” or “authorization” requirements. Has received formal training by an accredited body in accordance with the federal, provincial, or national regulations applicable in the location.
4.12 Rigger/Slinger shall be the appointed person(s) who is/are qualified and authorized by the lift supervisor to ensure that lifting gear or rigging (e.g., slings, chokers, shackles, lifting beams) is suitable, is properly attached to the load, and that all loads are correctly rigged or slinged.
4.13 Signalperson/Banksman is the qualified person appointed by the lift supervisor who is authorized to provide instructions to a crane operator during a lifting operation. If one signalperson is insufficient to monitor the lift operation, additional signalperson(s) or radio communication shall be used. Designated signalperson competency shall be documented and available for review during the duration of the contract.
4.14 Shipping Company: Any company that has been contracted to transport material or equipment onto an Air Products site.
4.15 Transporter Equipment: Industrial trucks, forklifts, flatbeds, trailers, dollies, and any devices specifically designed for the movements of equipment to or around the work site.
5. ERECTION AND LIFTING PROCEDURES
5.1 Cranes Overhead and Jib
5.1.1 Cranes will only be sourced from reputable suppliers approved by Air Products who can demonstrate procedures and policies that meet or exceed national, provincial, and local standards as a minimum.
5.1.2 All overhead cranes shall be equipped with a device (such as limit switches) either to prevent damage to the crane or to warn of or stop an operation when there is potential for the block(s) being brought into contact with any part of the crane structure. This device shall be tested at the start of each shift before operations. Limit switches may not be necessary for all jib cranes.
5.1.3 All overhead cranes shall be equipped with an audible device that the crane operator shall sound before starting any crane movement (movement of bridge and trolleys). A hand-held air horn may be used to satisfy this requirement if crane is not equipped with audible device.
5.1.4 The use of a crane to hoist employees in a personnel hoist basket (manbasket) is prohibited except when the erection, use, and dismantling of conventional means of reaching the work site (for example, personnel hoist, ladder, stairway, aerial lift, elevating work platform, or scaffold) would be more hazardous or is not possible. Use of manbaskets should be in accordance with Engineering specification 4WCE-600501, Personnel Lifting System (Manbasket) except that the full request form does not have to be completed as the operation will be carried out inside a building not using a mobile crane. It is recommended that the request form or similar checklist be used to ensure a safe system of work is in place prior to the lift taking place.
5.1.5 A portable fire extinguisher 5 kg (10 lb) minimum size of type ABC or greater shall be located in the cab of any overhead crane fitted with a cab.
5.1.6 When not in use, cranes shall be disabled/made safe in accordance with the manufacturer’s guidance.
5.1.7 All repairs made to crane structure sections shall be performed by qualified persons and in accordance with the manufacturer’s recommendations and guidelines. Repair documentation including repair person qualifications and the manufacturer’s approved repair procedures including Weld Procedure Specification (WPS) and Procedure Qualification Record (PQR) shall be available to Air Products upon request. Welders making the repairs must be qualified for weld procedure being used to make repair. Material mill certifications for replacement components shall be available for Air Products inspection.
5.1.8 Crane manufacturer’s operation and maintenance manual shall be readily available in the facility where the crane is being used.
5.1.9 New, reinstalled, altered, repaired, and modified cranes should be load tested prior to use, as determined by a competent, qualified person.
5.1.10 Preventive Maintenance
5.1.10.1 A preventive maintenance program shall be established. The program shall be based on the recommendations outlined in the crane manufacturer’s manuals and, when appropriate, by a qualified person based upon a review of the crane application and operating conditions.
5.1.10.2 The preventive maintenance program shall include any requirements laid down in national, provincial, local, and industry regulations.
5.1.10.3 As part of the preventive maintenance program, a daily pre-use check shall be performed on the crane (see appendix A). If the crane is not in daily use, the check shall be performed before each use.
5.1.10.4 Replacement parts shall be at least equal to the original manufacturer’s specifications.
5.2 Crane Capacity and Load Weight
5.2.1 The Safe Working Load (SWL) of the crane shall be clearly marked on each side of the crane such that it is easily legible from the ground.
5.2.1.1 If a crane has more than one hoisting unit, the SWL of each hoist shall be clearly marked on the crane and shall be clearly legible from the ground.
5.2.2 Allowance shall be made for the weight of slings, shackles, spreader/lifting beams, crane blocks, and other components that form a part of the crane load as defined in the manufacturer’s manuals.
5.2.3 Load Weight
5.2.3.1 Loads are to be verified from information provided on drawings prior to lifts commencing to ensure no crane is overloaded. If necessary the weight is to be verified using load cells, calibrated jacks, or similar.
5.2.3.2 The weight must be verified only if the estimated load is in excess of 75% of the lifting crane’s capacity.
5.3 Lift Plan
5.3.1 Each lifting crane’s rigging configuration shall (where necessary) be adequately shown on drawings or sketches to indicate clearance to all fixed obstructions and define any interference of the loads or spreader beams being lifted in relation to the booms and/or jibs of other cranes working in the vicinity.
5.3.2 The lift plan will need to address the risks identified by the risk assessment and identify the resources required, the procedures and the responsibilities so that any lifting operation is performed safely.
5.3.3 Routine lifting tasks a generic lift plan may be acceptable, for complex lifting operations a lift plan may be required for each individual lift.
6. RECEIVING AND SITE TRANSPORTATION
6.1 Dollies, trailers, lowboys, bogies, and all other equipment used to transport equipment from the offloading area shall be sized and designed for the load, transport route, site ground-support, height, width, and maneuvering conditions. Load capacities, movement routes, and a hauling plan shall be submitted for Air Products review and approval.
6.2 Before removal of equipment from the shipping transport and in the presence of the Air Products representative, the equipment shall be inspected for any damages. Any damage found shall be immediately documented and reported.
6.3 Air Products-furnished equipment might have several coats of prime paint and in some instances a finish coat in place at the time of delivery to the work site. Care shall be exercised to protect the paint coatings. Correct and satisfactory touchup to coated areas damaged during the execution of work shall be in accordance with the Air Products field paint specifications.
6.4 All temporary shipping supports shall be removed from the railcars or over-the-road transporters and disposed of properly as directed by the Air Products representative. The shipping plates and bolsters might be attached to the railcars by welding. Air Products or the shipping company shall remove the shipping plates from the shipping transport in a manner that will not cause damage or destruction to the transport structure. The emptied transport shall be in a condition acceptable to the carrier before Air Products releases them. Air Products or the shipping company may be required to load the transportation saddles, bolsters, and shipping plates onto other transport means for shipment back to the supplier. Such a requirement will be directed by the Air Products representative.
7. Crane Operation
7.1 There shall be a designated person supervising the lift.
7.2 No one shall stand near or pass under suspended loads.
7.3 Lifting multiple loads simultaneously with a single crane is not allowed.
7.4 Crane shall not be subject to side loads.
7.5 Where practical tag lines of sufficient length to control the load shall be attached in a manner that provides a method of control while the load is in the air or being moved into place. Multiple tag lines might be required, and they shall be of adequate length to suit the circumstances of the lift.
7.6 Before lifting any material or piece of equipment, the crane operator shall sound an audible device or horn to notify personnel in the surrounding area of the pending crane movement.
7.7 Sufficient clearance shall be maintained between the crane; suspended load; and any structures, equipment, other cranes or jibs, or any other obstruction that might interfere with the safe execution of the lift.
7.8 The load shall not be released from the crane until it is safely landed and properly blocked or secured.
7.9 Safe access to rigging attachment locations shall be provided for all rigging, connecting, and disconnecting activities.
7.10 The riding of crane hooks, loads, slings, or “headache balls” is prohibited.
7.11 Rapidly lowering or “free fall” of the crane hook or headache ball is prohibited.
7.12 Loads must be rigged correctly to ensure that they are lifted level where necessary.
7.13 Radio Controlled Cranes
7.13.1 Where radio controlled cranes are installed, the following shall be ensured:▪ They cannot be accidentally operated by other cranes,▪ They cannot be accidentally set in motion due to interference from electrical machinery in the surrounding area,▪ The batteries of the control set are maintained sufficiently charged for normal crane operation,▪ Spare batteries are readily available.
8. RIGGING, OPERATING, AND HOISTING PERSONNEL
8.1 Lift Supervisor
8.1.1 Air Products shall appoint a lift supervisor who is qualified through training and experience to oversee all rigging, crane, and lifting activities for each lift on-site. All personnel (e.g., operator, signalperson, rigger) involved in these activities shall be under their supervision. The lift supervisor shall be familiar with this specification.
8.1.2 The lift supervisor shall personally brief the crane operator, the signalperson/banksman, and the rigger/slinger on the work intended for the crane. Additionally, the lift supervisor shall review lift plans and pre-lift checklist with all personnel involved with the lift. The lift supervisor is responsible for ensuring that the crane operator and the signalperson/banksman and rigger/slinger understand the work required of the crane.
8.1.3 The lift supervisor shall instruct the operator that substitution of the signalperson/banksman or the rigger/slinger is forbidden without the lift supervisor’s authorization. Substitution of the crane operator is forbidden without the lift supervisor’s authorization.
8.2 Crane Operator
8.2.1 The operator shall not leave the crane controls while a load is suspended.
8.2.2 Personnel shall be required by Air Products to pass a practical operating examination for the specific type of crane to be operated.
8.2.3 The operator shall be familiar with and understand hand signals.
8.3 Signalpersons/Banksmen and Riggers/Slingers
8.3.1 The person(s) appointed as signalperson/banksman and rigger/slinger for signaling and slinging shall be qualified and able to perform their duties in a safe and controlled manner. Records of the training and qualification process shall be made available upon request.
8.3.2 The lift supervisor shall ensure that the means of giving signals and the signals used are fully understood between the crane operator and the signalperson/banksmen.
8.3.3 Except as noted below, the lift supervisor shall instruct the crane operator to obey only the instructions of the designated signalperson. If several signalpersons/banksmen are used, because of the working layout, only the instructions of the designated primary signalperson shall be obeyed by the crane operator. Secondary signalperson shall direct their signals to the designated primary signalperson/banksman. As an alternative to multiple signalperson(s)/banksmen, the use of radio communications shall be considered. Exception: An emergency-stop signal shall be obeyed regardless of who gives it.
8.3.4 One person shall be designated to perform signaling for crane lifts and movements and shall be visibly distinguishable by the use of colored/high visibility vests, jackets, tabards, hard hats, or other methods discernable to the operator.
9 RIGGING EQUIPMENT
9.1 All rigging equipment must have a valid test certificate and/or records of mandatory inspections. A copy of all test certificates and inspection records for rigging equipment shall be maintained and readily available at site.
9.1.1 Lifting Attachments: Equipment shall only be lifted using lifting lugs, trunnions, eye bolts, or other supplier-specified lifting points if fitted or specified on drawings. The lifting angle created by the lifting slings shall be evaluated to ensure that it does not impose excessive side loads on the lifting lugs or trunnions nor exceed sling angle as defined on equipment supplier transport and lifting diagram.
9.1.2 Other Lifting Methods: Where no lifting points, such as lifting lugs, trunnions, eye bolts or other supplier-specified lifting points are fitted alternative methods such as “choke hitch,” “basket hitch,” or other standard industry practices may be used.
9.1.3 Spreader Beams: Spreader or lifting beams of appropriate length and capacity shall be used when specified or when required to meet sling angle limitations. Their use is the preferred method for reducing or eliminating side loading of lifting lugs or trunnions.
9.1.4 Before lifting, a qualified person shall visually inspect all lifting lugs, trunnions, and other attachments at the lift site for any signs of damage or misuse.
9.1.5 Slings and Miscellaneous Wire Rope: Rigging equipment shall be inspected and marked by the qualified manufacturer or owner representatives before its use on the work site.
9.1.6 Slings shall be inspected before each use to verify that they do not have any of the deficiencies defined in the applicable sections of local, provincial, and national standards and manufacturer’s requirements. Slings with deficiencies shall be tagged and removed from service immediately.
9.1.7 All slings shall be marked with material, size, and safe weight limit. The imposed loads in use shall not exceed the safe weight limit of the component as defined by the manufacturer. Where safe weight limit is not defined or where rated capacity only is given, a safety factor of at least 5 to 1 based on ultimate strength shall be used.
9.1.8 Slings shall be checked visually to confirm that they are in good condition and of adequate size to ensure that their safe working load ratings are not exceeded.
9.1.9 Wire rope clips (cable clamps) shall not be used to fabricate eyes in slings.
9.1.10 The included angle of the rigging at the hook in a choke hitch or of a leg of a bridle shall not exceed 60 degrees unless supported by calculations demonstrating acceptability.
9.1.11 Shackles shall be visually checked to confirm that they are in good condition and of adequate size to ensure that their safe-working-load ratings are not exceeded.
9.1.12 Shackles used shall be properly sized for the load. The total imposed load shall not exceed the manufacturer’s safe weight limit for the shackle. Shackles shall only be of either a screw-pin or bolt type.
9.1.13 Shackle pins shall be shimmed so that a gap of no more than a total of 13 mm (1/2 in) exists between the shackle ears and the equipment lug.
9.1.14 Lifting Devices. Special, custom-designed grabs, hooks, clamps, spreader beams, or other lifting accessories for such units as modular panels, prefabricated structures, and similar materials shall be marked to indicate the safe working loads and shall be proof tested before use to 125% of their rated capacity. A copy of the test certification shall be available at the site during the use of the device. An alternative to this requirement may be considered: If device is designed, tested and marked in accordance with requirements of latest local, provincial, and national standards (e.g., ASME B30.20).
9.2 Chains
9.2.1 When chains are used, they must be heat-treated alloy steel and stamped with the letter “A” and have a load tag. If chains are permitted they shall be regularly inspected link by link by a competent inspector. Inspection and markings shall comply with recognized standards (e.g. ASTM A391-65).
9.3 Documentation
9.3.1 Detailed inspection reports shall be made as required by national, provincial and local legislation and maintained on file.
9.3.2 Load test information shall be maintained on file.
9.3.3 Operator training and qualification records shall be maintained on file.
Appendix A
| Functional Test Checklist Pendant Operated Overhead Traveling Crane | Crane No. | Crane Location | Month |
| Check | Part | Instructions |
| 1 | Pendant Box | Examine casing and buttons for damage and proper operation of each button*. Include horn and emergency stop*. |
| 2 | Pendant cable | Look for signs of damage to cable* and support wire. |
| 3 | Limits | Raise and lower hook(s) until limits stop movement.* (if fitted) |
| 4 | Limits | Move crab (trolley) across full width of crane until both limits stop movement* |
| 5 | Brakes | Run crane to ensure proper operation of LT & XT brakes.* (if fitted) |
| 6 | Catenary track | Slide pendant along the track to ensure smooth operation. |
| 7 | Labels | Ensure labels are in place for SWL, Crane No and Directional Color Code Discs. Button colors to match color discs. |
| 8 | Hook | Look for damage* and ensure safety latch (if fitted) operates. Check free movement of load pin & pulleys inside hook block. |
| 9 | Mains supply | Ensure access to Mains Isolator is clear. |
| 10 | Ropes | Visually check hoist ropes for deterioration and kinks*. |
| 11 12 | Structure Air & Hydraulic Systems | Visually check crane structure for any obvious damage* Visually check systems for signs of leakage*. |
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Items with a * are likely to need urgent attention; e.g., use of a personal danger board. If you are in doubt about any of the checks, please inform your Foreman or ask Maintenance for advice. This form is not a substitute for the existing system of maintenance requests. Notify Maintenance of any problem as soon as it develops. Do not wait until the next shift. There is no need to retrospectively amend this form when a problem occurs mid-shift.
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