Crane Operator Safety (API-U)

Course Objective

• Provide delegates assigned to crane and rigging duties the necessary skills to safely perform their jobs.
• Provide delegates with recommended practices and guidelines to perform safely while working with cranes.
• Delegates should be able to demonstrate the necessary skills during practical examination and demonstrate knowledge during written examination.

Course Design

• Power Point© / Lecture / Audio Video / Visual Aids
• Demonstrations
• Practical Exercises

Successful Course Completion

• Requires a minimum score of 75% or better.
• Grades shall be calculated by dividing the number of questions answered correctly by the total number of exam questions.
• Delegates will have no more than thirty (30) minutes to complete the exam.
• Successful completion of practical session is mandatory

Course Content Summary

• Classroom
• Practicals

Breaks: 10 minutes (approximately every hour)

Lunch: 1 Hour

Course Outline
Crane Safety

• Scope
• Definitions
  • Lifting Authority
  • Qualified
  • Qualified Crane Operator
  • Qualified Crane Inspector
• Qualified Crane Operator Qualifications
• Physical Requirements
• Operating Practices
• Hook Inspection
• Handling the Load
• Moving the Load
• Hand Signals
• Personnel Transfer
• Refueling
• Fire Extinguishers
• Conditions Requiring Load Testing
• Load Testing Requirements
  • Pull Test
• Usage and Inspection
• Crane Usage Categories
  • Infrequent Usage Production Duty Cycle
  • Moderate Usage Intermittent Duty Cycle
  • Heavy Usage
• Inspection Categories
  • Initial Inspection
  • Pre-Use Inspection
  • Monthly Inspection
  • Quarterly Inspection
  • Annual Inspection
• Inspection and Load Test Records
• Preventative Maintenance
• Maintenance Procedures
  • Repairs and Replacement
  • Lubrication
• Crane Re-rating & De-rating
• Wire Rope and Sling Inspection, Maintenance, and Replacement
  • Wire Rope
    • Inspections
    • Replacement
    • Maintenance
    • Testing
    • Pendant Lines

Crane Lift Planning

• General
• Lift Team
  • Responsibilities
    • Before Operations
    • During Operations
    • Post Operations
  • Members
    • Person in Charge
    • Lifting Authority
    • Rigger
    • Crane Operator
    • Vessel Captain
    • Technical Support
• Planning the Lift
• Lift Categorization
• Risk Assessment
• Personnel Transfer
• Qualifications
• Documentation
• Summary Questions for a Safe Lift

Annex A

• Crane Operation
  • Operational Considerations
  • Moving the Load

Annex B

• Usage, Inspection, Testing, and Maintenance
  • Determining Crane Usage
  • Crane Inspection
  • Pre-Use Inspection
  • Monthly Inspection
  • Quarterly Inspection
  • Annual Inspection
    • Crane Components
      • Hoist Assemblies
      • Foundation
      • Swing Circle Assembly
      • Hook Roller Assemblies
        • Ring Gear
        • Hook Rollers
        • Brackets, Bracket Pads, and Bolts
        • King Post
        • Ball/Roller Bearing
        • Bearing Wear
          • Depression Measurement Method
          • Rotation Method
        • Crane/Bearing Connection Integrity
        • Operating Characteristics
      • Anti-two Block
        • Testing
        • Proximity Warning Device
        • Stalling of the Hoist Drum
        • Control Override Device
        • No Override Two-blocking Systems

Annex C

• Crane-assisted Personnel Transfer
  • Purpose
  • General Information
  • Facility Personnel Transfer Procedures
  • Vessel Personnel Transfer Procedures
  • Personnel Transfer Device Operations
  • Personnel Transfer Device Procedures

Annex D

• Load Testing

Annex E

• Crane Maintenance
  • Maintenance Procedure
  • Repairs and Replacement

Annex F

• Wire Rope and Sling Inspection, Maintenance, and Replacement
  • Wire Rope Sling Selection Consideration
  • Rope Lay
  • Wire Rope Inspection
  • Sheave Inspection
    • Sheave Gauge
  • Wire Rope Rejection Criteria
  • Wire Rope Replacement Selection Criteria
  • Recommended Storage and Handling Procedures
  • Installation Guidelines
  • Wedge-type Socket Installation Guidelines
  • Recommended Methods of Lubrication
  • Wire Rope Operational Considerations
  • Types of Slings
  • Use of Slings
  • Sling Inspection
  • Guides for Fabrication and Lifting Procedures

Annex G

• Lift Categories
  • General
  • Routine Lifts
  • Non-routine Lifts
  • Simple Lifts
  • Complicated Lifts
  • Complex/Critical Lifts

Annex I

• Loading and Unloading Offshore Support Vessels
  • Lifting Operations – General
  • Load Chart Examples
  • Communications
  • Lift Planning
  • Toolbox Talk
    o Safety
    o Cranes – Fitness-for-Service

Practical Session
Practical training shall utilize a hydraulic crane, various slings, loads & rigging techniques.
Practical shall verify that the delegate is able to complete the following:

• Select and wear appropriate PPE during practical training
• Conduct proper pre-use inspection of crane and rigging gear
• Select the appropriate hardware/rigging gear to complete required lifts
• Effectively control the crane operations and uses operating indicators
• Accelerate, decelerate, and swing crane in a smooth safe manner
• Verify the load is not swinging prior to landing the load
• Respond to standardized hand signals from signal person
• Verify slings are properly connected/free before continuing operations
• Keep the hook clear of riggers while the slings are disconnected
• Ensure overall safety of the rigging team during crane operations
• Place the hook in a bucket (verify depth position)
• Stores hardware/rigging gear properly following its use

Training Center Provided Material

• PPE
• Crane with Operator
• Rigging Material

Delegate Requirements

• Must possess good physical health as the practical training is physical demanding.

Reference Material / Documents
API RP 2D Seventh