Crane Accidents and Emergencies – Causes, Repairs, and

Transcription

Crane Accidents and Emergencies – Causes, Repairs, and
Crane Accidents and Emergencies
Causes, Repairs and Prevention
Presented by
Portek International Limited
15 March 2007
Larry Lam
Soon Chong Tok
Chairman
Technical Director
For enquiries, please email: enquiry@portek.com
The contents of this document are copyrighted and proprietary, and may not be reproduced without the permission of Portek International Limited
Definitions
ƒ A Crane Accident is an unplanned and unintentional
event involving a crane or cranes, or other objects that
result in damage or injury of some kind and normally
involves a strong human element in its causation.
ƒ A Crane Emergency situation is an unexpected and
sudden event in which the crane is subject to damage,
and where the cause is not immediately linked to the
operator.
ƒ A Crane Incident is a general term for either a crane
accident or emergency
Crane Accidents
can happen in the following ways:
ƒ when a ship contacts a crane
ƒ when a crane contacts a ship
ƒ when cranes contact each other due to strong
wind gusts during operation, often resulting in
a multiple chain collision
ƒ when a crane contacts another crane or an
object during operation
Crane Accidents
Right seaside leg hit
diagonally by ship's
bow
(ship contacts crane)
Crane Accidents
Crane boom struck ship’s funnel (crane contacts ship)
Crane Accidents
Crane (blown by wind gusts) collapsed after collision
Crane emergency situations can arise from
ƒ Exceptional situation such as typhoons, hurricanes,
earthquakes resulting in crane collapse, derailment or
severe damage
ƒ Crane failure as in
‰ electrical fires in diesel generator or electrical room
‰ crane drive faults leading to free fall of load
‰ mechanical faults as in brake failure, twist-locks
failures, etc resulting in uncontrolled fall of load
‰ structural damage as in fatigue failure, poor
workmanship or design.
ƒ Heavy weather or inadequate lashing during ocean
transportation of cranes
Crane emergency situations
Structural failure - A-frame pylon bent and tipped forward
Crane emergency situations
Right tension rod broke from fatigue
Frequency of Crane Incidents
ƒ Crane Incidents are happening with increasing
frequencies, due to:
ƒ rapidly increasing population of cranes
ƒ increasing crane dimensions, hence decreasing visibility
and control
ƒ insufficient distance between fender face and seaside
rail, and increasing flare of ship’s bow, as ships get
bigger
ƒ standards of crane maintenance not keeping up
ƒ standards of safety in crane operation and terminal
operation failing to keep up
ƒ insufficient understanding of risks involved, and lack of
precautions taken
ƒ adverse and unpredictable weather
Typical Processes in a Crane
Incident
ƒ Recovery phase comprising Survey and
Salvage and Stabilization
ƒ Repairs and Re-commissioning
Typical damage
ƒ bending and buckling of the legs, sill beams
and portal beams
ƒ derailment seaside and landside bogies
ƒ tearing apart of joints between equalizer
beam and sill beam
Typical damage
Ship contacting
Crane boom
Damage from Ship contacting crane
Typical damage
Contact at seaside leg, only a nick is seen
Typical damage
Derailment at seaside
Typical damage
No derailment landside,
but severe damage to
leg
Typical damage
Severe bending of
landside leg
Typical damage
Buckling of sill beam landside
Typical damage
Joint at equalizer beam separated and twisted
Typical damage
Total destruction of boom snagged by a departing ship
Typical damage
Entire portal and boom twisted by ship pulling on boom
Typical damage
Wind gusts causing crane collisions
Damage from Collisions
Repairs
ƒ Design and Analysis
Fatigue failure of an unloader & computer modeling of crane structure
Repairs
Simulation of failure & Redesign and Repairs
Crane Supports for Repairs
Computer simulation of crane support
Crane Supports for Repairs
Robust support in place before cutting
Repair Methodology
Damaged plate removed and replaced
Repair Methodology
Damaged sill beam cut away
Repair Methodology
Replaced with new sill beam
Repair Methodology
Heavy damage due to constraints to side way displacement
Repair Methodology
Derailment allows displacement, therefore little or no damage
Repair Methodology
Structural bolts may be weakened and need replacement
Repair Methodology
Floating crane removing boom for repairs
Repair Methodology
Re-installing repaired boom
Repair Methodology
Boom hinge inspection and NDT checks
Repair Methodology
Line boring of boom hinge
Repair Methodology
Dimensional checks
using theodolite
equipment
Prevention
Prevention of crane incidents at
different levels:
ƒ at crane design and engineering level,
ƒ at crane operating level,
ƒ at terminal operation level
Prevention at crane design level
Double brake
machinery
Prevention at crane design level
Caliper brakes on flanges of boom hoist drums
Prevention at crane design level
Thruster disc brake for gantry instead of motor-mounted multi-disk brake
Prevention at crane design level
Caliper brakes on gantry wheel – To provide even more braking power
Prevention at the crane
operating level
ƒ Safety training of operator cannot be overemphasized. Emergency drills
ƒ “Boom down” is an open invitation to trouble
Prevention at the terminal
operating level
ƒ Berthing and un-berthing - Vessels should come
alongside quay as parallel as possible.
ƒ Equipment maintenance not to be compromised in
favour of operational expediency
Risk Management Plan
• Terminate the risks – not likely. Inherently
risky.
• Transfer the risks - Insurance
Policy. Consequential losses not covered
• Tolerate the risks – Accepting the risks. Self
insurance
• Treating the risks involves prevention, reducing
the likelihood of occurrence and severity of loss
Conclusion
ƒ Risks associated with container cranes will
increase, due to
‰Increasing probability of occurrence
‰Greater severity of loss.
‰Modern container quay cranes quantum
leap in size, and complexity, not yet fully
understood as to risk factors
Thank You