Approved Code of Practice for Cranes
Part 3: Operational requirements for controllers
The term "controller" means a person who is the owner, lessee, sub lessee or bailee of equipment in a place of work and is confined to equipment under the PECPR Regulations.
The controller of a crane is responsible for the safe testing, operation, inspection, repair and maintenance of that crane.
A principal has similar duties to a controller.
Evidence of competence
Both the Health and Safety in Employment Act 1992 and the Health and Safety in Employment (Pressure Equipment, Cranes, and Passenger Ropeways) Regulations 1999 require persons operating plant to be competent.
Increasingly, principals and others require proof of competence of persons entering their sites in order to discharge their own responsibilities. Controllers and employers should, therefore, be able to provide evidence that their crane operators have the skills, knowledge and experience necessary to safely operate their cranes.
An appropriate qualification from an appropriate industry training organisation may provide such evidence.
3.1 Operations
Training and supervision
In accordance with section 13 of the HSE Act, every employer shall take all practicable steps to ensure that every employee who does work of any kind, or uses plant of any kind, or deals with a substance of any kind, in a place of work:
(a) either -
(i). has; or
(ii). is so supervised, by a person who has -
such knowledge and experience if similar places, and work, plant or substances of that kind, as to ensure that the employee doing the work, using the plant, or dealing with the substance, is not likely to cause harm to the employee or other people; and
(b) is adequately trained in the safe use of all plant, objects, substances, and protective clothing and equipment that the employee is or may be required to use or handle.
Every controller of a crane is to take all practicable steps to:
(1) supervise every crane function or activity or delegate such powers as are required to enable the appointed competent person to carry out that function or activity, and ensure that the name of the competent person is known to any other persons who carry out any related activity in accordance with Table 4.1: Minimum Unit Standard Requirements
(2) ensure that every crane is operated in a safe manner by a competent person within the limits of its design
(3) ensure that procedures relating to the operation of the crane in any condition/situation are developed and kept under regular review. For exclusion areas, refer to the sections for the crane user and the crane operator of the Crane Safety Manual for Operators/Users published by the Crane Association of New Zealand. This manual also covers rope examination, communications and interference zones
(4) ensure that all drawings, manuals, specifications, certificates, operational procedures, rating sheets, hand signal charts etc, are maintained in current form and the operating manual is readily accessible to the crane operator
(5) ensure the means of securing ropes to a drum, hook block or structure of the crane are as specified by the manufacturer. Care is to be taken to ensure that anchorage points are securely fastened in accordance with instructions
(6) ensure that any crane that is considered unsafe is withdrawn from service or is made safe to the satisfaction of an equipment inspector before further use.
Electrical protection
Every controller of a crane is to take all practicable steps to:
(7) ensure that the electrical installation of every crane is in accordance with the appropriate requirements of AS/NZS 3000:Electrical Installations (known as the Australian/New Zealand Wiring Rules). At first commissioning, either a CPEng is to certify the functional safety of the crane or the manufacturer is to supply such a certificate from an engineer holding a current annual practicing certificate and registered on the International Professional Engineers' Register. This certificate must cover points 8 to 13 of section 3.1 as appropriate. An Electrical Inspector must certify the electrical safety of the installation via a Certificate of Compliance. This certification should be repeated after any subsequent design alteration to the electrical installation or controls.
Note: Such electrical installation may also be subject to the requirements of the AS 1418: Cranes, Hoists and Winches series of standards or other requirements of the relevant regulatory authorities.
Controls
Every controller of a crane is to take all practicable steps to:
(8) ensure that operating levers, wheels or buttons have clear markings, on or adjacent to them, to indicate their function and mode of operation. Control arrangements can be specifically designed for "joystick" control of two movements simultaneously, otherwise they shall be so designed that selection of one movement cannot cause any other movement unless it is for the operation of a safety device or interlock. Control valve systems shall be designed to return to the neutral position when released, except when operational characteristics dictate otherwise
(9) ensure that, on electrically powered cranes, if power is lost for any reason, it is not possible for any function of the crane to inadvertently restart without operator interaction
(10) ensure that the weight of any pendant control is supported independently of its electrical conductors. If a pendant control enclosure is made of metal, then it shall be earthed and the earth shall not depend on supporting chains for continuity
(11) ensure that the design of electrically operated overhead travelling cranes is such that all brakes will automatically apply in the event of power failure
(12) ensure that, when electro-magnetic lifting attachments are used and where there is any possibility of danger to persons or property as a result of a falling load, a backup system (e.g. a battery) is used in case power supply to the magnet fails
(13) an emergency stop device. The system used for this shall only be used for emergency stop where it introduces no additional inbuilt time delay and shall incorporate a reset device.
Radio-controlled equipment
Every controller of a crane is to take all practicable steps to:
(14) ensure that equipment that controls the operation of the crane by radio, induction or other non-conduct means includes:
(a) a key switch or equivalent security device on the transmitter that can be used to prevent unauthorised use of the transmitter. The transmitter should also be constructed so that it is capable of withstanding rough handling
(b) suitable visual indication on the crane indicating when the crane is on radio control
(15) ensure radio-controlled cranes operate such that when the transmitter range is exceeded the crane must come to rest with brakes applied as applicable.
Safe access and egress
Every controller of a crane is to take all practicable steps to:
(16) ensure a means of safe and adequate access and egress is provided for operation, maintenance and inspection of the crane
(17) ensure that safety lines, when fitted, comply with AS/NZS 1891: Industrial Fall Arrest Systems and Devices
(18) ensure a system for emergency escape from the operator's cab is provided.
Load handling
Every controller of a crane is to take all practicable steps to:
(19) ensure that any load-handling devices such as grapples, demolition balls, clamshells, piling hammers, magnets etc are maintained and operated in accordance with the manufacturer's recommendations and kept in a safe condition
(20) ensure that no crane with a load is operated in a free-fall situation on any site, other than clam shelling, draglining, pile driving, demolition and compaction.
Guarding
(21) Every controller of a crane is to take all practicable steps to ensure that moving parts and exposed equipment that may foreseeably cause injury are suitably guarded.
Overhead electric power lines
(22) Every operator of a mobile crane working in the vicinity of live overhead electric power lines shall ensure that the distance between any live overhead electric line and any part of any mobile plant or load carried shall be at least 4.0 metres, unless the operator has received written consent from the overhead electric line owner allowing a reduced distance.
(23) Mobile crane work carried out in the vicinity of overhead electric power lines shall be conducted in accordance with the Electricity Regulations 1997 (and any associated amendments) and NZECP 34:2001 - the New Zealand Electrical Code of Practice for Electrical Safe Distances.
3.2 Routine Checking
Every controller of a crane shall ensure that:
(1) operators carry out appropriate checks to enable the crane to be operated safely, according to the controller's written procedures based on the manufacturer's instructions where available, and that the controller can demonstrate that the checks have been carried out
(2) the controlled range feature, where fitted on radio-controlled cranes, is tested at suitable intervals, and that at the beginning of each shift, or where there is a change in the crane operator, the controlled range is checked to ensure that it is in accordance with the limits specified for its operation.
3.3 Inspection and Certification
Every controller of a crane shall ensure that:
(1) cranes are inspected by an equipment inspector and issued with a certificate of inspection by the inspection body at intervals not exceeding 12 months
(2) records are kept of the date, time and results of any inspection carried out and the name of the inspection body involved
(3) the inspection body engaged is currently an IANZ-accredited inspection body and the report or certificate of inspection must bear the name of the equipment inspector who either holds a current certificate appropriate for the type of crane, or is a trainee under the effective supervision of an equipment inspector who holds an appropriate current certificate of competence
(4) the unique identifier assigned by the inspection body is permanently and clearly marked on every crane when it is issued with a certificate of inspection for the first time
(5) maintenance records are made available to the equipment inspector
(6) where practical, factors affecting the remaining life, based on the actual conditions of use, are recorded at every inspection. Such factors may include, but are not limited to, operating hours, utilisation and service conditions (if variable)
(7) non-destructive testing (NDT) reports are approved by a suitably qualified signatory working for an IANZ-accredited inspection body. The NDT report must be IANZ-endorsed.
3.4 Alterations and Repairs
Every controller of a crane shall ensure that:
(1) the date and results of any structural alterations or repairs are recorded in a register
(2) alterations or repairs that require changes in the quality of the materials used on the crane, or changes to the dimensions of components providing structural integrity are subject to the manufacturer's written approval, or design verification. This documentation is to be made available to the inspection body. The alterations or repairs are to be carried out to the satisfaction of an equipment inspector and a new certificate of inspection may then be issued. Alterations or repairs carried out without involving an equipment inspector are likely to invalidate the certificate of inspection
Note: Such alterations or repairs should be designed by the manufacturer or a chartered professional engineer and must be design verified.
(3) any structural repair that requires welding is carried out by a qualified welder in accordance with the manufacturer's specific procedures. If a manufacturer's procedures cannot be obtained, procedures must either be proposed by a New Zealand-certified welding engineer (NZCWE) or the repairer must demonstrate to the equipment inspector that appropriate alternatives are available. In all cases, the repairs are to be carried out to the satisfaction of an equipment inspector, and a new certificate of inspection will be issued
(4) all New Zealand manufactured equipment is inspected and tested by an inspection body in accordance with the requirements of the manufacturing standard, and any inspection and test plan (ITP) specified by the designer. Where the designer does not provide an lTP, the manufacturer shall prepare the ITP. The equipment inspector shall review the manufacturer's ITP and, when satisfied, endorse it
(5) adjustments or repairs to any safety device are carried out by a competent person
(6) any tests required by the equipment inspector are carried out to the satisfaction of the equipment inspector in accordance with the standards listed in Appendix C: Reference Standards and Documents.
3.5 Maintenance
Every controller of a crane shall take all practicable steps to ensure that:
(1) every crane is maintained in a safe condition and in accordance with the manufacturers instructions at all times
(2) a procedure is in place that ensures a safety-related fault is immediately repaired and recorded
(3) all maintenance records, procedures, drawings, specifications and instructions are kept up to date.
3.6 Accident Notification
(1) Every controller shall take all practicable steps to ensure that, if an event occurs in a place of work which;
(a) causes damage that affects the operational safety of equipment; or
(b) causes damage to other property that may affect the safety of equipment and might in different circumstances have caused a person to be seriously harmed.
Then:
(c) the Secretary is notified as soon as possible after the event; and
(d) within 7 days of the event occurring, the Secretary is given a detailed written report of an investigation of the circumstances of the event, carried out by an inspection body or by a chartered professional engineer independent of the controller and the inspection body that carried out the previous inspection.
Further detail is available in the PECPR Regulations and the Health and Safety in Employment Act 1992.
3.7 Designated Design Life
A crane's design life may not be the same as its actual life and depends on such factors as its classification, usage and its operating environment.
In the Health and Safety in Employment (Pressure Equipment, Cranes, and Passenger Ropeways) Regulations 1999:
(1) regulation 18(c) requires designers to determine and specify in the design, the design life of the equipment
(2) regulation 20(3) requires suppliers to take all practicable steps to ensure, when importing for supply equipment manufactured in an overseas country, that it has not already exceeded its design life
(3) regulation 10(c) requires controllers to operate equipment within the limits that it was designed to operate within.
As the end of the design life of a crane approaches, at periodic intervals, or when a second-hand crane is imported into New Zealand, inspection and testing shall be carried out in order to determine that the crane will remain safe for continued use. This is likely to be over and above the routine inspection process.
This process may include but is not necessarily limited to:
- reference to the design criteria and standards
- review of any manufacturer's recommendations for examination or periodic replacement of safety critical components
- identification of states of loading producing highest stress or using finite element analysis data
- review of crane usage records
- examination of maintenance records
- stripping down or dismantling inaccessible parts
- non-destructive testing (NDT).
It is recognized however, that in many cases some of this evidence will not be available and hence the equipment inspector/ inspection body will need to assess information from different sources and exercise professional judgement in order to satisfy themselves as to the future safety of the crane.
If there is insufficient evidence to enable the inspector to make a proper assessment of the condition of the crane, the inspection body shall not certify it.