Learning Event

Failure of Lifting Equipment

Hazard Unwanted Event

led to
Lifting Dropped Object

Description
A Franna Mac 25 crane was being used to position a
500kV generator in a High Voltage transformer yard. As
the generator was passing over the fence line, the crane
wire broke and the generator fell unrestrained to the
ground from a height of 3 metres.
No personnel were injured. The crane and generator
were damaged. Approximately 40-60 litres of coolant
leaked out of the generator.
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Risk Event Habits Learnings

The top wear pad between the first and second extension was secured to the mounting base
Statement ✓ Exclusion by bronze screws. Stress corrosion cracking of these screws had occurred, initiated at the
Unidentified zones in thread roots. This caused the screws to fail.
mechanical place The wear pad dislodged from its normal location. It slid down on top of the second extension
failures in lifting and obeyed and was caught on the compensating sheave. This caused the C53 wire rope to ride up and
equipment can ✓ Lift plan in out of the compensating sheave (the last crane movement was telescoping out the boom). As
lead to dropped place and a result, all the lift load carried by the sheave was transferred onto the guides. The wire rope
objects during approved started cutting through the guides. This damaged strands of the wire rope, causing it to fail.
lifting which can The dislodged wear pad was not visible to the work crew and was not able to be identified
✓ Pre-start
cause prior to the incident. Catastrophic failures may still occur when all identified/planned controls
checks
equipment are in place.
conducted
damage, serious
on crane Observing Lifting Life Saving Rules (no-one was under the load when it fell) prevented
injury or fatality. possible injury.
The generator was “picked and carried” 660 metres. The flatbed truck that was used
to deliver the generator to site could have been unloaded closer to the lifting position to
eliminate the travel of the Franna crane.

Considerations
> Ensure exclusion zones are in place and observed for all lifting operations
> Inspect crane fleet. If the use of bronze screws to secure wear pads to mounting base is identified, consult the
Original Equipment Manufacturer.
> Include a section addressing safe pick and carry operations in lifting and hoisting procedures.

Could this happen to you?

> Do you put exclusion zones in place when lifting activities take place on your site? Do you observe them? Do you
make sure other people observe them?
> What equipment do you use that may have hidden faults that may pose a risk or have the potential to cause harm?
> What processes do you have in place to assess risks associated with the machinery and equipment you are using?
> What actions will you take to challenge the task at hand and ensure that you have the most appropriate equipment
and machinery available?

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August 2019 https://www.surveymonkey.com/failureofliftingequipment-generator safertogether.com.au