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Overhead Crane Inspection Procedure

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108 views9 pages

Overhead Crane Inspection Procedure

Uploaded by

kaungzayar1706
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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Overhead Crane

Inspection Procedure

Inspecting overhead cranes is critical to ensure safety and compliance with regulations.
Below is a standard inspection procedure:

Daily or Pre-Use Inspection (Operator-Level)


1. Visual Checks

 Look for visible damage or wear on hooks, hoist chains, wire ropes, and end
connections.
 Inspect for cracks, deformation, or corrosion on structural components.
 Check for fluid leaks from hydraulic systems.

2. Mechanical Components

 Test the limit switches by slowly operating the hoist.


 Confirm smooth operation of brakes, clutches, and gear mechanisms.
 Verify that the hook latch is functional and secure.

3. Electrical Components

 Ensure control buttons or pendants function properly and are clearly labeled.
 Inspect for exposed or damaged wiring and loose connections.
 Confirm that indicator lights (if any) are working.

4. Operational Check

 Lift a load slightly to ensure proper functioning of hoist and trolley.


 Listen for unusual noises or vibrations during operation.

5. EPP Check
 Verify operators are using appropriate PPE, including hard hats, gloves, and steel-toe
boots.

Monthly or Periodic Inspection (Qualified Personnel)


1. Wire Ropes and Chains

 Measure for elongation, wear, or broken wires/strands.


 Lubricate and clean as necessary.
 After every 100 Runing-hrs

2. Load Blocks and Sheaves

 Inspect sheaves for wear and ensure proper alignment.


 Check the load block for cracks or deformation.

3. End Stops and Rail Tracks

 Confirm end stops are secure and functioning.


 Inspect rail tracks for alignment, damage, or corrosion.

4. Safety Devices

 Test emergency stop buttons.


 Verify the proper functioning of overload protection systems.

5. Lubrication

 Lubricate moving parts (bearings, gears) as per the manufacturer's recommendations.



Annual Inspection (Certified Inspector)
 Conduct a comprehensive inspection following manufacturer and regulatory guidelines
(e.g., OSHA, ANSI, or ISO standards).
 Perform non-destructive testing (NDT) on critical components such as hooks and load-
bearing structures.
 Verify the crane’s certification and maintain records for regulatory compliance.
 500 Running-Hrs

Record Keeping
 Log all inspections in a maintenance and inspection record. Include dates, findings, and
corrective actions.
Corrective Actions

 Tag out and remove from service any crane that fails inspection until repairs are made
by qualified personnel.

Other Safety Factors for Overhead Travelling Cranes


1. Change in WLL (Working Load Limit) Over Time

 The WLL of an Overhead Travelling Crane does not change directly over time but can
be affected by wear, corrosion, fatigue, or improper maintenance.
 Factors that can influence WLL degradation include:

 Frequency of use: Heavy or frequent use may cause wear that reduces
capacity.
 Environmental conditions: Corrosive environments or extreme temperatures
can weaken materials.

 Improper handling: Overloading or impact damage can compromise structural


integrity.
Maintaining WLL

 Perform regular load testing and inspections to verify the crane's ability to handle its
rated capacity.

 Replace components showing wear or damage that could compromise load capacity.

2. Third-Party Load Test Inspection


Frequency:

 Typically required annually (Once on 3 Year) or as specified by local regulations and


manufacturer guidelines.
 Additional inspections may be needed after major repairs, modifications, or
relocation of the crane.
Purpose:

 Verifies the crane can handle its rated load.


 Identifies structural, mechanical, or electrical issues.

3. Critical Parts to Inspect Regularly


Structural Components:

 Main girders: Look for cracks, deformation, or signs of fatigue.


 End trucks: Inspect for wear and alignment issues.
 Welds and bolts: Check for looseness or fractures.
Mechanical Components:

 Wire ropes or chains: Inspect for fraying, kinking, or corrosion.


 Hooks: Check for cracks, wear, or deformation.
 Brakes: Ensure proper function and inspect for wear on pads or linings.
 Gearboxes: Check for lubrication levels, leaks, and abnormal noises.
Electrical Components:

 Control panels: Inspect for loose connections or overheating, malfunction.


 Limit switches: Verify proper function to prevent over-travel.
 Motors: Monitor for unusual vibrations or overheating.
4. Main Safety Issues to Consider
 Overloading: Ensure loads do not exceed the crane’s WLL.

 Poor maintenance: Regular maintenance is critical to prevent unexpected failures.

 Environmental hazards: Corrosion, moisture, and temperature extremes can impact


performance.

 Operator errors: Proper training is essential to avoid accidents caused by improper


handling.

 Electrical hazards: Exposed wiring or malfunctioning components can lead to shocks or


fires.

5. Required Safety Devices


 Overload Protection Device:
Prevents the crane from lifting loads beyond its rated capacity.

 Limit Switches:
Stop hoist travel at upper and lower limits to prevent over-travel.
 Emergency Stop Button:
Allows immediate halting of crane operations in emergencies.
 Anti-Collision Devices:
Prevents collisions with other cranes or structures.

 Load Indicators:
Displays the current load being lifted to help avoid overloading.

 Braking Systems:
Redundant brakes (e.g., electromagnetic and mechanical) ensure safe operation.

 Safety Latches on Hooks:


Prevent accidental load detachment.

 Alarm Systems:
Audible and visual alarms warn personnel during crane movement or lifting
operations.
1. Scheduled Maintenance
Daily Maintenance:

 Conduct pre-use inspections for visible damage or issues (e.g., loose bolts, frayed
wires, oil leaks).
 Check for unusual noises during operation.
Weekly Maintenance:

 Clean all moving parts to remove dust and debris.


 Check lubrication of key components like wire ropes, gears, and bearings.
Monthly Maintenance:

 Inspect structural components for cracks, deformation, or corrosion.


 Test safety devices such as limit switches, alarms, and overload protection systems.
Annual Maintenance:
 Perform comprehensive load testing and inspection by a qualified technician.
 Replace components nearing the end of their service life.

2. Key Components to Inspect


A. Structural Components

 Main Girder and End Trucks:


Inspect for cracks, weld integrity, and deformation.

 Runway Beams and Rails:


Ensure proper alignment and check for wear or corrosion.

 Bolts and Fasteners:


Tighten any loose connections to maintain structural stability.
B. Mechanical Components

 Wire Ropes or Chains:


Look for fraying, corrosion, kinks, or excessive wear.
Measure rope diameter and replace if it falls below the manufacturer’s recommended
limit.
 Hooks:
Check for cracks, deformation, and wear. Ensure safety latches are intact.
 Brakes:
Test for proper function and inspect pads or linings for wear.
 Gearbox and Bearings:
Monitor for abnormal noises, vibrations, and lubrication levels.
C. Electrical Components
 Control Panel:
Check for loose connections, overheating, or damage to wiring.

 Motors:
Inspect for unusual noises, overheating, or wear in brushes (if applicable).

 Limit Switches:
Test to ensure they stop the crane at the correct positions.

 Power Supply:
Ensure stable voltage and check for signs of electrical surges or faults.
D. Safety Devices

 Overload Protection:
Verify that the system prevents lifting beyond the crane’s WLL.

 Emergency Stop Button:


Test its functionality and accessibility.

 Anti-Collision Devices:
Check for proper calibration and response.
3. Lubrication and Cleaning
 Lubrication:
Use the manufacturer’s recommended grease or oil for bearings, wire ropes, and
gearboxes. Avoid over-lubricating as it may attract dust and debris.

 Cleaning:
Remove grease buildup, dust, and debris from all surfaces, especially electrical
components.

4. Calibration and Load Testing


 Calibration:
Ensure all instruments, such as load indicators and limit switches, are accurately
calibrated.

 Load Testing:
Conduct a load test at 100% of the crane’s rated capacity annually.
Perform an overload test (usually at 125% of WLL) as per regulatory requirements.

5. Operator Training and Reporting


 Training:
Ensure operators are trained to perform basic maintenance and report issues.

 Daily Logs:
Maintain a log of all inspections, anomalies, and corrective actions.

 incident Reports:
Document any failures or near misses to identify patterns and improve maintenance.

6. Compliance with Standards


 Adhere to local and international standards such as:
 OSHA: Occupational Safety and Health Administration guidelines.
 ISO 9927: Cranes—Maintenance guidelines.
 ASME B30: Safety standards for crane operations.
7. Emergency and Predictive Maintenance
 Emergency Maintenance:
Address critical failures immediately to avoid accidents or extended downtime.

 Predictive Maintenance:
Use advanced tools like vibration analysis, thermal imaging, or IoT-based monitoring
systems to predict failures before they occur.

8. Recordkeeping
Maintain records of:

 Inspection reports.
 Maintenance logs.
 Replacement parts and repairs.
 Load testing certificates.

Common Issues to Address


 Wear and Tear: Replace components showing significant wear before failure occurs.
 Misalignment: Regularly check alignment of rails and moving parts.
 Corrosion: Apply protective coatings or replace corroded parts.

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