7/27/2019 Article Should Crane Insp

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Be s t Pr a c t i c e s

Sh Ce Ispectis

Pevetive Mitece

be Tete the Sme?

For many overhead crane inspectioncompanies, perorming OSHAinspections and preventive maintenanceare considered two separate services oroverhead cranes and hoists. Based onregulation criterion, I simply cannotascertain how any experienced companyor inspector might ofer this limitedservice in good conscience.

Each OSHA inspection should includea complete preventive maintenanceservice. Te OSHA CFR 1910.179regulation, Periodic Inspections,provides the crane inspector with asimple 10-point checklist. However,the opening paragraph states that thisinspection must include the requirementso a Frequent Inspection.

wo items listed in the FrequentInspectionchecklist require more than

just a visual inspection. Tey includechecking all unctional operatingmechanisms or maladjustmentinterering with proper operation,and checking all unctional operatingmechanisms or excessive wear ocomponents. Tese two items alonetell us that a very through inspection

will be required, meaning coverswill be removed and, in many cases,

components disassembled to conrmconditions and operations.

Te inspection/preventive maintenanceservice also includes veriying thatthe equipment complies with ANSIB30.2 or top-riding double girdercranes, along with the inspection/maintenance requirements o theOEM. Additional requirements, suchas NEC, CMAA specications, andthe ANSI standards or other materialhandling equipment, including

monorails, single girder cranes, andhoists, have to be considered.

Inspection detailsLike many inspection companies,

Advanced Overhead Crane, Crosby,exas, uses a basic checklist that coverscomponents o the unit being inspectedand also doubles as a conditionmonitoring report. Components areevaluated or degree o wear andassigned a value. In determining theproper value, the inspector must takeinto account the degree o wear and theduty cycle o the equipment, along withthe requency o inspection and servicemaintenance to determine the lie othe component going orward. Tereport also addresses recommendationsto improve reliability and enhancesaety o the equipment.

Another important tool theinspector has on-site is a completecomputerized history o each unitbeing inspected. Every crane or hoistserviced, inspected, or repaired including any and all adjustmentsand corrections, no matter how smallthey may be is incorporated in thecomputerized history le. Te reporthelps recognize repetitious problemsand allows the inspector to see exactly

what has occurred with a particular

unit over the years. It is invaluablewhen analyzed with the conditionmonitoring report.

While having computerized reportsand ancy inspection checklists arene, they are worthless i the inspectordoes not get into the equipment whileinspecting it. Tis includes accessingthe underside o the crane or hoist toinspect load-bearing components thatare critical to the operation. Runninga crane through an operational check

and watching rom the foor is notan inspection.

Compliance and educationTe intent o all OSHA regulations

and ANSI standards is to maintaina sae working environment, but theregulations and standards have notkept up with the new technologyincorporated in the cranes and hoistso today. Te inspector must knowand understand the operations othe electronics and saety circuitsincorporated in the new equipmentbeing sold into the marketplace.

Continued education and trainingmust be a major concern or allinspection companies. Te CraneCertication Association o America,or example, oers the crane inspectorslicensing program, as well as continued

education programs or overhead andmobile cranes.Te chart at right detailsthe maintenance techniques o theCCAA program. Additionally, manycompanies involved with CCAA oerinspector and operator training acrossthe country.

Ensuring a degree o saety is thebiggest challenge or overhead craneinspection companies. Continuedtraining, a keen understanding o theequipment, and OSHA inspections

and preventive maintenance per-ormed as a single service makescertain your overhead cranes andhoists are working correctly.

10 | InduSTrIal lIfT and HoIST My-Je 2008

By Richard Wehrmeister

authorbio Richard Wehrmeister is co-owner

o Advanced Overhead Crane, Crosby, Texas,

and has been inspecting, servicing, and repair-

ing cranes since 1974. By trade, Wehrmeister

is a licensed master electrician and electrical

contractor in Texas. Additionally, he maintains

a Caliornia overhead cranes inspector license

(CA283) and CCS certifcation as a licensed

crane surveyor with the Crane Certifcation As-

sociation o America. For more inormation, visit

www.advancedoverheadcrane.com

7/27/2019 Article Should Crane Insp

2/2My-Je 2008 InduSTrIal lIfT and HoIST | 11

Hoist

Hoist duty classication. Circle one: H1, H2,

H3, H4, H5, mill duty, molten metal, nuclear or

other______________________. Is hoist used beyond

designed duty cycle?

Hoist rame and suspension (condition)

Upper tackle (sheaves, pins*, and bearings*)

Wire rope, drum, and anchorage (condition)

Wire ttings and end attachments

Load block, thrust bearing*, sheaves, load hook, and

hook latch

Gearing* and bearings*

Hoist gearbox oil level

Drive shat and couplings

Hoist load braking system. Circle one: regenerative,

eddy current, dynamic braking (DC motor), mechanical

load brake*, variable requency drive (VFD), or

other________________. Is system unctioning as

originally designed? Mechanical load brake can

be tested with load while releasing holding brake to

ensure proper operation.

Hoist motor brake: shoe, disc, or conical (AC or DC).

Is condition and adjustment correct?

Hoist control panel condition

Hoist wiring, magnetic controls, overloads, using,

and electrical unctions. Has OEM design been

compromised?

Hoist speed controls. VFD, magnetic, and wound

rotor motor speed resistors. Are controls working as

originally designed?

Hoist upper and lower limit switches (gravity, geared,

paddle, rope guide activated, over wrap limit, plugging

limit, or other____________)

Hoist overload limits (weight activated or slip clutch).

Test with load.

Hoist motors: AC squirrel cage, wound rotor, and DC

motor (brushes, brush holders, slip rings, rotor*, and

bearings*)

Bridge

Bridge duty classication. Circle one: Class A1,

A2, B, C, D, E, F, mill duty, molten metal, nuclear, or

other______________________. Is bridge used

beyond designed duty cycle?

Bridge end trucks (welds, bolts, connections, and

sweep plates)

Bridge girders (condition). Cracks, welds, etc.

Bridge girder to end truck using proper asteners

Bridge capacity signs

Bridge wheels (treads, fanges, alignment, and

condition)

Bridge wheel gears and pinions (condition)

Bridge axles* and bearings*

Bridge line shat, couplings, bearings*, and alignmentBridge reducer bearings*, gears*, and oil level

Bridge brake: shoe, disc, or conical (AC, DC, or

hydraulic). Is condition and adjustment correct?

Bridge wiring, magnetic controls, lockable

disconnect, overloads, using, and electrical unctions.

Are controls working as originally designed?

Bridge speed control (ballast resistors, electronic sot-

start, fuid coupling, wound rotor motor speed resistors,

or VFD). Has OEM design been compromised?

Bridge motors: AC squirrel cage, wound rotor, and

DC motor (brushes slip rings, brush holders, rotor*,

and bearings*)

Bridge travel limits or anti-collision

Bridge end stops and shock-absorbing bumpers

(condition)

Trolley

Trolley rame (welds, bolts, connections, and sweep

plates)

Trolley rails or running surace (condition)

Trolley wheels (treads, fanges, alignment and

condition), wheel gears, and pinions (condition)

Trolley axles* and bearings*

Trolley line shat, couplings bearings*, and alignment

Trolley reducer bearings*, gears*, and oil level

Trolley brake: shoe, disc, or conical (AC, DC, or

hydraulic). Is condition and adjustment correct?

Trolley control panel condition

Trolley wiring, magnetic controls, disconnect,

overloads, using, and electrical unctions. Are

controls working as originally designed?

Trolley speed control (ballast resistors, electronic sot-

start, fuid coupling, wound rotor motor speed resistors,

or VFD). Has OEM design been compromised?

Trolley motors: AC squirrel cage, wound rotor, and

DC motor (brushes, slip rings, rotor*, and bearings*)

Trolley travel limits or anti-collision

Trolley end stops (condition)

Trolley shock-absorbing bumpers (condition)

Cab and Catwalks

Clearance cab (7' above the working foor)

Is cab located to aord a minimum o 3" rom all xed

objects?

Access to cab or catwalk (no gap exceeding 12")

Do walkways have a minimum o 48" headroom, toe

boards a minimum o 4 high, and hand rails at 42"

high?

Does cab-operated crane have a re extinguisher o

at least 10 BC?

Are runway conductors guarded to prevent contact

when entering or leaving cab?

Does cab-operated crane have a warning device?

Foot-operated brakes shall not exceed 70 pounds o

orce when depressed.Cab disconnect switch

Note on cab controls: Cabs not equipped with spring

return controllers, spring return master switches, or

momentary contact push buttons shall be provided with

a device that will disconnect all motors rom the line in

the event o power ailure. This disconnect device shall

not permit any motor to be restarted until the controller

or master switch handle is brought to the o position, or

a reset switch or power on-button is operated.

General Electrical

Pendant (directional labels, unctions, and condition)

Radio (directional compass, unctions, and condition)

Radio-operated warning device (visual or audible)

Pendant cord and strain relie (condition)

Control and power conductors (cross bridge

electrication condition)

Runway conductors (condition)

Busbar collector shoes and alignment (condition)

Festoon track and trolleys (condition)

Roving pendant track and trolleys (condition)

Bridge and runway conductors guarded against

contact rom hoisting ropes during normal operations

Lockable runway disconnect switch

Saety labels (operator warning tag, runway

disconnect ID tag)

Operational test all unctions

General Structural/Mechanical

Bridge rails or running surace (condition) straight,

level and in span

Clearances bridge and hoist (3" overhead, 2" side)

Runway to column connection using proper

asteners.

Bridge and trolley truck rames have means to

prevent 1" o drop (saety drop lugs)?

Runway stops (condition)

Runway, support columns or hangers (condition)

Runway oundation and anchors (condition)

Deterioration due to rust, oxidation, chemicals, etc.

Explain________________.

MiscellaneousDoes inspection include the requirements o any

local city, state, or other government specications?

Crane manuactured per CMAA or other specication.

Speciy_______________.

New crane systems wired per NEC 2005 or NEC 2008

Engineers stamp on crane supporting structure and

ootings available

Maintenance and proo testing records available

OEM operational and repair manuals available

Does inspection ollow manuacturers specications?

Does inspection include below the hook attachment?

* Items checked through operational observation only.

CCAA Overhead Crane Inspection and Preventive Maintenance Checklist

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