Verification of Lifting Equipment

8/12/2019 Verification of Lifting Equipment

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UNIT 1.7 - VERIFICATION OF LIFTING EQUIPMENT

(TESTING AND EXAMINATION)

Contents

Into!"#t$on

1. Pe%&$n' o &n e&*$n&t$on

+. Con!"#t$n' &n e&*$n&t$on

2.1 Chain slings2.2 Hooks2.3 Shackles2.4 Eyebolts2.5 Wire ropes2.6 Fabricated ites2.! "i#ting achines2.$ %arking or re&arking

,. Test &n! e&*$n&t$on e"$%*ent

3.1 'est achines and #orce(load eas)ring e*)ipent3.2 +iensional eas)ring e*)ipent3.3 ,on&destr)cti-e test e*)ipent

. T/%es o test &n! 0&t te/ *$'t te22 "s

4.1 +iensional -eri#ication4.2 perational test4.3 "ight load test

4.4 SW" and de#lection eas)reent4.5 /roo# load test4.6 0reaking load test(ini) breaking load test4.! Hardness test4.$ "i*)id penetration crack detection4. %agnetic particle crack detection4.1 adiography &ray crack detection4.11 Eddy c)rrent crack detection4.12 7ltrasonic crack detection4.13 Electroagnetic 8ire rope e9aination

3. A#t$ons o22o0$n' &n e&*$n&t$on

1: "i#ting E*)ipent Engineers ;ssociation 211 < 7nit 1.!


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Into!"#t$on

;ll li#ting e*)ipent )st be -eri#ied=

a to ens)re it is sa#e be#ore #irst )se> and

b periodically once it is in ser-ice to ens)re it reains sa#e to )se.

7ntil the end o# the t8entieth cent)ry> all o# the -ario)s 7? reg)lations> and there#orethe standards> called #or li#ting e*)ipent to be proo# load tested and e9ained toens)re this 8as the case. 'his 8as irrespecti-e o# the logic or need #or s)ch a test.7sers 8ere then re*)ired to retain the @test certi#icate and e9aination reportsA.

%odern legislation> standards and codes o# practice take a ore sensible approach.For certain prod)cts> proo# load testing reains -alid. Ho8e-er> #or any coonites> this is not the case and other tests are ore eaning#)l.

Standards gi-e the -eri#ication ethods #or ne8 prod)cts> altho)gh it is no longer

necessary #or the )ser to be gi-en the res)lts. For in&ser-ice e*)ipent> ""Eplaces the d)ty #or deciding i#> and 8hat> tests are necessary on the @copetentpersonA aking a thoro)gh e9aination. Bt re*)ires the details o# any tests ade tobe incl)ded on the e9aination report. ,ote the 8ords @any testA. 'he report needsto incl)de any #)nctional> light load> non&destr)cti-e tests etc> not )st a proo# loadtest.

'his )nit considers the thoro)gh e9aination> the general re*)ireents #or teste*)ipent )sed in the e9aination> and the tests a-ailable to the e9ainer.

;s noted in )nit 1.1> ""E does not )se the 8ord @testA b)t instead re#ers to a

@thoro)gh e9ainationA. 'he p)rpose o# the e9aination is to deterine i# the itebeing e9ained is sa#e to )se or other8ise. For any ites> the e9aination 8ill beliited to a #)ll -is)al e9aination. For others it 8ill need to be s)ppleented by anyone o# a n)ber o# tests i# the correct concl)sion is to be reached.



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1. Pe%&$n' o &n e&*$n&t$on

Bn all b)t a #e8 cases> li#ting accessories and an)ally operated achines 8ill bereadily accessible #or e9aination. Bn contrast> #or a r)n8ay or crane> thee9aination )st be ade in sit) and special proced)res are necessary. St)dy isthere#ore con#ined to the ore basic types o# e9aination that can be ade at thebench or> in soe cases> on the #loor. Ho8e-er> the general principles are the sae#or all e9ainations.

'he area in 8hich the e9aination is to be ade )st be clean and clear o# anydebris that ay hinder the e9aination or har the ite )nder e9aination. Bt )stbe 8ell lit> either by nat)ral or arti#icial light> and #ree #ro shado8s or tinting> 8hichay ipede the -is)al detection o# #a)lts. B# it is necessary to s)spend an ite e.g.chain block> the s)spension point sho)ld be at the correct height to allo8 rele-antparts to be e9ained easily. Bn soe cases> additional lighting s)ch as a penciltorch or lead light ay be necessary. 'his is partic)larly the case 8ith s)spendedachines.

%ost e9ainations are ade by the naked eye. Ho8e-er> #or soe ites> the )se o#a agni#ying glass> dental irror or siilar -is)al aid ay be necessary.

'he ites )nder e9aination )st be clean and #ree #ro r)st> grease> paint etc>8hich ight obsc)re de#ects. Where ites re*)ire cleaning> an appropriate ethodsho)ld be )sed 8hich 8ill not har the ite. Bn the case o# coposite ites #ore9aple> a spreader 8ith top and botto slings shackled to the bea andachines> these sho)ld be stripped do8n as ay be necessary #or the e9aination>prior to cleaning. 'he parts )st be clearly identi#ied and kept together.

E9aples o# cleaning ethods=

0r)shing or 8ire br)shing to reo-e light r)st and debris.

'he )se o# proprietary sol)tions to reo-e stronger r)st

penetrations. Dreat care )st be e9ercised here. %any o# theseprod)cts are acid&based and> 8hilst dil)te acid preparation ay be)sed on soe ites o# li#ting gear> this is not generally the case. Bnpartic)lar> alloy steels are prone to hydrogen ebrittleent 8hen theyha-e been in contact 8ith acid or ca)stic conditions.

Shot blasting or r)bling to reo-e scale.

+egreasing to reo-e oils and #ats.

;ltho)gh it is not part o# the copetent personAs d)ty to strip do8n and reb)ilde*)ipent> in practice the e9ainer ay #ind it is necessary to do this to soee9tent. %)ch 8ill depend on the eployer> or the conditions that pre-ail on the site8here the e9aination is being )ndertaken. 'he re*)ireents 8ill also -ary 8ith thecople9ity o# the ites )nder e9aination. ;s part o# the preparation> thee9ainer sho)ld ens)re that all the necessary tools are to hand.

+iensional checks #or part o# any e9aination. 'he e9ainer sho)ld there#orealso ha-e all the appropriate eas)ring instr)ents e.g. r)le> icroeter etc andga)ges #or the ites )nder e9aination. For re#erence p)rposes> copies o# therele-ant 0ritish or other Standards> dra8ings or 8ork speci#ications sho)ld be



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a-ailable. Finally> the e9ainer sho)ld ha-e the necessary staps or otherappropriate arking de-ices to ark> or re&ark> the ite 8ith its disting)ishingn)ber> SW" and any other necessary in#oration.

+. Con!"#t$n' &n e&*$n&t$on

'he e9aination sho)ld start 8ith correct identi#ication o# the ite. Bn the case o# ane8ly an)#act)red ite> 8here the e9aination is ade #ollo8ing the initial test>the details sho)ld be checked against the test record. Bn the case o# an ite that hasbeen in ser-ice> i# there is any do)bt as to its identity and(or history> the pre-io)se9aination reports and aintenance records sho)ld be checked as appropriate.

eeber that ""E lea-es it to the discretion o# the copetent person indeciding i# a test is necessary and> i# so> the nat)re and #or o# any s)ch test> inreaching a concl)sion as to 8hether or not the ite is sa#e. 'he on)s as to 8hetheror not the e*)ipent ay enter> or ret)rn to ser-ice is on the )ser> not the e9ainer.'he d)ty o# the copetent person is only to deterine i# the e*)ipent is sa#e to )seor not & and to report the #act.

'he e9aination )st be cond)cted systeatically to ens)re all parts are thoro)ghlye9ained. Bn the case o# slings or long lengths o# chain> rope or 8ire rope> thee9aination sho)ld start at one end and proceed along the length ens)ring all partsare obser-ed. For e9aple> reeber to t)rn a chain #)lly < it has #o)r sides nott8o. B# the e9aination is interr)pted> it sho)ld be started again #ro the beginningto ens)re no part is issed.

Bt is iportant to reeber that the perissible ao)nts o# 8ear> elongation> broken8ires etc gi-en in this co)rse> standards> an)#act)rerAs instr)ctions and siilarso)rces are maximums. ; )dgeent has to be ade as to 8hether the ite is #it to

contin)e #or a period o# ser-ice < that is> it 8ill be sa#e to operate )ntil the ne9te9aination is d)e & in the pre-ailing ser-ice conditions.

Carry o)t diensional checks against the standard> speci#ication or dra8ing. Carryo)t any other checks necessary to ens)re the ite is in copliance 8ith thestandard and(or speci#ication. Carry o)t a #)ll -is)al e9aination. 0elo8 are soee9aples o# soe typical ites and a list o# the points to be considered d)ring theire9aination #ollo8ing a period o# ser-ice. Bn later )nits> 8hen speci#ic ites aredisc)ssed> these atters are considered in greater detail.

+.1 C&$n S2$n's

E9aine and check #or=

1. Sies o# chain> links and hooks #or loads re*)ired.

2. Stretch d)e to 8ear and loading 5 a9i)> -ariation in thelengths o# the legsG copare 8ith past records.

3. Hooks #or openings and distortion see belo8.

4. "inks and rings #or distortion or ro)ndness.

5. Chain #or bent and t8isted links. 'he links sho)ld artic)late #reely.

6. ;ll parts #or 8ear> $ red)ction in diaeter> corrosion> nicks andcheical attack.

!. Cracks> 8eld #a)lts and arks in 8eld areas.



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+.+ 4oo5s


1. pening o# hook against an)#act)rers catalog)e> 1(1th a9i) i#it e9ceeds this> scrap hook. ther distortion.

2. Wear in eye> saddle etc> ie $ red)ction in thickness.

3. Cracks> nicks> scores and gall arks in the body o# the hook.

4. Shank #or alignent> s8i-el #or #ree r)nning> so)ndness andcopleteness o# thread etc.

5. Corrosion and cheical attack.

+., S4es


1. Sies #or loads to be li#ted.

2. Correct pin #itted> #ree 8orking o# pin.

3. Wear o# the pin thread.

4. ;lignent o# holes in shackle.

5. Wear in pin and bo8 as per steel chain> ie $ red)ction in diaeter.

6. ;ll parts #or nicks> cracks> corrosion and cheical attack.

+. E/e6o2ts


1. Sie #or loads to be carried.

2. 'hread #or copleteness> 8ear and alignent. Correct )nderc)t orrelie-ing at the base o# the shank.

3. ;lignent o# shank and eye.

4. Cracks in shank and eye.

5. Wear in eye and link etc> ie $ red)ction in diaeter.

6. Corrosion and cheical attack.

+.3 $e Ro%es


1. Sie o# loads to be li#ted.

2. ?inks in the rope.

3. Wear in rope.

4. Change in diaeter increase or decrease and increase in length.

5. ")brication and internal condition.



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6. 0roken 8ire a9i) 5 in any length e*)al to 1 ties thediaeter. eeber that> in certain applications> e-en one broken8ire presents a haard to the )ser or e*)ipent.

!. Condition o# splices> #err)le sec)red eyes etc.

$. Corrosion and cheical attack. ,0= With soe constr)ctions o# 8irerope> internal corrosion can ca)se an increase in diaeter.

+.8 F&6$#&te! Ite*s


1. Deneral condition o# aterials> paying partic)lar attention to the #inisho# c)t and achined parts. 'hese sho)ld be sooth 8ith no stressraisers.

2. ,icks> cracks> distortion> corrosion and cheical attack.

3. 'he so)ndness o# 8elds. 'hey sho)ld be #ree o# slag> cracks> porosityand )nderc)t.

4. 0olts sho)ld be o# correct length and threaded sections sho)ld not bes)bect to shear. ,)ts sho)ld be #)lly engaged and sec)re. "ockingde-ices and 8ashers )st be in place.

+.7 L$t$n' M$nes


1. Deneral operation. 'his 8ill -ary 8ith the type o# achine> b)t sho)ldgenerally be sooth> 8itho)t erkiness.

2. peration o# brake or other s)staining echanis.

3. peration o# liits and sa#ety de-ices.

4. Correct ating o# o-ing parts> eg gears.

5. Deneral condition o# aterials and anchorages.

6. %echanical daage> cracks> distortion> corrosion and cheical attack.

Note9 Coposite ites> s)ch as a spreader bea 8ith t8o leg top s)spension chain

sling> shackles and pendant 8ire ropes> sho)ld be broken do8n into the coponentparts as necessary and e9ained on that basis. 'he coplete assebly sho)ldthen be checked #or correct #itting> alignent o# parts etc.

+.: M&5$n' o Re-*&5$n'

;s 8ell as arking ne8 e*)ipent> it is soeties necessary to re&ark thein#oration on in&ser-ice e*)ipent. Bt )st be realised that> in staping an ite> apotential #a)lt is being introd)ced> as the indentations act as stress raisers. 'hearking is there#ore ade on selected areas o# the ite 8here the e##ects are

iniised. Care )st be taken so that the staping is neither too sharp nore9cessi-e in depth> partic)larly 8hen )sing ne8 staps. 'he sie o# the staps)sed sho)ld not e9ceed the #ollo8ing=



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"EE; 'echnical e*)ireents> Cla)se 3.6> re*)ires that a proced)re is in place #orchecking and -eri#ying eas)ring de-ices at appropriate periods. 'he g)idance tothe re*)ireents says that> #or tapes and r)les> it 8ill probably only be necessary toreg)larly check the to ens)re that they are )ndaaged> partic)larly at the eroend> and reain legible. Ho8e-er> precision eas)ring e*)ipent 8ill re*)ireperiodic -eri#ication> e.g. against slip ga)ges> depending on the nat)re o# the de-iceand the d)ty #or 8hich it is )sed.

,., Non-!est"#t$=e test e"$%*ent

,.,.1C !ete#t$on

When dealing 8ith general li#ting gear> )s)ally only r)diental crack detection s)chas dye penetrate or agnetic particle is per#ored to e9aine 8elds. 'hese call #orbasic training o# the operati-e to enable the to interpret the res)lts. 'he e*)ipentre*)ires no calibration. 'hey are relati-ely ine9pensi-e> both in ters o# thee*)ipent and the labo)r necessary to per#or the tests.

For ore detailed crack detection e9ainations> partic)larly on high -al)e ites or8here additional sa#ety re*)ireents re*)ire a higher degree o# e9aination> otherethods )sed are eddy c)rrent> radiography and )ltrasonic. 'hese are e9pensi-e toper#or and call #or a high degree o# training and skill to interpret the res)lts.

,.,.+ 4&!ness test

Bndentation ethods are )sed to -eri#y the hardness o# li#ting gear #ollo8ing heattreatent or 8here e*)ipent is )sed in conditions that ight a##ect the heattreatent. 'here are three basic ethods= Kickers> 0rinell and ock8ell.

0rinell is the ost coon in the li#ting e*)ipent ind)stry. Bt is a relati-ely sipletest that can be ade on the #inished ite. Bt re*)ires only basic training in order tointerpret the res)lts.

,.,., E2e#to*&'net$# 0$e o%e e&*$n&t$on

'his is a #ast ethod o# detecting de#ects in long lengths o# 8ire rope. 'he rope ispassed thro)gh a agnetic #ield. 0reaks and dist)rbances in the agnetic #ield aredetected and a printo)t o# the #ield is gi-en. 'his calls #or a high degree o# trainingand skill to interpret the res)lts.

"EE; 'echnical e*)ireents> Cla)se 3.5> calls #or non&destr)cti-e test e*)ipentto be -eri#ied at appropriate inter-als in accordance 8ith the an)#act)rerAsinstr)ctions.

,. Ote e"$%*ent ne#ess&/ !"$n' &n e&*$n&t$on

Coparators> s)ch as thread ga)ges> ay occasionally be needed to ens)re correctidenti#ication and pro#ile o# thread types and sies> or as a siple go(no go ga)gee.g. to check #or chain 8ear.

$: "i#ting E*)ipent Engineers ;ssociation 211 < 7nit 1.!


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Bn addition to load(#orce application and eas)ring e*)ipent> distance eas)ringe*)ipent> and pro#ile eas)ring(coparison e*)ipent> the tester and e9ainer8ill> #ro tie to tie> re*)ire other basic aids. ;dditional lighting> s)ch as a 8anderlight or torch> 8ill o#ten be necessary> along 8ith -is)al aids s)ch as a agni#yingglass or dental irror.

Bn the case o# li#ting gear general> only the ost basic o# tools are generallynecessary. 'hese 8ill incl)de a haer> a set o# pin p)nches #or echanicallyassebled chain slings> dri#ts and arlin spikes #or 8ire ropes> a set o# letter andn)ber p)nches etc. Bn the case o# achines> spanners> scre8 dri-ers and circlippliers ay be re*)ired.

0asic cleaning e*)ipent> s)ch as a 8ire br)sh and cleaning cloth> ay also benecessary> to reo-e r)st> dirt or debris 8hich ay obsc)re #a)lts> #la8s> de#ects orarking.

. T/%es o test - &n! 0&t te/ te22 "s

Ha-ing considered the e*)ipent )sed d)ring an e9aination and test> this )nit no8looks at the -ario)s tests a-ailable & and 8hat they ight tell )s. Soe o# these8ere considered in )nit 1.6. 'hey are no8 p)t into conte9t.

.1 D$*ens$on&2 =e$$#&t$on

Ens)ring an ite is diensionally correct & eas)ring it & is )s)ally a #)nction o# theinitial -eri#ication to ens)re the ite is to the standard> speci#ication or dra8ing. Bn&ser-ice ites are also eas)red> to deterine the ao)nt o# 8ear> b)ild )p or losso# corrosion in 8ire ropes and siilar atters> and ens)re they are 8ithin theaccepted liits.

Coparators and ga)ges are help#)l 8hen eas)ring 8ear or identi#ying threads orthread 8ear.

.+ O%e&t$on&2 test

'his test has -ery liited application #or li#ting gear. Bt is ore appropriate to li#tingachines. Bt is a siple test to ens)re the ite operates as intended. +)ring thistest the ite is operated thro)gh its noral #)nctions> )s)ally 8ith a light load or noload. Bts )se is there#ore liited to ites o# li#ting gear that ha-e o-ing parts. Fore9aple> on a plate clap> to ens)re the a8s grip the plate and can be locked intoposition. Bt is )sed both d)ring the initial -eri#ication and d)ring the in&ser-icethoro)gh e9aination.

., L$'t 2o&! test

'his test is not applicable to li#ting gear. Bt is #or ites that ha-e scre8 brakes or #allarresting brakes that depend on the do8n8ard o-eent o# the load to operatethe> s)ch as a hand chain block. ; load o# bet8een 2 and 5 o# the W"" israised s)##icient height and then lo8ered. 'he operation is halted and the load )stbe s)stained by the brake.

'his is the ost onero)s test that can be applied to a brake> e.g. le-er hoist. ;s thebrake is the ost sa#ety critical part o# the )nit> it con#irs i# it is sa#e to operate.

: "i#ting E*)ipent Engineers ;ssociation 211 < 7nit 1.!


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. SL &n! !e2e#t$on *e&s"e*ent

;gain this test is o# liited )se d)ring the e9aination o# li#ting gear. Bt is oreappropriate to li#ting achines and str)ct)res. Bt ay be applied as part o# the initial-eri#ication o# a li#ting bea or spreader> to deterine i# any peranent de#lection orset has taken place.

'he ite is s)bected to a load or #orce> either in a test achine eg spreaders> orby li#ting a li-e load eg r)n8ays and cranes> 8hich is e*)i-alent to the SW" W"".'he de#lection )nder load is eas)red acc)racy I5 and recorded. 'he de#lection)st be 8ithin the liits set by the appropriate standard. When the load(#orce isreo-ed the ite is eas)red to see i# any peranent set has taken place and> i#so> 8hether or not this is 8ithin the acceptable liits.

.3 Poo 2o&! test

'his is a test 8hich is greatly is)nderstood. Bt erely con#irs that the ite iscapable o# s)staining the applied load at the tie o# the test. 'hat is> the ite is

strong eno)gh. +)ring the test a #orce e*)al to the W"" pl)s an o-erload> )s)ally1 #or ost li#ting gear> 5 #or an)al achines and 25 #or po8er operatedachines and str)ct)res> is applied and then released. ;s #ar as li#ting gear generalis concerned> its )se is )s)ally restricted to ne8 coponent parts> eg chainco)plers> lengths o# chain> #abricated ites> eg li#ting beas and spreaders> andites that rely on the action o# the load #or their e##ecti-e operation> eg plateclaps. Bt is also )sed to -eri#y ne8ly #itted parts 8hen #abricated ites> eg li#tingbeas> and load action reliant ites> eg plate claps> ha-e been repaired. Btreains an iportant test #or str)ct)ral ites> eg r)n8ays.

%any coon ites 8ere at one tie ro)tinely proo# load tested. 'his 8as despite

the #act that the res)lts 8ere )ncertain and the test co)ld daage> or shorten the8orking li#e> o# per#ectly ser-iceable e*)ipent. Considering these liitations helpsto e9plain 8hy this test is being )sed less #re*)ently.

B# the test is to be eaning#)l and latent de#ects are to be detected> the )se o# alloysteels in the an)#act)re o# chain and #ittings calls #or higher proo# loads than thetraditional 2 9 W"" pre-io)sly applied to chain slings. 0S E, $1$&2 gi-es a table o#proo# loads to be applied to ne8ly an)#act)red grade $ chain 8hich e*)ates to 2.59 W"". Siilarly> the -ario)s standards #or the #ittings also call #or a proo# load o# 2.59 W"". Ho8e-er> in this case> this allo8s the radii o# the #ittings to be s)pported topre-ent the collapsing d)ring the test. b-io)sly> d)ring a siilar test on a ade

)p chain sling it 8o)ld be ipossible to s)pport the radii and there 8o)ld e##ecti-elybe point contact bet8een the ating s)r#aces. 7nder load> #ittings and aster&links8o)ld distort and 8o)ld be daaged beyond #)rther )se. 0S E, $1$&4 #or Drade $chain slings does not there#ore re*)ire echanically assebled slings to be proo#load tested. Ho8e-er> the sa#ety o# the sling is reliant on its correct assebly> 8ithall retaining and locking pins in place. ; thoro)gh -is)al e9aination> a#ter asseblyor 8hen in ser-ice> is essential.

'he sae is tr)e o# 8ire rope slings. 'he traditional proo# loading o# a #err)lesec)red eye seldo detected incorrectly ade eyes. E-en an eye 8ith o-er sie#err)les 8o)ld hold the proo# load. 'here#ore the haronised standards #or 8ire

rope slings do not call #or proo# load testing> b)t 0S E, 13411&3 calls #or the #err)leterination to be -eri#ied by eas)reent and thoro)gh e9aination.



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Bn the case o# eyebolts> the old 0ritish Standard 42!$ reains in place and thisstandard does call #or proo# load testing.

When e9aining an in&ser-ice hand chain block> #or e9aple> the strength is alreadykno8n. S)becting it to an o-erload 8ill not there#ore re-eal anything that is notkno8n. Ho8e-er> it 8ill p)t additional stress on the 8orking parts and shorten their8orking li#e.

.8 >e&5$n' 2o&! test


12/14

is gi-en in the -ario)s prod)ct standards. 'ypically> #or ites o# grade 4 or %> anH0 n)ber o# 152&21! is re*)ired.

.: L$"$! %enet&t$on # !ete#t$on

'here are se-eral li*)id penetration ethods a-ailable> the ost coon being the)se o# t8o or three aerosol spray cans o# li*)id. "i*)id penetration crack detectioncan be applied to #erro)s and nonerro)s etal coponents. 'hese tests areho8e-er liited in that they 8ill only re-eal the position o# cracks and do not help toassess the depth. ,either do they re-eal #a)lts belo8 the s)r#ace o# the aterial>s)ch as lainations and blo8 holes.

;ltho)gh liited> it is a pop)lar test #or li#ting gear> 8here no s)r#ace cracks areperitted. Bt is coonly )sed to check the 8elds on #abrications s)ch as li#tingbeas> crane str)ct)res and siilar ites. 'his test is -ery siple> readily portable>and calls #or the ini) o# training in order to interpret the res)lts.

'he principle o# the -ario)s ethods is )ch the sae. 'hey )se lo8 -iscosity

li*)ids 8hich #lo8 -ery easily and penetrate s)r#ace cracks. Bn the ost siple o#these tests> the area to be checked is sprayed 8ith a backgro)nd> )s)ally 8hite. ;second spray is )sed 8hich 8ill r)n o## the backgro)nd> b)t 8ill penetrate and gatherin the cracks. 'his li*)id is o# a di##erent colo)r and so re-eals the crack as acolo)red line.

; siilar ethod )ses a peranent agnet to attract the arker #l)id into the crack.Bts )se is there#ore liited to agnetic aterials. Ho8e-er> this test )st not becon#)sed 8ith agnetic particle crack detection.

.? M&'net$# %&t$#2e # !ete#t$on

'his ethod o# crack detection 8ill re-eal both s)r#ace cracks and indicate theposition o# #iss)res 8ithin appro9iately 1 o# the s)r#ace. ;s the ite )nderin-estigation has to be agnetied> its )se is liited to #erroagnetic aterials anda #e8 nonerro)s etals> s)ch as nickel and t)ngsten.

Sall ites and coponents s)ch as shackles are agnetied by passing thethro)gh a coil. For larger ites> s)ch as li#ting beas> electrodes are attached to theite co-ering the area )nder in-estigation. 'he ite is then sprayed 8ith a sol)tiono# s)spended iron #ilings. ; crack or iper#ection near the aterialAs s)r#ace 8illdistort the agnetic #ield and attract the iron #ilings. 'he crack is then re-ealed by an

acc))lation o# particles along the line o# the crack and s)b&s)r#ace de#ects by anacc))lation in the area o-er the #a)lt. ;s cracks are only detectable 8hen the lineso# agnetic #orce are at a signi#icant angle to the crack> sall ites are rotated andt)rned d)ring the test. For larger ites> the electrodes are attached at -aryingpositions.

For ease o# identi#ication> an )ltra -iolet light is o#ten )sed. 'his reacts 8ith thesol)tion and re-eals the iron #ilings as a black line. ther systes )se a backgro)ndspray 8hich allo8s the #ilings to be readily seen.

;s the ite has been hea-ily agnetied it is iportant that it is de&agnetied a#ter

the test to pre-ent the collection o# agnetic particles 8hich 8o)ld daage the ite8hen it 8as p)t into ser-ice.



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'his test calls #or siple training and the res)lts are easily interpreted. Bt is 8idely)sed #or larger in&ser-ice ites that are s)sceptible to cracking> s)ch as #ork tr)ckars> and d)ring series prod)ction o# #orgings.

.1@ R&!$o'&%/ (X-&/s) # !ete#t$on

'his ethod o# crack detection 8ill locate a #a)lt any8here thro)gh the section 8hichis &rayed. Ho8e-er> it 8ill only locate the #a)lt in one plane. Bt 8ill not re-eal itsdepth> )nless a #)rther &ray is taken in the opposite plane. Bt is an e9pensi-eoperation and calls #or -ery high sa#ety eas)res to be #ollo8ed. ;s a general r)le itre*)ires the e*)ipent to be e9ained to be taken to a specialist location. Bt isainly )sed 8hen e9aining prod)ction ites eg the 8elds o# links> or 8henin-estigating a #ail)re.

'he article being &rayed is s)bected to radiation> )s)ally #ro a gaa ray so)rce>8hich passes thro)gh the ite and #alls onto photographic #il. When de-eloped>the #il gi-es a pict)re o# the internal str)ct)re o# the ite in the plane o# theradiation. ;s the radiation 8o)ld daage body tiss)e the area )st be #)lly shielded

to pre-ent stray radiation and contact 8ith persons. 'he so)rce o# the radiation isnorally an isotope 8hich )st also be handled care#)lly to a-oid h)an contact.'his is a specialist test> )s)ally carried o)t )nder laboratory conditions. Bt calls #orgreat care in interpreting the res)lts.

.11 E!!/ #"ent # !ete#t$on

'his ethod o# crack detection is s)itable #or )se on thin sections> gi-ing the bestres)lts #or aterials o# less than 25 thickness. Bts )se #or li#ting gear general isthere#ore -ery liited.

0y placing a sall 8ire coil near the test piece and then passing an alternatingc)rrent thro)gh the coil> an alternating agnetic #ield is created. 'his> in t)rn>ca)ses a c)rrent in the test piece. 'his e##ect is kno8n as electroagnetic ind)ctionand the c)rrents ind)ced in the test piece are kno8n as eddy c)rrents.

/ro-iding the test piece is consistent> the c)rrent #lo8ing in the coil 8ill reain)nchanged 8hen the coil is passed o-er the test piece. Ho8e-er> i# there is a crackor ip)rity> the c)rrent 8ill change. 0y onitoring the c)rrent in the coil it is possibleto detect #la8s in the test piece 8hich are not other8ise -isible.

'his is an e9pensi-e specialist test. 'he test e*)ipent is sei&portable and so

tests can be ade in s)itable locations. Bt calls #or e9tensi-e training and e9perienceto per#or the test and interpret the res)lts.

.1+ U2t&son$# # !ete#t$on

'his ethod o# crack detection enables the sie and location o# #a)lts to beidenti#ied. Bt is )s)ally )n8arranted #or ost ites o# li#ting gear> b)t is soeties)sed to detect #a)lts in -ery large li#ting beas and siilar ites.



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; probe containing a *)art crystal is passed o-er the s)r#ace o# the test piece. 'hecrystal transits and recei-es high #re*)ency -ibrations 8hich are apli#ied andrecorded as a 8a-e#or on a cathode ray oscilloscope t)be. ; de#ect 8ill bere-ealed as an interediate echo on the screen> its depth being proportional tohoriontal distance. Kario)s ethods o# placing the probe are )sed depending onthe sie and location o# the #a)lt.

;gain this is an e9pensi-e specialist test. 'he test e*)ipent is sei&portable and sotests can be ade in s)itable locations. Bt calls #or e9tensi-e training and e9perienceto per#or the test and interpret the res)lts.

.1, E2e#to*&'net$# 0$e o%e e&*$n&t$on

'his ethod is )sed to detect broken 8ires and corrosion in 8ire ropes. Bt is osts)itable #or long lengths o# rope> s)ch as crane ropes.

'he rope is passed thro)gh a t)b)lar detector head 8hich sat)rates the rope in aagnetic #ield. ;ny 8ire breaks or signi#icant changes o# 8ire section 8ithin the rope

ca)se a dist)rbance o# the agnetic #ield. 'his is detected and sho8n on acontin)o)s paper printo)t.

;s rope can be #ed thro)gh the detector head in a contin)o)s r)n> this a #ast tests)itable #or long lengths o# 8ire rope. Bt calls #or s)itable training and e9perience tointerpret the res)lts.

3. A#t$ons o22o0$n' &n e&*$n&t$on

Follo8ing an e9aination> the #irst thing the tester and e9ainer )st do is preparea report. 'his is regardless o# 8hether or not the ite has passed the e9aination.

'he in#oration to be gi-en in the report is detailed in Sched)le 1 to ""E see)nit 1.1. Bn soe cases this report ay be sipli#ied to a check list or siilar> #ors)bission to the copany o##ice #or the report to be prepared #or the client.

For in&ser-ice e*)ipent> i# the e9aination re-eals one or ore de#ects 8hichpresent an iediate or iinent risk o# serio)s or personal in)ry> a copy o# thereport )st be sent to the en#orcing a)thority )s)ally the HSE in the 7?. ;prosec)tion ay #ollo8 i# this is not done. 'his is a d)ty placed on the personaking the e9aination. ;ltho)gh yo)r copany ay ha-e a proced)re #or doingthis> it is yo)r legal responsibility to ens)re it has been done.

Con#2"s$on

+ependent on the types o# ite yo) are dealing 8ith> yo) 8ill already be #ailiar 8ithsoe o# the tests o)tlined abo-e. Soe o# the are carried o)t by the tester ande9ainer in the 8orkplace or on site as a atter o# daily ro)tine. thers arespecialist tests> only 8arranted in special circ)stances or in partic)lar prod)ctionsit)ations.

;s a tester and e9ainer yo) sho)ld be a8are o# all o# the tests that are a-ailable toyo) and 8hat they 8ill tell yo). When the -ario)s ites o# li#ting e*)ipent areconsidered in detail> 8e 8ill assess 8hich o# the are applicable.

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Verification of Lifting Equipment

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