25 year

CRANE INSPECTIONS TO AUSTRALIAN STANDARDS

Current changes to the Australian Standards AS2550.1-2011 and AS2550.3-2002 relating to overhead cranes and hoists, have resulted in more frequent general service inspections and additional in-depth inspections to be carried out at specific intervals during the working life of the overhead crane.

These changes now require the inspections to be carried out as per the following extracts from AS2550.3-2002:

  • Routine Maintenance Service – Section 7.2.2
    Routine maintenance service shall be carried out at intervals not exceeding three (3) months apart, unless the crane is not in service.
  • Major Inspection of Mechanical Components for Assessment for Continued Safe Operation – Section 7.3.4 & 7.4.1
    This assessment should be carried out at 10 year intervals for the mechanical components – Please refer to the 10 year mechanical inspection requirements for further details.
  • Re-certification for Continued Safe Operation – Section 7.4.1
    This assessment should be carried out at 25 year intervals or where the crane has been subjected to an overload greater than 10% of the rated capacity for either or both the structure and hoist – Please refer to the 25 year Re-certification requirements for further details.

25 YEAR RE-CERTIFICATION REQUIREMENTS

Note: An inspection and engineering assessment is recommended to be carried out prior to any upgrade work, this is to determine either the feasibility and or the scope of work necessary for Re-Certification for Suitability of Continues Safe Use as per AS2550.1-2011 and AS2550.3-2002.

This inspection is to be carried out after 25 years of operation or following the structure and or the hoist being subjected to an overload greater than 10% of the rated capacity, with the basic requirements being as follows:

The strip down of the machine to allow structural anomalies such as cracking, fatigue, and excessive stress to be identified by non-destructive examination, which involves the disassembly and removal of paint, grease and corrosion from critical areas and components for a thorough and complete examination.

It also includes a detailed visual inspection and tolerance checking of all wear components, along with thickness checking for wear and corrosion.

In carrying out the major inspection, the following items are to be checked;

  1. Non-destructive examination to an appropriate standard of the following items:
    1. Disassembly and inspect all wheels, axles, wheel retaining mechanism, gears and pinions.
    2. Main beam, runway rails and stop buffer attachments.
    3. Brake assemblies, linings, drums, levers, release units, pins and springs.
    4. Assembly of the structural integrity, amin beams, end carriages and structural welds.
    5. Assembly of the mounting integrity, fasteners, nuts, bolts and wedges with replacement after assembly.
    6. Winch drums, ropes, rope guides, mounting frame, shafts and gears.
    7. Any impact points during travel and all mounts.
    8. Hooks, sheave blocks with bearing replacement after disassembly.
    9. Open inspection and NDT of drive gearbox components and shafts – with replacement of all bearings and seals recommended.
  2. Electrical equipment inspected for condition and compliance:
    1. Switches and actuating devices, mains, isolating and crane switches, contactors and limit switches.
    2. Supply busbars, insulators, current collectors and cabling.
    3. Motors, brake release units, resistors, lighting, warning and signaling devices.
    4. Electrical protection equipment and overload indicators.
  3. Structural, mechanical, electrical, control and operating anomalies.
  4. Controls and emergency stop systems.
  5. Braking systems.
  6. Manufacturers' safety upgrades.
  7. Adequacy of safety instructions and manuals for operating and maintenance.
  8. The capacity and viability of upgrading the crane to the requirements of the latest standard.

 

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