Beruflich Dokumente
Kultur Dokumente
Classification:
Category: In-service Inspection & Verification/Equipment Inspection/ Lifting and handling equipment
Corporate Product Code: I 22 (or I 10 by default in case of Multi Technical Fields)
Editor(s): Ad Hoc Group: (i.e. Ananthakrishnan Mukundamony, Alain Chandèze, Arnaud Marquant,
Alexandre Crinière, and Alain Henckes)
Editor Manager: Arnaud Marquant
Approved by: Alain Henckes
Forward:
The objective of this guide is to define minimum requirements for in-service inspections and should be
mandatory used, unless a specific regulation in force is available in a country. In this latter case, the criteria
enclosed could be added for a professional management of a lifting equipment park.
This is the free synthesis of the following:
• Lifting Operation and Lifting Equipment Regulations 1998 (LOLER),
•
st
French Regulation which came in force on March 1 2004 for inspection of lifting equipment and
their hoisting accessories,
• BV experience feedback,
It gives a general indication of some of the main requirements focused on priority to safety criteria and it is
organised to be fulfilled during the inspection.
After satisfactory completion of examination a Certificate including an annex shall be issued, and a Defect
Report will be issued for equipment failing the acceptance criteria for thorough inspection.
If some appliances identified by the customer in a contract are not available, a Non Available Report has to be
issued including a detailed list of accessories not inspected.
Note: The paragraph numbering adopted in the following guides, for every equipment, is derived from a global
matrix valid for all lifting appliances and their accessories
As a result, the numbering for particular lifting equipment - e.g. Accessories - does not include all paragraphs of
this set.
0.0 DESCRIPTION 3
3.4 FIXATIONS – ASSEMBLIES 8
3.9 FRAME STRUCTURE 9
9.1 FASTENERS (CLAMPS, CLIPS, STRAPS) 10
9.2 GRIPPERS 13
9.4 MAIN RUNNERS AND LINES, GUYS (WIRE ROPES OR CHAINS) 16
10.8 DRIVE COMPONENTS, COUPLINGS, CONNECTIONS 19
15.0 BELOW-THE-HOOK E.G. C-HOOKS 20
15.1 BELOW-THE-HOOK E.G. COIL LIFTER 23
15.2 BELOW-THE-HOOK E.G. TONG GRAB 26
15.3 BELOW-THE-HOOK E.G. SPREADER BEAM 29
15.4 BELOW-THE-HOOK E.G. CHAINS, HOOKS AND SLINGS 33
CERTIFICATE OF THOROUGH INSPECTION OF LIFTING ACCESSORIES 37
ANNEX TO CERTIFICATE OF THOROUGH INSPECTION 38
REPORT OF NON-AVAILABLE 39
DEFECT REPORT 40
Spreaders
Vacuum spreader
Electromagnetic spreader
Lower blocks
C-Hooks Shackles
Drop of the suspended lifting tool Selection of appropriate lifting tool and fixing Inspect the lifting tool fixing assembly for structural deformation or cracks.
along with the load due to sudden assembly. Check there is no unwanted or uncontrolled movements of components during
break or distortion of the fixing operation.
Lifting tool fixing assemblies are to be
assembly.
designed, manufactured and tested to
Injury / death of personnel. specific standards by the manufacturer.
Lifting tool fixing assembly is maintained as
per manufacturer’s instruction.
Drop of the suspended load du to Framing or structure components of Inspect the frame/ structure of the lifting accessory for abnormal defects such as
the deformation or sudden breaking lifting accessories must be cracks, distortions, corrosion, etc.
of the frame structure manufactured in compliance with
Ensure that no un-approved repairs are carried out on the frame / structure.
manufacturer’s specifications and
Injury to personnel in the work area.
applicable regulations,
Damage to crane components.
Damage to the dropped load. Particular attention should be paid to
the conditions of their use. The safe
working load should be in
appropriateness (in particular by
ensuring they meet the hoist equipment
used),
Slip of the load hook from hoist wire Ensure the appropriate fasteners are selected and are Check by visual inspection:
rope resulting in the fall of load hook installed as per the manufacturer’s recommendation.
Clamping devices,
along with the suspended load
Fasteners are to be designed and manufactured to
Fixing devices,
specific standards by the manufacturer.
Clearances of mobile parts
Fasteners are maintained as per manufacturer’s
instruction. Accessories especially on tightened parts.
Inspect the connection pin and bulldog clamps.
The cable-clip should never be directly in contact with the wedge or with the box itself
(ensure that the tightening is secured exclusively by the box).
The cable-clip should, in no way, tighten the pulling strand whatever the outfitting direction
(risk of significant loss of resistance of the cable
Strands must be straight in the wedge-box, with no folding and no cut strands.
Ensure that:
Load failure Use a hook designed to prevent the accidental Visual inspection of the load-handling devices,
dropping of loads.
Inspect the hooks for free movement of the safety latches.
Install a safety latch on all types of hooks.
Prohibit access to the lifting areas where the
lifting is maintained by electromagnetic or
vacuum, by unsecured grabs, docker’s hooks,
clamshell buckets.
• That every overall part is safe for use and without any defect such as:
Excessive wear
Severe deformation
Check:
Condition of axis, stopping and removable devices,
clearances,
Condition of handling parts
No deformation
Wears
Clearance of pins, axles and actuating cylinders
Load failure due to snapping of wire rope. Proper design / selection of wire rope / chains as per relevant Inspect the physical condition of the wire rope for any
standards and Periodic maintenance. visual defects such as broken wires, crushing, corrosion
Damage to crane parts / pulleys due to
buildup, kinks, wire rope twists, etc.
damaged wire rope.
Note: ISO 4309 provides details on: Inspect the physical condition of the chain for any visual
Injury to operator / maintenance personnel.
defects such as corrosion buildup, kinks in th link, link
Maintenance, installation, testing and removal of wire
twists, etc.
ropes.
Failure of a strand or the core of a wire ropes Inspect and confirm the diameter of the wire rope or
Rupture of external and close wires of a wire ropes chain
(one or two rope lays). Inspect the diameter for any reduction.
Apparent and significant wears (that occur on the
portion of the wire ropes in contact with pulleys or friction
Verify the wire rope or chain certificate and ensure that
areas). the same is in line with the manufacturer’s specification
Corrosion (with complete disposal as soon as a wire is
attacked and starts to lose its section)
Important distortion (wire ropes enhance / lubrication of wire
rope.
Wire rope
Ensure the wire ropes are not worn or defective.
Check the proper condition of wire rope.
Apply the wire rope removal criteria:
Broken or cut strands
Flat areas caused by wearing
Reduction of the ND (Nominal Diameter) over than 10%
Excessive distortion
Crushing…
Bent, flattened, unstrained ... reduction of section when the wire rope
Brocken Strand Kink
is winded on pulleys
Brocken Strand
Chains
Check by visual inspection that the chains are not worn or defective.
Terms for disposal: the strength of a chain being the strength of the weakest link, it should
discard the chain that have a link :
Chain link Chan link cut Chain link Chain link warped
out-of-true out-of-true
For butt-joined link and roller chains ask for replacement of the whole chain where they are:
Twisted,
Having a broken link or bent link ...,
Which is longer over 3% of the nominal length.
Loss of control of horizontal or Ensure that all the below the hook lifting equipments During the inspection of the lifting tool, carry out a no-load function test
vertical movements, drop of are subjected to periodic maintenance as per to ensure that all the couplings and connection are functioning smoothly.
suspended loads, collapse of manufacturer’s instruction.
supports or devices (below gantry
crane)
Check :
Clearances
Every end-play take-up
Distortions
Seizing
Drop in load due to sudden break of C-Hook are to be designed and manufactured to specific Perform a complete visual inspections during no-load and on-load
the hook anchoring point from the standards by the manufacturer. tests to detect distortions or bents,
crane hook, unbalance due to
C-Hooks are maintained as per manufacturer’s Check paint parts and ask for NDT if doubt is raised.
deformation of the C-Hook structure
instruction.
Bear special attention about welds repaired and uncontrolled
deposition welding
2) The next inspection is to verify that the lower arm has not been bent so that it
is out of parallel with the C-hook, or bent down because of excessive load (note
that more than 12 mm variance would be considered unacceptable).
3) Pads that may be applied on the nose of the C-hook or on the back vertical
riser, revolving belts or other assemblies that protect the coil should be
inspected even it is usually not structural concern.
4) Finally the following items could be performed after removing paints and other
debris: Dye-penetrant checks at lower and upper crotch of the C-hook as well as
at all welds on the bail assembly (and bail pin if applicable)
Note 2: Pay attention especially when components of the work processing line are among the least expensive and repetitive used.
Drop in load due to sudden break of Coil Lifters are to be designed and manufactured to Perform a complete visual inspection during no-load and on-load
the coil lifter anchoring point from specific standards by the manufacturer. tests to detect distortions or bents,
the crane hook or deformation of the
Coil Lifters are maintained as per manufacturer’s Check paint parts and ask for NDT (Non Destructive Testing) if doubt
coil lifer structure.
instruction. is raised,
Injury to personnel
Check the electrical control components,
Damage to crane components
Bear special attention about geometrical alignments.
3) The welds at the “knee” of the slider (the 90° t urn when the slider becomes
the vertical leg) and the horizontal pads should be checked for obvious cracks.
4) Electrical devices, including the wiring to the sensors and motors should
reveal no indications of burned or cracked wire insulation, foreign material lying
or obvious loose connections. Discrepancies to look for include frayed wires,
sliced insulation, stretched or taut wires, discoloured insulation or broken
connectors.
Once the lifter is re-energized, the pendent should be tested through all of its
operations to verify that all controls function properly.
Measure the clear height with the sliders closed and then when opens. Most
models experience a difference in the clear height in these two positions when
the slider droops at their furthest extension. (If this clear height sharply increases
over time or the sliders hang up when fully extended, there is indication that the
wear surfaces have excessive wear).
Legs should operate simultaneously. If the coil grab has a drive and idler side
configuration, measure the difference between when the drive side starts
movement and when the idler actuates. If this difference sharply increases over
time, bearing, chain or belt failure may be indicated. Chains or belts should be
adjusted. An approximately 2% slack is allowed.
Drop in load due to sudden break of Tong Grab are to be designed and manufactured to Perform a complete visual inspection during no-load and on-load
the Tong Grab anchoring point from specific standards by the manufacturer. tests to detect distortions or bents,
the crane hook, deformation of the
Tong Grab are maintained as per manufacturer’s Check paint parts and ask for NDT if doubt is raised,
Tong Grab structure
instruction.
Check the electrical control components.
Injury to personnel
Bear special attention about geometrical alignments, cleanliness and
Damage to crane components
minimal maintenance requirements.
Ensure that the manufacturer’s nameplate and safety labels are attached.
Tong crabs
Drop in load due to sudden break of Spreader beams are to be designed and manufactured to Perform a complete visual inspection during no-load and on-load tests
the spreader beam anchoring point specific standards by the manufacturer. to detect distortions or bents,
from the crane hook or load
Spreader beams are maintained as per manufacturer’s Check paint parts and ask for NDT if doubt is raised,
anchoring points, deformation of the
instruction.
spreader beam structure Check the electrical control components,
Bear special attention about geometrical alignments, cleanliness and
minimal maintenance requirements.
The inspection starts with a global review of the beam, looking for obvious material
distortion, bent hooks, missing retaining pins, keeper bars, safety signs and
manufacturer’s labels.
Then inspect the hooks or attachment points of the load to the beam:
- Are the hooks bent? If so, they need to be replaced,
- Are the pins that connect the “J” hooks or other lifting points to the beam in
good condition? If there is more 3 to 5% (obvious indentations), ask for
manufacturer’s requirements,
- For beams with adjustable lifting points or bails, carefully inspect the
mechanism that holds the assembly in position. Is there sufficient wear or
degradation that would allow the assembly to slip out of position inadvertently
during a pick? Are the pins or clips that hold the position in good condition?
- Are the shackles/links/hooks/slings in proper condition? Do they have the pins
to prevent the load from being released? Are they sized properly if they have
been substituted from the original design?
Visually inspecting the lifting beam for obvious weld cracks or other signs of
distortion would be the next step.
Note 2: Maintenance
Maintenance of a lifting beam is usually limited to replacement of protective
pads, liners or hardware that attaches the load to the beam. On beams with
adjustable bails or hooks, properly greasing the contact points would be
advisable.
Drop in load due to sudden break of Chains, hooks and slings are to be designed and Perform complete visual examination of the chains, hooks and slings
the chain, hook or sling or the manufactured to specific standards by the manufacturer. for physical damage which can affect the integrity of the lifting tool.
anchoring point from the crane
Chains, hooks and slings shall be regularly maintained. Check paint parts and ask for NDT if doubt is raised on chains or
hook.
hooks.
Safety hook
Chain Gauges
Equipment Description
Type of equipment Serial number ID number Safe Working Status (*) Comments
Load
Based on Thorough Visual Examination, Functional Test of the accessories described above was found
satisfactory at the time of Inspection.
THIS IS TO CERTIFY THAT the above signed competent surveyor thoroughly examined the lifting equipment in the above-
mentioned place as per technical referential mentioned above. The liabilities are as per Bureau Veritas General Conditions of
Services.
GM IVS 002 / CERTIFICATE Page 1/1
GM IVS 002 – Thorough Inspection of Accessories Page 37/43
Rev 00
Annex to certificate Of Thorough Inspection
Of Accessories
Annex to certificate N°: Date of inspection:
Annex to certificate Of Thorough Inspection
CONDITION / REMARKS / PERFORMANCE TESTS
DESIGNATION Refer to the list of equipment in the certificate if
necessary
0.0 Description
3 FRAMING
Fixations, connections, brackets,
3.4
assemblies, joints
3.9 Frame, boom, arm, turret
Comment :
Equipment Description
The accessories described above was not found or non available at the time of Inspection.
THIS IS TO CERTIFY THAT the above signed competent surveyor thoroughly examined the lifting equipment in the above-mentioned
place as per technical referential mentioned above. The liabilities are as per Bureau Veritas General Conditions of Services.
GM IVS 002 / NON AVAILABLE Page 1/1
Equipment Description
Based on Thorough Visual Examination, Functional Test of the accessories described above was found
non-satisfactory at the time of Inspection.
THIS IS TO CERTIFY THAT the above signed competent surveyor thoroughly examined the lifting equipment in the above-mentioned
place as per technical referential mentioned above. The liabilities are as per Bureau Veritas General Conditions of Services.
GM IVS 002 / DEFECT REPORT Page 1/1