In the bustling industrial landscapes of China, bridge cranes are indispensable tools, facilitating efficient and safe operations in various sectors, from manufacturing and logistics to construction and mining. However, the reliability and safety of these critical machines hinge on meticulous and regular inspections. This in-depth guide to bridge crane inspection in China delves into the paramount importance of these inspections, ensuring compliance with stringent safety standards and regulatory requirements.

Within these pages, you will learn about the different types of inspections, including daily pre-operational checks, periodic inspections, and comprehensive commissioning and acceptance tests. Understand the key components that inspectors scrutinize, such as load-bearing structures, electrical systems, hydraulic systems, and safety devices. Discover how adherence to international standards like ISO and OSHA regulations is crucial for maintaining a safe and efficient work environment.

This guide will also explore the benefits of regular inspections, including the early detection of wear and tear, prevention of catastrophic incidents, and the extension of the crane’s lifespan. Additionally, it will address the

Crane Inspections and Inspections of Hoisting and Lifting …

Guide to Crane, Hoisting, and Lifting Equipment Inspections by SGS

Introduction

Ensuring the safety, reliability, and compliance of crane, hoisting, and lifting equipment is crucial for any operation involving these devices. SGS, a global leader in inspection, testing, verification, and certification, offers comprehensive services to meet these needs.

Why Use SGS for Crane Inspections?

• Global Expertise: SGS is the world’s leading company for inspection, testing, verification, and certification of all types of crane, hoisting, and lifting equipment.
• Compliance with Regulations: SGS ensures that all inspections are conducted in accordance with applicable regulations, standards, and engineering practices.
• Safety and Reliability: The primary goal is to assure the safe and proper working capability and condition of the equipment.

Scope of Inspection Services

Material-Handling Devices

• Includes cranes, derricks, fork-lifts, truck-mounted cranes, shackles, hooks, elevating platforms, and telehandlers.

Personnel Handling Devices

• Includes elevators, escalators, ski lifts, cable cars, and mobile elevating work platforms (MEWPs).

Detailed Inspection Services

Mechanical and Structural Inspections

• Checking of Brakes, Clutches, Sheaves, and Wire Rope Assemblies: Ensuring these critical components are in good condition.
• Design Studies and Calculation Reviews: Verifying that the design and calculations meet the required standards.
• Dynamic and Static Load Testing: Conducting tests to ensure the equipment can handle the intended loads.
• Inspection of Structural Load Bearing Members: Including sheaves, crane girders, rails, and columns of overhead cranes to assure structural integrity.
• Line Level and Span Crane Gantry Surveys: Ensuring the crane gantry is properly aligned and level.

Electrical and Safety Systems Inspections

• Operational Tests: Conducting tests to ensure all units are functioning properly.
• Inspection Prior to Use: Inspecting mechanical, structural, electrical, and safety systems before initial use.
• Periodic Inspections: Regular inspections to maintain equipment condition and compliance.
• Re-examination of Safety Devices: Ensuring all safety devices are in good working order.

Non-Destructive Testing (NDT)

• NDT of Load Hooks: Testing for cracks and visual inspections for distortions.
• Visual Inspections: Identifying any visible defects or distortions in critical components.

Regulatory Compliance and Maintenance

• Regulatory Compliance Assessments: Ensuring all equipment meets statutory requirements.
• Remnant Life Assessment: Evaluating the remaining lifespan of the equipment.
• Repairs Supervision: Overseeing any necessary repairs to ensure they are done correctly.

Benefits of SGS Crane Inspections

Ensuring Safety

• Identifying and eliminating potential safety hazards through thorough inspections.

Maintaining Compliance

• Ensuring all equipment meets the relevant regulatory requirements.

Maximizing Uptime

• Conducting planned inspections to minimize operational impact and maintain equipment availability.

Training and Support

• Providing training for operators of cranes and elevating platforms in accordance with local and international standards.

Conclusion

SGS offers a comprehensive range of inspection services for crane, hoisting, and lifting equipment, ensuring safety, reliability, and compliance with statutory requirements. Their expertise and global reach make them a trusted partner for maintaining the integrity and functionality of these critical pieces of equipment.

Crane Inspections and Inspections of Hoisting and Lifting …

Comprehensive Guide to Crane, Hoisting, and Lifting Equipment Inspections by SGS

Introduction

Ensuring the safety, compliance, and proper functioning of crane, hoisting, and lifting equipment is crucial for various industries. SGS, a global leader in inspection, testing, verification, and certification, offers comprehensive services to meet these needs.

Why Use SGS for Crane Inspections?

• Expertise and Experience: SGS boasts unrivaled expertise and experience in conducting professional statutory and voluntary inspections for all types of crane, hoisting, and lifting equipment.
• Global Reach: With a global presence, SGS can perform inspections across the world, adhering to local and international standards.
• Compliance: SGS ensures that inspections meet all associated regulatory requirements, helping clients comply with applicable regulations, standards, and engineering practices.

Types of Equipment Inspected

• Material-Handling Devices:
• Cranes
• Derricks
• Fork-lifts
• Truck-mounted cranes
• Shackles
• Hooks
• Elevating platforms
• Telehandlers
• Personnel Handling Devices:
• Elevators
• Escalators
• Ski lifts
• Cable cars
• Mobile elevating work platforms (MEWPs)

Scope of Inspection Services

Pre-Use and Periodic Inspections

• Inspections are conducted prior to the initial use of any mechanical, structural, electrical, and safety systems, as well as wire ropes and chains.
• Periodic inspections continue after the equipment is introduced to ensure ongoing safety and compliance.

Components Inspected

• Brakes, Clutches, Sheaves, and Wire Rope Assemblies: These critical components are checked to ensure proper functioning.
• Structural Load Bearing Members: Inspections include crane girders, rails, and columns of overhead cranes to assure structural integrity.
• Dynamic and Static Load Testing: These tests are performed to verify the equipment’s load-bearing capacity.
• Line Level and Span Crane Gantry Surveys: Ensures the crane’s gantry is properly aligned and level.
• Non-Destructive Testing (NDT): NDT is used on load hooks to expose cracks and visual inspections are conducted to find distortions.

Safety Devices and Operational Tests

• Re-examination of Safety Devices: All safety devices are re-examined to ensure they are functioning correctly.
• Operational Tests: Conducted to assure that the units are functioning properly.

Design Studies and Calculation Reviews

• SGS experts perform design studies and review calculations to ensure that the equipment is designed and built according to applicable standards.

Repairs Supervision

• Specialists supervise any necessary repairs to ensure they are done correctly and safely.

Benefits of SGS Crane Inspections

• Safety Assurance: Ensures the safe and proper working capability and condition of the crane or lifting and hoisting equipment.
• Regulatory Compliance: Helps meet all associated regulatory requirements.
• Maximize Uptime: Minimizes operational impact by maintaining the capability and availability of the equipment.
• Training and Certification: Provides training for operators of cranes and elevating platforms in accordance with local and international standards.

Additional Services

• Conformity Assessments: SGS is accredited to perform conformity assessments.
• Statutory and Voluntary Inspections: Conducts both statutory and voluntary inspections across the world.
• Remnant Life Assessments: Evaluates the remaining life of the equipment to plan for future maintenance or replacement.

Conclusion

SGS’s comprehensive crane, hoisting, and lifting equipment inspection services are designed to ensure safety, reliability, and compliance with statutory requirements. With their global expertise and extensive range of inspection services, SGS helps clients maintain the integrity and functionality of their equipment, minimizing risks and maximizing operational efficiency.

Crane equipment

Guide to Crane Equipment Services by Bureau Veritas

Introduction

Bureau Veritas offers a comprehensive range of services related to crane equipment, catering to various industries including transport infrastructure, factories, engineering, and construction. This guide outlines the scope, services, and expertise provided by Bureau Veritas in the field of crane equipment.

Service Coverage

Types of Crane Equipment

Bureau Veritas provides services for a wide variety of crane equipment, including:
– Port Equipment:
– Ship to Shore cranes
– Ship Loaders & Ship Un-loaders
– Rubber Tyred Gantry cranes
– Rail Mounted Gantry cranes
– Mobile Harbor Cranes
– Factory Equipment:
– Goliath cranes
– Portal cranes
– Workshop cranes
– Hoists
– Suspended Cranes
– Bridge cranes
– Engineering & Construction Equipment:
– Floating cranes
– Tower cranes
– Crawler Cranes
– Mobile cranes
– Construction hoists
– Fork Lifts
– Scissor Lifts
– Bridge launchers
– Conveyors
– Steel Structures:
– Bridge Steel Structures
– Factory Steel Structures
– Steel Structures for various industrial equipment

Services Provided

Design Review

Bureau Veritas conducts thorough design reviews to ensure that crane equipment meets all relevant standards and regulations. This includes:
– Structural Assessment: Evaluating the structural integrity of the crane and its components.
– Loading Cases: Assessing various loading conditions to ensure the crane can handle different types of loads safely.
– Material Strength: Verifying the strength and suitability of materials used in the construction of the crane.

Inspection of New Construction

Bureau Veritas performs inspections during the new construction phase of crane equipment to ensure compliance with industry standards. This includes:
– Quality Assurance: Supervising the manufacturing process to guarantee quality.
– Testing and Validation: Conducting tests to validate the performance and safety of the crane equipment.

Inspection of Cranes In-Service

For existing crane equipment, Bureau Veritas offers regular inspection services to maintain safety and efficiency. This includes:
– Periodic Inspections: Regular checks to identify any wear and tear or potential issues.
– Maintenance Advice: Providing recommendations for maintenance and repairs.
– Load Testing: Performing load tests to ensure the crane is operating within safe limits.

Roles and Responsibilities

Third Party Inspection (TPI)

Bureau Veritas acts as a third-party inspector to ensure the quality and compliance of crane equipment. This involves:
– Quality and Expedition Inspection: Supervising the quality and timely delivery of crane equipment.
– Compliance with Standards: Ensuring that the equipment meets all relevant industry standards and regulations.

Client’s Representative

As the client’s representative, Bureau Veritas provides inspection and supervision services to protect the client’s interests. This includes:
– Quality Assurance: Ensuring the equipment meets the client’s specifications and quality standards.
– Project Oversight: Supervising the project to ensure it is completed on time and within budget.

User’s Consultant

Bureau Veritas offers consulting services to users of crane equipment, focusing on:
– In-Service Equipment Inspection: Regular inspections to ensure the equipment remains safe and efficient.
– Consulting on Maintenance: Providing advice on maintenance and repair to extend the life of the equipment.

Manufacturer’s Consultant

For manufacturers, Bureau Veritas provides consulting and quality assurance services, including:
– Design and Manufacturing Advice: Offering expert advice on design and manufacturing processes.
– Quality Assurance: Ensuring that the manufactured equipment meets all quality and safety standards.

Conclusion

Bureau Veritas is a one-stop shop for all crane equipment needs, offering a comprehensive range of services from design review to in-service inspections. Their expertise ensures that crane equipment is safe, efficient, and compliant with all relevant industry standards. Whether you are a manufacturer, user, or client, Bureau Veritas provides the necessary support to maintain and optimize your crane equipment.

Inspections for overhead cranes and hoists

Guide to Crane Inspections and Preventive Maintenance

Introduction

Crane inspections and preventive maintenance are crucial for ensuring the safety, compliance, and productivity of overhead cranes and hoists. This guide outlines the key aspects of these processes, highlighting the types of inspections, maintenance procedures, and compliance requirements.

Types of Inspections

CSA Initial Inspection

• This inspection is required before a new crane is taken into use.
• It is also necessary if a crane has been out of operation for a long period, moved to another location, or undergone major modifications.
• The inspection checks for deficiencies and deviations according to the Occupational Health and Safety Regulations and the Canadian Standards Association (CSA-B167 Standard).

CSA Periodic Compliance Inspection

• Conducted at intervals defined by the CSA-B167 Standard, based on crane usage and operating environment.
• Inspects equipment for deficiencies and deviations to ensure compliance with health and safety regulations.

CSA Frequent Compliance Inspection

• More frequent inspections for cranes that are used extensively or in harsh environments.
• The interval is determined by the CSA-B167 Standard, taking into account the specific usage and environment of the crane.

Inspection for Cranes Not in Regular Use

• For cranes not used regularly, inspections are still necessary to ensure safety and compliance.
• The frequency of these inspections is determined based on the crane’s usage and environment, as per the CSA-B167 Standard.

Load Testing

• Verifies that the equipment can lift and move the rated load through all designed motions.
• Conducted to meet local statutory requirements, with a maximum interval of 12 months.
• An observer from the Mechanical Engineer Chamber or an accredited third-party company attends the test, and a certificate is granted upon successful completion.

Slings and Accessories Inspection

• Inspects non-maintainable load lifting attachments and accessories attached to the crane hook.
• Identifies deficiencies and deviations from local statutory safety and health regulations.
• Uses radio frequency identification (RFID) tags and a smartphone app to record and identify attachments.

Preventive Maintenance

Establishing a Preventive Maintenance Program

• A program based on the crane manufacturer’s recommendations must be established to ensure safe and proper maintenance procedures[2][3][4].

Maintenance Procedures

• Before starting adjustments or repairs, the crane must be moved to a location that minimizes interference with other operations.
• All controllers must be in the off position, and the main or emergency switch must be open and locked.
• Warning or “out of order” signs must be placed on the crane and on the floor beneath or on the hook.
• After repairs, the crane must not be operated until all guards are reinstalled, safety devices are reactivated, and maintenance equipment is removed[2][3].

Adjustments and Repairs

• Any unsafe conditions disclosed during inspections must be corrected before the crane is returned to operation.
• Adjustments and repairs must be done by designated personnel to ensure correct functioning of components such as functional operating mechanisms, limit switches, control systems, brakes, and power plants.
• Critical parts that are cracked, broken, bent, or excessively worn must be replaced promptly. Repairs by welding or reshaping are generally not recommended unless done under competent supervision and tested according to load requirements[2][3].

Compliance and Regulatory Requirements

OSHA Regulations

• Preventive maintenance must be conducted in accordance with the manufacturer’s recommendations and OSHA standards (OSHA 1910.179).
• Compliance inspections are designed to satisfy regulatory requirements established by governmental authorities, such as OSHA and local health and safety regulations[2][3].

State and Local Laws

• State laws may mandate different safety and maintenance standards. It is essential to consult applicable state laws and original equipment manufacturer specifications for further guidance.

Inspection and Reporting

MAINMAN® Inspection and Preventive Maintenance Program

• This program uses MobilTec handheld devices to capture and analyze field data, which is then uploaded to the MAINMAN® database.
• Inspectors perform multi-point visual inspections, and findings are analyzed and reported.
• Safety deficiencies are communicated and confirmed by the customer before the inspector leaves the site.
• Reports are organized from highest priority (e.g., safety) to least urgent (e.g., general maintenance) and are both OSHA and MSHA compliant[5].

Crane Report Card

• Ranks the overall condition and criticality of each crane, aiding in decision-making and tracking progress.
• Records of inspections, maintenance, and corrective actions are secured in the MAINMAN® database and available online for easy retrieval[5].

Additional Services

Operator Training

• Training is provided to improve safety and productivity while reducing maintenance costs.
• On-site training is tailored to the user’s needs, budget, and schedule[5].

Advanced Diagnostic and Analytical Services

• Includes in-depth inspections, non-destructive testing of critical load-bearing components, service life analysis, and runway and crane geometric surveys.
• Services such as equipment overhauls, rebuilds, and engineered modernizations are available to enhance safety and performance and extend the life of the equipment[5].

By following these guidelines, users can ensure their overhead cranes and hoists are maintained safely, efficiently, and in compliance with regulatory requirements.

Crane Inspection Protocols – China

Crane Inspection Protocols: A Comprehensive Guide

Introduction

Crane inspections are crucial for ensuring the safety, efficiency, and compliance of cranes with various regulatory standards. This guide outlines the key protocols and steps involved in conducting thorough crane inspections, particularly for cranes imported from or manufactured in China.

Pre-Inspection Planning

Determining Frequency and Scope

• The frequency of crane inspections depends on factors such as crane usage, environmental conditions, and manufacturer recommendations. Regular inspections can be periodic, annual, or triggered by specific events like accidents or complaints[1][2][4].

Gathering Necessary Resources

• Ensure all necessary equipment, documentation, and personnel are available. This includes inspection checklists, maintenance records, and relevant regulations or standards[1][2][5].

Pre-Inspection Preparation

Familiarization with Specifications

• Review the reference specifications of the crane model to be inspected. These specifications include load capacity, hoisting speed, trolley speed, and other essential parameters provided by the manufacturer[2].

Reviewing Maintenance History

• Examine the crane’s maintenance history to identify potential hazards and determine the scope of the inspection[2].

Visual Inspection

Initial Examination

• Begin with a visual inspection to look for any signs of damage, wear, corrosion, or defects on the crane’s structure and components. This includes inspecting wires and ropes, hooks, chains, and other critical parts[1][2][5].

Critical Components

• Pay special attention to critical components such as the boom, mast, jib, outriggers, and safety devices like limit switches and emergency stop buttons[1][2].

Functional Testing

Load Testing

• Conduct load tests to evaluate the crane’s capacity and performance under maximum load conditions. This involves applying a load equal to or exceeding the rated load of the crane to verify its hoisting, traveling, and rotating actions[2][3][4].

Stability Testing

• Perform stability tests by placing a test load under the most adverse conditions to ensure the crane’s stability without the use of runaway prevention devices and rail clip devices[3][4].

Non-Destructive Testing (NDT)

Techniques and Applications

• Use NDT techniques such as magnetic particle testing, ultrasonic testing, radiographic testing, and dye penetrant inspection to evaluate critical crane components without causing damage. These tests help identify defects or weaknesses not visible to the naked eye[2].

Post-Inspection Documentation

Inspection Reports

• Compile detailed inspection reports that include a checklist, photographs, and recommendations for any necessary adjustments, repairs, or replacements. These reports are essential for maintaining compliance and facilitating future audits[1][2].

Maintenance Records

• Keep comprehensive maintenance records, including inspection reports, repairs, maintenance activities, and certifications. This ensures ongoing compliance and helps in tracking the crane’s condition over time[1].

OSHA Compliance and Regulatory Requirements

OSHA Inspections

• Ensure that crane inspections comply with Occupational Safety and Health Administration (OSHA) regulations in the United States. OSHA inspections assess the crane’s compliance with proper maintenance, load capacity, and operational safety requirements[1].

Local Regulations

• Adhere to local and international regulatory standards such as those specified by ISO and other relevant authorities. This includes obtaining necessary qualification certificates and stamps from inspecting organizations[1][3][4].

Third-Party Inspections

Pre-Delivery Inspections

• Engage certified and independent third-party inspection agencies to conduct pre-delivery inspections (PDI) of cranes before shipment from China. These inspections should cover all key components and ensure compliance with international standards[1][2].

On-Site Inspections

• Conduct on-site inspections at the manufacturing facility or at the buyer’s location to ensure the crane meets all safety and functional requirements. This includes aesthetic, visual, and functional checks as well as measurements and size verifications[5].

Periodic and Annual Inspections

Regular Maintenance

• Conduct periodic inspections at regular intervals as recommended by the manufacturer or local regulatory authorities. Annual inspections are more comprehensive and cover all aspects of the crane’s structure, components, and systems[1][2][4].

Application for Periodic Inspection

• Apply for periodic inspections before the expiry of the qualification certificate. The crane should be prohibited from operation if the inspection is not applied for within the specified time limit or if it does not pass the inspection[3][4].

Conclusion

Crane inspections are a critical component of ensuring safety, efficiency, and compliance in various industrial settings. By following a structured approach that includes pre-inspection planning, visual and functional testing, NDT, and post-inspection documentation, users can ensure their cranes operate safely and effectively. Adhering to regulatory requirements and engaging third-party inspection services further enhances the reliability and safety of crane operations.

Crane Inspection And Certification China Manufacturer Guide

Crane Inspection and Certification: A Comprehensive Guide

Introduction

Crane inspection and certification are crucial for ensuring the safety and operational integrity of cranes in various industries. This guide outlines the key requirements, procedures, and qualifications necessary for becoming a certified crane inspector and for conducting thorough crane inspections.

Eligibility and Qualifications for Crane Inspectors

Experience Requirements

To become a certified crane inspector, an individual must have a minimum of 2,000 hours of documented work experience within a five-year period related to maintaining, inspecting, servicing, repairing, or modifying cranes[1][3].

Formal Training

Inspectors must undergo formal training every two years, which includes learning about safety measures, the proper use of tools, and how to operate cranes safely. This training also covers how to write reports and use additional equipment like meters, man-lifts, ladders, and jacks[3].

Written and Practical Exams

Candidates must pass written and practical exams specific to the type of crane they wish to inspect. For example, exams are available for Articulating Crane Inspector, Mobile Crane Inspector, Tower Crane Inspector, and Overhead Crane Inspector. Candidates must also pass the respective operator exam, although currently certified operators may be exempt from this requirement[1][3].

Types of Crane Inspections

Daily/Pre-Shift Inspections

• Conducted by a competent person before each shift.
• Includes a visual inspection of major crane components such as control mechanisms, pressurized lines, hydraulic systems, hooks and latches, wire rope and reeving, electrical apparatus, tires, ground conditions, and cab windows.
• No documentation is required, but using a daily crane inspection checklist is recommended[2].

Monthly Inspections

• Also conducted by a competent person.
• Focuses on a more detailed inspection of crane components compared to daily inspections.
• Records of these inspections should be retained for a minimum period[2].

Annual/Comprehensive Inspections

• Must be conducted by a qualified person, such as a certified crane inspector, a registered professional engineer familiar with cranes, or a qualified third-party inspector.
• Involves a thorough assessment of all critical components, including structural, mechanical, and control system components.
• The inspection must be documented, and records must be retained for at least 3-12 months[2][4].

OSHA Requirements

Competent and Qualified Persons

• Daily and monthly inspections must be conducted by a competent person who can identify existing and predictable hazards and take corrective measures.
• Annual inspections must be conducted by a qualified person who has demonstrated the ability to identify hazards and resolve problems related to crane operation[2].

Documentation and Records

• While daily inspections do not require documentation, it is best practice to use a checklist.
• Monthly and annual inspections must be documented, and records retained for the specified periods[2].

Certification Process

Application and Experience Form

• Candidates must submit a completed Experience Form detailing their pertinent experience, education, training, and references at least two weeks prior to submitting their exam candidate applications[1][3].

Written Examinations

• The certification process includes passing a Core Examination and specialty examinations for specific crane types.
• Candidates have 12 months after passing the first exam to pass the corresponding exams for additional crane types[1][3].

Certification Validity and Renewal

• Certification is valid for five years.
• Inspectors must recertify during the 12 months prior to their certifications’ expiration date.
• If a new designation is added within the final 24 months of the certification period, the certificant is exempt from recertifying for the new designation after five years[1][3].

Additional Considerations

Third-Party Inspections

• Many companies prefer or are required to engage third-party inspectors for comprehensive assessments, especially for high-risk jobs or those involving public or government contracts.
• Third-party inspectors provide neutral and unbiased assessments, ensuring compliance with safety regulations[2].

Certification Bureaus

• Organizations like the Crane Inspection & Certification Bureau (CICB) offer third-party inspections, training, and certification services for crane operators and equipment, helping companies ensure compliance with OSHA standards[2].

Conclusion

Crane inspection and certification are critical for maintaining safety and compliance in industries that use cranes. By understanding the eligibility requirements, types of inspections, OSHA regulations, and the certification process, individuals and companies can ensure that their crane inspection practices are thorough and compliant with industry standards.

Explore the problem of bridge crane inspection – Knowledge

Given that the specific website content from https://www.chinacranemanufacturer.com/info/explore-the-problem-of-bridge-crane-inspection-22375174.html is not provided, I will create a comprehensive guide based on the general best practices and guidelines for bridge crane inspections, drawing from the other sources provided.

Guide to Bridge Crane Inspections

Introduction

Bridge crane inspections are crucial for ensuring the safety, reliability, and efficiency of overhead crane operations. Regular inspections help in identifying potential issues before they lead to serious problems, thereby preventing accidents, reducing downtime, and extending the lifespan of the crane.

Types of Inspections

Daily Inspections

Daily inspections are essential and should be performed by the crane operator or workshop foreman before the crane is used.

Checklist for Daily Inspections

• Visual Inspection: Check for any visible signs of damage, corrosion, or wear on components such as hooks, slings, chains, and riggings.
• Operational Checks:
• Ensure all buttons and controls are operating smoothly.
• Verify the crane warning device is operational.
• Test the hoist to ensure it rises and descends correctly.
• Check all basic controls for proper function.
• Inspect safety latches and ensure they are in place and working properly.
• Check for any cracks in components.
• Ensure no wire has kinks, nicks, or corrosion[2][5].

“Look Up and Listen”

• Look Up: Visually inspect the crane system above eye level for any bent, deformed, or out-of-place components, including electrical wiring.
• Listen: Listen for any unusual noises such as grinding, squealing, or pops that are not part of the normal crane operation[1].

Periodic Inspections

Periodic inspections are more detailed and should be conducted at intervals depending on the crane’s usage and service class.

Frequency of Periodic Inspections

• Monthly to Annually: Depending on the crane’s service class, periodic inspections can range from monthly for severe service classes to annually for normal service classes[4][5].

Checklist for Periodic Inspections

• Structural Components:
• Check for deformities, corrosion, and unsecured members.
• Inspect connection points for loose or broken bolts and rivets.
• Mechanical Components:
• Check the proper function of electric control brakes and excessive wear of brake linings.
• Re-calibrate indicators and gauges if necessary.
• Inspect for excessive wear of chain sprockets and chain stretch.
• Electrical Components:
• Check for damaged wiring and loose wiring connections.
• Trolley and Runway Rails:
• Inspect for gaps and misalignment[2][5].

Initial Inspections

Initial inspections are mandatory before the first use of a new, altered, or used crane.

Checklist for Initial Inspections

• Functional Test: Evaluate how the crane works and ensure it is operating normally.
• Load Testing: Perform a load test to ensure the crane can handle the intended loads.
• Component Inspection: Inspect all critical crane components, including the control system, braking system, power plant, and load-sustaining structural components[5].

Inspection Procedures

Pre-Operational Checks

Before each use, the operator must perform pre-operational checks, which include:
– Visual Inspection: Check hooks, load lines, trolley, and bridge for any signs of damage or wear.
– Leakage Check: Ensure no obvious signs of air/hydraulic leakage.
– Safety Checks: Verify no lock-out tags, exposed electrical hazards, and ensure the pendant emergency stop is functional.
– Control Checks: Ensure control functions are clearly labeled and operational controls (speed and direction) are functioning correctly[1].

Detailed Structural Inspection

• Start at the Top: Begin the inspection from the top of the trolley and work down to the bridge.
• Use Appropriate Tools: Use tools like a hammer to tap on the heads of rivets and bolts to check for looseness or breakage.
• Check Elevation Profiles: Use a laser level to measure the elevation profiles of trolley rails and check for any dips or local deformation of the girder flange[3].

Importance of Inspections

Safety

Regular inspections help in identifying and addressing safety issues before they become critical, thereby preventing accidents and ensuring the safety of operators and other workers.

Performance and Reliability

Inspections improve the performance and reliability of the crane by detecting and resolving issues early, which helps in maintaining smooth operations and reducing unplanned downtime.

Compliance

Inspections ensure compliance with laws and regulations such as OSHA standards, which is essential for avoiding legal penalties and maintaining a safe working environment.

Cost Savings

Early detection of issues can save on expensive repair bills by addressing problems before they escalate into major failures.

Conclusion

Bridge crane inspections are a critical component of maintaining safe, efficient, and reliable crane operations. By following a structured inspection schedule that includes daily, periodic, and initial inspections, operators and maintenance personnel can ensure the longevity of the crane, enhance safety, and comply with regulatory standards. Regular inspections are not just a necessity but a proactive measure to prevent accidents and maintain optimal crane performance.

Dongqi Crane: Overhead Crane Hoist Manufacturer and …

Guide to DQCRANES: A Leading Crane Manufacturer and Supplier

Company Overview

• Establishment and Background: HENAN DONGQI MACHINERY CO., LTD, known as DQCRANES, is a Sino-New Zealand joint venture established on advanced European technology research and development.
• Location: The company is based in Dongqi Industry Park in Changyuan, Henan, China, often referred to as the “Cradleland of Cranes”.
• Mission: DQCRANES is committed to providing the best customized crane services to clients with high technology and economic efficiency.

Manufacturing Capabilities

Factory and Workforce

• Factory Size: The factory spans 240,000 square meters.
• Workforce: The company employs over 3600 employees, including 500 technicians and more than 70 senior engineers.
• Production Capacity: DQCRANES produces over 10,000 sets of cranes and hoists annually.

Advanced Facilities and Equipment

• Manufacturing Equipment: The factory is equipped with over 2000 sets of manufacturing and detection devices, including advanced facilities from domestic and international brands.
• Automation and Precision: The manufacturing plant is highly automated, ensuring precision, cost-efficiency, and high-quality levels.
• Key Equipment: Includes four guns air protection portal shaped weld, impeller blasting descaling machine, digital control plain drill, hoist spray paint line, and various other specialized machines.

Research and Development

R&D Center

• Advanced Technology Support: The R&D Center provides advanced technology support, enabling the manufacture of advanced lifting equipment.
• Technical Departments: The center includes gantry crane design room, bridge crane design room, hoist design room, electric apparatus design room, testing room, and craft design room.
• Technicians and Engineers: More than 60 medium and superior project technicians are dedicated to meeting personal material handling requirements.

Product Range

Types of Cranes

• Overhead Cranes: Available in various capacities, including LH type double girder and LD type single girder cranes.
• Capacity Range: From 1 ton to 50 tons.
• Gantry Cranes: Common type single girder gantry cranes applied to open warehouses or rail along for general handling.
• Capacity Range: From 1 ton to various higher capacities.
• Jib Cranes: Customizable for different material handling needs.
• Other Cranes: Includes port cranes, container cranes, and specialized cranes.

Hoists and Lifting Equipment

• European Electric Hoists: Designed and manufactured according to European standards.
• Ball Surface Worm Inner Gearing Reducers: High-quality components integrated into the cranes.

Global Reach and Certifications

International Presence

• Export Markets: DQCRANES supplies cranes to various countries and regions, including South Africa, Malaysia, United Arab Emirates, Singapore, Canada, Saudi Arabia, Philippines, Australia, United States, Thailand, United Kingdom, Indonesia, Egypt, India, Brazil, Sweden, and Taiwan.
• Global Distribution: Products are distributed throughout Southeast Asia, East Europe, Middle East, Africa, and other areas.

Certifications

• ISO9001: International quality system certification.
• ISO14004: Environment management system certification.
• OHSA18001: Occupational health and safety management system certification.
• European Standards Compliance: Components are designed and manufactured strictly according to European standards.

Quality and Craftsmanship

Skilled Workforce

• Certified and Skilled Employees: Fabrication craftsmen are certified and experienced, with many participating in continuous training to develop professional skills.
• Professional Attitudes: Employees are serious about their work, modest in learning from each other, and diligent in polishing their professional skills.

Comprehensive Annual Output

• Annual Output Value: The comprehensive annual output value reached 15 billion RMB in 2014.
• Annual Production Capacity: The company produces up to 10,000 sets of cranes per year.

Customized Services

Tailored Solutions

• Customized Crane Services: DQCRANES offers customized crane services to meet the specific material handling requirements of clients.
• High Technology and Economic Efficiency: The company ensures high technology integration and economic efficiency in all its products and services.

Conclusion

DQCRANES stands as a leading crane manufacturer and supplier, leveraging advanced European technology and a highly skilled workforce to deliver high-quality, customized lifting solutions. With a strong global presence, stringent quality certifications, and a commitment to innovation, DQCRANES is a reliable partner for various industries requiring advanced material handling equipment.

Overhead Crane Inspections

Overhead Crane Inspections: A Comprehensive Guide

Introduction

Overhead crane inspections are crucial for ensuring the safety and efficiency of crane operations. These inspections are mandated by regulatory bodies such as OSHA and ASME to prevent accidents, reduce downtime, and maintain the integrity of the equipment.

Types of Inspections

Initial Inspection

An initial inspection is required before the first use of a new, altered, or used crane. This inspection involves:
– Testing the basic crane functions
– Performing a load test
– Reviewing and replacing any damaged parts
– This process is repeated every four years after the initial inspection[2][4].

Frequent Inspections

Frequent inspections can occur at daily to monthly intervals and are essential for ongoing crane operation. These inspections include:
– Checking all functional operating mechanisms for maladjustment or excessive wear
– Inspecting air and hydraulic systems for deterioration or leakage
– Examining hooks for deformation or cracks
– Inspecting hoist chains and end connections for excessive wear, twist, or distortion
– Verifying rope reeving compliance with manufacturer’s recommendations
– Ensuring the area around the crane is clear and the crane can travel without restrictions[2][4][5].

Periodic Inspections

Periodic inspections are conducted at intervals such as bimonthly, quarterly, or annually, depending on the crane’s activity, severity of service, and work environment. These inspections involve:
– Checking for deformed, cracked, or corroded members
– Inspecting loose bolts or rivets
– Examining sheaves and drums for cracks or wear
– Inspecting worn, cracked, or distorted components like pins, bearings, and gears
– Evaluating brake system parts for excessive wear
– Testing load, wind, and other indicators for inaccuracies
– Checking for excessive wear on chain drive sprockets and chain stretch
– Ensuring proper performance of power plants and electrical apparatus parts[2][4].

Inspection Checklist Items

Pre-Operation Checks

Before each use, the following items must be checked:
– Ensure the surrounding area is clear
– Verify load ratings are displayed and visible
– Check warning labels for cleanliness and legibility
– Inspect hooks for cracks, bends, deformations, and thread damage
– Ensure the hook safety latch is functioning correctly
– Check the hook attachment and means of securing
– Inspect hoist chains and end connections for stretch, excessive wear, twist, or distortion
– Check wire cables and end connections for proper lubrication, broken strands, or excessive wear
– Ensure chains, ropes, and wire cables are correctly seated into drum and pulley grooves[3][5].

Equipment Checks

• Inspect the hoist, trolley, bridge, runway, and electric systems for loose, broken, or damaged parts
• Check the load block, sheaves, and drums for signs of deformation
• Ensure all end stops are properly placed and attached
• Check for loose items that could fall or break free during operation
• Inspect pendant controls for damage or missing/illegible labels
• Ensure pendant controls move in the correct direction and operate properly
• Check all operating mechanisms for proper adjustment or unusual sounds[3][5].

Inspector Qualifications and Documentation

Competent Inspector

Inspections must be conducted by a competent individual who is familiar with crane components and capable of identifying potential hazards. This person must also be authorized to take measures to eliminate those hazards[2][4].

Documentation

• Inspectors must sign and date the inspection log or checklist to confirm completion
• Records of all frequent and periodic inspections must be kept for at least one year
• Any deficiencies identified during the inspection must be addressed before the crane is used again. Cranes with deficiencies must be tagged “out of service” until repairs are made[1][4][5].

Maintenance and Safety Considerations

Preventive Maintenance

Regular preventive maintenance should be performed in accordance with the manufacturer’s recommendations. This includes routine checks and repairs to prevent mechanical problems and ensure safe operation[1][5].

Safety Procedures

• Only trained and authorized personnel can inspect or operate the crane
• If any issues are identified, the crane must not be used until the problems are resolved
• The crane area must be clear, and the crane must be able to travel without restrictions
• All safety equipment must be present and in use before operating the crane[3][5].

Factors Influencing Inspection Frequency

Age and Usage

• Older cranes and those with extensive usage require more frequent inspections
• Cranes that are idle for 1 to 6 months must have a documented frequent inspection before use, while those idle for more than 6 months require a periodic inspection[1][3].

Function and Capacity

• Cranes performing complex activities or handling higher-capacity loads should be inspected more frequently due to the additional components and assemblies involved[3].

By following these guidelines, companies can ensure their overhead cranes are safe, efficient, and compliant with regulatory standards, thereby protecting workers and preventing costly downtime.

Crane test and crane inspection for overhead …

Overhead Crane Commissioning and Acceptance: A Comprehensive Guide

Introduction

Overhead crane commissioning and acceptance are critical processes that ensure the safety and operational integrity of newly installed or overhauled overhead cranes. These procedures involve thorough inspections and tests to verify that the crane meets all safety and operational standards before it is put into service.

Pre-Commissioning Inspection

Preparation

Before starting the inspection, it is essential to assemble a team of experienced electricians, fitters, crane operators, and other relevant technical personnel. Here are the key steps and components to check:

Power Supply

• Cut off the power supply of the overhead crane before inspection.

Rotating Devices

• Check and ensure all rotating devices are installed correctly and can rotate freely and flexibly.
• Turn the wheel by hand to observe the movement of the output shaft and the revolving of the driven organization, ensuring stable rotation without any blockage or sticking.

Brake System

• Verify that the overhead crane brake is accurate and reliable.
• Ensure that the two brakes installed for the running mechanism of the overhead crane are consistent with each other.

Lubrication

• Check that all lubricating points are lubricated with the required lubricating oil according to the guidelines.
• Ensure the oil amount on the reducer is within the prescribed scope.

Electrical Equipment

• Inspect all electrical equipment to ensure it is in good working condition.

Crane Operation Test

The operation test of the overhead crane is divided into three main steps:

No-Load Test

• This test involves checking the crane’s functionality without any load.
• Crane Trolley Travelling Test: Verify the smooth movement of the trolley along the runway.
• Overhead Crane Travel Test: Check the crane’s movement along the runway.
• No-Load Hook Test: Ensure the hook moves freely and accurately.

Static Load Test

• This test involves applying a rated load (typically 125% of the rated load) to the crane while it is stationary.
• Prepare a testing object that is 1.25 times the overhead crane’s rated capacity.
• Use a steel wire rope or belt to lift the load.
• Ensure the crane can hold the load without any issues.

Movement Test

• This test involves moving the crane with the rated load applied.
• Check the crane’s performance during movement, ensuring smooth and stable operation.
• Verify that all safety devices, such as limit switches and brakes, function correctly.

Regular Maintenance and Inspection

Frequency of Inspections

In addition to the initial commissioning and acceptance inspections, regular inspections are mandatory to maintain the crane’s safety and functionality.

Initial Inspection

• Conducted after a new crane is installed or an existing crane is modified or repaired to ensure all safety and operational functions are intact.

Pre-Shift Inspection

• Also known as daily inspection or pre-operational check, conducted at the start of each shift to ensure the crane is in good working order.
• Check for out-of-order signs, alignment of motions with control device markings, condition of the hook and latch, wire rope, load chain, travel limits, and hoist limit switches.

Frequent Inspection

• The frequency depends on the crane’s usage and service class (normal, heavy, severe).
• For example, a class C crane may require inspections every 100 hours of use.

Periodic Inspection

• Conducted at intervals such as annually, semi-annually, or quarterly, depending on the crane’s service class.
• These inspections are more detailed and cover all components, including electrical, indicators, gages, connection points, trolley and runway rail, bumpers, and end stops.

Importance of Compliance with Standards

OSHA Regulations

• Adhere to Occupational Safety and Health Administration (OSHA) regulations, such as OSHA 1910.179, which outline the requirements for crane inspections and load testing.
• Ensure that all inspections are conducted by OSHA-certified inspectors.

CMAA and ASME Standards

• Follow standards and guidelines provided by the Crane Manufacturers Association of America (CMAA) and the American Society of Mechanical Engineers (ASME), such as CMAA 78 and ASME B30.2.
• These standards provide detailed guidelines for the inspection and maintenance of overhead cranes.

Conclusion

Commissioning and accepting an overhead crane involves a meticulous process of inspections and tests to ensure the crane’s safety and operational efficiency. Regular maintenance and inspections are crucial to maintaining these standards and preventing potential hazards. By adhering to industry standards and regulations, you can guarantee the safe and effective operation of your overhead crane.

Frequently Asked Questions (FAQs)

What are the primary regulations and standards governing bridge crane inspections in China?

Bridge crane inspections in China are governed by a series of regulations and standards to ensure safety and compliance. The Special Equipment Safety Law, promulgated in 2014, lays down comprehensive regulations on the manufacture, installation, use, and inspection of lifting machinery, including bridge cranes. Specific standards such as the “Rules for the Supervision and Inspection of Major Maintenance and Repair of Lifting Machinery” (TSG Q7016-2008), “Rules for Periodic Inspection of Hoisting Machinery” (TSG Q7015-2008), and “Safety Regulations for Lifting Appliances – Part 1: General Principles” (GB 6067.1-2010) are also crucial. These standards dictate the technical specifications and procedures for inspections to ensure the safe operation of bridge cranes.

What components and systems are typically inspected during a bridge crane inspection?

During a bridge crane inspection, several critical components and systems are thoroughly examined to ensure safety and functionality. Inspectors check the technical documents and previous inspection reports before proceeding to the site. Key components include hooks, ropes, pulleys, and other major structural elements. The inspection also covers the motor, brakes, drums, wheels, and the condition of the tracks. Additionally, the electrical system is inspected, focusing on protection measures such as voltage loss protection, zero protection, and positive and negative contactor protection, as well as the measurement of insulation and grounding resistance. Safety accessories like height limits, travel limits, and weight limiters are tested to ensure they are functioning correctly.

How often are periodic inspections required for bridge cranes in China?

Periodic inspections for bridge cranes in China are mandatory and must be conducted at specified intervals to ensure ongoing safety and compliance. Employers are required to apply for periodic inspections one month before the expiry of the qualification certificate for the inspection of fixed type cranes. If the inspection is not applied for within the time limit or if the crane does not pass the test, it is prohibited from operation. The frequency of inspections can vary based on crane usage and the operating environment, but generally, periodic compliance inspections are required at intervals not exceeding one year.

What are the consequences of non-compliance with bridge crane inspection regulations in China?

Non-compliance with bridge crane inspection regulations in China can result in significant consequences. If a crane does not undergo the required inspections or fails to meet the safety standards, it is prohibited from operation. This can lead to production downtime and financial losses. Additionally, non-compliance can result in legal penalties and fines. Small and medium-sized enterprises, especially those that do not adhere strictly to the regulations, risk facing severe repercussions, including the possibility of being shut down. Ensuring compliance is crucial to avoid major accidents and maintain a safe working environment.

Who is responsible for conducting bridge crane inspections in China, and what qualifications are required?

In China, bridge crane inspections must be conducted by qualified and authorized personnel. The inspections are typically carried out by Labor Inspection Agencies or Inspection Agencies designated by the central competent authority. Inspectors must have the necessary qualifications, certifications, and training to perform accurate assessments. They need to be knowledgeable in crane safety standards and regulations, and they must follow specific guidelines and procedures outlined in the relevant standards and regulations. The inspecting organization issues qualification certificates for inspectors, ensuring they have the educational background and working experience required to conduct thorough and reliable inspections.