In the bustling industrial landscape of China, ensuring the safety and efficiency of crane operations is paramount. Crane load testing stands as a critical component in this endeavor, serving as a robust safeguard against potential accidents and equipment failures. This in-depth guide delves into the intricate world of crane load testing requirements in China, providing a comprehensive overview of the regulatory standards, testing procedures, and safety protocols that govern this essential process.

Readers can expect to gain a thorough understanding of the reference specifications set by regulatory bodies and industry standards, such as those outlined by the American Society of Mechanical Engineers (ASME) and local Chinese regulations. The guide will walk you through the step-by-step process of conducting load tests, including determining load capacities, preparing test weights, and evaluating the crane’s performance under various loads.

Additionally, you will learn about the different types of tests, including load tests and stability tests, and how these are applied to verify the hoisting, traveling, and rotating actions of cranes. The importance of

Crane Inspection Protocols – China

Comprehensive Guide to Crane Inspection Protocols in China

Introduction

Crane inspections are crucial for ensuring the safety, functionality, and compliance of cranes with regulatory standards. This guide outlines the key protocols and procedures for conducting thorough crane inspections, particularly for cranes imported from or operated in China.

Pre-Inspection Planning and Preparation

Determining Inspection Frequency and Scope

• The frequency and scope of crane inspections depend on factors such as the type of crane, its usage, and the working environment. Regular inspections may be annual, semi-annual, or more frequent based on the crane’s operational conditions[2][4].

Gathering Necessary Resources

• Ensure all necessary equipment and documentation are available, including inspection checklists, maintenance records, and relevant regulations or standards. The crane should not be in operation during the inspection[1][2].

Visual Inspection

Initial Visual Examination

• Start with a thorough visual inspection to identify any signs of damage, wear, or defects. This includes examining the structure, wires and ropes, hooks, chains, and other critical components. Look for signs of cracking, corrosion, misalignment, or loose connections[1][2].

Critical Components

• Pay special attention to critical components such as wire ropes, sheaves, hooks, and load-carrying members. Ensure all safety devices, including limit switches and emergency stop buttons, are in place and functioning properly[2][4].

Functional Testing and Load Testing

Functional Testing

• Conduct functional tests to ensure the crane is operating correctly. This includes checking the mechanical, structural, electrical, and safety systems. Operational tests verify that the crane is functioning as intended[4][5].

Load Testing

• Load testing involves applying a load to the crane to evaluate its capacity and performance under maximum load conditions. For example, a load equal to 1.25 times the rated load of the crane may be used to test hoisting, traveling, and rotating actions[3][4].

Non-Destructive Testing (NDT)

NDT Techniques

• Use NDT techniques such as magnetic particle testing, ultrasonic testing, radiographic testing, and dye penetrant inspection to detect defects or weaknesses that may not be visible. These tests are crucial for evaluating critical crane components like welds, bolts, and structural elements without causing damage[2][4].

Post-Inspection Documentation and Compliance

Inspection Reports

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

Regulatory Compliance

• Ensure the crane complies with all relevant regulatory requirements, including those set by OSHA in the U.S. or local labor regulations in China. This involves assessing the crane’s compliance with proper maintenance, load capacity, and operational safety requirements[1][3].

Maintenance Records

• Keep comprehensive maintenance records, including inspection reports, repairs, maintenance activities, and certifications. This documentation is vital for demonstrating compliance and ensuring the crane remains in safe working condition[1][4].

Periodic and Completion Inspections

Periodic Inspections

• Conduct periodic inspections as required by regulatory bodies or manufacturer recommendations. These inspections may include annual or semi-annual checks and are more comprehensive than pre-operational inspections[1][3].

Completion Inspections

• For new or modified cranes, completion inspections are necessary before they are put into operation. These inspections involve submitting type inspection applications, conducting load tests, and stability tests to ensure the crane meets all safety and performance standards[3].

Training and Certification

Operator Training

• Ensure that crane operators receive training in accordance with local and international standards. This training is crucial for safe operation and compliance with regulatory requirements[4][5].

Inspector Certification

• Inspections should be conducted by certified and experienced inspectors who have the necessary expertise in crane inspections. This ensures that the inspections are thorough and comply with all relevant standards and regulations[1][2].

Conclusion

Crane inspections are a critical aspect of ensuring safety and compliance in various industries. By following a structured approach that includes pre-inspection planning, visual inspections, functional and load testing, NDT, and maintaining detailed documentation, you can ensure that your cranes are safe, reliable, and compliant with all regulatory requirements. Regular inspections and proper maintenance are key to maximizing the uptime and safety of crane operations.

Crane Inspections and Inspections of Hoisting and Lifting …

Comprehensive Guide to Crane, Hoisting, and Lifting Equipment Inspections

Introduction

Ensuring the safety, reliability, and compliance of crane, hoisting, and lifting equipment is crucial for any operation that involves these devices. Here is a detailed guide on the importance, scope, and processes involved in these inspections.

Why Conduct Crane, Hoisting, and Lifting Equipment Inspections?

• Safety: Ensuring that the equipment is in good working condition to prevent accidents and injuries.
• Regulatory Compliance: Meeting all applicable regulations, standards, and engineering practices.
• Equipment Maintenance: Maintaining the capability and availability of the equipment to maximize uptime and minimize operational impact.
• Reliability: Assuring the proper working capability and condition of the equipment.

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

Comprehensive Inspection Checklist

• Brakes, Clutches, Sheaves, and Wire Rope Assemblies: Checking these components for wear, damage, or malfunction.
• Design Studies and Calculation Reviews: Reviewing design specifications and calculations to ensure they meet current standards.
• Dynamic and Static Load Testing: Conducting load tests to verify the equipment’s load-bearing capacity.
• Structural Load Bearing Members: Inspecting all structural components, including sheaves, to assure structural integrity.
• Crane Girders, Rails, and Columns: Checking these components of overhead cranes to ensure they are in good condition.
• Line Level and Span Crane Gantry Surveys: Conducting surveys to ensure the crane’s alignment and stability.
• Non-Destructive Testing (NDT): Performing NDT on load hooks for cracks and visual inspections for distortions.
• Operational Tests: Conducting operational tests to ensure the equipment functions properly.
• Periodic Inspections: Performing regular inspections of mechanical, structural, electrical, and safety systems, as well as wire ropes and chains.
• Re-examination of Safety Devices: Ensuring all safety devices are functioning correctly.
• Regulatory Compliance Assessments: Verifying compliance with all relevant regulations and standards.
• Remnant Life Assessment: Evaluating the remaining lifespan of the equipment.
• Repairs Supervision: Overseeing any necessary repairs to ensure they are done correctly.

Frequency of Inspections

• Mobile and Self-Propelled Cranes:
• Cranes less than 6 years old: Inspections every 3 years.
• Cranes between 6 and 10 years old: Inspections every 2 years.
• Cranes over 10 years old: Inspections every year.
• Tower Cranes:
• Initial inspection before the start of service.
• Inspections every 2 years for cranes installed for extended periods.

Benefits of Professional Inspections

• Enhanced Safety: Reduces the risk of accidents and ensures a safe working environment.
• Compliance: Ensures adherence to all relevant regulations and standards.
• Equipment Longevity: Helps maintain the equipment in good condition, extending its lifespan.
• Operational Efficiency: Minimizes downtime and ensures the equipment is available when needed.
• Training and Support: Provides training for operators and support for repairs and maintenance.

Additional Services

• Pre-Purchase Inspections: Independent inspections for buyers of used cranes to evaluate condition and value.
• Rental Inspections: Inspections before and after rental periods to document the condition of the equipment.
• Valuations: Evaluating the current value of used cranes for various purposes.

Choosing the Right Inspection Service

• Expertise and Experience: Select a service provider with extensive experience and expertise in crane inspections.
• Global Reach: Opt for a provider with a global network to ensure services are available wherever needed.
• Accreditation: Ensure the provider is accredited to perform conformity assessments and statutory inspections.
• Comprehensive Reports: Choose a service that provides detailed inspection reports and supports with photos, videos, and checklists.

By following this guide, you can ensure that your crane, hoisting, and lifting equipment are safe, reliable, and compliant with all regulatory requirements.

Laws & Regulations Database of The Republic of China …

Regulations for Safety Inspection of Hazardous Machines and Equipment

General Principles

Article 1: Enactment

These regulations are enacted pursuant to the provisions of Paragraph 4 of Article 16 of the Safety and Health Act.

Article 2: Terminology

Unless otherwise defined in these Regulations, the terminology relating to dangerous machines and equipment shall follow the relevant stipulations of occupational safety and health.

Article 3: Scope of Application

These Regulations apply to dangerous machines with specified capacities. The inspection of domestic (homemade) hazardous machines/equipment shall be subject to these regulations, the Occupational Safety and Health Act, and relevant national, international, or association standards endorsed by the central governing authority.

Inspection and Certification

Article 10: Strength Calculation and Assembly Drawings

• The strength calculation basis for major structural components of fixed type cranes must be described in detail using mathematical formulas as per relevant regulations.
• Assembly drawings must include specific items such as strength calculation basis and other structural details.

Article 12: Completion Inspection

• Upon completing the installation or altering the location of fixed type cranes, the employer must submit an Application Form for Completion Inspection along with required documents, including:
• Qualification Certification for type inspection of manufacturing facilities.
• Area drawings and a fundamental summary of the installation location.
• Specification of Fixed Type Cranes.
• Strength calculation basis and assembly drawings.
• If load or stability tests cannot be conducted due to location disadvantages, the employer must submit an Application Form for the Simulated Load Test.

Article 15: Simulated Load Test

• Fixed type cranes that pass the simulated load test are exempt from the load test or safety test stipulated before the completion inspection.
• The inspecting organization issues a Report for the Results of the Simulated Load Test for qualifiers.

Reporting and Alterations

Reporting Alterations

Any alteration of the equipment or personnel stipulated in the regulations must be reported to the local inspecting organization.

Qualification and Certification

Type Inspection

• The inspecting organization issues a Qualification Certificate of Type Inspection for Manufacturing Equipment for qualifiers in the type inspection.
• Manufacturing or modification work cannot be carried out without passing the inspection, except for cranes that have already qualified through type inspection.

Compliance and Enforcement

Compliance with Standards

Hazardous machines/equipment, whether locally designed and manufactured or imported, must comply with the stipulations of the relevant standards, including material selection, mechanical properties, construction methods, and inspection methods.

Conclusion

The Regulations for Safety Inspection of Hazardous Machines and Equipment are comprehensive and stringent, ensuring the safety and compliance of dangerous machines and equipment in Taiwan. They outline detailed procedures for inspection, certification, and reporting, and emphasize adherence to national and international standards. Employers and manufacturers must carefully follow these regulations to avoid non-compliance and ensure the safe operation of hazardous machines and equipment.

Crane Load Test China Manufacturer Guide

Guide to Conducting a Crane Load Test

Introduction

Crane load testing is a critical procedure to ensure the safety, reliability, and performance of overhead and gantry cranes. This guide provides a comprehensive overview of the steps, best practices, and regulatory requirements for conducting a crane load test.

Why is Crane Load Testing Important?

Crane load testing is essential for verifying that a crane can safely handle its maximum rated load. It helps identify potential issues or weaknesses in the crane’s structure or components, ensuring the safety of the crane and its operators. Regulatory bodies like OSHA mandate these tests to prevent accidents and ensure compliance with safety standards[2][4].

Pre-Test Preparation

Inspection of the Entire Crane

Before conducting the load test, it is crucial to inspect the entire crane and its components. This includes checking for signs of wear and tear, ensuring all safety features are in proper working order, and verifying that all electrical insulation and grounding are intact[3][4].

Site Preparation

Ensure the working environment is safe and free from hazards. Check the crane rail surface to ensure it is in good condition and complies with relevant standards. Prepare firefighting and medical rescue equipment to respond promptly in case of an accident[3].

Preparation of Load Blocks

Load blocks used for testing must be marked and prepared according to specific parameters. For example, the load blocks should be set to 100% to 125% of the rated load capacity, unless otherwise recommended by the manufacturer[3][4].

Conducting the Load Test

No-Load Test

Perform a no-load test to check the mechanisms of the crane independently and in combination. This involves operating all mechanisms at different speeds, checking for unusual noises, vibrations, or looseness, and verifying the reliability of the brakes and the tightness of bolts. Measure and record the current, voltage, and other relevant parameters at each speed[3].

Static Load Test

• Lifting the Test Load: Lift the test load at the slowest speed and acceleration, without causing load shock, to about 200-300 mm above the ground. Hold the load for 10 minutes to ensure the crane can safely support it.
• Transporting the Load: Transport the test load along the full length of the bridge and runway, ensuring the load is supported by the crane and held by the hoist brake(s)[2][3][4].

Dynamic Load Test

• Lifting and Lowering: Perform dynamic load tests by lifting and lowering the load multiple times. Check the transmission mechanism for any abnormal vibrations and record the motor voltage, current, and lifting speed.
• Travel Mechanism Testing: Test the travel mechanism by moving it along the runway and bridge, recording the travel speed, voltage, and rotation speed of the travel motor[3].

Key Procedures and Requirements

Hoisting and Transporting the Load

• Hoist the test load a distance to ensure it is supported by the crane and held by the hoist brake(s).
• Transport the test load along the full length of the bridge and runway, with the trolley at the extreme ends of the crane[2][3].

Load Levels

• The test load should be at least 100% and no more than 125% of the equipment’s rated capacity, unless otherwise recommended by the manufacturer[2][4].

Safety and Monitoring

• Monitor the load indicators throughout the lifting process and take note of any fluctuations or irregularities.
• Ensure the crane can safely support the load without any signs of strain or failure[1][3].

Post-Test Procedures

Documentation

• Document and record the results of the load test for future reference and comparison. This includes any measurements, observations, and outcomes of the test[1][4].

Maintenance and Repair

• If any issues or weaknesses are identified during the test, address them promptly. This may involve repairing or replacing worn or damaged parts[1].

Regulatory Compliance

OSHA and ASME Standards

• Crane load testing must comply with OSHA standards (CFR 1910.179) and ASME standards (B30.2, B30.16, B30.17). These standards specify the procedures and requirements for load testing, including the need for tests after new installations, alterations, repairs, or modifications[2][4].

Frequency of Load Tests

• Existing crane and hoist systems should be load tested at a minimum of once every four years, or as specified by the manufacturer or regulatory standards[4].

Best Practices

Qualified Personnel

• Ensure the test is conducted by qualified and experienced personnel who are familiar with the specific crane being tested. This minimizes the risk of accidents and errors during the testing process[1].

Manufacturer Guidelines

• Follow the manufacturer’s guidelines and recommendations for load testing. These guidelines are tailored to the specific crane and ensure compliance with safety standards[1].

Safety Precautions

• Ensure all safety precautions are in place, including the presence of firefighting and medical rescue equipment. Conduct the test in a safe and controlled environment to prevent accidents[3].

By following these steps, best practices, and regulatory requirements, you can ensure the safety and reliability of your crane, protecting both the equipment and the operators.

Lifting Equipment Inspection & Certification – China

Given that the specific website you mentioned is not accessible in the search results, I will create a comprehensive guide to lifting equipment inspections based on the information from the other reliable sources provided.

Lifting Equipment Inspection Guide

Introduction

Lifting equipment inspections are crucial for ensuring the safety and compliance of workplaces that utilize such equipment. These inspections help in identifying potential hazards, preventing accidents, and maintaining the reliability of the equipment.

Types of Lifting Equipment Requiring Inspections

• Cranes
• Forklifts
• Boom lifts
• Scissor lifts
• Hoists
• Pallet jacks
• Air hoists
• Chain hoists
• Winches
• Slings, hooks, and chains[4][5].

Inspection Checklist

Visual Inspection

• Check for any visible signs of damage such as cracks, dents, bends, or corrosion.
• Inspect for loose or missing bolts, nuts, pins, or other fasteners.
• Look for signs of wear on load-bearing components, such as hooks, shackles, slings, and chains[1][2].

Operational Checks

• Test controls and mechanisms to ensure they operate smoothly and effectively.
• Verify that safety devices, such as limit switches and overload protection, are functioning correctly.
• Test emergency stop buttons and other safety features[1].

Documentation

• Review the equipment’s logbook or maintenance records to ensure it has been regularly inspected and serviced.
• Confirm that the equipment has undergone any required certifications or inspections by regulatory bodies[1].

Load Capacity and Rating

• Check that the equipment’s load rating is suitable for the intended task.
• Ensure that the load capacity markings are clear and legible[1].

Wire Rope/Chain Inspection

• Inspect wire ropes or chains for signs of wear, such as broken wires or links, kinks, or flattening.
• Check for proper lubrication and cleanliness.
• Verify that terminations (e.g., splices, end fittings) are secure and undamaged[1].

Hook and Attachment Points

• Examine hooks for deformation, cracks, or wear beyond acceptable limits.
• Ensure that latch mechanisms are functional and properly engaged.
• Inspect attachment points on the equipment for wear or damage[1].

Electrical Components (if applicable)

• Inspect power cords, plugs, and sockets for damage or wear.
• Test electrical connections and circuits for proper functioning.
• Check for signs of overheating or electrical faults[1].

Hydraulic Systems (if applicable)

• Inspect hydraulic hoses, fittings, and seals for leaks or damage.
• Check fluid levels and quality.
• Test hydraulic controls for responsiveness and smooth operation[1].

Additional Inspection Areas

Environment and Surroundings

• Assess the working environment for potential hazards, such as overhead obstacles, uneven terrain, or inclement weather conditions.
• Ensure adequate lighting for safe operation[1].

Operator Training and Awareness

• Confirm that operators are adequately trained and competent to use the lifting equipment.
• Remind operators of safe lifting practices and procedures[1].

Emergency Preparedness

• Verify the availability and functionality of emergency response equipment, such as fire extinguishers, first aid kits, and rescue gear.
• Ensure that emergency procedures are clearly posted and understood by all personnel[1].

Regulatory Compliance

• Ensure that the equipment meets all relevant regulatory requirements and standards.
• Check for any updates or changes in regulations that may affect the safe operation of the equipment[1].

Types of Inspections

In-Service Inspections

• A visual assessment of the equipment prior to each use to look for any wear or damage.
• Verify that the weight limit tag is visible and legible.
• If any defects are observed, the equipment should be removed from service and inspected by a qualified individual[4].

Periodic Inspections

• A more thorough examination of the equipment, typically conducted at specified intervals (e.g., monthly, quarterly, annually).
• These inspections should be done in a well-lit area by an inspector with the necessary training and good vision.
• The equipment should be cleaned, and all components should be inspected for wear, damage, or other issues[4].

Frequency of Inspections

The frequency of inspections depends on several factors, including:
– The amount of use the equipment gets.
– The intensity of the job it is being used for.
– The working conditions, such as contaminated or corrosive environments.
– Specific types of equipment, such as slings made from synthetic fibers and wire rope slings, which may require more frequent inspection[4].

Performing LOLER Inspections (for UK compliance)

LOLER (Lifting Operations and Lifting Equipment Regulations) inspections are mandatory in the UK and involve:
– Ensuring the strength and stability of the equipment.
– Checking the positioning and installation of the equipment.
– Verifying the marking of the lifting equipment.
– Organizing lifting operations safely.
– Conducting thorough examinations and inspections at specified intervals (e.g., bi-annually or annually).
– Keeping records of inspections and reporting any defects or unsafe operations[5].

Reporting Defects and Corrective Actions

• If any defects or issues are identified during the inspection, they should be documented and addressed promptly.
• The equipment should be removed from service until the necessary repairs or maintenance are completed.
• Ensure that all inspection findings are recorded, and corrective actions are taken as needed[1][4].

By following this comprehensive guide, you can ensure that your lifting equipment is safe, reliable, and compliant with regulatory standards, thereby reducing the risk of accidents and maintaining a safe working environment.

Crane Inspection And Certification China Manufacturer Guide

Given that the specific website you mentioned is not accessible in the search results provided, I will create a comprehensive guide based on the information from the other reliable sources on the topic of crane inspection and certification.

Crane Inspection and Certification Guide

Introduction

Crane inspections are crucial for ensuring the safety and proper functioning of cranes in various industries. This guide outlines the key requirements, procedures, and certifications involved in crane inspections.

Eligibility and Certification for Crane Inspectors

Age and Experience Requirements

To become a certified crane inspector, one must be at least 18 years old and 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].

Certification Process

• Written Examinations: Candidates must pass written exams, which include a Core Examination and specialty examinations depending on the type of crane (e.g., Mobile Crane Inspector, Tower Crane Inspector, Overhead Crane Inspector)[1][5].
• Substance Abuse Policy and Code of Ethics: Candidates must comply with the National Commission for the Certification of Crane Operators (NCCCO) Substance Abuse Policy and Code of Ethics[1].

Types of Crane Inspector Certifications

• Articulating Crane Inspector (ACI)
• Mobile Crane Inspector (MCI)
• Tower Crane Inspector (TCI)
• Overhead Crane Inspector (OCI)[1].

OSHA Crane Inspection Requirements

Competent Individual

Crane inspections must be performed by a “competent individual” who is familiar with crane components and capable of identifying potential hazards. This individual must also be authorized to take corrective measures if hazards are found[2][3].

Types of Inspections

• Frequent Inspections: Daily, weekly, or monthly inspections to test the crane’s function and proper operation.
• Includes visual inspections of major crane components such as control mechanisms, pressurized lines, hydraulic systems, hooks and latches, wire rope, electrical apparatus, tires, ground conditions, and safety devices[2][3].
• Periodic Inspections: Bimonthly, quarterly, or yearly inspections to test global structure integrity and other critical components.
• 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][3].

Initial Inspection

An initial inspection must be done prior to the first use of the crane, including any new, altered, or used crane. This inspection involves testing basic crane functions and performing a load test[2].

Conducting Crane Safety Inspections

Pre-Shift Inspections

• Conduct a visual inspection before each shift to determine if any deficiencies are present.
• Check components such as control mechanisms, pressurized lines, hydraulic systems, hooks and latches, wire rope, electrical apparatus, tires, ground conditions, and safety devices[3].

Monthly Inspections

• Perform more detailed inspections on a monthly basis to ensure the crane is in good working condition.
• Document any findings and corrective actions taken[3].

Annual/Comprehensive Inspections

• Conduct thorough inspections annually to test the global structure integrity and all critical components.
• These inspections must be performed by a qualified person and documented accordingly[3].

Documentation and Record Keeping

• Daily Inspections: While no documentation is required, using a daily crane inspection checklist is a best practice to ensure nothing is missed.
• Monthly and Annual Inspections: Records must be retained for a minimum of 3-12 months[3].

Training and Certification for Crane Inspectors

Recommended Training

• Hands-on experience working with cranes.
• Passing crane inspection training courses, including written and practical evaluations.
• Ability to present findings and perform consistent, comprehensive crane inspections[4].

Certification Bodies

• NCCCO: Offers certifications for various types of crane inspectors and requires passing written exams and complying with their policies.
• Crane Inspection & Certification Bureau (CICB): Provides third-party inspections, training, and certification services for crane operators and companies[1][3].

Conclusion

Crane inspections are critical for maintaining safety and compliance with regulatory standards. Ensuring that inspections are conducted by competent and certified individuals, following the prescribed frequencies and procedures, and maintaining proper documentation are essential for the safe operation of cranes.

Crane operation and load testing

Guide to Crane Safety Inspections and Operations

Introduction

Crane safety inspections and proper operation are crucial for ensuring the safety of personnel, preventing equipment failures, and complying with regulatory requirements. This guide outlines the key aspects of crane inspections, operation checks, and maintenance to help users understand and implement best practices.

Types of Crane Inspections

Frequent Inspections

Frequent inspections are conducted at daily to monthly intervals, focusing on components that are subject to daily wear and tear.
– Daily Checks:
– All functional operating mechanisms for maladjustment or interference with proper operation.
– Deterioration or leakage in air or hydraulic systems.
– Hooks for deformation or cracks; visual inspection daily and detailed inspection monthly.
– Hoist chains for excessive wear, twist, or stretch beyond manufacturer’s recommendations.
– Rope reeving for noncompliance with manufacturer’s recommendations.
– Functional operating mechanisms for excessive wear of components[2].

Periodic Inspections

Periodic inspections are performed at intervals ranging from 1 to 12 months, depending on the crane’s activity, severity of service, and environment.
– Inspection Items:
– Deformed, cracked, or corroded members.
– Loose bolts or rivets.
– Cracked or worn sheaves and drums.
– Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers, locking and clamping devices.
– Excessive wear on brake system parts, linings, pawls, and ratchets.
– Load, wind, and other indicators for any significant inaccuracies.
– Powerplants for improper performance or noncompliance with safety requirements.
– Excessive wear of chain drive sprockets and excessive chain stretch.
– Electrical apparatus for signs of pitting or deterioration of controller contactors, limit switches, and pushbutton stations[1].

Inspections for Idle and Standby Cranes

• Cranes Idle for 1 Month to 6 Months:
• Inspect conforming with requirements of paragraphs (j)(2) and (m)(2) before placing in service.
• Cranes Idle for Over 6 Months:
• Complete inspection conforming with requirements of paragraphs (j)(2) and (3) and paragraph (m)(2) before placing in service.
• Standby Cranes:
• Inspect at least semi-annually in accordance with requirements of paragraphs (j)(2) and (m)(2)[1].

Pre-Operation Safety Checks

Daily and Pre-Shift Inspections

Before operating a crane, several safety checks must be performed:
– Test Run:
– Test the crane the full length of the runway and bridge span to ensure no obstructions.
– Ensure all motion travel speeds match designed specifications.
– Control and Motion Tests:
– Turn the crane off, engage the hoist “up” switch, and ensure the hook does not rise.
– Engage all other motions to ensure no movement is possible.
– Test the upper limit switch and ensure all travel and hoist motions match control labeling directions.
– Wire Rope and Limit Devices:
– Check that the wire rope is properly seated and not twisted, kinked, or damaged.
– Ensure all limit devices are functioning properly.
– Operator Training:
– Train all crane operators on the functionality of the crane.
– Inspections and Maintenance:
– Perform inspections and maintenance as required by local regulations and recommended by the Original Equipment Manufacturer (OEM)[3].

Detailed Daily Inspection Points

Crane and Hoist Inspection

• Hook Inspection:
• Check for visually identifiable twist, cracks, nicks, gouges, corrosion, traces of welding, deformation of the throat opening, and wear on the saddle or load bearing point.
• Rotate the hook horizontally to ensure no abnormal sounds.
• Ensure the hook hangs perpendicularly; if not, a more comprehensive inspection is needed.
• Test the safety latch to ensure it works properly.
• Wire Rope and Chains:
• Check for signs of deformation, damage, or excessive wear.
• Control Devices:
• Ensure control device enclosures, button rubbers, and cables show no damages.
• Test all crane motions to ensure they correspond to control device markings.
• Test the emergency stop button to ensure the crane does not move when using direction controls.
• Warning and Indicating Devices:
• Check for any visual damages and test each device for correct operation.
• Operating Area:
• Ensure the floor/ground is free of dangerous holes, bumps, or slippery spots.
• Check that lighting conditions are adequate for safe work.
• Ensure no obstacles, oil spots, or other hazards within the operating area[4].

Compliance and Preventive Maintenance

Compliance Inspections

• Regularly scheduled inspections to verify compliance with local regulations and highlight safety and production issues.
• Inspections include checking for deficiencies and deviations from local statutory safety and health regulations.

Preventive Maintenance

• Programs designed to improve equipment safety and productivity through preventive maintenance inspections, compliance inspections, and routine maintenance.
• Document safety and production risks and make recommendations to address these concerns[5].

Load Testing and Other Special Inspections

Load Testing

• Verifies that the equipment is capable of lifting and moving the rated load through all designed motions.
• Conducted to meet local statutory requirements, with a frequency not exceeding 12 months.

DWP Calculation

• An estimate of the accumulated duty of a crane and assessment of its remaining life.

Slings and Accessories Inspection

• Inspects non-maintainable load lifting attachments and accessories attached to the crane hook during operation.
• Uses radio frequency identification (RFID) tags to record load lifting attachment inspection data[5].

By following these guidelines, users can ensure that their crane operations are safe, compliant with regulations, and maintained to the highest standards, thereby reducing the risk of accidents and equipment failures.

Regulations for Safety Inspection of Hazardous Machines …

Regulations for Safety Inspection of Hazardous Machines and Equipment

General Principles

Article 1: Enactment

These regulations are enacted pursuant to the provisions of Paragraph 4 of Article 16 of the Safety and Health Act.

Article 2: Terminology

Unless otherwise defined in these Regulations, the terminology relating to dangerous machines and equipment shall apply as specified in the relevant stipulations of occupational safety and health.

Article 3: Scope of Application

These Regulations shall apply to the dangerous machines with the specified capacity. The inspection of domestic (homemade) hazardous machines/equipment shall be subject to this regulation, the Occupational Safety and Health Act, and relevant national, international, or association standards endorsed and designated by the central governing authority.

Inspection and Certification

Article 10: Strength Calculation and Assembly Drawings

• The strength calculation basis for the major structural components of fixed type cranes must be described in detail using mathematical formulas as per relevant regulations.
• The assembly drawings must include specific items such as strength calculation basis and other necessary details.

Article 12: Completion Inspection

• Upon completing the installation of fixed type cranes or altering their location, the employer must submit an Application Form for Completion Inspection of Fixed Type Cranes along with required documents, including:
• Qualification Certification for the type inspection of manufacturing facilities.
• Area drawings and a fundamental summary of the installation location.
• Specification of Fixed Type Cranes.
• Strength calculation basis and assembly drawings.

Simulated Load Test

• If the load test or stability test cannot be carried out due to the location or other reasons, the employer must entrust the manufacturer to fill out the Application Form for the Simulated Load Test of Fixed Cranes.
• The inspecting organization will issue the Report for the Results of the Simulated Load Test.
• Fixed type cranes qualified in the simulated load test are exempt from the load test or safety test stipulated before the completion inspection.

Reporting and Alterations

Article 3: Reporting Alterations

Any alteration of the equipment or personnel stipulated must be reported to the local inspecting organization.

Article 12: Notification of Changes

The employer must notify the inspecting organization of any changes in the installation or location of the fixed type cranes.

Certification and Qualification

Qualification Certificate

The inspecting organization shall issue the Qualification Certificate of Type Inspection for Manufacturing Equipment for qualifiers in the type inspection.

Exemptions

Fixed type cranes that have already qualified through the type inspection are exempt from certain inspections, but this does not apply to all types of cranes.

Compliance and Enforcement

Article 3: Compliance with Standards

Hazardous machines/equipment, whether directly imported or locally designed and manufactured, must comply with international standards based on contractual agreements and relevant stipulations.

Article 12: Mandatory Inspections

Manufacturing or modification work shall not be carried out without passing the inspection, except for cranes that have already qualified through the type inspection.

Conclusion

The Regulations for Safety Inspection of Hazardous Machines and Equipment are comprehensive and stringent, ensuring the safety and compliance of dangerous machinery in various settings. They outline detailed procedures for inspections, certifications, and reporting, and emphasize the importance of adhering to national, international, and association standards. Employers and manufacturers must carefully follow these regulations to avoid non-compliance and ensure the safe operation of hazardous machines and equipment.

Crane Load Test using Water Weight Bags

DOOWIN Underwater Lift Bags and Water Weight Bags: A Comprehensive Guide

Company Overview

DOOWIN, or Qingdao Doowin Rubber and Plastic Co., Ltd., is a leading Chinese manufacturer specializing in underwater lift bags, marine salvage bags, water-filled proof load bags, and various other inflatable buoyancy units. The company is known for its commitment to quality, innovation, and customer satisfaction.

Product Range

Underwater Lift Bags

• Types: DOOWIN offers several types of underwater lift bags, including open bottom parachute type, totally enclosed type, pillow type, and customized shapes.
• Open Bottom Parachute Type: Can be used at any depth for marine salvage or refloating objects from the seabed. This design is safer due to its open bottom[4].
• Totally Enclosed Type: Has a cover at the bottom that can be opened according to the salvage project’s conditions[4].
• Applications: These bags are used for marine salvage, diving work, pipeline laying, and buoyancy support.
• Capacity: The buoyancy capacity ranges from 50kg to 50ton[1][3][4].
• Materials: Made from heavy-duty PVC coated polyester fabric, ensuring durability and strength[4].
• Certifications: Manufactured in compliance with IMCA D016 standards, with a safety factor of 5:1[1][3][4].

Water Weight Bags

• Types: Include crane test water weight bags, low headroom load test water bags, deck load test water weights, lifeboat load test water bags, and davit load test weights.
• Applications: Used for proof load testing of cranes, lifeboats, davits, and other lifting equipment.
• Capacity: Load testing capacity ranges from 1ton to 100ton[1][3][5].
• Certifications: Comply with LEEA 051 standards, with a safety factor of 6:1[2][3].

Pipeline Buoyancy Bags

• Applications: Used for pipeline laying work and buoyancy support.
• Capacity: Lift capacity ranges from 250kg to 50ton[3].

Lifeboat Testing Bags

• Design: Professionally designed with air valves, relief valves, and hands.
• Safety Factor: 6:1 safety factor.
• Capacity: Standard capacity ranges from 100kg to 1ton[3].

Quality Assurance and Certifications

• ISO 9001:2008: All production processes are controlled under this quality management system.
• IMCA D016 and LEEA 051: Products comply with these international standards for underwater lift bags and crane test water bags, respectively[1][2][3].
• Third-Party Certifications: Products are inspected and approved by third-party organizations such as BV, ABS, LR, and SGS[1][2][4].
• Dynamic Drop Test: Water weight bags are certified with a 6:1 safety factor through dynamic drop tests[2].

Materials and Construction

• Heavy-Duty Materials: Products are made from high-quality PVC coated polyester fabric and TPU coating fabric, ensuring durability and performance[2][4].
• Welding Technology: Seams are welded using high-frequency welding technology without the use of glue[4].

Accessories and Design

• High-Quality Accessories: Accessories such as shackles, master links, water hoses, lifting belts, and quick connectors are used to ensure overall performance[2].
• Reasonable Structure Design: Complex and strict design and testing ensure the best and reasonable water-pressure distribution[2].

Applications and Industries

• Marine Salvage: Used for refloating and salvaging operations.
• Commercial Diving: Utilized for diving operations.
• Pipeline Laying: Provide buoyancy support for pipeline work.
• Offshore Projects: Used for proof load testing of cranes, hoists, and other lifting equipment.
• Water Storage: Includes various water tank bladders for potable and non-potable water.
• Other Industries: Serve industries such as oil and gas, fire fighting, and construction[1][3][4].

Client Testimonials and Partnerships

• Client Feedback: DOOWIN has received positive feedback from clients such as MODEC (Singapore), China Harbour, and McDERMOTT, praising the quality and reliability of their products[2][3][4].
• Industry Associations: DOOWIN is a member of the China Diving & Salvage Contractors Association[2].

Core Values and Philosophies

• Honesty, Hard Work, Love for Others, Responsibility: These core values are integrated into all departments and management standards.
• People Oriented, Innovation: The company philosophy emphasizes a people-oriented approach and continuous innovation[1][2].

By adhering to strict quality standards, using advanced production technologies, and maintaining a strong commitment to customer satisfaction, DOOWIN has established itself as a leading supplier of underwater lift bags and water weight bags in the industry.

Overhead Crane load testing project video

Overhead Crane Load Testing: A Comprehensive Guide

Importance of Load Testing

Load testing is a crucial procedure for ensuring the safety, reliability, and performance of overhead cranes. It verifies that the crane can safely handle its maximum rated load and identifies any potential issues or weaknesses in the crane’s structure or components.

When to Conduct Load Testing

• New Cranes: Load testing is mandatory before putting a new overhead crane into operation to ensure it meets design specifications and safety standards[3][4][5].
• Altered or Repaired Cranes: Cranes that have been modified, repaired, or re-rated must undergo load testing to validate their new or altered configurations[3][4][5].
• Periodic Testing: Existing crane systems should be load tested once every four years to maintain compliance with safety regulations and standards[2][3][4].

Pre-Test Procedures

Inspection of the Crane

Before conducting the load test, it is essential to inspect the entire crane and its components thoroughly. This includes:
– Checking for any signs of wear and tear.
– Ensuring all safety features are in proper working order.
– Verifying that the crane rail surface is in good condition and complies with relevant standards[1][5].

Site Preparation

• Ensure the working environment is safe and free from hazards.
• Prepare firefighting and medical rescue equipment in case of an emergency.
• Align the crane mechanisms and ensure they are reliable before the test run[5].

Preparation of Load Blocks

• The load blocks used for testing must be marked and prepared according to the test parameters.
• Typically, the test load should be at least 100% to 125% of the rated lifting capacity of the crane[3][4][5].

Conducting the Load Test

No-Load Test

• Operate all mechanisms independently and then together, including one-way and two-way movements at all levels.
• Check for smooth operation, unusual noise, vibration, or looseness.
• Verify the reliability of the brakes and the tightness of the bolts.
• Measure and record current and voltage at each speed[5].

Static Load Test

• Conduct the static load test after the no-load test is completed and all hazards have been eliminated.
• Lift the test load at the slowest speed and slowest acceleration without causing load shock.
• Lift the test load about 200-300 mm above the ground and hold it for 10 minutes.
• Check the crane mechanisms and steel structure for any signs of strain or failure[5].

Dynamic Load Test

• Hoist the test load a distance to ensure it is supported by the crane and held by the hoist brake(s).
• Transport the test load by means of the trolley for the full length of the bridge.
• Transport the test load by means of the bridge for the full length of the runway in both directions.
• Lower the test load and stop and hold it with the brake(s)[4].

Monitoring and Recording

• Monitor the load indicators throughout the lifting process and take note of any fluctuations or irregularities.
• Document and record the results of the load test, including any observations and measurements.
• File the load test reports where they can be accessed by personnel in charge[1][3][4].

Best Practices

Qualified Personnel

• Ensure the test is conducted by qualified and experienced personnel familiar with the specific crane being tested[1].

Manufacturer Guidelines

• Follow the manufacturer’s guidelines and recommendations for load testing, as these are tailored to the specific crane[1].

Safety Compliance

• Adhere to safety standards and regulations such as OSHA CFR 1910.179 and ASME B30.2 to ensure a safe and compliant load testing process[3][4].

Post-Test Procedures

• After the testing is complete, slowly lower the crane to the ground and monitor the load indicators for any anomalies.
• Perform a post-test inspection to ensure that no damage occurred during the testing process[1][5].

By following these steps and best practices, you can ensure the safety, reliability, and performance of your overhead crane, thereby protecting your workers and maintaining operational efficiency.

Frequently Asked Questions (FAQs)

What is the purpose of crane load testing in China?

Crane load testing in China is conducted to ensure the safe and efficient operation of cranes. The primary purpose is to verify that the crane can handle its rated load capacity without compromising its structural integrity or safety mechanisms. This testing is crucial for certification and compliance with local regulations and safety standards, such as those set by labor inspection authorities. It helps identify any manufacturing defects, installation errors, or potential safety hazards, thereby ensuring the crane operates reliably and safely.

What are the key steps involved in conducting a crane load test in China?

The process of conducting a crane load test in China involves several critical steps. First, the maximum load capacity of the crane must be determined from the manufacturer’s documentation or load charts. Next, a load test weight equivalent to this capacity, often 1.25 times the rated load (or 50 tons plus the rated load if it exceeds 200 tons), is prepared and securely attached to the crane’s hook or lifting mechanism. The crane is then subjected to this load to test its hoisting, traveling, and rotating actions, as well as the traveling action of the trolley. The test is conducted for a predetermined period to simulate actual working conditions and evaluate the crane’s stability and endurance.

What are the different types of tests included in crane load testing in China?

In China, crane load testing encompasses several types of tests to ensure comprehensive safety and performance evaluation. The load test itself involves applying a load of 1.25 times the rated load to verify the crane’s hoisting, traveling, and rotating functions. Additionally, a stability test is performed by placing a load of 1.27 times the rated load on the hoisting equipment under the most adverse conditions regarding stability, without using runaway prevention devices and rail clip devices. These tests are designed to assess the crane’s structural integrity, stability, and overall safety under various operational conditions.

Can crane load tests be exempted under certain conditions in China?

Yes, under specific conditions, crane load tests can be exempted in China. If the load test or stability test cannot be carried out due to disadvantageous location conditions or other reasons, the employer can entrust the manufacturer to conduct a simulated load test. The manufacturer must fill out the Application Form for the Simulated Load Test of Fixed Cranes and submit it along with the crane’s specifications to the inspecting organization. Cranes that pass this simulated load test may be exempt from the load test or safety test requirements before the completion inspection. Additionally, cranes with valid qualification certificates from previous inspections may also be granted exemptions if they remain in intact condition and are not dismantled and reassembled.

What documentation and certification are required after completing a crane load test in China?

After completing a crane load test in China, it is necessary to obtain and maintain specific documentation and certification. The inspecting organization issues a Report for the Results of the Load Test or Stability Test, and for cranes that pass these tests, a qualification mark is stamped on the crane’s specification. This qualification mark is signed by the labor inspector and a copy of the specification is delivered to the applicant. The qualification mark must be printed, painted, or posted on a distinct part of the crane for identification. Additionally, a certification may be awarded if the crane meets all required specifications, providing evidence that the crane has been thoroughly inspected and deemed safe for operation.