overhead crane general use & inspection criteria the selection process for both overhead cranes...
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Overhead Crane Overhead Crane General Use & Inspection CriteriaGeneral Use & Inspection Criteria
• The Selection Process For Both Overhead Cranes & Underhung Hoists, Should Not Be Taken Lightly.
• A Significant Amount Of Pre-planning Is Needed To Place The Proper Crane Or Hoist Into The Proper Environment.
• The Key To Equipment Longevity Is Complete And Through Inspections
Different Equipment TypesDifferent Equipment Types
• Overhead Cranes• Gantry, Semi-gantry,
Bridge, Cantilever etc• Underhung Hoist
• Monorail, Underhung Bridge, Wall jib, Floor jib, etc
• Electric, Air (pneumatic), Manual powered
Duty Cycle ClassesDuty Cycle Classes
• There Differences Between Overhead and Underhung Crane Classifications
Duty Cycles - Overhead CranesDuty Cycles - Overhead Cranes
• CMAA spec 70• ASME B30.2
Duty Cycles - Overhead CranesDuty Cycles - Overhead Cranes
There are six Service Class designations for the Overhead Cranes based on their Load Class and Load Cycles.• Class A – F
• Class A – Standby or Infrequent Service• Class B – Light Service• Class C – Moderate Usage• Class D – Heavy Service• Class E – Severe Service• Class F – Continuous Severe Usage
Duty Cycles - Underhung HoistsDuty Cycles - Underhung Hoists
• CMAA spec 74• ASME B30.16
Duty Cycles – Underhung HoistsDuty Cycles – Underhung Hoists
There are four Service Class designations for the Overhead Cranes based on there Load Class and Load Cycles.• Class A – D
• Class A – Standby or Infrequent Service• Class B – Light Service• Class C – Moderate Usage• Class D – Heavy Service
Duty Cycle & Maintenance CostDuty Cycle & Maintenance Cost
• Placing Class B Crane Into A Class C Environment is Tantamount to ….
Flushing Your Maintenance Dollars Down The Toilet!
Overhead Crane InspectionsOverhead Crane Inspections
There Are Two Reasons For The Correct And Timely Performance Of Inspections, And Testing On Overhead Cranes.
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Overhead Crane InspectionsOverhead Crane Inspections
Humanitarian• Decrease The Probability
For Equipment Failures That Result In Personnel Injuries/Death.
• Provide A Safer Working Environment For All Workers.
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Overhead Crane InspectionsOverhead Crane Inspections
Economic• Increased
Productivity.• Decrease Repair &
Replacement Cost.
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LOCKOUT/TAGOUTLOCKOUT/TAGOUT
29 CFR 1910.147
Procedures Designed To Save Lives And Prevent Injuries Prior To Maintenance And Inspection Procedures
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TYPES OF STANDARDSTYPES OF STANDARDS
Regulatory Standards Federal OSHA State OSHA
• Must Be “At Least As Effective” As Federal OSHA
• 25 States & Two Territories
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TYPES OF STANDARDSTYPES OF STANDARDS
Regulatory Standards (cont.) Local Requirements Employer Practices Manufacturer
Specifications/ Recommendations
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TYPES OF STANDARDSTYPES OF STANDARDS
Consensus Standards
• ASME (American Society of Mechanical)
• CMAA (Crane Manufacturers Association of America)
• NEC (National Electric Code)
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INSPECTION REQUIREMENTSINSPECTION REQUIREMENTS
Federal - General Industry
• Initial (29 CFR 1910.179 (j) (1))
• Regular (29 CFR 1910.179 (j) (2))
• Frequent: 29 CFR 1910.179 (j) (2) and ASME B30.2
• Periodic: 29 CFR 1910.179 (j) (3) and ASME B30.2
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INSPECTION REQUIREMENTSINSPECTION REQUIREMENTS
Federal – Construction• Permanently Installed Cranes Exempted
1926.1438
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INSPECTION REQUIREMENTSINSPECTION REQUIREMENTS
Federal – Construction• Non-Permanently Installed Overhead
Cranes Used in Construction Must comply with the following:• Modified Equipment (1926.1412 (a))• Repaired/Adjusted Equipment (1926.1412 (b))• Post-assembly (1926.1412 (c))• Each Shift (1926.1412 (d))• Monthly (1926.1412 (e))• Annual/Comprehensive (1926.1412 (f))• Severe Service (1926.1412 (g))• Equipment Not In Regular Use (1926.1412 (h))
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INSPECTION PROCESSINSPECTION PROCESS
Inspections may be broken down into systems, i.e. • Mechanical
– Brakes (not including the actuators)
– Brake lining
– Gear Box(s)
– Drive (End) Trucks
– Drive Shafts, etc.
• Structural– Runway
– Rails
– Bridge Girders, etc.
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INSPECTION PROCESSINSPECTION PROCESS
Inspections may be broken down into systems, i.e. • Electrical
– Motors
– Controllers
– Brake actuators
– Buss Bars
– Electrical Cabinets, etc.
• Hydraulic/Pneumatic– Brake Actuators
– Master Cylinder, etc.
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INSPECTION PROCESSINSPECTION PROCESS
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• Drive Wheel, Gearbox & Driveshaft
Mec
han
ical
Insp
ecti
on
Mec
han
ical
Insp
ecti
on
INSPECTION PROCESSINSPECTION PROCESS
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• Brake Lining, Drums & Components
Mec
han
ical
Insp
ecti
on
Mec
han
ical
Insp
ecti
on
INSPECTION PROCESSINSPECTION PROCESS
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• Catwalk & Driveshaft Alignment & Mounting
Mec
han
ical
Insp
ecti
on
Mec
han
ical
Insp
ecti
on
INSPECTION PROCESSINSPECTION PROCESS
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• Gear Box Inspection
Mec
han
ical
Insp
ecti
on
Mec
han
ical
Insp
ecti
on
INSPECTION PROCESSINSPECTION PROCESS
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• Runway & Rails
Str
uct
ura
l In
spec
tio
nS
tru
ctu
ral I
nsp
ecti
on
INSPECTION PROCESSINSPECTION PROCESS
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• Support Column Alignment & Missing Hardware
Str
uct
ura
l In
spec
tio
nS
tru
ctu
ral I
nsp
ecti
on
INSPECTION PROCESSINSPECTION PROCESS
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• Bumpers & End Stops
Str
uct
ura
l In
spec
tio
nS
tru
ctu
ral I
nsp
ecti
on
INSPECTION PROCESSINSPECTION PROCESS
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• Confirm Square of Bumpers &Rails
Str
uct
ura
l In
spec
tio
nS
tru
ctu
ral I
nsp
ecti
on
INSPECTION PROCESSINSPECTION PROCESS
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• Wiring and Wire Terminations
Ele
ctri
cal I
nsp
ecti
on
Ele
ctri
cal I
nsp
ecti
on
INSPECTION PROCESSINSPECTION PROCESS
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• Hoist Motor
Ele
ctri
cal I
nsp
ecti
on
Ele
ctri
cal I
nsp
ecti
on
INSPECTION PROCESSINSPECTION PROCESS
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• Collectors & Conductors
Ele
ctri
cal I
nsp
ecti
on
Ele
ctri
cal I
nsp
ecti
on
INSPECTION PROCESSINSPECTION PROCESS
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• Hydraulic Brake for Leakage
Hyd
rau
lic/P
neu
mat
ic
Hyd
rau
lic/P
neu
mat
ic
Insp
ecti
on
Insp
ecti
on
REQUIREMENTS FORREQUIREMENTS FORLOAD TESTINGLOAD TESTING
Operational Tests and Rated Load Tests: Initial Installation (NEW)
After Alterations, Repairs Or Modifications
29 CFR 1910.179 (K) (1)
ASME B30.2-2.1 And 2-2.2.2
Some State OSHA’s Require Load Testing
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DOCUMENTATIONDOCUMENTATION
Required Annual
Monthly On Critical Items And Running Rope
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DOCUMENTATIONDOCUMENTATION
Recommended Documentation And Retention Time• Daily (Current And Previous Month)
• Weekly (Latest Plus Previous 4)
• Monthly/Quarterly (Latest Plus Previous Year)
• Semi-annual/Annual (Latest Plus Previous Year)
• Others (Latest Plus Previous Year)
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DOCUMENTATIONDOCUMENTATION
• Required Documentation And Retention Time Per 29 CFR 1926 Subpart CC
• Monthly (29 CFR 1926.1412 (e)(3) (document must be retained for a minimum of three months)
• Annual (29 CFR 1926.1412 (f)(7) (document must be maintained and retained for a minimum of 12 months)
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• Maintains A Complete Inspection, Maintenance, And Testing History Of The Equipment.
• Allows End User To Establish Life Cycle Cost.
• Assist In Establishing Trend Analysis.
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DOCUMENTATIONDOCUMENTATION
DOCUMENTATIONDOCUMENTATION
Can Establish Requirements For On-hand Spare Parts To Decrease Replacement Lead Time
Provides Statistical Data To Predict Mean Time Between Failure (MTBF)
Provides Statistical Data To Predict Mean Time To Repair (MTTR)
To Defend Against Liability
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STORAGE OF DOCUMENTATION STORAGE OF DOCUMENTATION
Documents should be stored in a place where they are readily available. All workers, most importantly the operator, should know where these papers are.
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SUMMARYSUMMARY
The Inspection And Testing Of Overhead Cranes And Hoists Is Crucial To Safe Workplace Conditions.
Any Kind Of Equipment Begins Depreciating After Its First Use.
A Defect In Equipment Can Bring A Quick End To The Day, In A Best-case Scenario.
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