Overhead Crane General Use & Inspection Criteria The Selection Process For Both Overhead Cranes & Underhung Hoists, Should Not Be Taken Lightly. A Significant.

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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