Inspection procedure for hoists in regular service is divided into two general classifications as outlined in ASME B30.16. Inspection procedure for trolleys in regular service is also divided into two general classifications as outlined in ASME B30.11 or ASME B30.17. These two general classifications are based upon the intervals at which inspections should be performed. The intervals are also dependent upon the nature of the critical components of the equipment, and the degree of exposure of equipment components and parts to wear and deterioration. The degree of exposure is dependent upon hoist activity, severity of hoist service, and the environment of hoist location. These two general classifica- tions of inspection are designated as frequent and periodic.
FREQUENT INSPECTION: Frequent inspections are visual and audio external inspections and examinations by the operator or other designated personnel with no records required. Usual or mini- mum inspection intervals are as follows:
Normal service - monthly
Heavy service - weekly to monthly Severe service - daily to weekly
PERIODIC INSPECTION: Periodic inspections are visual, hands-on, and audio external inspec- tions and examinations by designated personnel making written records of external conditions to pro- vide the basis for a continuing evaluation of the hoist and components. If the external inspection indicates the need, disassembly may be required to make a more detailed inspection and examination.
Usual or minimum inspection intervals are as follows:
Normal service - annually Heavy service - semiannually Severe service - quarterly
THE INSPECTION INTERVALS LISTED ABOVE ARE THE USUAL OR MINIMUM RECOM- MENDATIONS AND ARE FOR REFERENCE PURPOSES ONLY. THEY ARE BASED ON SINGLE SHIFT OPERATION UNDER NORMAL OPERATING CONDITIONS AND NORMAL ENVIRONMENTAL CONDITIONS. ACTUAL OPERATING AND ENVIRONMENTAL CON- DITIONS SHOULD BE REVIEWED BY A QUALIFIED PERSON AND APPROPRIATE IN- SPECTION INTERVALS ESTABLISHED ON THE RECOMMENDATIONS OF THE QUALI- FIED PERSON.
FREQUENT AND PERIODIC HOIST INSPECTIONS
Definitions of service taken from ASME B30.16 for hoists and from ASME B30.11 and B30.17 for trolleys are as follows:
Normal service involves operation of the equipment with randomly distributed loads within the rated load limit, or uniform loads less than 65% of rated load, for not more than 15% of the time of a single work shift for manually-operated equipment and not more than 25% of the time of a single work shift for electric-powered equipment.
Heavy service involves operation of the equipment within the rated load limit that exceeds normal service.
Severe service involves operation of the equipment in normal service or heavy service with abnormal operating conditions.
The ASME standards state: A hoist or crane that is not in regular service, that has been idle for a period of one month or more, but less than one year, shall be inspected in accordance with the requirements for frequent inspection before being placed into service.
The ASME standards state: A hoist or crane that is not in regular service, that has been idle for a period of one year or more, shall be inspected in accordance with the requirements for periodic inspection before being placed into service.
Recommended items to be checked for deficiencies or damage during frequent and periodic inspec- tions are outlined in Table 3 for hand chain manually operated hoists; and in Table 4 for electric pow- ered or air powered hoists. Also, refer to the manual furnished by the manufacturer of the hoist for additional information on frequent and periodic inspections.
Detailed inspection procedures for some items should be found in specific sections of the manual furnished by the manufacturer with the equipment. Inspections may be performed with the hoist in its normal location and do not require that the hoist be disassembled. Covers and other items normally supplied to allow inspection of components should be opened or removed for these inspections. Any deficiencies or damage such as those listed in Tables 3, page 31, or 4, page 33, shall be examined by a designated person to determine whether they constitute a hazard, or whether any disassembly is neces- sary for a more detailed inspection. The hoist operator should make observations during regular opera- tion for any deficiencies or damage that might appear between inspections.
All Functional Operating Mechanisms
Unusual Sounds
Brake System
Oil or Grease Leakage
Hook
Hook Latch
Load Chain
Hand Chain
Reeving
Lubricant Levels
(For detailed inspection pro- cedures, refer to manual fur- nished by the hoist manufac-
Check for maladjustment or damage that inter- feres with proper operation, and unusual sounds.
Check for any unusual sounds from the hoist and hoist mechanism while operating the hoist.
Check for proper operation and that the hoist motion does not have excessive drift and that stopping distance is normal.
Check for any sign of oil or grease leakage on the hoist and on the floor area beneath the hoist.
Check for damage, cracks, nicks, gouges, deformat of the throat opening, wear on saddle or load bearing point, and twist.
Check that hook latch, if provided, is not miss- ing and that it operates properly.
Check for nicks, gouges, and any type of defor- mation or damage to the chain. Check for lubri- cation of the load chain.
Check for nicks, gouges, and any type of defor- mation or damage to the chain. Check for open links or open connecting links.
Check that load chain is properly reeved and that load chain is not kinked or twisted and that load chain parts are not twisted about each other.
Check whether lubrican must be added or re- placed.
TABLE 3
HAND CHAIN MANUALLY OPERATED HOISTS FREQUENT AND PERIODIC INSPECTIONS
(REFER ALSO TO THE MANUAL FURNISHED BY THE HOIST MANUFACTURER)
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
FREQUENT AND PERIODIC HOIST INSPECTIONS
INSPECTION
ITEM FREQUENT
INSPECTION PERIODIC
DESCRIPTION OF RECOMMENDED INSPECTION CHECK POINTS
FREQUENT AND PERIODIC HOIST INSPECTIONS
Load Sprockets, Hand Chain Sprokets, and Chain Guides Load block, Suspension, and Frame
Chain Attachments, Clevises, Yokes, Suspension Bolts, Shafts, Gears, Bearings, Pins, Rollers, and Locking and Clamping Devices
Supporting Structure, and Trolley
Trolley Wheels
Hook Retaining Devices
Brake Mechanism
Load Chain End Connection
Capacity Warning and Safety Labels
Check for cracks, damage to grooves, and ex- cessive wear.
Check for cracks, damage, and distortion.
Check for wear, corrosion, damage and distor- tion.
Check for cracks, damage, and distortion.
Check for flat spots, damage, and excessive wear.
Check for damage to hook retaining nuts, col- lars, pins, welds, rivets, etc. used to secure hooks.
Check for worn, glazed, or oil-contaminated fric- tion discs; worn pawls, cams or ratchet; corroded, stretched, or broken pawl springs.
Check for looseness, cracks, damage, and dis- tortion.
Check that capacity, warning and other safety labels are not missing and that they are legible.
TABLE 3 (CONTINUED)
HAND CHAIN MANUALLY OPERATED HOISTS FREQUENT AND PERIODIC INSPECTIONS
(REFER ALSO TO THE MANUAL FURNISHED BY THE HOIST MANUFACTURER)
•
•
•
•
•
•
•
•
• INSPECTION
ITEM FREQUENT
INSPECTION PERIODIC
DESCRIPTION OF RECOMMENDED INSPECTION CHECK POINTS
All Functional Operating Mechanisms
Unusual Sounds
Control Devices
All Limit Switch Devices Brake System
Oil or Grease Leakage
Air Lines, Valves, Etc.
Hook
Hook Latch
Load Chain
Wire Rope
Check for maladjustment or damage that inter- feres with proper operation and unusual sounds.
Check for any unusual sounds from the hoist and hoist mechanism while operating the hoist.
Check for improper operation.
Check for maladjustment or malfunction.
Check for proper operation and that the hoist motion does not have excessive drift and that stopping distance is normal. Check for worn, glazed, or contaminated friction discs; worn pawls, cams or ratchets; corroded, stretched, or broken springs.
Check for any sign of oil or grease leakage on the hoist and on the floor area beneath the hoist.
Check for leakage.
Check for damage, cracks, nicks, gouges, defor- mation of the throat opening, wear on saddle or load bearing point, and twist.
Check that hook latch, if provided, is not miss- ing and that it operates properly.
Check for nicks, gouges, and any type of defor- mation or damage to the chain. Check for lubri- cation of load chain.
Check for broken wires, broken strands, wear, twist, kinks, distortion of rope structure, end con- nections, rope clamps, deposits of foreign mate- TABLE 4
ELECTRIC POWERED AND AIR POWERED HOISTS FREQUENT AND PERIODIC INSPECTIONS
(REFER ALSO TO THE MANUAL FURNISHED BY THE HOIST MANUFACTURER)
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
FREQUENT AND PERIODIC HOIST INSPECTIONS
INSPECTION
ITEM FREQUENT
INSPECTION PERIODIC
DESCRIPTION OF RECOMMENDED INSPECTION CHECK POINTS
•
Lubrican Levels
(For detailed inspection pro- cedures, refer to manual fur- nished by the hoist manufac- turer.)
Fastening Devices (bolts, nuts, pins, etc.)
Load Sprockets, Chain Guides, Drums, and Sheaves Load block, Suspension, and Frame
Chain or Rope Attachments, Clevises, Yokes, Suspension Bolts, Shafts, Gears, Bear- ings, Pins, Rollers, and Lock- ing and Clamping Devices Supporting Structure, and Trolley
Trolley Wheels
Hook Retaining Devices
Load Chain or Wire Rope End Connection
Electrical Apparatus Contactors
Wiring and Fittings
Check whether lubricant must be added or re- placed.
Check for items not properly secured (tightened), damaged, or missing. (Torque bolts per hoist manufacturer’s recommended values.)
Check for cracks, damage to grooves, and ex- cessive wear.
Check for cracks, damage, and distortion.
Check for wear, corrosion, damage and distor- tion.
Check for cracks, damage, and distortion.
Check for flat spots, damage, and excessive wear.
Check for damage to hook retaining nuts, col- lars, pins, welds, rivets, etc. used to secure hooks.
Check for looseness, cracks, damage, and dis- tortion.
Check for pitting, deterioration, and wear.
Check for pitting, deterioration, wear, and im- proper operation.
Check for loose connections, and abraded, cut , TABLE 4 (CONTINUED)
ELECTRIC POWERED AND AIR POWERED HOISTS FREQUENT AND PERIODIC INSPECTIONS
(REFER ALSO TO THE MANUAL FURNISHED BY THE HOIST MANUFACTURER)
•
•
•
•
•
•
•
•
•
•
•
FREQUENT AND PERIODIC HOIST INSPECTIONS
INSPECTION
ITEM FREQUENT
INSPECTION PERIODIC
DESCRIPTION OF RECOMMENDED INSPECTION CHECK POINTS
•
Capacity, Warning and Safety Labels
Control Device Markings
Check that capacity, warning and other safety la- bels are not missing and that they are legible.
Check that function labels are not missing or il- legible.
TABLE 4 (CONTINUED)
ELECTRIC POWERED AND AIR POWERED HOISTS FREQUENT AND PERIODIC INSPECTIONS
(REFER ALSO TO THE MANUAL FURNISHED BY THE HOIST MANUFACTURER)
•
•
FREQUENT AND PERIODIC HOIST INSPECTIONS
INSPECTION
ITEM FREQUENT
INSPECTION PERIODIC
DESCRIPTION OF RECOMMENDED INSPECTION CHECK POINTS
Records of the condition of critical components such as wire rope, load chain, hooks, and brakes ob- served during frequent and periodic inspections should be established. This record should also record replacement, maintenance, and repair information. Use of this recorded information should be a basis for the establishment of a preventative maintenance program for replacement of wearing components on a regular basis, thereby eliminating or reducing unscheduled downtime situations.
IF ANY DAMAGE OR MALFUNCTIONS ARE NOTED BY THE FREQUENT OR PERIODIC INSPECTION ITEMS OF TABLES 3 OR 4, THE HOIST SHALL BE TAGGED WITH AN OUT- OF-ORDER SIGN AND SHALL NOT BE RETURNED TO REGULAR OPERATION UNTIL MAINTENANCE AND REPAIR OF THE DAMAGE OR DEFICIENCIES FOUND DURING THE INSPECTION HAVE BEEN CORRECTED.