L4-OCP-23.

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EXAMINATION OF POWER DRIVEN MOBILE CRANES


Rev No. 0 Date :20May2009 Page 1 of 7
1.0 Purpose
To define the procedural requirements for Examination of Power Driven Mobile
Cranes

2.0 Scope
Code of Practice for the Safe Use of Lifting Equipment: Power Driven Mobile
Cranes

3.0 Definition
Nil

4.0 Responsibility
Assurance of Quality Inspection and correct acceptance level of Lifting Equipment
by a qualified Lifting Equipment Inspector

5.0 Procedure
PRE-EXAMINATION

All paperwork relevant to the inspection shall be obtained and examined for
correctness, inspection maintenance records, and current Examination and Proof
Load Test certificates, and last inspection report.

Test certificates should be checked against manufacturers recommendations to
ensure that all rigging requirements, ropes and hooks comply with the maker's
specification.

The crane operator should be informed and a method of communication
established so that all required operations can be carried out.

The crane jib shall be lowered to enable all parts of the hoist, luffing and whip line
ropes are available for inspection.

The rope sizes shall be physically measured, recorded and checked against test
certificate the and manufacturers specification.

The crane shall then be inspected in accordance with the standard checklist, i.e.
Power Driven Mobile and crawler Crane Inspection check list

Carrier unit, tyres and wheels
Inspect tread condition, side walls for cracks, cuts and bulges.
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EXAMINATION OF POWER DRIVEN MOBILE CRANES


Rev No. 0 Date :20May2009 Page 2 of 7
Inspect wheel nuts, loose or missing.
Hub end cap seals for oil leaks, drive axles.
Inspect lights, indicators and rear stop lights and driving mirrors

Extend all out riggers and raise the crane clear of the ground.
Inspect all out riggers for hydraulic leaks, condition of hoses, damage or weld
cracks.
Inspect jack cylinders for leaks and damage piston rods.
Inspect all out rigger pads for damage and they are all of the same size.

Operator cab and superstructure.
Check that crane capacity charts are in the operators cab and are specific for the
crane.
Check that the capacities on the load chart correspond with the SLI.
Check all control levers for correct movement and are marked correctly to indicate
each function.
Check crane control valves for hydraulic leaks.
Check deck plates for damaged and missing covers and the presence of any oil
that could cause a slip hazard.
Check for that the correct amount of counter weight is fitted to the crane and is
secure.
Check the boom rest for damage, cracks or missing boom rest pads.
Check swing collector for hydraulic leaks.

Operational inspection.
With the boom on the boom rest lower the hook block to the ground so that hoist
rope is slack.

Inspect the hook for wear and that the safety latch is present and is operational,
inspect the hook swivel and cross shaft bearings.

Check the hook block sheaves for damage, worn bearings and that the sheaves
rotate freely.

Check the boom tip sheaves for the above; composite sheaves must have no
cracks or damage as they can collapse under load.

Inspect that the wedge socket termination is correct, inspect the wire rope in the
top of the wedge socket for damage, corrosion and that the wire rope clips are
fitted correctly

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EXAMINATION OF POWER DRIVEN MOBILE CRANES


Rev No. 0 Date :20May2009 Page 3 of 7
Raise and extend the boom to its maximum extension, observe the straightness of
the boom, each section when fully extended should be straight with no deflection.
Deflection of the boom can indicate boom wear pads worn.

Inspect for repairs that may have been carried out on the boom sections. All
repairs must have approval from the manufacturer of the crane and follow all there
correct procedures.

Lower the main hoist till there are only two wraps left on the hoist drum; check the
wire rope termination on the hoist drum.

With the hook block in the lowered position, using a tape measure, measure the
radius and confirm that the boom radius reading is correct on the SLI.

Rewind the hoist rope slowly back on to the hoist drum, observe the rope as it
comes down the boom looking for any damage or kinks, if damage is observed
stop the hoisting motion and inspect.

Periodically stop the hoisting motion and measure the diameter of the hoist rope in
several places and record each measurement, compare measurements to the
allowable reduction in diameter of the hoist rope.

Inspect for correct spooling of the hoist rope on the hoist drum to avoid crushing of
the hoist rope.

Retract the boom and observe for any jerking motion or vibration that could
indicate worn wear pads or lack of lubrication.

Operate the swing motion observe for smoothness of operation and that the swing
brake operates correctly.

PROOF LOAD TESTING OF MOBILE CRANES

Crane manufacturer/crane erection team, including mechanical / electrical
engineers and inspection surveyor

Before commencing any overload test a meeting must be held as regards the test
procedures, area must be barricaded to prevent entry of unauthorized personnel

Test loads should be available for each selected load of crane capacity as per the
Load chart.
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EXAMINATION OF POWER DRIVEN MOBILE CRANES


Rev No. 0 Date :20May2009 Page 4 of 7

Prior to overload test the overload protection system should be adjusted to
facilitate the overload test

The rated capacity load should be increased by 125% and the load hoisted so
each tooth of the gear train has been subjected to the overload, then lowered to
between 100mm to 200mm above the ground and the crane operated through its
permitted motions.

At least three 125% SWL tests shall be carried out in different boom length
configuration ( Shortest boom, intermediate boom and longest boom) at
appropriate radii.

All safety switches should be checked for correct operation. Any switch overridden
during the test shall be re-set and checked for correct functioning after the proof
load test.

Following the completion of the overload test, all overload protection systems
must be re-set using a calibrated load cell to confirm that the system is correct at
each radius for

Qatar Petroleum Lifting Equipment Regulations.
It is a requirement of the regulations that a 100% safe working load and line pull
test be carried out at each examination and recorded on the certificate.

The line pull, for test purposes, is calculated using the capacity of the single line
multiplied by the number of rope falls, e.g. 5.0 tonne single line pull multiplied by
four falls =a lifting capacity of twenty tonnes.

A 125% safe working load test to at least 50% of the crane maximum rated
capacity shall be conducted every Four years termed as proof load.

6.0 Associated documents

Engineering Standards and manufacturing literature :
BS7121 Part 1 1989 Code of Practice for the Safe Use of Cranes General
BS7121Part 2 2003 Inspection, Testing and Examination of Cranes
BS 7262. Automatic safe load indicators
BS EN 12385-1 Specification for ropes for general requirements
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EXAMINATION OF POWER DRIVEN MOBILE CRANES


Rev No. 0 Date :20May2009 Page 5 of 7
BS 2573. Rules for the design of crane-stress calculations
LEEA Handbook 1987 Load Rope, Hooks and Bottom blocks.
Qatar Petroleum Lifting Equipment Regulations
7.0 Revision History

Rev. Date Section Outline of Change Authorization Sign
0 First Issue First Issue M Coles




MOBILE CRANE
INSPECTION CHECK LIST


CHECK LIST NO: DATE:

OWNER: LOCATION

SURVEYOR

SERIAL NO: REGISTRATION No.

FLEET No. / ID No. MODEL

MAKE YEAR

MAX CAPACITY BASIC BOOM
LENGTH



EQUIPMENT HISTORY

PREVENTIVE MAINTENANCE
SCHEDULE

LAST CHECKING
DATE

PREVENTIVE MAINTENANCE
RECORD
LAST REPAIR

BREAKDOWN RECORD TYPE OF REPAIR

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EXAMINATION OF POWER DRIVEN MOBILE CRANES


Rev No. 0 Date :20May2009 Page 6 of 7


TYRES AND WHEELS OK NOT OK OK NOT OK
Tread condition Parking brake
Side wall / cracks Service brake
Wheel nuts
Hub end seals OUTRIGGERS
Air pressure Cylinder seals (beam)
BRAKES Cylinder seals (jacks)
Swing brake Hyd. Hoses and fittings
Hoist (main and auxiliary) Out rigger pads and retainers
System oil leaks Hyd. Oil leaks
Hoses (condition and leaks) Box sections.
Line fittings and valves Retaining pins
Holding Valves
STEERING SYSTEM (mobile) OK NOT OK BOOM OK NOT OK
All linkages Operation (Telescoping)
Hoses and Fittings Operation (Raise/lower)
Cylinders/Valves Boom sections
Rear Wheel Alignment Manual Pin extension(if any)
Swing Away (In Use)
SUPERSTRUCTURE Swing Away (stowed)
Swing motion Wear Pads
Motion control levers Heel Pins and Bushings
Duty / Load charts Lift Cylinder Pins and Bushings
Load range charts Tip Sheaves and Shafts
Crane control valves Wedge Socket connection
Swing bearing assembly
Swing gear and pinion HOIST AND ROPE
Counter weight mounting Main Hoist (Reeving)
Counter weight function Aux. Hoist (Reeving)
Clutch operation Hoist / Winch Units
Operational Guards Planetary Gear (Free Fall)
LOAD BLOCKS (Main and Aux.)
ELECTRICS Sheaves / Shafts
Gauges (Instrument Panel) Hook & Safety Latch
Wiring Swivel
Lights/Indicators/Hazard Crosshead
Light/Reversing & Audible Anchor Becket
Horn Cable Anchor (Dead End)
Over Head warning light (beacon) Head Ache Ball (Aux. hook)
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EXAMINATION OF POWER DRIVEN MOBILE CRANES


Rev No. 0 Date :20May2009 Page 7 of 7
GENERAL SAFETY DEVICES
Al Functions (Operation) Load Indicator (SLI)
Hyd. Oil Level Angle Indicator
All Panels (Superstructure) Anti Two Block System
Doors / Windows / Cowling Positive Swing Lock
Fire Extinguishers Rear Axle Locks
Engine Oil Leaks Level Indicators
Housekeeping (Cabs) Anemometer
OTHERS (to be specified)