Inspections

Pre-operational Inspection

This is a visual inspection and functional test that should be carried out by a competent crane operator prior to each shift during which the crane is to be used.

Routine Inspection and Maintenance

Includes visual inspection of most components of the crane, functional tests of all motions and lubrication of all moving parts.

Must be carried out by a competent crane technician who must provide a written report to the crane owner/operator on completion of the inspection.

Minimum frequency quarterly.

Periodic Inspection

A more comprehensive inspection and service than the Routine Inspection and Maintenance.

Must be carried out by a competent crane technician who must provide a written report to the crane owner/operator on completion of the inspection.

Minimum frequency annually.

Major Inspection

A very comprehensive inspection that must be carried out:

  • When a crane has reached the end of its design life, or where this is unknown, after 10 years for mechanical components and 25 years for structural components.
  • When an old crane is to be re-commissioned, and Cranes, that are to be upgraded or modified.


Assessment for suitability for continued safe use

This inspection/assessment must be carried out by a competent crane inspector supervised by a professional engineer, and is required when a crane has reached the end of its design life, or where this is unknown, after 10 years for mechanical components and 25 years for structural components.

Assessment for changed operation

Necessary where the fundamental usage of the crane is to be (or has) changed.

10 and 25 Year overhauls / Inspections / Major inspection

When it comes to completing 10 and 25 year service and inspections, our technicians will first calculate weather a crane is actually due for a major service or if the crane may have an extended life.

It makes financial sense to assess whether it is more economical to proceed with a major inspection or if it’s more cost effective to replace the piece of equipment. Iceage incorporate this strategy right from the start to save on the costs of initial inspections.

At Iceage we manage the completion of all aspects of the major service stage by only completing what is required for reliability, safety and compliance, while creating an economical outcome.

Understanding Design working period according to AS2550.1-11

  • Periodic inspections are to be conducted by an independent third party at least once a year (i.e. not the organisations either operating or maintaining the crane). AS 2550.1.7.3.4
  • These inspections should include an estimation of remaining design working period (DWP) according to processes and calculations summarised in a new section (9) of AS2550.1. DWP is then used to determine when a major inspection (and subsequent general overhaul) is due.
  • If DWP is not estimated according to this process, then the major inspection interval is to be reduced to two-thirds of design life or, if this is unknown, to a maximum of 7 years. AS 2550.1.7.3.5
  • Periodic third party inspections are to include verification of the past state of loading and utilisation (as well as intended future state) as compared to the crane classifications.
  • “The purpose of the assessment of DWP is to estimate accumulated duty of the crane and assess its remaining life.” (AS 2550.1.9.3.1) “Failure to keep records of use will dictate the necessity for more frequent major inspections.”1 (AS 2550.1.9.2.1)
  • This is implemented by using a safety factor when estimating DWP that compensates for the unreliability in the duty recording and estimation. The safety factor ranges between 1.1 and 1.5 depending on duty estimation method, as shown in Table 9.6.2 below.
  • The only method of duty estimation that does not require DWP to be reduced by a factor of safety is using an automatic data recording system.
  • Section 9 of AS2550.1-2011 uses a slightly different calculation for DWP than preceding international standards (e.g. ISO12482-1, 1995). To apply the calculations described in AS2550.1-2011, in addition to design information, the following operating data is required:
    • Number of operating cycles;
    • Handled payloads in each operating cycle;
    • Loaded hoist time in motion and respective load;
    • Unloaded hoist time in motion and dead load.

Table 9.6.2 from AS2550.1-2011

Method of recording

Factor of Safety

Expected DWP for a typical crane hoist operating to its capacity

Expected DWP for a typical crane structure operating to its capacity

Automatic recording system.

1.0

10 years

25 years

Counters and manual documentation OR Estimation based on a special documentation process.

1.1

9.1 years

22.7 years

Estimation based on documented production of the site.

1.2

8.3 years

20.8 years

Estimation based on undocumented, estimated production of the site.

1.3

7.7 years

19.2 years

Crane duty history is unknown. (i.e. all other cases)

1.5

6.7 years

16.7 years

 

We can help you with all aspects of meeting compliance requirements.

 Inspections

To ensure you get the longest working life possible out of your crane; & to lessen your liability in the event of your crane being involved in an accident, regular inspections & servicing is a must for any commercial operation.

Iceage can perform inspections, identify & effect repairs & ensure that you are in compliance with all relevant laws & regulations.

Frequency of inspections

The frequency of inspections is determined by the design classification of the equipment, the duty cycles and the working environment.  AS 2550.1-2011 includes a table in Section 7 that sets out the recommended frequencies.  (see table below extracted from AS 2550.1-2011)

It can be reasonably concluded that the minimum frequency of service on any crane, hoist or winch in service, is quarterly.  The annual maintenance plan would include 3 routine maintenance services and 1 periodic inspection. Depending on the variables of duty classification vs. duty cycles, working environment and operator competency, Iceage may recommend more frequent inspections for some or all of the cranes in your business.

The Major Inspection

The key objective of the Major Inspection is to assess the viability of upgrading the crane to the requirements of the Australian Standards.  Certification for continued safe use will therefore be subject to the crane conforming to the current Australian Standards.

Where applicable exemptions from local work cover authorities may be granted to allow deviations from the Australian Standards requirements. Major consideration has to be taken when assessing a crane’s suitability for continued safe use, the analysing of the past, present and future utilisation of the crane needs to be considered and compared to the original design capabilities of the crane. The actual life of the crane (Years in operation after commissioning + Future years) may differ greatly from its theoretical life or original Design Life of the crane. Therefore a general overhaul may not be necessary if the utilisation shows that the crane, based on its original design capabilities has not been fully utilised. This according to AS 2550.1 section 7.3.5 is 25 years for the structure and 10 years for the mechanical components.

Modernization as a cost effective means of 10year overhaul.

A comprehensive range of new designed and manufactured products as well as reconditioned products are available to bring your old crane(s) up to modern standards of safety, reliability and operational performance. This could consist of any number of components namely; hoist replacements, component replacement, drive system replacement, power system replacements, control system replacement or upgrading, variable speed drive installation.

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