Director Crane Certification Association of America(CCAA)
Crane certification requires that the crane be placed temporarily out of service. This usually creates a significant cost to the owner. Therefore, it is incumbent on the surveyor to be organized and efficient so that the cost can be minimized. Part of the responsibility of the surveyor is to appraise the client of the conditions and limitations of the process so that the client can plan accordingly. Then the inspector must prepare himself to accomplish the task. The following elements should be part of the preparation.
1. An estimate of the time required for test/inspection will help the client plan. The surveyor should be able to estimate the time required with the understanding that if the crane is not maintained well or if extra testing is required for auxiliary equipment, the inspection will take longer.
2. The client should be advised of the work area required for the test/inspection. The crane must be operated through its full operational range and the boom must be lowered and extended for inspection. Similarly, bridge and track gantry cranes must be operated throughout their range.
3. The crane should be presented to the surveyor in clean well-maintained condition. It should be configured with the full compliment of boom and accessory equipment that the client wishes to be certified. The surveyor should discuss the crane description and limitations sections of the certificate so that the owner can make informed decisions about the crane configuration.
4. The surveyor must be able to study the load chart(s) and owner’s manual for the particular crane before the actual inspection/test date to determine test limitations and special inspection requirements required by the manufacturer. With this information he can add to his checklists as necessary and properly design the load tests. If the surveyor has previously inspected the particular crane, a review of his records may provide all the required information.
5. In order to plan for sufficient test loads, the surveyor must have access to the load charts for the crane. Using the load chart(s) the surveyor can arrange for the minimum number of weights that will test the crane’s structural integrity, stability and provide for testing line pull and accessory equipment such as jibs and extensions. Again, prior records may provide all required information.
6. The surveyor should not inspect/test a crane without having the client’s operator or mechanic available. The surveyor’s job is to inspect and test, so the operation and adjustments should be left to the client’s personnel both for operational as well as liability reasons. If the surveyor is required to operate the crane he should have a hold harmless clause in the contract, so that if the crane fails and causes damage during testing the surveyor is protected from litigation to some extent.
7. It is always wise to review the test/inspection procedure as well as the certification process with the client before the work commences. This will usually generate any questions about the process and details can be worked out before they become problems.
8. The documents that will be provided to the client should be fully explained before hand. The client should be advised of the limitations and time constraints of the compliance certificate, deficiency report, check lists, and material certifications.
One of the best ways to present the foregoing information is in the form of a comprehensive written description, which includes the elements noted above. Depending on the surveyor’s scope of work, a few versions of this “Crane Inspection Preparation” can be developed which will cover all the different cranes in his client base, can be copied repeatedly, and sent out in advance to the client.
The actual inspection/test should be conducted in a well-planned, efficient manner. This maximizes the surveyor’s effectiveness and presents a professional impression to the client and his personnel. The surveyor should be fully equipped to do the job, having the correct tools and gauges.
The “static” inspection should begin with verification of the data plate information as to make, model and serial number, as well as a brief review of any special inspection requirements given in the owner’s manual. Then follows the visual, static inspection of hook, block, reeving, drum, controls, safety devices, draw works, carrier and any accessory equipment in methodical order that best suits the surveyor. The idea is to get all the static inspection done that is practical before starting up the crane.
After completing the “static” inspection, the surveyor should verify operation of all controls, let out and inspect the amount of reeving required for the type of inspection, lower and inspect the boom, gauge the sheaves and grooved drums, check pins and operating components for wear, check safety devices and operator aids for function, check brake, clutch and pressure adjustments, including carrier components as applicable.
A partial load functional test is required by most authorities for all periodic inspections. This is conducted to determine that all operating mechanisms are functioning as they should. This test can also be used to do a rated load stability test using a relatively light load. With a little planning it can also be used to verify rated line pull, load indicator accuracy, and boom elevation function. Some jurisdictions require an overload test which should be done following the partial load test. (See the CCAA Recommended Load Test Procedure.)
Following the load test, the structural components must be carefully inspected for damage, distortion, paint dislocation, loose fasteners, or any other evidence of existing or impending structural deficiencies. During this inspection, hook bearings, slew bearing fasteners, and structural components under the carrier and at the outriggers should be carefully viewed. The surveyor should always be sensitive to any change in characteristics, as a result of rated condition testing, such as excessive clutch/brake temperatures, engine power loss, malfunctioning hydraulic system components, and unusual noises or vibration.
After reviewing and completing all check lists, a deficiency or inspection report should be prepared and reviewed with the client’s representative. The surveyor should cite the standards that were not met and indicate the level of correction that will be acceptable. The client should be advised if an inspection of corrections is required or if documentary evidence will suffice. The surveyor should advise the client of any time limits for correction that apply.
One of the best customer relations methods is proper planning that saves the client expense, confusion, and worry. Good planning is also one of the best safeguards against undeserved lawsuits and devastating liability. Inspectors will serve themselves and their clients well if they use a comprehensive planning system.
The purpose of CCAA is to promote crane safety, improve the certification profession and address the subject of crane safety in governmental forums.
No comments:
Post a Comment