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DOCUMENT TITLE: THOROUGH EXAMINATION AND TEST

PROCEDURE FOR PNEUMATIC & ELECTRICAL

OVERHEAD TRAVELLING CRANES

INDEX

SECTION TITLE PAGE

1 PURPOSE 2
2 SCOPE 2
3 REFERENCE 2
4 DEFINITINS 2
5 RESPONSIBILITIES 2
6 PROCEDURE 3-6
7 RECORDS 6

PREPARED BY MOHAMMED RIZWAN AHMED 10/05/2017

APPROVED BY SALIM AL HARTHY 10/05/2017
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1. PURPOSE

The purpose of the procedure is to establish and test method for electrical and pneumatic over head
travelling crane.

2. SCOPE

This document describes how to carry out a thorough examination of electrical and pneumatic
overhead travelling cranes

3. REFERENCES

3.1 BS 7121-2-7:2012+A1:2015
3.2 SP 2275

4. DEFINATIONS

4.1 Competent Person

Is someone who has the necessary theoretical practical knowledge, experience, training, skill
and legal authority to carry out a thorough examination of this equipment type. As such, defects
and weaknesses should not only be detected, but their impact, potential or otherwise, on site
health and safety should be assessed, and the appropriate action taken.
4.2 Responsible Person
A Responsible Person is a person who has sufficient knowledge and training to enable him/her to
recognize obvious defects and is responsible to his/her employer for the in-service inspection of
the equipment.
4.3 Thorough Examination
A Thorough Examination is a mandatory critical visual examination carried out by a Competent
Person and where deemed necessary by that person, supplemented by other means such as
measurement and testing in order to check whether the equipment is safe to operate.

5. RESPONSIBILITIES
5.1 The Client is responsible for ensuring that any equipment they provide for their employees, is
suitable for its purpose, maintained, inspected to ensure that it has been correctly installed,
remains in a serviceable condition, that the people who use it are trained to do so, that they
have the information and instructions that they need, and, that records are kept. This is the law.
5.2 The Client’s Employees have a duty to cooperate with their Employer and use the equipment in
the way it was intended. This is the law.
5.3 I Safety is responsible for ensuring that the Thorough Examination is carried out by a Competent
Person.
5.4 The competent person is responsible for ensuring that the overhead travelling crane is
thoroughly examined as per the requirements of this procedure to meet those of LOLER.
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6. PROCEDURE

6.1 WHEN THOROUGH EXAMINATIONS SHOULD TAKE PLACE

Under BS 7121-2-7 , an electrical or pneumatic overhead travelling crane should be thoroughly

examined as follows: -
(a) After Installation and Before First Use.
(b) After being moved to a new location or re-sited.
(c) Every 12 months thereafter, unless a written scheme of examination is in place.
(d) After being modified or repaired.
(e) After an exceptional circumstance or incident has occurred that may have affected the safety of
the equipment. (At the discretion of the Competent Person).

6.2 EXAMINATION PROCEDURE FOR ELECTRICAL OVERHEAD TRAVELLING CRANES

Prior to carrying out the examination, isolate the crane and remove the fuses, collect work permit.

Examine the hoist unit, ensure that all fixing bolts are correctly fitted and secure, all welds
are intact and free from cracks and carry out safety procedures.

Examine crab hoist unit cross travel wheels for wear and correct fitment.

Ensure that all wheels are not contaminated with oil or grease which could cause slippage.

Examine rope drum for wear on grooves, cracks and sharp edges, ensure that load rope is reeved
correctly, that there is at least 3 turns of wire rope left on the drum when the bottom hook is at its
lowest working point, and that the load rope is anchored correctly.

Examine the rope bands and guides for wear, damage and correct fitment.

Examine the bridge girder for wear, impact damage, bending and deformation, ensure that all fixing
bolts are secure and welds are free from cracks.

Examine the end carriages and long travel wheels for wear, impact damage and deformation, ensure
that all fixing bolts are properly fitted and secure and that all welds are intact and free from cracks.
Ensure that buffer end stops are fitted and free from defect.

Examine all motors and gearboxes, ensure that all fixing bolts are correctly fitted and secure, all seals
are intact and free from leaks.

Examine brake units for wear and if necessary reset to correct tolerance, check that all oil levels are
correct, lubrication points are clean and unblocked and that the crane is adequately lubricated.
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Examine the cross travel festoon system, ensure that all track, support brackets, connection joints,
trolleys and fixing bolts are properly fitted and secure, examine cables for cracks, breaks and damage
to insulation.

Examine down shop lead system, ensure that all track, support brackets, connection joints and fixing
bolts are correctly fitted and secure, ensure that expansion joints are fitted, examine collector arms
and contact shoes for wear and misalignment.

Examine the bottom block load sheaves for wear in grooves, cracks and sharp edges, examine the
cross head fitting for wear and impact damage, ensure that top nut is correctly fitted and securely
locked, ensure that side plates are free from cracks and correctly aligned.

Examine the pendant cable for cracks, breaks and damage to insulation, ensure that strainer
wire is fitted correctly, supporting the weight of the control box.

Examine the pendant control box for damage to casing, ensure that push buttons make good
contact and that the directional controls are clearly marked and function correctly.

Examine the load rope in accordance with the relevant examination procedure.
Refit fuses and function test crane through all motions, check for correct adjustments of all
safety devices and that limit switches function correctly.

Sign off permit and return crane to work.

NOTE : An emergency stop button should be fitted to the pendant control box, activation of
the emergency stop should arrest all motions of the crane and shut down the crane power supply.

6.3 EXAMINATION PROCEDURE FOR PNEUMATIC OVERHEAD TRAVELLING CRANES

Prior to carrying out the examination, isolate the crane and lock off the air supply, collect work
permit and carry out safety procedures.

Examine the hoist unit, ensure that all the fixing bolts are correctly fitted and secure, all welds are
intact and free from cracks.

Examine hoist unit cross travel wheels for wear and correct fitment.

Ensure that all wheels are not contaminated with oil or grease which could cause slippage.

Examine rope drum for wear on grooves, cracks and sharp edges, ensure that load rope is reeved
correctly, that there is at least 3 turns of wire rope left on the drum when the bottom hook is at its
lowest position and that the load rope is anchored correctly.

Examine the rope bands and guides for wear and damage.
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Examine the bridge girder for wear, impact damage, bending and deformation, ensure all fixing bolts
are correctly fitted and secure and that all welds are intact and free from cracks.

Examine the end carriages and long travel wheels for wear, impact damage and deformation, ensure
that all fixing bolts are properly fitted and secure and that all welds are intact and free from cracks.

Ensure buffer end stops are fitted.

Examine all motors and gearboxes, ensure that all fixing bolts are correctly fitted and secure, all seals
are intact and free from leaks.

Examine brake units for wear and if necessary reset to correct tolerance.

Examine all pipe work for cross and long travel, ensure that it is correctly installed, secure and there
are no leaks.

Examine the bottom hook block sheaves for wear in grooves, cracks and sharp edges, examine the
cross head fitting for wear and impact damage, ensure that top nut is properly fitted and securely
locked, ensure that side plates are free from cracks and correctly aligned.

Examine the pendant hose for cracks and perishing, ensure that there are no leaks and that they are
correctly fitted into their connections and are secure and that re-strainer wire is fitted to take weight
of pendant control box and hoses.

Examine the pendant control box for damage to casing, ensure that push buttons and the directional
controls are clearly marked, and they function correctly.

Examine the hoist wire rope in accordance with the relevant examination procedure.

Reconnect air supply and function test crane through all motions, check for correct adjustment of
overload devices (if fitted) and that the over hoist and over lower limit switches function correctly.

NOTE : An air filter lubricator should be fitted to prevent ingress of contaminated air into crane
motors.

6.4 TESTING PROCEDURE

Overload Test

An overload of 125% of the SWL should be raised just clear of the ground and the crane bridge
travelled the full length of the gantry track with the load positioned at the minimum distance from
the centre of each gantry track.

The load should then be traversed along the length of the crane bridge and finally
positioned in the centre of the bridge. The lifting unit drum shall then be rotated through one
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revolution such that all gear teeth and other load bearing components are subjected to the full
overload .

The test is deemed successful if no cracks, permanent deformation, paint flaking or damage that
affects the function and safety of the crane is visible and no connection has been loosened or
damaged.

7. RECORDS

7.1 DETAILS TO BE INCLUDED ON THE REPORT OF THOROUGH EXAMINATION

On completion of the Thorough Examination, a report of Thorough Examination will be issued. This
should comply in strict accordance with the Schedule 1 of LOLER.

7.2 DEFECT REPORTING

When a defect is found, a defect report shall be issued to a person identified by the client as being
the Responsible Person.
If any faults are found at the time of examination, which could affect the safe use of the item, then it
must be withdrawn from service, labelled as defective and the details recorded on the Report of
Thorough Examination.
Where there is an immediate danger or imminent risk of personal injury, a copy of the report should
be forwarded to the relevant enforcing authority.