FEMA - v2

Standardize of FMEA _ high level map
1- Divided the crane into components as per GOS (Reference SMP)

2- Divided the components into mechanical and electrical sections
3- Define the Failure mode to the mechanical component (definition of the failure mode as per ISO 14224)
3- Define the Failure mode to the electrical component (definition of the failure mode as per ISO 14224)
4- Define the probable causes of the mechanical failure modes
5- Define the probable causes of the electrical failure modes
6- Link the PM instructions to the failure mode and to the failure cause
GOS + PM instructions'!A1
High level plan
GOS_Path
Quay crane|Operator cabin|Body
Quay crane|Operator cabin|Seat
Quay crane|Operator cabin|Seat|Trainer's/Auxiliary Seat
Quay crane|Operator cabin|Seat|Trainer's/Auxiliary Seat
Quay crane|Control/Mointoring system|Control Station
Quay crane|Control/Mointoring system|Control Station|Operator cabin-Console/display/joystick/Padels
Quay crane|Control/Mointoring system|Emergency Stop
Quay crane|Control/Mointoring system|Emergency Stop
Quay crane|Control/Mointoring system|Crane monitoring system
Quay crane|Control/Mointoring system|Crane monitoring system|Spreader Status Indication in Operator Cabin
Quay crane|Control/Mointoring system|PLC
Quay crane|Control/Mointoring system|Remote CMS/Control System|High Voltage Optical Fiber Slip Ring
Quay crane|Structure|A-frame|Sea Side (Main) A-Frame
Quay crane|Structure|A-frame|Land Side A-Frame
Quay crane|Structure|A-frame|Land Side A-Frame
Quay crane|Structure|Backstay/forestay/strut
Quay crane|Structure|Boom
Quay crane|Structure|Boom|Boom Hinges
Quay crane|Structure|Boom|Boom Cushion/Support
Quay crane|Structure|Boom|Access Doors
Quay crane|Structure|Electrical house
Quay crane|Structure|Gantry
Quay crane|Structure|Gantry
Quay crane|Structure|Gantry|Large Equalizer Beam
Quay crane|Structure|Gantry|Bogie
Quay crane|Structure|Trolley
Quay crane|Structure|Trolley|Access Doors
Quay crane|Structure|Lightning/Earthing Protection
Quay crane|Structure|Headblock
Quay crane|Structure|Machinery house
Quay crane|Structure|Stair/ladder/walkw/platf.
Quay crane|Gantry|Tiedown/stow pin|Stowage System
Quay crane|Gantry|Tiedown/stow pin|Tie Down System
Quay crane|LV / Power system|Power Outlet
Quay crane|LV / Power system|Power Outlet
Quay crane|LV / Power system|Auxiliary power supply
Quay crane|LV / Power system|Auxiliary power supply
Quay crane|LV / Power system|Rectifier System
Quay crane|LV / Power system|Lighting|Floodlights
Quay crane|LV / Power system|Lighting|Walkway Lighting
Quay crane|LV / Power system|Lighting|Walkway Lighting
Quay crane|LV / Power system|Lighting|Indoor Lighting
Quay crane|LV / Power system|Lighting|Emergency Lighting
Quay crane|LV / Power system|Lighting|Air Craft Lights
Quay crane|LV / Power system|Low Voltage installation|LV Distribution Boxes
Quay crane|LV / Power system|Low Voltage installation|Electrical Panels
Quay crane|Main hoist
Quay crane|Main hoist|Anti sway system
Quay crane|Main hoist|Auxiliary drive system
Quay crane|Main hoist|Clamping system
Quay crane|Main hoist|Drum
Quay crane|Main hoist|Drum|Coupling
Quay crane|Main hoist|Electrical drive
Quay crane|Main hoist|Emergency brake
Quay crane|Main hoist|Position and Speed Feedback Devices
Quay crane|Main hoist|Gearbox
Quay crane|Main hoist|Emergency Brake Hydraulic system
Quay crane|Main hoist|Load cell
Quay crane|Main hoist|Motor
Quay crane|Main hoist|Motor|Coupling
Quay crane|Main hoist|Operational brake
Quay crane|Main hoist|Sheave
Quay crane|Main hoist|Slack rope detection
Quay crane|Main hoist|TLS System
Quay crane|Main hoist|Wire rope
Quay crane|Trolley
Quay crane|Trolley|Auxiliary drive system
Quay crane|Trolley|Buffer
Quay crane|Trolley|Drum
Quay crane|Trolley|Drum|Coupling
Quay crane|Trolley|Electrical drive
Quay crane|Trolley|Position and Speed Feedback Devices
Quay crane|Trolley|Gearbox
Quay crane|Trolley|Motor
Quay crane|Trolley|Motor|Coupling
Quay crane|Trolley|Operational brake
Quay crane|Trolley|Clamping system
Quay crane|Trolley|Wheel
Quay crane|Trolley|Wheel/guide roller
Quay crane|Trolley|Wire rope
Quay crane|Gantry
Quay crane|Gantry|Anti collis. sys-crane to cr.
Quay crane|Gantry|Electrical drive
Quay crane|Gantry|Position and Speed Feedback Devices
Quay crane|Gantry|Position and Speed Feedback Devices
Quay crane|Gantry|Gearbox
Quay crane|Gantry|Guard & sweep
Quay crane|Gantry|Emergency Brake Hydraulic system
Quay crane|Gantry|Motor
Quay crane|Gantry|Motor|Coupling
Quay crane|Gantry|Operational brake
Quay crane|Gantry|Wheel
Quay crane|Gantry|Emergency Brake
Quay crane|Boom hoist
Quay crane|Boom hoist|Anti collision sys-boom to ship
Quay crane|Boom hoist|Auxiliary drive system
Quay crane|Boom hoist|Boom latching system
Quay crane|Boom hoist|Drum
Quay crane|Boom hoist|Drum|Coupling
Quay crane|Boom hoist|Emergency brake
Quay crane|Boom hoist|Position and Speed Feedback Devices
Quay crane|Boom hoist|Gearbox
Quay crane|Boom hoist|Motor
Quay crane|Boom hoist|Motor|Coupling
Quay crane|Boom hoist|Operational brake
Quay crane|Boom hoist|Sheave
Quay crane|Boom hoist|Slack rope detection
Quay crane|Boom hoist|Clamping system
Quay crane|Boom hoist|Wire rope
Quay crane|Boom hoist|Buffer
Quay crane|Festoon
Quay crane|Festoon
Quay crane|Festoon|Buffer
Quay crane|Festoon|Buffer
Quay crane|Festoon|Cable
Quay crane|Festoon|Electrical drive
Quay crane|Festoon|Position and Speed Feedback Devices
Quay crane|Festoon|Gearbox/Mech. Power Transmission
Quay crane|Festoon|Motor
Quay crane|Festoon|Carriers Structure
Quay crane|Festoon|Rail/rail clips
Quay crane|Festoon|Rubber/wire rope
Quay crane|Festoon|Wheel/guide roller
Quay crane|Headblock|Electrical system
Quay crane|Headblock|Electrical system
Quay crane|Headblock|Twistlock/Connecting Eye system
Quay crane|Elevator
Quay crane|Elevator|Cabin/Doors
Quay crane|Elevator|Cage/Enclosure
Quay crane|Elevator|Control system
Quay crane|Elevator|Electrical drive
Quay crane|Elevator|Electrical drive
Quay crane|Elevator|Electrical system
Quay crane|Elevator|Emergency system|Safety Device
Quay crane|Elevator|Emergency system|Centrifugal Brakes
Quay crane|Elevator|Emergency system|Brake Manual Release Mechanism
Quay crane|Elevator|Operational brake
Quay crane|Elevator|Gearbox
Quay crane|Elevator|Motor
Quay crane|Elevator|Motor|Coupling
Quay crane|Elevator|Motor|Coupling
Quay crane|Elevator|Pinion/rack/guide
Quay crane|Climate control system|Split Units
Quay crane|Climate control system|Central Units
Quay crane|Climate control system|Machinery House Ventilation System|Turbin Ventilation System
Quay crane|High Voltage system|Electrical drive
Quay crane|High Voltage system|Cable reel
Quay crane|High Voltage system|Gearbox
Quay crane|High Voltage system|High voltage cable
Quay crane|High Voltage system|High voltage cable guide
Quay crane|High Voltage system|Motor
Quay crane|High Voltage system|Operational Brake
Quay crane|High Voltage system|Slip ring system
Quay crane|High Voltage system|Step down transformer
Quay crane|High Voltage system|Auxiliary Step down transformer
Quay crane|High Voltage system|Position and Speed Feedback Devices
Quay crane|Checker cabin
Quay crane|Boom hoist cabin
Quay crane|Spreader control
Quay crane|Spreader control|Cable
Quay crane|Spreader control|Cable
Quay crane|Spreader control|Drum/Cable Reel
Quay crane|Spreader control|Operational Brake
Quay crane|Spreader control|Cable Damper System
Quay crane|Spreader control|Electrical drive
Quay crane|Spreader control|Gearbox
Quay crane|Spreader control|Motor
Quay crane|Spreader control|Motor|Coupling
Quay crane|Spreader control|Slip ring system
Quay crane|Spreader control|Position and Speed Feedback Devices
Quay crane|Wire Rope Support System|L shape System
Quay crane|Wire Rope Support System|Wire Friction Parts
Quay crane|Other|Anemometer
Quay crane|Other|Anemometer
Quay crane|Other|Fire detection system
Quay crane|Other|Fire extinguisher
Quay crane|Other|Rope reeving system
Quay crane|Other|Service crane|Electrical Service Crane
Quay crane|Other|Communication system|Local Communication System
Quay crane|Spreader
Quay crane|Spreader
Quay crane|Spreader
Quay crane|Spreader
Quay crane|Spreader
Quay crane|Spreader
Quay crane|Spreader
Quay crane|Spreader
Quay crane|Spreader
Quay crane|Spreader
Failure Mode Description Failure Mode Code Failure Cause Inst_ID Index_ID
Erraticoutput ERO 9470 19456
Breakdown BRD 9471 19468
Highoutput HIO 9489 19684
Breakdown #N/A 9492 19720
Lowoutput #N/A 9917 23560
Lowoutput #N/A 9929 23656
Erraticoutput #N/A 9936 23740
Instruction
Clean and tidy the operator cabin.
Clean cabin glass and windows.
Inspect the condition and mounting of the cabin access door. Test its function.
Inspect the condition and mounting of the curtains.
Inspect the condition of the floor mats.
Inspect the condition of the cabin frame.
Inspect the condition and mounting of cabin glass.
Inspect the condition and mounting of the windows. Test its function.
Inspect the condition and mounting of the glass protection gratings.
Lubricate the cabin door hinges.
Inspect the mounting and condition of the mirrors. Clean if required.
Inspect the cabin mounting.
Inspect the cabin mounting buffers.
Inspect the condition and mounting of glass wipers. Test it's function.
Inspect the mounting and condition of wiper fluid sprayer system. test its function and top up the tank.
Inspect the condition and wiring of the glass heater. Test its function.
Clean the seat and console if required.
Inspect the condition and mounting of the consoles.
Test the function of console movements.
Inspect the condition and mounting of the foot rest.
Inspect the condition and mounting of the seat.
Inspect the condition and mounting of the seat belt. Test it's function.
Test the function of seat movements.
Inspect the seat movement mechanisms.
Inspect the condition and mounting of the auxiliary seat.
Inspect the condition and mounting of the seat belt. Test its function.
Inspect the condition and mounting of control station internal components.
Check the control station components for labeling and clean if required.
Check the cables, wirings, and connections of control station components.
Test the function of the control station control inputs.
Inspect the condition and mounting of control station panel door.
Inspect the condition and mounting of control station inputs components.
Inspect the condition and mounting of the control station housing.
Inspect the control station components and wirings using the IR camera.
Test the function of the consoles movements.
Inspect the condition, mounting, and function of the flippers pedal/joystick/buttons
Inspect cables, wirings, and connections under operator seat and inside control station/consoles.
Inspect the condition, mounting, function of hatch cover alarms.
Check the control station/consoles components for labeling and clean if required.
Test the function of the control station/consoles inputs.
Inspect the condition and mounting of control station/consoles panel door.
Inspect the condition and mounting of control station/consoles inputs components.
Inspect the condition and mounting of the control station/consoles housing.
Inspect the control station/consoles components and wirings using the IR camera.
Inspect condition and mounting of emergeny stop button and its wiring. Clean if required.
Test the function of emergency stop button.
Inspect the condition and mounting of crane monitoring display and its wirings/plugs. Clean if required.
Test the function of the crane monitoring display.
Inspect the condition of the PC hardware and software. Clean if required.
Inspect the PC panel chassis and its cooling fan.
Inspect the condition, mounting, and function of the UPS.
Test the CMS software functions.
Inspect the condition and mounting of spreader indicator lights and its wirings.
Test the function of the spreader indicator lights.
Inspect the condition and mounting of spreader indicator lights and its wirings.
Test the function of the spreader indicator lights.
Inspect PLC modules using the IR camera.
Measure the voltage of PLC backup batteries.
Inspect condition and mounting of the PLC modules. Clean if required.
Inspect the wiring and connections of the PLC modules.
Check the PLC overrides and repair their cause then remove them.
Check the integrity of PLC software program.
Check trolley park position range values at PLC program.
Check Hoist CAM switch and position encoder values at PLC program.
Check Hoist overload values at PLC program.
Check Hoist load cell values at PLC program.
Check Boom CAM switch and position encoder values at PLC program.
Check Trolley CAM switch and position encoder values at PLC program.
Check TLS cylinders zero/home position on PLC.
Inspect the condition and mounting of the fiber optic system.
Lubricate the A-fram beams pins.
Inspect the mounting of the A-frame beams.
Inspect the condition of the A-frame beams.
Inspect the mounting of the A-frame beams.
Inspect the condition of the A-frame beams.
Lubricate the pins of the forestay.
Lubricate the pins of the backstay.
Lubricate the pins of the staybars.
Inspect forestay mountings.
Inspect backstay mountings.
Inspect staybars mountings.
Inspect the condition of the forestay links.
Inspect the condition of the backstay links.
Inspect the condition of the staybars links.
Inspect the condition of the forestay guide supports.
Inspect the condition and mounting of the soft pads of forestay guide supports.
Inspect the condition and mounting of boom girders brace beams and damping wires.
Test the function of the boom hinges.
Lubricate the boom hinges bearings.
Inspect the mounting of boom hinge assembly base.
Inspect the mounting of boom bearing brackets.
Inspect the mounting of boom bearing shaft.
Inspect the structure condition of boom hinge assembly.
Lubricate the boom cushion/support assembly.
Inspect boom cushion/support structure.
Inspect boom cushion/support mounting.
Inspect soft pads/rollers condition and mounting.
Inspect the condition and mounting of access door and its hinges.
Lubricate the access door hinges.
Inspect the condition and mounting of the door lock.
Test the function of the door and door lock.
Test the interlock between the lock and boom movement.
Inspect the wiring, button, and junction box of the magnetic lock.
Clean and tidy the electrical house if required.
Inspect the condition of the access doors. Lubricate doors hinges if required.
Close all doors before leaving.
Inspect the floor mats.
Inspect electrical house walls, floor, and roof.
Inspect condition and mounting of electrical house earthing cables.
Test the function of the gantry and check for abnormal sounds in structure.
Clean equalizer beams and bogies if required.
Lubricate the equalizer beam mounting pin.
Inspect the equalizer beam mounting.
Inspect the equalizer beam condition.
Inspect the mounting and condition of the equalizer angle limiting block.
Inspect the alignment of the eualizer beam.
Inspect the equalizer earthing cable condition and fixation.
Lubricate the equalizer beam mounting pin.
Inspect the equalizer beam mounting.
Inspect the equalizer beam condition.
Inspect the mounting and condition of the equalizer angle limiting block.
Inspect the alignment of the eualizer beam.
Inspect the equalizer earthing cable condition and fixation.
Lubricate the bogie mounting pin.
Inspect the bogie mounting.
Inspect the bogie condition.
Inspect the mounting and condition of the bogie angle limiting block.
Inspect the alignment of the bogie and wheels.
Inspect the bogie earthing cable condition and fixation.
Inspect trolley bogies shafts, sleeves, and journal bearings.
Measure the width of bogie rubber block. Inspect its condition and mounting.
Inspect bogies mounting.
Inspect bogies structure for cracks or deformation.
Clean and tidy trolley area if required.
Inspect trolley girders for cracks or deformation.
Inspect the condition and mounting of access door and its hinges.
Lubricate the access door hinges.
Inspect the condition and mounting of the door lock.
Test the function of the door and door lock.
Test the interlock between the lock and trolley movement.
Inspect the wiring, button, and junction box of the magnetic lock.
Inspect the condition and mounting of lightning arrester bar.
Inspect the earthing cables of the lightning arrester bar.
Inspect the condition and mounting of earthing pads on gantry rails, their mechanism, and earthing cable.
Inspect mounting and condition of all storage boxes on head block.
Inspect head block structure condition. Inspect welds.
Clean and tidy head block.
Clean and tidy the machinery house.
Inspect the condition of the access doors.
Lubricate the hinges of doors and hatchs.
Close all doors and hatches before leaving.
Inspect machinery house walls, floor, and roof.
Inspect the mountings of the machinery house.
Inspect information signs at ladders.
Inspect the condition and mounting of the ladder and its cage if any. Clean if required.
Inspect that festoon platform does not interfere with festoon cables.
Inspect the condition and mounting of the platform and its structure. Clean and tidy if required.
Inspect the condition and mounting of the platform gratings. Clean if required.
Inspect the condition and mounting of the stairs. Clean if required.
Inspect the handrails condition and mounting. Clean if required.
Inspect the condition of the access doors.
Lubricate the hinges of the access doors.
Inspect the hatch cover.
Lubricate hatch cover hinges.
Test the function of the Stowage System.
Inspect the sensors and cam mountings.
Inspect the sensors wiring and junction box
Measure the air gap of the sensors.
Clean the sensors if required.
Test the function of the sensors.
Inspect the structure, pins, and foundation of the stowage system.
Lubricate the hinges if required.
Inspect the mounting of the Stowage System.
Test the function of the tie down system.
Inspect the structure, pins, and foundation of the tie down system.
Lubricate the thread and hinges if required. Ensure thread is well covered.
Inspect the tie down system mounting.
Measure the voltage of the power outlet.
Inspect the condition and mounting of the power outlet. Clean if required.
Inspect the auxiliary power supply socket and cables.
Inspect the Auxiliary power-Main power interlock mechanism.
Measure the batteries voltage of UPS.
Inspect condition and mounting of all cables and wires.
Inspect condition and mounting of the bus bars.
Inspect the capacitors.
Inspect all rectifier components using the IR camera.
Inspect all rectifier components using the Ultrasound device.
Inspect rectifier components for cleanliness.
Inspect rectifier components and connections integrity.
Inspect the rectifier cooling fan function and fixation.
Inspect the rectifier cooling air filters for cleanliness and damage.
Measure the rectifier cooling fan motor current.
Inspect the fuses for proper fixation.
Inspect the rectifier units for faults history.
Check the current status of the rectifier units to be ready.
Inspect the panel heater function using the IR camera.
Check all information tags, labels, and hazards signs.
Inspect the rectifier panels chassis, doors, and covers.
Check the panel lighting.
Inspect the condition and mounting of the floodlights.
Check the condition and mounting of the safety chains/wires.
Test the function of the floodlights.
Measure the illumination level of the floodlights.
Clean the glass surface of the floodlights. Check its mounting.
Inspect the condition and mounting of the floodlights wirings and junction boxes.
Check the direction of the floodlight. Adjust if required.
Inpect lighting switches and buttons.
Inspect the condition and mounting of the walkway lights. Clean and test the function.
Test the function of the indoor lights.
Inspect the condition and mounting of the indoor lights. Clean if required.
Inspect the condition and mounting of indoor lights wirings and junction boxes.
Inpect lighting switches and buttons.
Test the function of the emergency lights.
Inspect the condition and mounting of the emergency lights. Clean if required.
Inspect the condition and mounting of emergency lights wirings and junction boxes.
Inspect the aircraft lights wirings and junction boxes.
Test the function of the aircraft UPS.
Measure the voltage of the aircraft UPS batteries.
Test the function of the aircraft lights.
Inspect the condition and mounting of the aircraft lights. Clean it.
Inspect the distribution box wirings and connections.
Inspect the condition and mounting of distribution box chassis and door.
Inspect the condition and mounting of the electrical cables.
Inspect the electrical panel components using the IR camera.
Inspect the electrical panel components using the Ultrasound device.
Inspect the condition and mounting of the panel electrical components. Clean if required.
Inspect the condition and mounting of the panel wirings, bus bars, and connections.
Inspect the condition and mounting of the electrical panel chassis and door.
Inspect the panel cooling fan function, wirings, and mountings.
Inspect the condition of panel cooling air filters. Clean or replace if required.
Inspect the function, condition, wirings, and mounting of the panel heater.
Check the electrical panel lighting. Inspect the doors limit switches.
Inspect the panel indicators.
Check the electrical drawings condition and accessibility.
Check condition and mounting of thermostat. Adjust if required.
Carry out a load test to check the brakes integrity.
Test the function of the Camera System.
Inspect the antisway system camera.
Inspect the antisway system reflector.
Inspect the condition and mounting of the gears covers.
Inspect the chain for damage. Ensure it's well preserved.
Inspect the driving and driven sprocket
Inspect the driving and driven sprocket mountings.
Clean the auxiliary system if required.
Inspect the motor, gearbox, and foundation for cracks.
Inspect the gearbox mountings.
Inspect the motor mountings.
Inspect the motor cooling fan.
Test the function of the auxiliary system.
Lubricate the chain if required.
Inspect motor cables and junction boxes.
Measure the current of the motor heater. Inspect cables and terminals.
Check the gearbox oil level.
Inspect the gearbox for oil leakage.
Test the function of the gearbox air breather. Clean if required.
Inspect the condition, mounting, and wiring of sensors. Clean if required.
Inspect the motor-gearbox coupling.
Inspect clamps mountings.
Inspect for any signs of hoist wire rope slipping from the clamps.
Inspect the whole clamps structure for cracks or deformation.
Inspect all wire rope reeving pulleys.
Check that the clamps are holding the wires correctly.
Inspect drum pedestal mountings.
Inspect the pedestal structure.
Inspect wire rope mounting clamps, studs, and nuts on drum.
Measure the drum groove geometry. Inspect the groove.
Inspect the general condition of the drum.
Inspect the drum bearings using the IR camera.
Inspect the drum bearings using the Ultrasound inspection device.
Lubricate the drum pedestal bearings.
Inspect drum pedestal bearings brackets mountings.
Clean the surroundings of the drums if required.
Check the wrapping wire at hoist wire rope ends.
Lubricate the hoist drum coupling.
Inspect the drum coupling for wear.
Inspect drum coupling mountings.
Clean the drum coupling if required.
Test the function of the coupling.
Inspect all drive components using the IR camera.
Inspect drive components for cleanliness.
Inspect drive components and connections integrity.
Inspect the drive panel chassis, doors, and covers.
Inspect the drive cooling fan function and fixation.
Inspect the drive cooling air filters for cleanliness and damage.
Measure the drive cooling fan motor current.
Inspect the drive units for faults history.
Check the current status of the drive units to be ready.
Inspect the panel doors limit switches.
Inspect all cables and wires.
Inspect the bus bars.
Inspect brake mountings.
Check the brake lining to be clean.
Inspect brake disc mountings.
Measure the air gap of both sides of brake linings.
Inspect the brake for oil leakage.
Inspect the sensors mounting, wiring. Clean if required.
Check visually the general condition of the brake.
Inspect the brake lining to be parallel to the disc.
Measure the visible piston rod length.
Test the brake function.
Inspect the sensors adjustment.
Test the function of brake sensors.
Measure the brake disc thickness.
Measure brake pad lining thickness. Inspect the lining condition.
Inspect the brake by IR camera.
Inspect the brake disc for damage. Clean if required.
Inspect the brake hinges and links.
Inspect the mounting of encoders,CAM switch, and overspeed switch.
Inspect the hoist up final limit switch mountings. Inspect its mechanism.
Inspect the coupling of encoders,CAM switch, and overspeed switch.
Inspect the hoist up final limit switch activation cam on head block.
Check overspeed switch adjustment.
Test the function of the hoist CAM Switch and Position Encoder.
Test the function of the hoist up final limit switch.
Test the function of the Cam/Encoder gearbox.
Replace and renew the lubricant of the Cam/Encoder gearbox.
Inspect the coupling between the Cam/Encoder gearbox and the drum.
Inspect the Cam/Encoder gearbox mountings.
Check the lubricant condition and quantity of the Cam/Encoder gearbox.
Inspect the wiring and plugs of the hoist speed and position feedback devices.
Inspect the wiring and plugs of the hoist up final limit switch.
Inspect gearbox mountings.
Check visually the general condition of the gearbox.
Inspect the gearbox and foundation for cracks.
Inspect for oil leakage.
Check the oil level.
Check the visual oil condition.
Collect an oil sample for analysis.
Inspect the gearbox bearings using the Ultrasound device.
Inspect the gearbox using the IR camera.
Replace the gearbox oil.
Carry out gearbox internal components inspection job.
Inspect all components inside the gearbox.
Test the function of the gearbox.
Lubricate the bearings covers seals at output and input shafts.
Clean the gearbox if required.
Inspect the electrical junction boxes.
Inspect the pressure gauges for correct indication.
Inspect motor/pump mountings.
Clean the hydraulic system if required.
Measure the operating current of the hydraulic pump electrical motor.
Test the accumulator function.
Test the function of the oil tank air breather. Clean if required.
Inspect the electrical plugs.
Inspect the electrical wiring.
Check the hydraulic oil filters clogging indicator.
Replace the hydraulic oil.
Replace the hydraulic oil filters.
Test the function of the power pack.
Test the function of manual release system.
Inspect the power pack components using the IR camera.
Inspect the electrical motor bearings using the Ultrasound device.
Inspect the power pack for oil leakage.
Inspect all hydraulic hoses and pipes.
Inspect the settings of oil temprature switch.
Measure the system operating pressure.
Check all manual shut-off valves positions are correct.
Clean the hydraulic oil strainer. Inspect it.
Inspect the oil level switch.
Inspect the load cells electrical plugs.
Inspect the load cells electrical junction boxes.
Inspect the load cells electrical wiring.
Test the overload function.
Test the load cells function with no load.
Test the load cells function with full load (SWL).
Inspect load cells mountings.
Lubricate the load cells bearings.
Clean the load cells if required.
Inspect the motor and foundation for cracks.
Inspect motor cables, earthing cables, and junction box.
Inspect the motor using the IR camera.
Inspect the motor bearings using the Ultrasound device.
Clean the motor if required.
Inspect the cooling fan/blower and its cover for fixation.
Test the function of cooling fan/blower.
Inspect motor mountings.
Check visually the general condition of the motor.
Test the function of the motor.
Lubricate the motor bearings.
Measure the current of the motor heater. Inspect heater cables and terminals.
Clean fan/blower fins if required.
Measure the motor alignment.
Inspect motor coupling mountings.
Inspect the motor coupling set screw.
Clean the motor coupling if required.
Inspect the motor coupling for cracks.
Inspect the motor coupling for indication of slipping in the axial direction.
Inspect the general condition of the motor coupling.
Test the function of the motor coupling.
Inspect the motor coupling elastic/rubber element.
Lubricate the brake hinges.
Inspect the catch pin.
Measure catch pin air gap.
Inspect the Automatic Wear Compensator (AWC) mountings.
Measure the air gap of sensor.
Inspect condition and mounting of brake sensors and cam. Clean If required.
Inspect thruster motor cables and junction box.
Inspect the brake thruster motors contactors by IR camera.
Check the brake thruster motor oil level. Inspect for leakage.
Inspect the brake disc for damage.
Clean the brake disc if required.
Measure brake pad lining thickness. Inspect the lining.
Check brake torque adjustment.
Measure the clearance between both brake linings and the brake disc.
Measure the thruster motor reserve stroke.
Clean the brake assembly if required.
Inspect thruster motor mountings.
Inspect the Integrity of the spring and spring mountings.
Inspect the condition and mounting of the disc covers.
Inspect the sheave bearings for play.
Clean the sheaves if required.
Inspect the condition and mounting of sheave counter roller/plate/pipe.
Measure the smallest diameter of the counter roller.
Inspect the sheaves covers and guards for fixation and condition.
Test the fucntion of the sheaves.
Lubricate the sheaves bearings.
Measure the sheaves groove curvature.
Inspect sheaves and sheaves shafts mountings.
Inspect the sheaves general condition.
Measure the gap of the hoist wire rope slack sensors.
Test the function of the hoist wire rope slack sensors.
Inspect the hoist wire rope slack sensors electrical wiring.
Clean the hoist wire rope slack sensors if required.
Inspect TLS cylinders holding structure.
Inspect pump/motor mountings.
Inspect pump/motor housing and foundation for cracks.
Inspect the TLS cylinders position sensors.
Inspect the general condition of the electrical switches.
Inspect the general condition of hydraulic valves.
Inspect the power pack enclosure and foundation.
Inspect the power pack enclosure doors. Lubricate doors hinges if required.
Check visually the general condition of the TLS system.
Test the function of the TLS system.
Inspect the spreader level when TLS cylinders are in zero/home position.
Lubricate the TLS cylinders sliding rollers bearings.
Lubricate the TLS cylinders end bearings.
Lubricate the TLS cylinders fixation/pivot pins.
Clean the TLS system if required.
Check the oil level. Check the visual oil condition.
Inspect the settings and reading of oil temprature switch/sensor.
Inspect the condition and mounting of the oil cooler. Clean if required.
Test the function of the oil cooler fan.
Inspect the pump-motor coupling and coupling rubber condition.
Inspect the TLS cylinders rod rubber boot.
Inspect the TLS cylinders mountings.
Inspect all TLS cylinders sliding assistant mechanisms.
Inspect the TLS cylinders end bearings.
Lubricate the wire rope.
Inspect the wire rope path to be free from friction with other components.
Replace the wire rope.
Count the wire rope wires breaks.
Inspect the wire rope visually for abnormality.
Measure any waviness in the wire rope if found.
Inspect the wire rope on the drum for overlap.
Measure the diameter of the wire rope.
Inspect the trolley alignment.
Inspect the trolley buffer cylinders mountings.
Inspect the condition of trolley buffer cylinders.
Inspect the rubber boots of the trolley buffer cylinders.
Inspect the fixed bumbers structure of the trolley buffers.
Lubricate the trolley drum coupling.
Inspect the couplings of the encoders.
Test the function of the trolley position encoder.
Inspect the condition, wiring, and mounting of encoders. Clean if required.
Inspect the condition, wiring, and mounting of trolley position sensors. Clean if required.
Inspect the condition and mounting of trolley position sensors activation cams/magnets. Clean if required.
Test the function of the trolley position sensors.
Lubricate the arm of trolley position sensors if required.
Inspect the brake hinges and links if required.
Lubricate the brake hinges if required.
Inspect the condition and mounting of the disc covers. Close it
Inspect the rail clamps and clips condition. Clean if required.
Inspect the clamps and clips mounting bolts. Tighten the bolts if required.
Inspect the rail welded fix blocks.
Inspect the rail pads condition and to be exactly aligned under the rail.
Inspect the whole rail for visual damage, deformation, and cracks.
Measure the horizontal distance between boom rail and girder rail axes at hinge point. (Lateral Shift)
Measure the hight of the rail pad.
Measure the vertical distance between boom rail and girder rail surfaces at hinge point.
Measure the gap between the boom rail and girder rail at hinge point.
Measure the span between both rails at several points.
Measure the hight of the rail at several points.
Measure the difference in hight between the left and right rails at several points.
Inspect the sheaves covers and guards for fixation and condition.
Inspect the tension cylinders end bearings.
Inspect the tension cylinders rod rubber boot.
Inspect the tension cylinders mountings.
Inspect tension cylinders holding structure.
Test the function of trolley rope tensioning system.
Test the function of the accumulator
Inspect the electrical plugs and solenoids.
Measure the length of the cylinder piston rod.
Inspect the tensioner cylinders and its hoses/pipes for oil leakage.
Lubricate the tensioner cyclinders end bearings.
Lubricate the tensioner cylinders arms hinges.
Measure the operating hydraulic pressure.
Inspect the motor coupling.
Inspect motor wiring and junction boxes.
Test the function of the rope slack/tension sensors.
Inspect the rope slack/tension sensors condition, wiring, mounting. Clean if required.
Inspect the rope slack/tension sensors activation cam.
Inspect the pump isolation valve sensor.
Lubricate the rope slack/tension sensors arms.
Inspect the tensioning arms structure.
Check that the clamps are holding the wires correctly. Inspect for signs of wire rope slipping.
Inspect the whole clamps structure for cracks or deformation.
Inspect the clamping bolts.
Inspect clamps mountings.
Lubricate the wheels bearings.
Test the function of the trolley wheels.
Inspect the trolley wheels mountings.
Measure the wheel surface wear.
Measure the wheel flange thickness
Inspect the wheel surface and flange visually. Clean if required.
Measure the guide rollers diameter.
Clean and tidy the area.
Inspect the buffers mountings.
Inspect the rubber boots of the buffer cylinders.
Inspect the condition of the buffer.
Test the function of the buffer.
Test the function of the gantry warning system (Beacons, flash lights, Sirens)
Inspect the sensors of anti-collision system. Clean if required.
Inspect the wiring and junction boxes of the sensors.
Inspect the gantry sirens.
Inspect the gantry beacon/warninig lights.
Inspect the human protection guard.
Inspect the sensor activation cam/rod.
Clean and inspect the sensors reflectors.
Inspect the condition, wiring, and mounting of encoders. Clean if required.
Inspect the couplings of the encoders.
Inspect the mounting of drive train guards.
Inspect the mounting of the wheels guards.
Inspect the structure and foundation of drive train guards.
Inspect the structure and foundation of wheels guards.
Inspect the pump-motor coupling and coupling rubber condition.
Inspect the power pack enclosure and foundation.
Inspect the power pack enclosure doors. Lubricate doors hinges if required.
Check visually the general condition of the power pack.
Test the function of the power pack.
Clean the power pack components if required.
Check the oil level. Check the visual oil condition.
Inspect the settings and reading of oil temprature switch/sensor.
Inspect the general condition of the electrical switches.
Inspect the general condition of hydraulic valves.
Test the accumulator function.
Inspect motor cover for damage. Inspect cover mounting and close it.
Inspect the condition and mounting of the brake cover. Close it.
Lubricate the wheels bearings.
Test the function of the gantry wheels.
Inspect the gantry wheels mountings.
Measure the wheel surface wear.
Measure the wheel flange thickness
Inspect the wheel surface and flange visually. Clean if required.
Inspect the wheel side flange (disc) condition.
Clean the wheel side flange (disc) and brake parts if required.
Inspect the condition, wiring, and mounting of sensors and cams. Clean if required.
Inspect the manual hydraulic valve at brake cylinder.
Inspect the brake cylinder and cylinder force spring for damage.
Inspect the brake lining alignment spring.
Inspect brake hydraulic hoses and pipes.
Test the boom function.
Test the function of the boom to ship anti-collision.
Inspect the anti-collision wire rope condition and tension.
Inspect the fixation of the wire rope at both ends.
Inspect the supports structure that holds the wire ropes at both ends.
Inspect the wire rope pulley.
Inspect the condition of wire rope tension spring.
Inspect the sensors activation cam.
Lubricate the limit switchs arm.
Inspect the condition and the mounting of the sensors. Clean if required.
Inspect the wiring, plugs, and junction box of the sensors.
Lubricate the limit switches if required.
Check the adjustment of the sensors.
Inspect the mechanism and structure.
Test the function of the latching system.
Lubricate the drum coupling.
Inspect the brake disc for damage. Clean if required.
Inspect the sensors mounting, wiring. Clean if required.
Measure the visible piston rod length.
Measure brake pad lining thickness. Inspect the lining condition.
Inspect the boom up limit switch activation cam/element.
Inspect the coupling of encoders, CAM Switch, and overspeed switch.
Inspect the coupling between gearbox and drum (the gearbox of Cam/Encoder).
Inspect the condition and the mounting of encoders, CAM Switch, and overspeed switch.
Inspect the wiring and plugs of encoders, CAM Switch, and overspeed switch.
Test the function of the boom CAM Switch and Position Encoder.
Check overspeed switch adjustment.
Test the function of the Cam/Encoder gearbox.
Replace and renew the lubricant of the Cam/Encoder gearbox.
Inspect the Cam/Encoder gearbox mountings.
Check the lubricant condition and quantity of the Cam/Encoder gearbox.
Inspect the condition, wiring, plugs, and mounting of the boom up sensors. Clean if required.
Test the function of the boom up sensors.
Check the adjustment of the boom up sensors.
Lubricate the boom up limit switches if required.
Inspect the condition and mounting of the disc covers.
Inspect lubrication pipes and hoses.
Test the function of the system.
Lubricate the mechanism.
Inspect the condition, wiring, plugs, Junction box, and mounting of the sensors. Clean if required.
Lubricate the limit switches if required.
Check the adjustment of the sensors.
Inspect the mechanism.
Measure the distance between clamp edges and both sides stoppers.
Inspect clamps bolts.
Inspect for any signs of wire rope slipping from the clamps.
Inspect the clamps for cracks or damage.
Check the clamps are holding the wire rope correctly.
Inspect the clamp position sensors. Adjust position if required.
Clean the clamp position sensors if required.
Inspect the clamp soft stoppers.
Inspect the slap block. (Soft pad under clamp)
Inspect the buffer mountings.
Inspect the bumper structure at the boom.
Inspect the buffer condition.
Check that boom bumper is not in contact with buffer when boom is up.
Inspect the buffer anti-falling protection element.
Test the function of the festoon cars.
Clean and tidy festoon platform. Inspect for possible falling objects.
Inspect the condition and mounting of cars rubber buffers.
Inspect the condition and mounting of damping piston.
Inspect cables collector rings arround calbles loops.
Inspect the condition of the electrical cables. Check for slipping signs.
Inspect the mounting and rubber of the electrical cables clamps.
Inspect the mounting of the electrical drive. Clean drive and its components if required.
Inspect drive panel lights.
Inspect the general condition of the drive and its components.
Inspect drive wirings, terminals, and plugs.
Test the function of drive cooling fan. Clean if required.
Inspect the electrical drive components and wiring using IR camera.
Inspect drive doors, hinges, and locks.
Check the drive status and faults.
Inspect the mounting, condition, and wiring of the limit switches. Clean if required.
Test the function of the limit switches.
Inspect the mounting and condition of the limit switches cams. Clean if required.
Inspect the condition of the drive belts. Inspect belts tension.
Inspect the alignment of the drive belts.
Replace the drive belts.
Inspect the condition and mounting of all drive pulleys.
Inspect the condition and mounting of all cars guards and covers.
Inspect the integrity of motor falling protection wires and clamps.
Inspect motor mounting and mounting rubber. Inspect motor foundation mounting.
Inspect the condition of the motor.
Inspect the condition of the motor wiring and junction boxes.
Inspect all cars and cables saddles structure condition.
Inspect all cars assembly bolts.
Inspect the mounting of towing car to the trolley.
Inspect the mounting of fixed car to its foundation.
Measure air gap between rails at hinge point.
Inspect rails alignment along the whole rail.
Inspect all rails mountings.
Inspect the rails condition.
Measure rails alignment at hinge point.
Inspect the mounting and condition of the elastic ropes.
Lubricate the uncovered areas of the steel ropes and their mounting shackles/clamps.
Inspect the condition of steel ropes, ropes thimbles.
Inspect the condition and mounting of the steel ropes shackles/clamps.
Inspect main and guide rollers mountings.
Inspect the condition of main and guide rollers.
Measure the diameter of guide and main rollers.
Inspect the condtion and mounting of anti-lift plates. Measure their thickness.
Measure the gap between guide rollers and the rail.
Inspect the condition and mounting of anti-lift rollers. Measure their diameter.
Inspect the condition and mounting of main and guide rollers brackets/side shields.
Inspect the condition and mounting of spreader electrical cable between Head block and spreader.
Inspect the spreader cable plug at head block. Clean if required.
Inspect the TWL pins foundation structure.
Inspect the condition and mounting of the TWL guide block.
Lubricate the TWL rotating mechanism assembly.
Measure the gap between TWL pin and guide block.
Inspect the condition, mounting, wiring, and junction box of the head block TWL position sensors. Clean if required.
Test the function of the TWL position sensors.
Measure the gap of the TWL position sensors. Adjust if required.
Inspect the TWL pin visually for deformation or cracks.
Inspect the TWL pin with MT/UT/DPI for cracks. Inspect TWL Key.
Inspect the TWL pin nut and nut lock.
Replace the TWL pin and nut assembly.
Inspect the condition and mounting of TWL rotating mechanism components.
Test the function of the TWL rotating mechanism.
Inspect the TWL rotating mechanism lock. Ensure all locks are well locked.
Test the function of the elevator.
Clean and tidy up cabin and roof if required.
Inspect elevator cabin condition and mounting.
Inspect condition and mounting of handrails on cabin roof.
Inspect the condition of doors, doors hinges, and doors glass.
Lubricate the doors hinges.
Inspect the condition and mounting of doors mechanical interlock mechanism. Clean if required.
Test the function of doors mechanical interlock mechanism.
Lubricate the doors mechanical interlock mechanism.
Check the signs inside and outside the cabin.
Inspect condition and mounting of the ladder.
Inspect the elevator way protection cage.
Inspect buttons and switches condition, wiring, and mounting.
Clean the electrical panel if required.
Inspect fan and fan filters. Clean if required.
Test the function of maintenance control.
Test the function of landings calling buttons.
Test the function of in-cabin operating buttons. Check slowdown and stop positions.
Inspect the electrical panel chassis and doors condition and mounting.
Inspect all panel wiring and wiring glands.
Inspect PLC condition, wiring, and mounting. Clean if required.
Inspect the sensors condition and mounting. Clean if required.
Inspect sensors wiring and junction boxes.
Test the funtion of the overtravel sensors.
Test the funtion of the overload sensor.
Test the function of doors interlock sensors.
Lubricate the mechanical limit switches if required.
Inspect sensors activation cams.
Check the signs on electrical panel.
Inspect all electrical components inside the panel.
Inspect the electrical panel components using IR camera.
Test the function of alarming systems.
Inspect the condition, mounting, and wiring of the electrical drive.
Inspect electrical drive faults and check status.
Test the funcion of the cabin fan. Inspect condition and mounting.
Test the function of the lighting. Inspect condition and mounting.
Inspect main electrical cable condition and mounting.
Inspect condition and mounting of cable rack/guide
Inspect motor braking resistors boxes. Clean if required.
Inspect junction boxes.
Measure the resistance of the motor braking resistors.
Test the function of elevator emergency stop. Inspect button condition.
Inspect condition and mounting of ground collision buffers and their foundation.
Inspect the safety device for noise while running.
Test the function of the safety device. (Drop Test)
Inspect the condition and mounting of the safety device.
Lubricate the safety device.
Replace the safety device.
Inspect the condition of the centrifugal brake mechanism.
Measure the brake lining thickness.
Measure the linings air gap. Ensure air gap is equal along the whole lining length.
Inspect the brake lining and shoe condition and mounting.
Inspect the condition and wear of the brake drum.
Test the function of the centrifugal brake.
Test the function of emergency lowering system.
Inspect the condition and mounting of emergency lowering mechanism.
Lubricate the emergency lowering mechanism.
Measure brake lining thickness.
Measure brake lining air gap.
Test the function of the brake.
Clean the brake internal components if required.
Inspect brake condition and mounting.
Inspect brake wiring and junction box.
Measure the brake braking torque.
Lubricate the worm gear.
Inspect condition of gearbox.
Inspect mounting of gearbox.
Inspect oil level.
Replace gearbox oil.
Inspect condition and mounting of the motor and foundation. Clean if required.
Inspect motor wiring, earthing, and junction box.
Inspect the cooling fan/blower and its cover for fixation. Clean if required.
Inspect the condition and mounting of the motor coupling.
Measure the wear of guide rollers.
Measure the gap of guide rollers
Lubricate guide rollers bearings.
Inspect guide rollers condition and mounting.
Measure mast wear.
Inspect mast condition and mounting.
Inspect the drive pinion condition and mounting.
Measure the drive pinion wear.
Measure the meshing clearance between drive pinion and rack.
Inspect drive pinion alignment with rack.
Inspect condition and mounting of pressure/counter wheel of drive pinion.
Measure the wear of pressure/counter wheel of drive pinion.
Inspect mounting and condition of the rack.
Lubricate the rack.
Measure the wear of the rack.
Inspect the safety device pinion condition and mounting.
Measure the safety device pinion wear.
Measure the meshing clearance between safety device pinion and rack.
Inspect safety device pinion alignment with rack.
Inspect condition and mounting of pressure/counter wheel of safety device pinion.
Measure the wear of pressure/counter wheel of safety device pinion.
Inspect condition and mounting of safety hooks.
Lubricate the bearing of pressure/counter wheel of drive pinion.
Lubricate the bearing of pressure/counter wheel of safety device pinion.
Clean the indoor unit.
Clean and inspect indoor unit air filters. Replace if required.
Clean the outdoor unit.
Inspect the condition and mounting of the indoor unit.
Inspect the condensate draining system condition, function, and mounting.
Inspect indoor unit power supply wiring, plugs, junction box.
Inspect outdoor unit power supply wiring, plugs, junction box.
Inspect the condition and mounting of the outdoor unit.
Inspect the condition and mounting of indoor unit blower. Test its function
Inspect the condition and mounting of outdoor unit fan. Test its function
Test the function of the A/C unit.
Check the functions of the remote control.
Inspect the condition and mounting of refrigerant pipes and hoses between both units. Inspect insulation.
Measure the superheat and subcooling temperatures to determine refrigerant charge.
Check temperature set point as per criterion. Adjust all settings to correct function.
Inspect the refrigerant pipes and hoses for leaks.
Inspect the condition and mounting of the compressor.
Inspect the refrigerant pipes and hoses for leaks.
Measure the superheat and subcooling temperatures to determine refrigerant charge.
Inspect the condition, mounting, and wiring of the sensors.
Check temperature set point as per criterion. Adjust all settings to correct function.
Inspect the condition, mounting, and wiring of the thermostat unit.
Inspect the air ducts and grilles condition and mounting.
Check that the TXV sensing bulb is firmly tied to the suction line and insulated.
Inspect the tension, alignment, and condition of the blower drive belt.
Clean all internal components of the outdoor unit.
Clean the air filters. Replace if required.
Inspect the condensate draining system condition, function, and mounting. Clean if required.
Inspect all wirings, plugs, and junction boxes.
Inspect all electrical components inside the control panel. Clean if required.
Inspect the condition and mounting of condenser fan and evaporator blower. Clean if required.
Inspect compressor and motors terminals and wiring.
Test the function of the A/C unit.
Inspect the condition and mounting of the blower and fan motors.
Inspect the condition and mounting of the unit housing and doors.
Lubricate the blower bearing.
Measure the current of the compressor.
Measure the current of the evaporator blower motor.
Measure the current of the condenser fan motor.
Inspect the A/C unit components using the IR camera.
Inspect the condition and mounting of refrigerant pipes and hoses. Inspect insulation.
Test the function of the turbines.
Inspect the condition and mounting of the turbine. Clean if required.
Inspect the sealing of the turbine base with MH roof.
Inspect all cables and wires.
Inspect drive components and connections integrity. Clean if required.
Inspect the panel doors limit switches. Test its function.
Check the panel lighting. Test its function.
Inspect the drive chassis and doors.
Test the function of cable reel system.
Inspect the condition and mounting of the cable reel.
Inspect the condition and mounting of HV cable clamps on reel.
Measure reel gap.
Inspect the condition and layout/route of HV cable.
Inspect HV cable track and pit. Inspect HV plug/termination.
Check the number of cable safety loops on the reel.
Inspect cable alignment in cable guider.
Inspect the condition and mounting of guide rollers foundations and frames.
Inspect the condition and mounting of high voltage cable guide rollers.
Inspect the condition and mountings of the chassis of high voltage cable guide assembly.
Measure sensors air gap / Limit switch
Inspect the condition and mounting of sensors wirings and junction boxes.
Inspect the condition and mounting of sensors and activation cams. Clean if required.
Test the function of sensors.
Test the function of guide rollers rotation.
Inspect the mechanism of direction arm.
Inspect high voltage switch gear using the IR camera.
Check switch gear indicator lights.
Check that hazard labels of switch gear are in place.
Collect readings of voltage/ampere/watt meters. Inspect all indicators.
Inspect condition and mounting of switch gear housing.
Check the switch gear levers are in place.
Inspect the condition and mounting of switch gear electrical components. Clean if required.
Inspect the high voltage switch gear using the Ultrasound device.
Inspect the condition and function of the breakers.
Drain the water condensate from motor.
Inspect motor cover condition and mounting.
Check motor protection setting.
Inspect cooling fan/blower for fixation.
Test the function of motor cooling fan/blower.
Clean motor cooling fan/blower if required.
Test the function of the manual release mechanism. Inspect mechanism condition.
Measure the air gap of manual release bolts.
Inspect the condition of internal components.
Measure the height of the brushes.
Inspect the condition and mounting of the rotor shaft.
Inspect the slip ring using the Ultrasound device.
Inspect high voltage slip ring box for abnormal sound.
Check high voltage box covers, inspection covers, and sealing.
Inspect condition and mounting of high voltage slip ring box and foundation. Clean inside if required.
Inspect condition and mounting of cables.
Inspect condition and mounting of slip ring heater and heater cables.
Measure the current of the slip ring heater.
Inspect the condition and mounting of the slip ring isolators. Clean if required.
Inspect condition and mounting of brushes.
Inspect condition and mounting of brushes holders.
Clean the slip ring surface if required.
Inspect condition and mounting of the rings.
Inspect the slip ring using the IR camera.
Check condition and mounting of all cables and terminals.
Inspect the transformer body. Clean if required.
Inspect the transformer using the IR camera.
Inspect the transformer using the Ultra sound device.
Inspect transformer windings/coils. Clean if required.
Clean and tidy the transformer room. Inspect room condition.
Inspect the condition and function of the temperature control/monitoring devices.
Inspect the transfomer base support insulator.
Inspect the transfomer base support insulator.
Inspect the transformer using the IR camera.
Inspect the transformer using the Ultra sound device.
Inspect the transformer body. Clean if required.
Check condition and mounting of all cables and terminals.
Inspect transformer windings/coils. Clean if required.
Inspect the condition and function of the temperature control/monitoring devices.
Inspect the condition, function, and mounting of the heater.
Test the function of CAM switch.
Inspect condition and mounting of CAM switch.
Inspect condition and mounting of speed encoder.
Measure the drive chain tension. Inspect chain and sprockets condition.
Lubricate the drive chain.
Inspect condition and mounting of the speed encoder coupling.
Inspect the condition and mounting of CAM switch box.
Inspect the wiring and junction box of CAM switch.
Inspect the wiring and junction box of the speed encoder.
Clean and tidy the cabin.
Inspect cabin structure, foundation, and mountings.
Inspect the cabin door. Lubricate hinges if required.
Inspect the cabin windows and glass.
Inspect the condition and mounting of the seat/chair and desk.
Clean and tidy the cabin.
Inspect cabin structure, foundation, and mountings.
Inspect the cabin door. Lubricate door hinges if required.
Inspect the cabin windows and glass.
Test the function of the SCR system
Inspect the condition and layout/route of spreader cable.
Inspect the mounting and the condition of the spreader cable plug.
Inspect the condition and mounting of all spreader cable clamps.
Measure reel gap.
Inspect reel structure and its foundation mounting.
Inspect reel structure assembly bolts.
Inspect the condition of guide rollers. Test their function.
Clean the brake internal components if required.
Test the function of the manual release mechanism. Inspect mechanism condition.
Measure the air gap of manual release bolts.
Inspect the condition of internal components.
Inspect the condition and mounting of all spreader cable clamps.
Inspect the cable protection sheilds and covers.
Inspect the condition and mounting of the damper.
Inspect the condition and the mounting of the end buffer/stopper.
Lubricate all lubrication points in the drum and damper.
Inspect the mounting of the drum and its foundation.
Inspect the condition of the drum and drum mounting buffers.
Inspect the condition and mounting of the rollers. Test their function.
Inspect the condition and mounting of the anti-friction pads/blocks.
Inspect the condition of the drum structure, hinges, and its foundation.
Test the function of the system.
Inspect condition and mounting all cables and wires.
Inspect the braking resistors.
Lubricate the bearings at input shafts.
Inspect motor cover condition and mounting.
Clean the coupling if required.
Inspect the condition and mounting of the coupling cover.
Measure the coupling torque.
Inspect coupling condition and mounting.
Inspect the condition and sealing of slip ring box.
Inspect the condition of the brushes and brushes holders.
Clean inside the slip ring box if required.
Inspect the space heater function and fixation.
Measure the current drawn by the space heater.
Inspect the mounting of the slip ring shaft and box.
Inspect the bolts and nuts tightness inside the box.
Inspect the condition of the rings.
Test the function of the slip ring system.
Inspect the wiring, terminals, glands, and junctions inside the box.
Inspect the general condition of components inside the box.
Lubricate the slip ring box bearings.
Measure cam switch chain tension. Inspect chain and sprockets condition.
Lubricate the cam switch chain.
Inspect cam switch mounting. Inspect internal components condition. Clean if required.
Inspect cam switch wirings, plugs, and junction box.
Test the function of the cam switch.
Inspect the mounting and condition of the wire protection pipes at hinge point.
Inspect the L-shape protection wire ropes condition.
Inspect the mounting and end clamps of the L-shape protection wire ropes.
Lubricate the L-shape protection wire ropes if required.
Inspect the condition of L-shape structure.
Lubricate the wire rope rollers.
Inspect the condition and function of trolley/hoist wire ropes support rollers.
Inspect the mounting of the trolley/hoist wire ropes support rollers.
Inspect the condition and mounting of the wire ropes teflon slabs/plates.
Measure the wear of trolley/hoist wire ropes support rollers.
Measure the thickness of the wire rope teflon plates/slabs.
Test the function of the anemometer.
Inspect the condition and mounting of the anemometer.
Test the function of the actuator.
Check function of Heat Detector.
Inspect Control panel.
Check function of smoke/fire detectors.
Check interlock function of ventilation system with fire alarm.
Inspect general condition of fire extinguisher cylinders.
Check operation of alarming system.
Check and clean fire system components.
Check load of the Extinguishers.
Inspect the condition and mounting of the fire extinguisher.
Test the function of the reeving system.
Inspect the condition and mounting of the brake. Test its function.
Inspection the condition and mounting of the coupling.
Inspection the condition and mounting of the gearbox.
Inspect the condition and mounting of the drum.
Lubricate all reeving system points.
Inspect the condition and mounting of the motor.
Check gearbox oil level and adjust
Inspect the condition and mounting of reeving system structure and platforms.
Inspect the condition of the hook assembly.
Inspect the condition and mounting of end buffers.
Inspect the electrical wirings and cables.
Inspect the condition and mounting of platform, gratings, handrails, and ladders.
Lubricate bearings.
Inspection condition and mounting of hoist rope drum assembly.
Inspect the condition and mounting of the wire rope clamps.
Measure groove diameter on drum. Inspect its condition.
Inspect the condition and mounting of cables festoon system.
Clean service crane components if required.
Test the function of service crane.
Lubricate Wire rope.
Lubricate Load chain.
Check gearbox oil level.
Check oil level of oil cup for drums gear coupling.
Inspect the condition of hoist wire rope.
Inspect the condition of the crane structures.
Carry out dynamic and static loading test.
Test the function of the brakes.
Check the condition and mounting of the electrical control panel and its components. Clean if required.
Inspect the condition and wiring of brakes coils.
Measure the brake lining air gap.
Inspect the condition and mounting of the gearbox. Clean breather.
Inspect the condition and mounting of the motors.
Inspect the condition and mounting of the operating handheld/pendant.
Inspect the condition and mounting of the gantry and trolley rails.
Test the function of all safety interlocks.
Inspect the condition and mounting of trolley and gantry wheels.
Inspect the condition and mounting of the motor coupling.
Inspect the condition and mounting of the brake. Clean if required.
Inspect the condition of brake disc and lining.
Check the hook is secured against sway.
Replace gearboxes oil.
Inspect wire ropes guiding system components. Test its function.
Inspect the condition and mounting of the hoist rope pulleys. Test its function.
Inspect the safety interlock mechanisms and sensors / Limit switch
Measure the thickness of gantry and trolley wheels flange.
Measure the diameter of gantry and trolley wheels.
Inspect the arrangement of hoist wire rope on drum.
Inspect the rails and wheels.
Inspect the swivel and its lock.
Inspection the condition and mounting of the manual service crane.
Lubricate the hinges and chains.
Test the function of the local communication system unit.
Inspect the condition and mounting of the local communication system unit.
Inspect the condition and mounting of the radio antenna.
Test the function of the radio system.
Inspect the condition and mounting of the radio system components.
Check all spreader status signals feedback to crane PLC.
Inspect the general condition of the spreader for damage and deformations.
Check oil level. Inspect oil leaks in all hydrulic circuit.
Inspect condition and mounting of flipper arms and their actuators. Inspect flipper arm safety chain/wire.
Inspect the condition and mounting of TWL assembly.
Test the function of the spreader.
Inspect the condition and mounting of the landing pin assembly.
Inspect the condition and mounting of the Locking/unlocking mechanism.
Measure air gap between guide block and TWL.
Check all spreader position signals feedback to crane PLC.
Description Code
Failure to start on demand FTS
Failure to stop on demand STP
Spurious stop UST
Breakdown BRD
High output HIO
Low output LOO
Erratic output ERO
External leakage – fuel ELF
External leakage – process medium ELP
Vibration VIB
Noise NOI
Parameter deviation PDE
Abnormal instrument reading AIR
Structural deficiency STD
Minor in-service problems SER
Other OTH
Unknown UNK
Breakdown BRD
Insufficient heat transfer IHT
Failure to connect FCO
Failure to function as intended FTI
Failure to rotate FRO
Failure to disconnect FDC
Insufficient heat transfer IHT
Internal leakage INL
Low oil supply pressure LBP
Low output LOO
Load drop LOA
Loss of buoyancy LOB
Mooring failure MOF
Plugged/choked PLU
Power/signal transmission failure PTF
Slippage SLP
Spurious operation SPO
Faulty output frequency FOF
Faulty output voltage FOV
Abnormal instrument reading AIR
Internal leakage INL
Failure to open on demand FTO
Failure to close on demand FTC
Delayed operation DOP
Very low output VLO
No output NOO
Spurious high alarm level SHH
Spurious low alarm level SLL
Leakage in closed position LCP
Failure to lock/unlock FTL
Failure to set/retrieve SET
Insufficient power POW
Loss of barrier LOB
No immediate effect NON
Well-to-control-line communication WCL
Control-line-to-well communication CLW
Premature closure PCL
Failure to function on demand FTF
External leakage – utility medium ELU
Erratic output ERO
High output HIO
Overheating OHE
Loss of redundancy LOR
Loss of functions on both pods POD
Fails to connect FCO
Fails to disconnect FTD
Invisible sight IVS
Failure to extend/retract FTE
Falling Objects FOJ
Collision with another object COI
Examples
Doesn't start on demand
Doesn't stop on demand
Unexpected shutdown
Serious damage (seizure, breakage)
Overspeed/output above acceptance
Delivery/output below acceptance
Oscillating, hunting, instability
External leakage of supplied fuel/gas
Oil, gas, condensate, water
Abnormal vibration or excessive vibration
Abnormal noise or Excessive noise
Monitored parameter exceeding limits, e.g. high/low alarm
False alarm, faulty instrument indication
Material damages (cracks, wear, fracture, corrosion)
Loose items, discoloration, dirt
Failure modes not covered before
Too little information to define a failure mode
Breakdown
Cooling/heating below acceptance
Failure to connect
General operation failure
Failure to rotate
Failure to disconnect when demanded
Missing, or too low, heat transfer
Leakage internally of process or utility fluids
Low oil supply pressure
Performance below specifications
Load drop
Loss of buoyancy in idle position
Mooring failure
Partial or full flow restriction due to contamination, objects, wax, etc.
Power/signal transmission failure
Wire slippage
Unexpected operation, e.g. false alarm
Wrong/oscillating frequency
Wrong/unstable output voltage
Wrong oil level indication
Oil leakage
Doesn't open on demand
Doesn't close on demand
Opening/closing time below spec.
No output
e.g. 60 % of Lower Explosion Limit (LEL)
e.g. 20 % of Lower Explosion Limit (LEL)
Leak through valve in closed position
Doesn’t lock or unlock when demanded
Failed set/retrieve operations
Lack of or too low power supply
One or more barriers against oil/gas escape lost
No effect on function
Influx of well fluids into valve control line
Loss of hydraulic control fluids into the well bore
Spurious closure of valve without command
Failure to respond on signal/activation (e.g. failure to shear)
Hydraulic oil, lubrication oil, coolant, mud, water, etc.
Oscillating or instable operation
Output torque above specifications
Overheating
Loss of one or more redundancies (e.g. main control system, backup system)
Both pods are not functioning as desired
Failure to connect upper connector
Failure to disconnect upper connector
Difficult to see or limited vision
Doesn’t extend or retract when demanded
Objects fallen from height
Collision with another object
The failure modes can be categorized into three types:
a) desired function is not obtained (e.g. failure to start);

b) specified function lost or outside accepted operational limits (e.g. spurious stop, high output);
c) failure indication is observed but there is no immediate and critical impact on the equipment-unit function
[these are typically non-critical failures related to some degradation or incipient fault condition (e.g. initial
wear)]
pment-unit function
dition (e.g. initial
Description
Failuretostartondemand
Failuretostopondemand
Spuriousstop
Breakdown
Highoutput
Lowoutput
Erraticoutput
Externalleakage–fuel
Externalleakage–processmedium
Vibration
Noise
Parameterdeviation
Abnormalinstrumentreading
Structuraldeficiency
Minorin-serviceproblems
Other
Unknown
Breakdown
Insufficientheattransfer
Failuretoconnect
Failuretofunctionasintended
Failuretorotate
Failuretodisconnect
Insufficientheattransfer
Internalleakage
Lowoilsupplypressure
Lowoutput
Loaddrop
Lossofbuoyancy
Mooringfailure
Plugged/choked
Power/signaltransmissionfailure
Slippage
Spuriousoperation
Faultyoutputfrequency
Faultyoutputvoltage
Abnormalinstrumentreading
Internalleakage
Failuretoopenondemand
Failuretocloseondemand
Delayedoperation
Verylowoutput
Nooutput
Spurioushighalarmlevel
Spuriouslowalarmlevel
Leakageinclosedposition
Failuretolock/unlock
Failuretoset/retrieve
Insufficientpower
Lossofbarrier
Noimmediateeffect
Well-to-control-linecommunication
Control-line-to-wellcommunication
Prematureclosure
Failuretofunctionondemand
Externalleakage–utilitymedium
Erraticoutput
Highoutput
Overheating
Lossofredundancy
Lossoffunctionsonbothpods
Failstoconnect
Failstodisconnect
Invisiblesight
Failuretoextend/retract
Fallingobjects
Collisionwithanotherobject
Examples Code
Doesn't start on demand FTS
Doesn't stop on demand STP
Unexpected shutdown UST
Serious damage (seizure, breakage) BRD
Overspeed/output above acceptance HIO
Delivery/output below acceptance LOO
Oscillating, hunting, instability ERO
External leakage of supplied fuel/gas ELF
Oil, gas, condensate, water ELP
Abnormal vibration or excessive vibration VIB
Abnormal noise or Excessive noise NOI
Monitored parameter exceeding limits, e.g. high/low alarm PDE
False alarm, faulty instrument indication AIR
Material damages (cracks, wear, fracture, corrosion) STD
Loose items, discoloration, dirt SER
Failure modes not covered before OTH
Too little information to define a failure mode UNK
Breakdown BRD
Cooling/heating below acceptance IHT
Failure to connect FCO
General operation failure FTI
Failure to rotate FRO
Failure to disconnect when demanded FDC
Missing, or too low, heat transfer IHT
Leakage internally of process or utility fluids INL
Low oil supply pressure LBP
Performance below specifications LOO
Load drop LOA
Loss of buoyancy in idle position LOB
Mooring failure MOF
Partial or full flow restriction due to contamination, objects, wax, etc. PLU
Power/signal transmission failure PTF
Wire slippage SLP
Unexpected operation, e.g. false alarm SPO
Wrong/oscillating frequency FOF
Wrong/unstable output voltage FOV
Wrong oil level indication AIR
Oil leakage INL
Doesn't open on demand FTO
Doesn't close on demand FTC
Opening/closing time below spec. DOP
VLO
No output NOO
e.g. 60 % of Lower Explosion Limit (LEL) SHH
e.g. 20 % of Lower Explosion Limit (LEL) SLL
Leak through valve in closed position LCP
Doesn’t lock or unlock when demanded FTL
Failed set/retrieve operations SET
Lack of or too low power supply POW
One or more barriers against oil/gas escape lost LOB
No effect on function NON
Influx of well fluids into valve control line WCL
Loss of hydraulic control fluids into the well bore CLW
Spurious closure of valve without command PCL
Failure to respond on signal/activation (e.g. failure to shear) FTF
Hydraulic oil, lubrication oil, coolant, mud, water, etc. ELU
Oscillating or instable operation ERO
Output torque above specifications HIO
Overheating OHE
Loss of one or more redundancies (e.g. main control system, backup system)LOR
Both pods are not functioning as desired POD
Failure to connect upper connector FCO
Failure to disconnect upper connector FTD
Difficult to see or limited vision IVS
Doesn’t extend or retract when demanded FTE
Objects fallen from height FOJ
Collision with another object COI
The objective of these data is to identify the initiating event (“root causes”) in the sequence leading up to a
failure of an equipment item.
The failure causes are classified in the following categories:

1) design-related causes;
2) fabrication/installation-related causes;
3) failures related to operation/maintenance;
4) failures related to management;
5) miscellaneous.
) in the sequence leading up to a
Subdivision code
Code number Notation
number
1
Design-related
1
causes 1.1
1.2
2
Fabrication/
2 installation-
related causes 2.1
2.2
Failure related to 3.1

3 operation/
maintenance 3.2
3.3
3.4
4
Failure related to
4 management 4.1
4.2
5
5.1
5.2
5 Miscellaneous
5.3
5.4
5.5
Subdivision of the failure cause Description of the failure cause
Inadequate equipment design or configuration (shape, size, technology,
General configuration, operability, maintainability, etc.), but no further details
known
Improper capacity Inadequate dimensioning/capacity
Improper material Improper material selection
General Failure related to fabrication or installation, but no further details known
Fabrication error Manufacturing or processing failure

Installation or assembly failure (assembly after maintenance not
Installation error
included)
Failure related to operation/use or maintenance of the equipment but

General
no further details known
Off-design or unintended service conditions, e.g. compressor operation

Off-design service
outside envelope, pressure above specification, etc.
Operating error Mistake, misuse, negligence, oversights, etc. during operation
Maintenance error Mistake, errors, negligence, oversights, etc. during maintenance
Failure caused by wear and tear resulting from normal operation of the
Expected wear and tear
equipment unit
General Failure related to management issues, but no further details known

Documentation error Failure related to procedures, specifications, drawings, reporting, etc.
Management error Failure related to planning, organization, quality assurance, etc.
Miscellaneous - general Causes that do not fall into one of the categories listed above
No cause found Failure investigated but no specific cause found
Common cause Common cause/mode
Several causes are acting simultaneously. If one cause is predominant,
Combined causes
this cause should be highlighted.
Other None of the above codes applies. Specify cause as free text.
Unknown No information available related to the failure cause
ails known

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Standardize of FMEA _ high level map

1- Divided the crane into components as per GOS (Reference SMP)

a) desired function is not obtained (e.g. failure to start);

The failure causes are classified in the following categories:

Failure related to 3.1

General Failure related to fabrication or installation, but no further details known

Fabrication error Manufacturing or processing failure

Failure related to operation/use or maintenance of the equipment but

Off-design or unintended service conditions, e.g. compressor operation

General Failure related to management issues, but no further details known

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