Company Licence for IHS Markit - Maral Kasanova - order 424229

FEDERATION EUROPEENNE DE LA MANUTENTION

Section IX
FEM
SERIAL HOIST UNITS 9.755
Measures for achieving safe working periods for
motorized seriar hoist units (S.W.P.) 06.1993 (E)

1 Introduction, definitions and other relevant guidelines, standards and rules

For technical reasons, it is of advantage for a user to adapt serial hoist units as far as possible to the actual loads.
For this purpose, serial hoist units are classified into 8 groups of mechanisms in accordance with table 1 resulting
from the application of the following regulations (ISO 4301/1, FEM 9.511, FEM 9.661, FEM 9.671).
Many elements involved in the distribution of forces in a serial hoist unit are not visible during the prescribed ins-
pection intervals and cannot be checked. The onset of damage, therefore, cannot be or hardly be recognized. On
reaching the theoretical utilization D, at the latest, hazards may occur with increasing probability.
The theoretical utilization D given in table 1 determines, in conjunction with the actual operating condi.
tions, safe working periods (~afe Working Eeriods; see definitions), for all elements of serial hoist
units.
It is therefore the objective of this rule to determine measures for achieving §.afe Yllorking J;2eriods over the entire
duration of service, although - according to the state of the art - premature failure cannot be ruled out.
Furthermore, the fulfillment of the basic safety and health requirements of the guideline of the Council
89/392/EWG and supplement guideline 91/368/EWG for avoiding special hazards resulting from lifting proces-
ses, e.g. due to fatigue and aging, makes it necessary to adhere to the measures contained in this rule.

1.1 Definitions
- Theoretical duration of service D
Is the calculated total operating time of a serial hoist unit for a duration of service of approx. 10 years classified
according to groups of mechanisms based on FEM 9.511.
- Safe working period (S.W.P.)
The safe working period results from:

actual duration of service S < 1

theoretical duration of service D - .

- Actual duration.of service S (h)

The actual duration of service of the serial hoist unit is defined as the effective operation, based on operating
hours, load spectra and any factors f.
- kmi documented actual load spectrum factor per inspection interval
- Ti effective number of operating hours per inspection interval (h).
- f factor depending on the type of recording in accordance with 3.1, 3.2, 3.3, 6.2.1 and 6.2.2
- km1 to km4: .factors of the load spectrum (see table 1)
- Total duration of service (h)
The total duration of service of a serial hoist unit is defined as the period from commissioning to final taking out
of operation.

continued on pages 2 to 5

Federation Europeenne de la Manutentlon (Section IX)

Copyright by FEM Section IX. Available in English (E), French (F). German (D) Sources of supply see back page
Company Licence for IHS Markit - Maral Kasanova - order 424229

Page 2 FEM 9.755 (06.93)

Table 1: Theoretical duration of service 0 (h)

tOm lCm lBm lAm 2m 3m 4m 5m
Groups of mechanisms
Ml*) M2 M3 M4 M5 M6 M7 M8

Line Load spectra, load

spectrum factor Theoretical utilization D (h)

light 11 L1
1 K=0.5 800 1600 3200 6300 12500 25000 50000 100000
(Kml = 0.125 ~ 0.5 3)
medium 2/L2
2 0.5 < K < 0.63 400 800 1600 3200 6300 12500 25000 50000
(Km2 = 0.25 ~ 0.63 3)
- - f------
-heavy 3/L3 I
3 0:63 < K < 0.8
(Km3 = 0.5 ~ 0.8 3)
200 400
-
i 800 1600 3200 6300 12500 25000

very heavy 4 1 L4
4 0.8 < K < 1 100 200 400 800 1600 3200 6300 12500
(Km4 = 1 ~ 1_0 3)

*) M1 to M8 according to ISO 4301/1 (currently being revised)

For safe operation during the entire duration of service, the following assumptions are made:
- load-related selection of serial hoist units to FEM 9.511
- adherence to prescribed inspection intervals
- adherence to operating, inspection and maintenance instructions of the manufacturer
- carrying out general overhaul (GO)

Operation
G03: recording acc.
14 Theoretical duration of service to 3.2 and 3.3
12
G03: recording acc.
G01 G02
1O+-~-------k--------:llIr----'-------+--~ to 3.1

8
6
4 /n)
/
2 / years
O-F-+-:--i--+-+-t-+-+-I-t-1'--t--+-+-+-I-t-+~-+--+-t-I--+-+-+--t-+-t-l--+~-t-+-+-If-+-+-+-t--+ __
2 468 10 12 14 16 18 20 22 24 26 34 36 38 40

-
A
=S.W.P.1 ~S.W.P.2 ~S.W.P.3
acc. to 3.2; 3.3
A
=S.W.P.3
acc. to 3.1
total duration of service

GO : general overhaul 1 general overhauls

1) : operation as classified
2) : variable operation per year, operation higher than classified
3) : operation lower than classified: theoretical duration of service is not reached after 10 years
n) : the new theoretical duration of service determined after each GO can be identical with, lower or higher than
the previous one and must be specified by the manufacturer

1.2 Other relevant guidelines, standards and rules

89/3921EWG,91/368/EWG,
ISO 4301/1,I80/DI8 9927/1,
FEM 9.511, "FEM 9.661, FEM 9.671
Company Licence for IHS Markit - Maral Kasanova - order 424229

(06.93) FEM 9.755 Page 3

2 Indication of theoretical duration of service D

Suppliers of serial hoist units (manufacturers, suppliers, importers, etc.) must document the theoretical duration of
service D in the operating instructions. It must also be stated: .
- which parts, components or equipment must always be replaced during a GO (even if no damage can be detec-
ted).
- the parts, components or equipment which must be checked during a GO, by which methods and in which
cases they must be replaced. . .
The operating conditions on which the above is based must also be described. They may be defined by specifying
the group of mechanisms (ISO 4301/1, FEM 9.511) or the load spectrum factor km.
The following calculation is based on a comparison of the actual duration of service S with the theoretical duration
of service D In load spectrum 4, very heavy, with km4 = 1.

3 Recording the operating conditions

Recording of the operating conditions can be subdivided into three classes (3.1 to 3.3). The user is responsible for
recording and documenting them in the test book. Documentation must be carried out at least once a year during
the prescribed inspections (ISO/DIS 9927/1).

3.1 Recording using instruments

(e.g. load spectrum recorder)
The load spectra and the corresponding operating hours are recorded by suitable equipment. The actual duration
of service S is obtained by evaluating the recorded data.

3.2 Doc·umentation and suitable counters

(e.g. elapsed time indicator)
The actual load spectra andlor the factors of the load spectrum (km1 to km4) as well as the corresponding opera-·
ting hours Tj are documented by the user. The serial hoist unit is fitted with a suitable counter (for time or distance)
for calculating the effective operating hours Ti.
The serial hoist unit is fitted with a lifting load Iimiter (overload protection device), (friction coupling, electrical over-
load cut-out device, etc.).;·~
'\
3.3 Documentation without counting devices
The user documents the load spectra and operating hours in accordance with 3.2, however, without suitable
counting devices. ..:

4 Assessment of safe working period (S.W.P.) .

During each recurring inspection; the person in charge of inspection (expert engineer) checks whether the serial
hoist unit is still being operated within the SW.P.
Depending on the method of recording (3.1 to 3.3), the theoretical duration ofservice D has been reached, when:

4.1 For recording according to 3.1

The recording device indicates value D as actual duration of service S or can be calculated as

n
S = . I. (Kmi x Ti) ~ D
1=1
The serial hoist unit is operated within a safe working period when

S
D
D taken from table 1, line 4.
Company Licence for IHS Markit - Maral Kasanova - order 424229

Page 4 FEM 9.755 (06.93)

4.2 For recording according to 3.2

In each documented period of time i, a partial duration of service Si is calculated and multiplied by a factor f = 1.1.
The theoretical duration of service D has been reached, when:

n
S = . L (1.1 x Si) ~ D
1=1
where Si = Kmi x Tj

The serial hoist unit is operated within a safe working period when

S
D
D taken from table 1, line 4.

4.3 For recording according to 3.3

Since time overruns are not limited and therefore cannot be recorded, partial duration of service values Si must be
multiplied by a factor f = 1.2. .
The theoretical duration of service 0 has been reached, when:

n
S= L (1.2 x Si) ~ D
i= 1
where Si = Kmi x Tj

The serial hoist unit is operated within a safe working period when

S S 1
o
o taken from table 1, line 4.

5 Measures applicable on reaching the theoretical duration of service

It is assumed that all inspections prescribed for the serial hoist unit or the equipment in which the serial hoist unit is
used are carried out, that prior to reaching the theoretical duration of service D, any damage is appropriately
repaired and that maintenance work as well as replacement of wear parts is carried out competently in accordan-
ce with the specifications of the manufacturer. .
When reaching the theoretical duration of service 0, i.e.
s
·0
the serial hoist units may only be used after a general overhaul has been carried out.
When recording operating conditions according to 3.2 and 3.3, the general overhaul must be carried out
no later than 10 years after commissioning.
The general overhaul must be initiated by the user and carried out by the manufacturer or persons authorized by
the manufacturer, and it must be documented in the test book.
For each general overhaul, the manufacturer must specify the following:
- which new theoretical duration of service D is applicable
- the new maximum period up to the next general overhaul GO (max. 10 years in the case of recording according to 3.2 and
3.3).
Company Licence for IHS Markit - Maral Kasanova - order 424229

(06.93) FEM 9.755 Page 5

6 Interim criteria
The following interim rules apply to serial hoist units already in operation prior to rule 9.511 becoming effective:

6.1 Theoretical duration of service D*

The value subsequently indicated by the manufacturer, supplier, importer, etc. has to be entered for 0* (h).
If no information is available and no conclusions can be drawn by comparison with applicable rules and thus appli-
cable design values, a theoretical remaining duration of service of 5 % of the values, line 4 of table 1 is assumed.

6.2 Retroactive recording of operating conditions

In accordance with section 3, the operating conditions must be documented retroactively starting with commissio-
ning. This total period may be divided into periods covering different operating conditions (and particularly, peri-
ods where these are known or not known, and periods out of use).
- For periods with different but known operating conditions, the calculation of the actual partial duration of service
is carried out retroactively in accordance with section 4.214.3.
- For periods with unknown operating conditions, 6.2.1 applies.
- For periods out of use, 6.2.2 applies.
Ouring the first check (annual inspection) after this rule has become effective, the sum of all partial duration of ser-
vice values S* calculated retroactively must be entered into the test book.

6.2.1 Periods with unknown operating conditions

The following assumptions are made:
- Operating conditions of km = 0.25 are assumed.
- The annual operating time is assumed to be 250 (h).
(1 h per day x 250 days per year).
The partial duration of service S* determined retroactively must be multiplied by a factor f = 1.5.
S* = (1.5 x 0.25 x 1 x 250 x number of years)

6.2.2 Periods out of use

As a precaution, the following assumptions are made:
- Operating conditions are determined theoretically to be km = 0.125.
- Theoretical annual operating time is assumed to be 125 (h). (0.5 (h) per day; 250 days per year).
The partial duration of service S* determined retroactively must be multiplied by a factor f == 1.5.
S*= (1.5 x 0.125 x 0.5 x 250 x number of years)

6.3 Measures applicable on reaching the theoretical duration of service and when frequency of defects
increases
A general overhaul in accordance with section 5 must be carried out if:
- the sum of all partial duration of service values determined retroactively equals the value of the theoretical
duration of service 0*
- the theoretical duration of service 0* has been reached'during the annual inspection
- the frequency of defects increases or the condition of the serial hoist unit deteriorates considerably before the
theoretical duration of service 0* has been reached
- the theoretical remaining duration of service of 5 % of the value in the table has been reached.
If a manufacturer cannot specify a necessary general overhaul (in accordance with section 5), the serial
hoist unit must be taken out of operation.
Company Licence for IHS Markit - Maral Kasanova - order 424229

Erstellt durch den Technischen AusschuB der Sektion IX der

Pr~pared by the Technical Committee of Section IX of the
Etabli par le Comite Technique de la section IX de la } Federation Europeenne de la Manutention (FEM)

Sekretarlat der FEM Sektlon IX

Sekretariat: c/oVOMA
Secretariat: Fachgemelnschaft Fordertechnlk
Secretariat: Postfach 71 08 64
0·60498 Frankfurt

Zu beziehen durch das oben angegebene Sekretariat oder durch die folgenden Nationalkomitees der FEM
Available from the above secretariat or from the following national committees of the FEM
En vente aupres du secretariat ou des comites nationaux suivants de la FEM

Belgique Italia
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1- 20133 Milano

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Deutschland
Comite National Luxembourgeois de la FEM
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VDMA
Grande-Duche de Luxembourg
Fachgemeinschaft F6rdertechnik R. Alcide de Gasperi 7/B.P. 1304
Lyoner StraBe 18 L-1013 Luxembourg
Postfach 71 08 64
0-60498 Frankfurt/Main
Nederland
Nederlands Nationaal Comite bij de FEM .
FME/GKT
Espafia Bredewater 20
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Asociaci6n Nacional de Manutencion (AEM) NL - 2700 Ad Zoetermeer
ETSEIB - PABELLON I
Diagonal, 647 Norge
E - 08028 Barcelona Norwegian FEM Groups
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Standardiseringssentral NVS
Oscars gate 20 I P.O. Box 7072 H
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Engineering and Electrotechnicallndustries FIMET
Comissao Nacional Portuguesa da FEM
Etelaranta 10
Federa<;:ao Nacional do Metal
SF - 00131 Helsinki
FENAME
Rua do Quelhas, 22-3
P- 1200 Lisboa
France
Schweiz / Suisse / Svizze{a
Comite National Fran<;:ais de la FEM
clo Syndicat des industries de materiels de manutention Schweizerisches Nationalkomitee der FEM
39/41 rue Louis Blanc - 92400 Courbevoie Verein Schweizerischer Maschinen-Industrieller (VSM)
cedex 72 - 92038 Paris la Defense Kirchenweg 41 Postfach 179
CH - 8032 Zurich

Sverige
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Bridge House Storgatan 5, Box 5510
Smallbrook Queensway S - 11485 Stockholm
GB - Birmingham B5 4JP