Structure Maintenance Manual

钢结构维修手册

2 增加内容 2015/10 龚振青 张明海

1 第一版 2015/8 龚振青 张明海

版本号 说明 日期 编辑 审核

上海振华重工（集团）股份有限公司
ZPMC Structure Maintenance Manual 钢结构维修手册

INDEX 目录

PREFACE 前言 .................................................................................................................................. 2

1. General 总则........................................................................................................................... 8

2. TESTING PROCEDURE 检查方法 .................................................................................................. 9

3. INSPECTION 检查 ....................................................................................................................... 10

4. REPORTING PROCEDURE 检查报告 ........................................................................................... 11

5. INSPECTION PERIOD 维修周期 .................................................................................................. 13

6. TYPICAL REPAIRE PROCEDURE 典型的维修程序....................................................................... 14

7. SAFETY 安全 ............................................................................................................................... 15

本文得到陆工院国际专家 Feroze Vazifdar 的协助和指导，在此感谢。

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ZPMC Structure Maintenance Manual 钢结构维修手册

PREFACE 前言

This manual is a crane structure inspecting program for fatigue cracks to improve the structural
reliability. Cracks are one of defects, also have porosities, slag inclusions etc. From inspection
aspect, steel plates and weldings are determine whether or not qualified by specific standard. If
the base metal or welding internal discontinuity length and slag inclusion size are comply the
standard, than it's qualified. Imperfections are unavoidable, it's normal that base metals or
weldings are inspect to be qualified which still have micro defects. That is to say, all welded steel
structures contain millions of micro undetected defects, even qualified base metals or weldings
will still have defects like undercut porosities, slag inclusions etc. Some of these cracks will grow
when subjected to fluctuating stresses beyond a threshold value. Stress fluctuation is the only
mechanism that causes cracks to grow. A crack grows by zipping atomic bonds. The rate of
growth increases dramatically as the crack grows larger. Under the premise that design and
manufacture meet the specification, there is no method today to guarantee the emergence and
growth of random cracks.

本手册用于检查起重机钢结构疲劳裂纹来提高结构的可靠性。裂纹只是缺陷的一种表现型
式，还有夹渣气孔等。从检验的角度，不管是钢板还是焊缝，按照一定的标准规范来判别只
有合同与不合格，如母材或焊缝内部的晶料不连续性长度及夹渣大小在标准许用范围内，就
是合格的。世上不存在完美无瑕的东西，任何检验合格的钢材及焊缝，存在微小缺陷是非常
正常的。也就是说，所有的焊接钢结构都包含成千上万的、未被发现的微小缺陷，即使合格
的母材或焊缝仍然存在标准允许的咬边，气孔，夹渣等缺陷，缺陷是不可避免的。当受到的
交变应力超过一定值时，其中一部分缺陷会逐渐变大。交变应力是导致缺陷增长的唯一机制。
裂纹随着原子键的撕裂而增长。当裂缝越来越大时，裂缝的增长速度也会越来越快。在设计
和制造等符合相应规范的前提下，现如今没有任何办法保证结构不产生随机的疲劳裂纹及其
扩展。

Crane manufacturers base their fatigue criteria on producing a “Damage Tolerant Design”.
Normal structures are designed so that some damage is tolerated in case of failure. Satisfactory
performance of the “Damage Tolerant Design” depends on adequate methods of fatigue crack
detection and the ability to repair or replace the damaged component. The intent of a proper
Structural Maintenance Program is to define a method of routinely inspecting for fatigue cracks
to significantly improve the structural reliability of the structure against failure.

起重机制造商以“损伤容限设计”作为疲劳设计标准。正常结构设计指的是，在结构发生问
题时，是允许一些小范围的损伤的。符合要求的损伤容限设计取决于适当的疲劳裂纹检测方
法，以及修理或更换损伤部件的能力。合理的结构维修计划目的正在于定义一套常规的疲劳
裂纹的检测方法，从而显著提高抵抗结构失效的结构可靠性。

A damage tolerant design provides a reliability of two standard deviations on the Gaussian curve.
Two standard deviations provides a reliability of 97.7%. This means that even if the

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ZPMC Structure Maintenance Manual 钢结构维修手册

manufacturer minimizes the effect of fatigue cracks using proper design, fabrication, material
selection, and quality control, there is still likelihood that 2.3% (approx. 1 in 50 probability of
failure) of all details will develop fatigue cracks. To most Customers and to most crane
Manufacturers, this reliability is unacceptable. Some other methods is needed to improve the
reliability..

损伤容限设计提供了正态分布的两个标准偏差的可靠度。两倍标准偏差可靠度为 97.7%。
这意味着，即使制造商通过采用合理的设计、制造、材料选型、质量控制等手段使疲劳裂纹
的影响降到最低，仍有 2.3%（约 1/50）的可能性细微的裂纹会发展成为疲劳裂缝。对于大
多数客户和大多数起重机制造商来说，这是不可接受的，需要采取其它措施提高其可靠性。

The only way to improve the reliability from two standard deviations to three standard deviations
(99.9% reliability, 1 in 1000 probability of failure) is to inspect the crane details using appropriate
NDT examination (VT,MT or DPT, UT, RT) at inspection intervals based on the principles of fracture
mechanics, and cumulative fatigue damage analysis. Hence, the necessity for a Comprehensive
Inspection and Structural Maintenance Program is obvious.

将可靠度从两倍标准偏差提高到三倍标准偏差的唯一途径（99.9%的可靠度，1/1000）是采
用适当的无损探伤检查（VT，MT 或 DPT，UT，RT）对起重机的细节以一定的周期进行检
查，其检查周期的确定是基于断裂力学原理和疲劳累积损伤分析。

因此，进行全面的结构检查和维修程序的必要性是显而易见的。

ZPMC’s NDT inspection intervals are divided into 6 year(600,000 cycle), 12 year(1.2million cycle)
and 24 year(2.4million cycle) inspection intervals. Typically 6 and 12 year intervals are reserved
for Fracture Critical Members (FCM) and a few highly stressed Non‐fracture Critical Members
(NFCM). FCM’s are non‐redundant members whose failure can result in failure of the crane or
trolley or dropping of the load. 6 year intervals are reserved for highly restrained details with
Cumulative damage ratios greater than 0.5. In addition, as a minimum, all welds are required
be visually inspected annually. Special attention is, the number of years and the number of cycles
shall adopt whichever comes first.

ZPMC 的产品 NDT 检查周期分为 6 年（60 万循环），12 年（120 万循环）和 24 年（240

万循环）。6 和 12 年的周期一般适用于重要的受拉危险构件（FCM）和一些高应力的非受
拉危险构件（NFCM）。受拉危险构件（FCM）是非冗余构件，其失效会导致起重机或小车
结构的失效，或是吊载坠落的重大事故。6 年的周期适用于累积损伤率大于 0.5 的高约束细
节部位。此外，作为最基本的要求，至少每年都要对所有焊缝进行目测检查。特别注意的是，
年限和循环数数以先到为准。

Warranty Inspection

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ZPMC Structure Maintenance Manual 钢结构维修手册

保用检查

The first NDT inspections shall be made during the warranty period by an independent agency
retained by the owner, in accordance with the structural maintenance program. T The
procedures and inspection interval shall be the same as used for the routine periodic inspections.
The inspection results shall be reported to ZPMC. ZPMC shall submit relevant guidance or a plan
to repair any defects found.

在保用期内，应该由客户负责或牵头组织独立的第三方检测机构按照结构维修手册对整机进
行定期检查。检查程序和检查周期与维修手册规定的例行定期检查程序相同。检查结果应当
告知 ZPMC，如果发现任何的缺陷，ZPMC 将免费提交相应的指导意见或维修方案。

Customer may understand any warranty has it's limitation. The conditions which are not specified
in contract or technical specification, manufacturer reserves the right of interpretation. Crane
one year operating corresponding to 100,000 cycles. Warranty period and related moving cycles
shall adopt whichever comes first.

用户应理解任何保用都是有前提的，凡是没有在合同、技术规格书等写明前提的，制造厂保
留前提的设定权和解释权。起重机使用一年时间所对应的循环数为 10 万，在保用期和相对
应的循环数之间，保用期以先到者为准。

In warranty period, customer uses the cranes under specific conditions, defects which are caused
by the crane design not comply with standards or technical specification at the time sign the
contract, unqualified materials, manufacture not comply to design after check and confirm by
manufacturer, manufacturer will provide maintenance or change relevant parts for free. The
inspection after repair will responsible by owner. Normal wearing will not include in the warranty.

在保修期内，用户在规定的使用条件下，起重机由于制造厂设计没有符合当时的规范或合同
签订时的技术规格书，材料采用了不合格产品，生产没有按照设计图纸要求制造，所造成的
故障(或问题)经制造厂检验并确认后均由制造厂负责维修或更换相应备件。维修后的验收由
用户负责。正常的磨损和损耗也不包括在保用范围内。

When cranes under long period of operating(normally 5 years or 500,000 moves, whichever
comes first), the fatigue cracks, and these cracks extension will be acceptable, crane will be safe
as soon as repair in time. The owner should repair these fatigue cracks use repair program
provided by manufacturer. Because these cracks are not due to neither design not comply with
standards or technical specification at the time sign the contract, nor unqualified materials or
manufacture not comply to design ZPMC will take no responsibility if there is any damage or loss
due to absent/irregular/improper/defective inspection carried out by customer or his designated
representative.

起重机在长时间使用（一般在起重机投入使用 5 年或 50 万循环---以先到为准）之后，产生

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ZPMC Structure Maintenance Manual 钢结构维修手册

疲劳裂纹、以及这些裂纹出现扩展是必然现象，是可接受的，只要得到及时修理仍可以保证
起重机安全作业。即使在保用期内用户也应该对这些疲劳裂纹按照制造厂提供的维修程序负
责修复。因为这些裂纹不是因为制造厂的设计没有符合当时的规范或合同签订时的技术规格
书，也不是因为生产过程中采用了不合格材料或没有按照设计图纸制造而产生的。由于用户
或用户指定的任何人员缺乏检查/不规范检查/错误检查导致的事故和损失，振华制造厂将不
承担任何责任。

If the owner modify the crane specification, parameter, working condition and manufacturer
original design etc., or transfer the possession to others without agreed by manufacturer, than
manufacturer's warranty will be ended.

若用户自己擅自改变了起重机性能、参数、使用条件以及制造厂的最初设计，或未经制造商
同意将起重机转给其他用户等，制造厂的保用期以及其它承诺将自动终止。

All Subsequent Inspections

所有的后续检查

All inspections after the warranty inspection will be made according to the recommended
inspection intervals, which is included in the Structural Maintenance Program prepared by
ZPMC’s responsible Structural Engineer. The inspection method shall be selected based on the
Structural maintenance Program. The Customer will as a minimum carry out the inspection
provided in the inspection manual. However, he may at his discretion increase the level and
location for the inspections. Also, if local codes and ordinances require more stringent or more
frequent inspections than provided in the manual, the local codes and ordinances shall govern.

在保用期之后的所有后续检查，应该按照由 ZPMC 的责任结构工程师编写的结构维修手册

建议的检查周期进行。检查方法的选择也应基于结构维修手册。客户应至少完成结构维修手
册中要求的检查内容。当然，客户也可以酌情增加检查的等级和位置。与此同时，如果当地
法规和条例要求比手册中给出的更为严格、更为频繁的检查，应遵从当地法规和条例的规定。

Inspection records shall be prepared by the Customer’s inspector as shown in the reporting
procedure provided in the manual. The inspection record should be kept by the owner and one
copy of the inspector’s records and the repair procedures shall be provided to ZPMC. The cost
of all inspections subsequent to the warranty inspection, and the repairs resulting from the
subsequent inspections shall be at the Customer’s expense. ZPMC shall have no responsibility
for the subsequent inspections or repairs, carried out by the Customer. Nor shall ZPMC be
responsible for any consequences resulting from failure of the Customer to carry out the
inspections at the recommended intervals as provided in the manual.

检查记录应由客户的检查员根据维修手册中提供的报告程序完成。检验员的记录和维修程序

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应做好归档，在保用期内的检查记录可供 ZPMC 随时抽查。在保用期过后，所有的后续检

查以及由后续检查产生的维修费用应由客户承担。ZPMC 将不对用户进行的后续检查和维
修负责，也不对由于用户没有按照维修手册要求的周期进行检查而产生的一切后果负责。

Only critical locations are selected in the Inspection manual to detect fatigue cracks. Critical
locations on all members are those locations where fatigue cracks if any would be expected to
initiate. These locations need to be inspected by NDT methods such as MT or UT. The
inspection region shall extend a reasonable distance beyond the critical point. MT shall be used
at critical locations of fillet and partial penetration welds and UT shall be used at critical locations
of complete joint penetration welds. VT shall be used at all locations of all potential fatigue
cracks.

维修手册只选取对关键部位进行疲劳裂紋检测。所有构件上预期可能发生疲劳裂紋的部位都
是关键部位。这些部位需要用无损检测方法如 MT 或 UT 对其进行检查。检查区域应在关键
点周围进行适当距离的延伸。磁粉探伤（MT）应用于角焊缝和部分熔透焊缝；超声波探伤
（UT）应用于重要的全熔透焊缝；目测检查（VT）应用于所有可能发生疲劳开裂的部位。

If a crack is found at a point of inspection, the inspection region of weld shall be extended to
similar structure, similar position, similar working load parts etc. If necessary, The region shall be
approved by a qualified structural engineer.

如果检查中发现某点存在裂紋，应增加检查范围，如类似的结构、类似的位置、相似受力大
小或状况的构件等，必要时检查范围需由有资质的结构工程师认可。

The inspection report should be in English and owner required language. Especially inspection
report in warranty period should be in English, so ZPMC may provide proper service in time.

检查报告应推荐采用英文及用户指定的当地语言，尤其是保用期内的检查报告要采用英文，
以让 ZPMC 制造厂能够及时、准确地为用户提供服务。

ZPMC design and manufacture the crane structure according to AWS D1.1, this manual also
based on AWS D1.1, but if projects use other standards, than specific standards applied, but shall
not less than the requirement in this manual.

ZPMC 一般按 AWSD1.1 标准设计制造起重机钢结构，本手册中也基于 AWSD1.1 相关的要

求，但如有项目约定采用其它的标准，需符合相关的标准要求，但应不低于本文中的相关要
求。

ZPMC may offer customers support in this maintenance program, under customer requirement.

用户在维修时若有任何问题，ZPMC 均能提供技术支持。

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ZPMC Structure Maintenance Manual 钢结构维修手册

This manual is for crane owner do the maintenance, it has same effect with other crane
documents( drawings etc.).

本维修手册供起重机用户维修保养使用，与其它起重机资料（如设计图纸等）具有同等效力。

The definitions of warranty in this manual are especially for structure, but shall not against
definitions in contract.

本维修手册关于保用的解释，是尤指结构方面的，但该保用应不违背主合同中的规定。

ZPMC reserve all the rights of this manual, ZPMC has the final power of interpretation.

本维修手册版权归 ZPMC，解释权属于 ZPMC。

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ZPMC Structure Maintenance Manual 钢结构维修手册

1. General 总则

The Structure Maintenance Manual consists of developing inspection procedures and

determining inspects intervals based on rational analysis using the principles of fracture
mechanics.

钢结构维修手册由设定检查程序和制定检查周期两部分组成。这些内容基于断裂力学原理进
行理论分析。

All welded steel structures contain millions of undetected micro defects. Imperfections are
unavoidable. The owner has responsibility to periodic inspect the crane according to structure
maintenance manual, and repair the defects according to repair procedure in time.

所有的焊接钢结构都包含成千上万的、未被发现的微小焊接缺陷。缺陷是不可避免的。鉴于
裂纹的随机性和不可预见性，用户有责任在结构维修手册的基础上进行周期性检查，并按照
维修程序及时迅速地修复缺陷。

Periodic inspection is required to detect fatigue to avoid serious failure in the crane structure.
The inspection method shall be selected to detect the fatigue crack. The critical locations on all
members are those locations where fatigue cracks, if any, would be expected to initiate. These
locations need to be inspected by NDT methods such as MT or UT. The inspection region shall
extend a reasonable distance beyond the critical point. MT shall be used at critical location of
fillet and partial penetration welds and UT shall be used at critical locations of complete
penetration welds. VT shall be used at locations of all potential fatigue cracks. Dye Penetrate
Testing (DPT) may be substituted for magnetic testing where applicable.

为避免起重机结构的严重破坏，必须对疲劳裂纹进行周期性的检测。必须选择合适的检查方
法检测疲劳裂纹。所有构件中的关键位置都是预计会发生疲劳初始裂纹的位置。这些部位需
要用无损检测方法如磁粉检测或超声波检测对其进行检查。如果检查中发现某点存在裂纹，
应增加检查范围。磁粉检测适用于角焊缝和部分全熔透焊缝；超声波检测适用于重要的全熔
透焊缝;目视检测应用于所有可能发生疲劳裂纹位置，也包括结构中的母材。染料渗透检测
方法在一些区域可以替代磁粉检测方法。

When cracks are found, repair is necessary. It's normal to restore the structure to its original
condition, or if it's not practical, modify the cracked detail maybe necessary, this should be
decided by professional engineer. It may have some different modify plans, the manufacturer
plan shall take place.

发现裂缝后需要进行修复。一般的做法是把裂缝处修复到结构的原状态，如果复原不能实现
时，就需要修改裂纹处的结构细节，这应当由专业的工程师确定。 修复的方案可能有很多
种，应以制造商认可的方案为准。

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If fatigue cracks are found with significant frequently than expected, it's may be caused by over
stress during crane operation. A review of the operation should be made to check if over stress is
occurring. Further measures should be developed to avoid happen again.

如果发现疲劳裂缝数量大大多于预期，可能是由于起重机操作中有超载的情况。应当检查操
作程序，检查是否有超载的情况发生。并采取措施防止再次发生。

2. TESTING PROCEDURE 检查方法

In general, non destructive testing(NDT) is sensitive to the external condition and to the
characteristic of the structure details. Inspections must be carried out by qualified professionals
using recognized methods.

一般的，无损探伤（NDT）对结构的外表状态和细节特性是敏感的。检查应由有资质的人员
用认可的方法进行。

The inspection tables in this manual list all inspect requirement. The structure details which
require NDT in inspection table, if VT check not find surface defects, it may possible determine by
qualified professional engineer if it still need required NDT inspection or need what method of
NDT.

结构检查附表中，罗列了各个点的检查要求，其中关于 NDT 检查要求和方法的，若表面 VT

检查未发现任何缺陷，则可由有资质的专业工程师决定是否仍需要进行 NDT 或采用何种更
有效的 NDT 检查方法。

2.1. Visual Testing

The surface should be free of dirt and grease. Cracked paint requires further inspection
by MT or UT.

目视检测

测试表面应当去除污垢和油脂。油漆破裂处需要进一步使用磁粉检测和超声波检测

2.2. Magnetic Partial Testing

The test surface must be free of loose rust and moisture. If required, clean painted surface
with power tools by grinding or needle scaling.

An electromagnetic device, such as a yoke, shall be used to develop a magnetic field.

磁粉检测

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检测表面一定要去除浮绣以及湿汽。如果有需要，可以使用光滑的除锈工具清洁油漆
表面。

利用电磁装置如偏转线圈进行磁性区域的设定。

2.3. Ultrasonic Testing

Testing should be done in accordance with approved method and the requirements
shown in "INSPECTION".

超声波检测

检测应该按照手册中“INSPECTION”这一节中提到的方法和要求执行。

2.4. Bolt Testing

Bolt testing shall according to <crane maintenance manual> Chapter 2.4.

螺栓测试

螺栓测试应按《起重机维修手册》2.4 节进行测试。

3. INSPECTION 检查

3.1. Inspection procedures shown on one side of the center line of symmetry, apply to both sides,
Inspection shown on near side apply to the inspection of the far side also.

在对称结构中心线的一侧中显示的检查程序，适用于对称结构的另一侧。在近端显示的检
查同样适用于远端。

3.2. All bolted and welded joints shall be visual inspected (VT).

所有的螺栓连接和焊接都应进行目视检测。

3.3. Visual inspection shall be performed by a certified welding inspector per AWS QC‐1 or
equivalent contract required qualifications.

目视检测应当由具有 AWS QC‐1 或合同所要求的资格认证的焊缝检查员执行。

3.4. NDT inspection shall be performed by an ASNT Level II inspector under direct supervision of
an ASNT Level III inspector or equivalent contract required qualifications.

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ZPMC Structure Maintenance Manual 钢结构维修手册

无损检测应当由 ASNT II 级检查员在 ASNT III 级检查员的指导下完成, 或合同所要求的资格

认证的焊缝检查员执行。

3.5. NDT shall comply with the requirements of AWS D1.1 latest edition, including "Section 6
Inspection", and all provisions applicable to cyclically loaded structures. For FCM AWS D1.5
applied.

无损检测应当遵守 AWS D1.1 最新版本的要求。该规范包含“第 6 节.检查”和所有适用于

周期载荷结构的要求。FCM 构件按 AWSD1.5 要求执行。

3.6. Required inspection is shown on the attached sketches for the critical details.

对于危险细节的必要检查在附上的概略图中已经标出。

3.7. Where MT or UT inspection is indicated on one side only, the inspector shall inspect the
weld from both side unless otherwise noted.

在仅于焊缝一侧标示磁粉检测和超声波检测的地方，除非另有说明，检查员应从焊缝两侧
进行检查。

3.8. At least 10% of all bolts in each areas shall be ring tested according to crane <maintenance
manual> Chapter 2.4.

在各区域内，至少 10%的螺栓按《起重机维修手册》2.4 节进行测试。

3.9. The inspection shall be recorded. The records shall include inspection progress, inspection
result, and inspectors etc. to make sure the documents can be reviewed in whole crane
service life.

对起重机检查和保养必须做好记录，保证在使用寿命年限内检查过程、检查结果、维修过
程、维修内容、检修人员、验收人员等有案可稽。

4. REPORTING PROCEDURE 检查报告

All indications of detected defects should be shown on the table attached with sketches of the
weld detail. The following information should accompany the report:

所有检查到的缺陷都应当在附上的焊缝细节概略图后的表格中标记出来。报告应包括以下内
容：

The owner of the crane is responsible for keeping complete records of all inspections. Where
defects are found, the owner must ensure that the repair is made. The complete documents of all

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defects, repairs and subsequent re‐inspections must be maintained for the full operational life of
the crane.

起重机业主有责任保留所有检查的记录。当发现缺陷业主必须确保已经进行修复。起重机整
个寿命中所有的缺陷，修复，和再检查文件都必须保留。

4.1. Crane identification.

起重机编号

4.2. Defect location: right hand side, left hand side, which boom panel, crane leg number,
seaside, landside, distance in cm to nearest station, etc. Marked on drawing will be a good
method.

缺陷位置：右手边，左手边，哪个平面，起重机立柱编号，海侧，陆侧，离最近的基准
的距离（以 cm 为单位）等。为更清晰，图纸表达是较好的方法。

4.3. The size and extent of defect.

缺陷的尺寸和范围。

4.4. Whether the defect is in the toe of the weld, propagating into the base metal, etc.

缺陷是否位于焊缝的根部，是否扩展到了母材上等。

4.5. Method of testing: VT, MT UT and DPT.

检测方法：目视检测、磁粉检测、染料渗透检测以及超声波检测。

4.6. Inspector's comments and signature of approval by the ASNT Level III inspector in charge.

检查员的意见和负责的 ASNT III 级或相当的检查员的批准签名

4.7. Inspection shall be carried out on each side of the center line of the symmetry.

对称结构中心线两侧和相似结构检查都应当执行。

4.8. Inspector shall advise ZPMC if connection details to be inspected are different than those
shown in the manual, so ZPMC can provide revised inspection for the detail.

如果检查的连接细节与手册中显示的不同，检查员应向 ZPMC 提出建议。ZPMC 可以提

供针对这些细节专门修改的检查。

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5. INSPECTION PERIOD 维修周期

5.1. Initial inspection: Visual inspection six months after cranes acceptance. Subsequent visual
inspection to be carried out annually. More frequent check may be added decide by
situation. Meanwhile if the local regular require more serious or more frequent inspection,
shall be applied. If the crane usage more than 100,000 move/year, VT inspection interval
shall reduce to less than 6month.

初始检查：在起重机交机后 6 个月进行目视检测。随后，目视检测可以一年执行一次。
也可以酌情增加检查的水平等级和位置。与此同时，如果当地法规和条例要求比手册中
给出的更为严格、更为频繁的检查，应遵从当地法规和条例的规定。若起重机使用频繁
程度超过 10 万循环/年，目视检测间隔期不能超过半年。

If the visual inspections give reason to suspect crack growth, additional NDT inspections
must be carried out. These additional test requirements are restricted to the specific welds
that are showing crack growth.

如果目视检查发现怀疑裂缝扩展的情况，就需要增加 NDT 检查。这些增加的检查只限

于发现裂纹扩展处。

5.2. Other maintenance inspection at intervals as shown in manual.

其他维修检查周期在手册中已经指出。

5.3. The first inspection period after repairs should be reduced to half of the original inspection
period, subsequent inspection periods can be increased to the original inspection period if
no further cracking is detected in the first post‐repair inspection.

起重机维修之后，第一次的检查周期减少为原来检查周期的一半。之后，当第一次维修
后的检查没有发现新的裂纹，检查周期可以恢复到原来的周期。

After crane operating 12 years or 1.2 million moves(whichever comes first), VT inspection
interval shall be reduced to half of the original inspection interval. The owner shall notice,
with the crane usage time close to design life, inspection interval shall be reduced.

在运行 12 年或 120 万次循环操作之后（以先到者为先），VT 检查间隔应减少到原来检

查间隔的一半。用户必须清醒地认识到并确保，随着起重机使用时间越来越接近设计寿
命，检查必须越来越频繁，检测周期也越来越短。

After 24 years since start up, the NDT results for some welds may show that there are a
significant number of new cracks since the previous NDT inspection. For these welds, the
NDT must be repeated every year, for the remaining life the crane.

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ZPMC Structure Maintenance Manual 钢结构维修手册

起重机投入使用 24 年后，NDT 检查可能发现一些焊缝在上次 NDT 检查后又有很多新的

裂缝。对这些裂缝在起重机的剩余寿命中，必须每年进行 NDT 检查。

6. TYPICAL REPAIRE PROCEDURE 典型的维修程序

6.1. The repair procedure shall be prepared by qualified structure engineer. It shall comply to the
requirement of AWS D1.1 Structural Welding Code, latest edition, including all provisions
applicable to cyclically loaded structures and Section 8, "Strengthening and Repairing
Existing Structures". For FCM AWS D1.5 applied.

应根据缺陷情况由有资质的结构工程师制定维修工艺。应遵守设计文件和 AWS D1.1 结

构焊接规范的要求。AWSD1.1 结构焊接规范包含所有适用于周期载荷的结构的规定以及
第 8 节“加强和修复现有的结构”， FCM 构件按 AWSD1.5 要求执行。

6.2. All temporary attachments shall be removed after completion of work. Removed weld area
shall be ground smooth and a prime paint coat applied to the surface at once.

在维修工作完成之后，去除所有临时的附件。去除的焊缝区域应当磨光并立即在表面涂
上底漆。

6.3. All repaired joints exposed to weather shall be seal welded.

所有暴露在外的接头应当密封焊接。

6.4. Welders and welding operators shall have current AWS certificates for the material and
processes being used. The repair contractor shall maintain current files of these certificates
and shall provide the certificates to the owner at the owner's request.

焊工和焊缝处理人员必需拥有当前的与材料和工艺相关的 AWS 证书。维修承包商保管

这些证书的文件，在用户有要求的情况下，向他们提供。

6.5. Weld procedures shall be qualified in accordance with AWS D1.1 latest edition.

焊接程序应与 AWS D1.1 最新版本的要求一致。

6.6. NDT may apply according to repair process.

修复后按要求进行 NDT 检查。

6.7. The structural drawings identify fracture critical members(FCM) are also indicated on the
general arrangement drawing in this manual.

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ZPMC Structure Maintenance Manual 钢结构维修手册

结构图纸中标出了断裂危险构件（FCM）。断裂危险构件在该手册中的总图中标出。

6.8. Weld materials shall comply to AWS A5.1‐00 or table 4. For other welding processes, see
applicable AWS standards.

焊接材料应符合 AWS A5.1‐00 或者最新版本中表 4。其他的焊接程序参考适用的 AWS

标准。

6.9. All areas where paint has been removed, or damaged, shall be restored to its original
condition in accordance with the original crane specifications.

所有油漆脱落或破坏的区域应当恢复到原来的情况，与起重机原标准相同。

CAUTION

The structural integrity of this crane requires that no attachments or fixtures of any
kind be welded to any part of the crane without prior written permission from the
manufacturer.

起重机结构的完整性要求在没有得到制造商的许可时，任何附件和装置都不能焊
接到起重机结构的任何部件上，

If design modification is required, the instructions must be got from the

manufacturer.

如需设计变更，需从制造商获得指导。

7. SAFETY 安全

In inspection, rigging and repair process, the repair contractor shall be solely and completely
responsible for the safety conditions for the job site, including safety of the persons and
property, and for all necessary independent engineering reviews of these conditions.

在检查、装配和维修的工作中，维修分包商独立且完全地负责包括工作人员和财产在内
的工作场地的安全以及工作中所有必需的对这些条件的独立审查。

Stairs, ladders railing, or walkways furnished, or modified, by the contractor shall conform to
specifications requirements.

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ZPMC Structure Maintenance Manual 钢结构维修手册

承包商对于斜梯、直梯、栏杆、走道等的安装或修改应当遵守规范要求。

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