It's usual to cut back on regular expenses when business slows down to keep the business continuing. Companies need to maintain their budget first but also need to split their maintenance budget as well. Cutting back on the crane maintenance and its inspection costs might be vulnerable and expensive in the long run and short run.
It's important to maintain Crane and hoists both as well as possible. It is because cranes and hoists are the most important and effective things on a construction site. Failing to maintain this may cause the following obstructions-
- Lack of crane and hoist inspection may cause crane accidents. Such accidents can injure and take the lives of hundreds of workers and people. If there is any malfunction in any components of cranes and hoists may lead to an accident. This unsafe environment can create panic among workers.
- It will also decrease the reputation of the company. Because the organization, which does not value the employees' life, should be completely responsible for that mess.
- These crane accidents also cause damage to the property of the company. It will damage the land as well as the nearby entities. It would be best if you fixed that damaged things first before restarting the project. It will also delay the project time duration. These will make your client unhappy, and you might lose some of your good clients for these unwanted delays.
- You need to repair that massively damaged Crane also, which can lead you to huge expensive repairs. Thus, poor maintenance and inspection may take your Crane into a fatal condition.
How often you should inspect your Crane
There are four categories for Crane and hoist inspection, according to ANSI (American National Standard). They are-
- Initial Inspection
It is a routine inspection for newly installed Crane or hoists and for reinstalled, alternated, or modified equipment types.
- Functional Test Inspection
You need to test the functionality of your Crane before every shift. According to OSHA, you need to do the test daily-
- Functional operating mechanisms against malfunction with suitable actions
- Hoist chains also need monthly Inspections. There should be a record of it with the date of inspection, a serial number of the inspection, and the signature of the person who performed the inspection.
- Watch out for any cracks or deformation in hooks. It should have an inspection record like a hoist chain also.
- Frequent Inspection
This inspection depends on the usage of your Crane. A crane under 'normal service' should have a monthly inspection, whereas a crane under 'heavy service' should have a daily or weekly review.
This frequent inspection does not need a record like a functional test inspection. But there should be some documentation that will show your concern about your company's safety measurements.
- Periodic Inspection
Like the Frequent Inspection, Periodic Inspection also depends on the usage of the Crane. For this inspection, cranes under 'normal service' should have a yearly inspection, and cranes under 'severe service' should have a quarterly review.
According to OSHA, if the Crane is not active for more than a month but has been used within six months, you need to perform both a Periodic and Functional test inspection before using it.
According to CMAA (Crane Manufacturer Association of America), an experienced crane inspector should have a minimum of 2000 hours of field hours of crane servicing, maintenance, repairing, functional testing experience.
This criterion has to be fulfilled under any circumstances; if a person has not received such training, he should not be eligible for such inspection.
CMAA also define that the inspector should have -
- Training in the Overhead Crane's area related to safety and design codes.
- They should be aware of how to write a report and documentation report.
- Fully used to with crane and hoist terminology.
- Effective communication skills.
- Ability to operate crane instruments and hoists properly.
OSHA overhead crane and hoist inspection by certified inspector includes-
- Introduction of the sight
- Check that all motions agree with control device marking.
- Check that hoist is not out of service.
- Check if there is any unusual sound from hoist mechanisms during hoist operation.
- All controls should be at an off position.
- Inspection of the electrification system.
- Inspection of the safety lock-out of the electrical system during operation
- Inspection of the lubrication system. Check if there is any leakage on the Crane and the floor as well.
- Check that the lower and upper limits of the hoist stop lifting.
- Check out if there is any runway problem; provide rail stops or any other suitable thing to prevent the malfunctioned Crane's involvement.
- Write down the inspection report in detail and note down if any malfunction is there in the system.
At last, regular inspection is the best way to maintain your Crane. The routine inspection identifies problems earlier and helps to fix them before having major issues. It will keep up the capability of your cranes and hoists at best. It will also help you keep your employees safe, increase the company's reputation, reduce costly maintenance, and extend the activity period of the pieces of equipment. That’s why you should never neglect to inspect the cranes of your factory.
Why Shouldn’t You Neglect Crane And Hoist Inspections?
Overhead crane and hoist systems are one of the most crucial components of any industrial facility or manufacturing plant. They can lift, lower and horizontally move a heavy load. Almost all of the facilities and plants use them for loading, unloading and moving heavy cargo where other equipment cannot. In short, they are the pillar of any manufacturing plant or industrial facility. As a result, they are always on some task and end up being heavily used. Any equipment can take damage and wear out due to heavy lifting and hoisting.
Overhead crane and hoist systems can result in mechanical failure. This can be the worst nightmare for any manufacturing plant as it can completely stop the manufacturing procedure. Also, a poorly operated crane and hoist system can compromise the safety of the workers and other equipment. Regular and periodic inspections of the overhead crane and hoist systems can minimize all the risks of working with faulty equipment. It does not only ensure security but also improves overall functionality.
Importance of regular inspections and their benefits
Overhead crane and hoist systems are an integral part of any industry. Frequent inspection of the equipment makes sure that they run smoothly. This makes the procedure very important. They also have benefits in the long run.
- Avoid mechanical failure
You want your equipment to be worth their cost. That is why inspections of overhead crane and hoist systems can prove to be beneficial. Though it can be time-consuming for the programmes to run regularly, ignoring them can cost you more in the future. The total failure of the equipment can take several days to several weeks to repair. In those periods, you lose your productive hours and also a lot of money for the repair.
Regular inspections by a professional can highlight the minor issues and avoid them forming into a larger issue. By that, it can prevent mechanical failure and disruption in the production facility. Fixing the short-term damages can help you to avoid any major problem and dysfunctionality of overhead crane and hoist systems.
- To be compliant with industry standards.
There are laws by the Government for industry standards and maintenance. It is important that the crane and hoist systems comply with the standards set by the Government. Maintenance and security standards are necessary for any manufacturing plant. The higher quality standards often minimize the damage, which affects the different components of the crane and hoist system. With that, periodic inspections by professionals are essential for the equipment to work at its optimal level.
Hiring a professional to inspect your machinery regularly will assure compliance with the law and regulations. Not only does it minimize technical hazards but also increases the safety of the work environment.
- Ensuring the safety of employees
Employees in an industry or manufacturing plant rely on the full functionality of the equipment. Lack of inspection of the crane and hoist systems leave very little room for repairs. Thus, the lifting equipment becomes prone to failure. This can be the cause of disastrous consequences for the employees.
Inspecting the overhead crane and hoist systems regularly diminishes the chances of equipment breakdown. It also helps to find out the weak spots, and working on it immediately eliminates any potential reason for accidents. The employees must feel safe and confident while working with and around overhead crane and hoist systems.
How the inspection procedure works
We have known why it is important to inspect overhead crane and hoist systems and their benefits. Now let’s know how the inspection and maintenance procedure is completed.
It takes place before putting the equipment into work for continued safe operation. Due to constant usage, several mechanical components operate at the same time. So, each of them requires individual attention.
There are also mechanical and electrical parts that need separate testing methods. The overhead crane and hoist system go through two types of inspection. The two types constitute frequent and periodic inspections of the system.
The former mainly focuses on physical damage, corrosion and deformation. These can happen on a daily, weekly or even monthly basis. Leakage check-in pipelines, hydraulic systems inspection, checking for deformities in the hook, hoist and connection inspection are performed daily or weekly. The electrical components, power supply equipment, gauge inaccuracy and switches inspection are done on a quarterly or annual basis. Checking bolts and rivets, motors and warning devices also fall under the quarterly programme.
After its completion, the defective parts are repaired or changed as per requirement. Then, the personnel make sure that all the components are synchronized and ready. Once they are ready to operate, the crane and hoist systems are tested using heavy loads until it reaches their optimum manoeuvrability. A certified professional can take care of the entire programme efficiently.
Summary
Regular inspections of overhead crane and hoist systems can serve in many ways. It helps to be in compliance with the industrial standards, helps minimize crane downtime and ensures the safety of the employees. Moreover, it makes the plant run efficiently. For all these benefits, an inspection of overhead crane and hoist systems regularly is mandatory.
