SECTION ION 4-2.4: 4-2.4: MAINTEMAINTENANCNANCEE
4-2.4.1
4-2.4.1 Preventive Preventive MaintenanceMaintenance
(a)
(a) The manufactThe manufacturer shall furnisurer shall furnish operation h operation andand main
maintenantenancece informinformationation (para(paras.s. 4-1.3.4-1.3.33 throthroughugh 4-1.3.4-1.3.6).6). A preventive maintenance program shall be established A preventive maintenance program shall be established and should be based on the recommendations of the and should be based on the recommendations of the crane
crane manufmanufacturacturer orer or a qualifa qualifiedied persperson. Dateon. Datedd recrecordsords should be kept available.
should be kept available.
(15) (15)
(15) (15)
Copyright ASME International Copyright ASME International Provided by IHS under license with ASME
Provided by IHS under license with ASME Licensee=University of Alberta/5966844001, User=ahmadi, rozitaLicensee=University of Alberta/5966844001, User=ahmadi, rozita
- - - - ` ` , , ` ` , , ` ` , , ` ` , , , , ` ` , , , , , , ` ` ` ` ` ` , , , , ` ` , , , , , , ` ` ` ` ` ` , , , , , , ` ` ` ` - - ` ` - - ` ` , , , , ` ` , , , , ` ` , , ` ` , , , , ` ` - - - - - -
ASME B30.4-2015 ASME B30.4-2015
(b)
(b) Replacement parts shall be at least equal to the Replacement parts shall be at least equal to the original manufacturer’s specifications.
original manufacturer’s specifications.
4-2.4.2
4-2.4.2 Maintenance Maintenance ProcedureProcedure
(a)
(a) Before major adjustments or repairs are started, Before major adjustments or repairs are started, the following precautions shall be taken:
the following precautions shall be taken: (1)
(1) A traveling-type crane to be repaired should A traveling-type crane to be repaired should be
be moved moved to to a a location location where where it it will will cause cause the the leastleast in
interterferferencencee witwithh othotherer cracraneness andand opeoperatrationionss inin theareathearea.. (2)
(2) All controllers shall be at the OFF position. All controllers shall be at the OFF position. (3)
(3) The main or emergency switch shall be open The main or emergency switch shall be open and locked in the OPEN position, except for test and locked in the OPEN position, except for test purposes.
purposes. (4
(4)) Warning or OUT OF ORDER signs shall be Warning or OUT OF ORDER signs shall be placed by appointed personnel.
placed by appointed personnel. (5)
(5) WhWhereree ototheherr crcrananeses araree inin opopereratiationon onon ththee sasameme runway, rail stops or other suitable means shall be pro- runway, rail stops or other suitable means shall be pro- vided to prevent interference with the idle crane. vided to prevent interference with the idle crane.
(6)
(6) Where temporary protective rail stops are not Where temporary protective rail stops are not available, or practical, a signalperson shall be placed at available, or practical, a signalperson shall be placed at a visual vantage point for observing the approach of an a visual vantage point for observing the approach of an active crane and warning its operator.
active crane and warning its operator. (b)
(b) After adjustments or repairs have been made, the After adjustments or repairs have been made, the crane shall not be returned to service until all guards crane shall not be returned to service until all guards have been reinstalled, limiting and protective devices have been reinstalled, limiting and protective devices reactivated, trapped air removed from hydraulic sys- reactivated, trapped air removed from hydraulic sys- tems, and maintenance equipment removed. Warning tems, and maintenance equipment removed. Warning or
or OUOUTT OFOF ORORDEDERR sisigngnss shshalalll bebe reremomovevedd byby apappopoinintedted personnel
personnel onlyonly..
4-2.4.3
4-2.4.3 AdjusAdjustmenttments and Repairss and Repairs
(a)
(a) Any hazardous condition disclosed by the inspec- Any hazardous condition disclosed by the inspec- tion requirements of Section 4-2.1 shall be corrected tion requirements of Section 4-2.1 shall be corrected before
before operation operation of of the the crane crane is is resumed. resumed. AdjustmentsAdjustments and repairs shall be performed only by designated and repairs shall be performed only by designated personnel.
personnel. (b)
(b) AdjustAdjustmenments shats shallll be maibe maintainntaineded to ensto ensureure corrcorrectect fun
functioctioninningg ofof comcomponponenents.ts. TheThe folfollowilowingng araree exaexamplmples:es: (1)
(1) functional operating mechanisms functional operating mechanisms (2)
(2) limiting devices limiting devices (3)
(3) control systems control systems (4)
(4) braking systems braking systems (5)
(5) power plants power plants (c
(c)) Repairs or replacements shall be provided as Repairs or replacements shall be provided as needed for operation. The following are examples: needed for operation. The following are examples:
(1
(1 )) crane hooks showing defects described in crane hooks showing defects described in para. 4-2.1.3(h) shall be taken out of service; repairs by para. 4-2.1.3(h) shall be taken out of service; repairs by welding or reshaping are not recommended.
welding or reshaping are not recommended. (2)
(2) critical parts that are cracked, broken, bent, or critical parts that are cracked, broken, bent, or excessively worn or corroded.
excessively worn or corroded. (3)
(3) pitted or burned electrical contacts should be pitted or burned electrical contacts should be corrected only by replacement and in sets. Controller corrected only by replacement and in sets. Controller par
partsts shoshoulduld bebe lublubricricateatedd asas rerecomcommenmendedded byby thethe manman-- ufacturer or a qualified person.
ufacturer or a qualified person. (d)
(d) Remote-control stations shall be kept clean with Remote-control stations shall be kept clean with function identification labels legible.
function identification labels legible.
18 18
4-2.4.4
4-2.4.4 WelWelded Construded Constructionction
Welding procedures and welding operator qualifica- Welding procedures and welding operator qualifica- tions for use in repair or alteration of load-sustaining tions for use in repair or alteration of load-sustaining members shall be in accordance with ANSI/AWS D14.3 members shall be in accordance with ANSI/AWS D14.3 or ANSI/AWS D1.1. Where special steels or other mate- or ANSI/AWS D1.1. Where special steels or other mate- rials are used, the manufacturer shall provide welding rials are used, the manufacturer shall provide welding procedure instructions. The type of metal used for load- procedure instructions. The type of metal used for load- sustaining members shall be identified by the manufac- sustaining members shall be identified by the manufac- ture
turer r (see para. (see para. 4-1.3.54-1.3.5).).
4-2.4.5
4-2.4.5 LubricLubricationation
(a)
(a) All moving parts of the crane, for which lubrica- All moving parts of the crane, for which lubrica- tion is specified, should be regularly lubricated. Lubri- tion is specified, should be regularly lubricated. Lubri- cating systems should be checked for delivery of cating systems should be checked for delivery of lub
lubricricanant.t. CarCaree shoshoulduld bebe taketakenn toto folfollowlow manmanufaufactucturerer’sr’s recommendations as to points of lubrication, mainte- recommendations as to points of lubrication, mainte- nance of lubricant levels, and types of lubricant to be nance of lubricant levels, and types of lubricant to be used.
used. (b)
(b) Machinery should be stationary while lubricants Machinery should be stationary while lubricants are being applied and protection provided as called for are being applied and protection provided as called for in paras. 4-2.4.2(a)(1) through (a)(6), unless equipped in paras. 4-2.4.2(a)(1) through (a)(6), unless equipped for automatic lubrication.
for automatic lubrication.
SECT
SECTION ION 4-2.5: 4-2.5: ROPE ROPE INSPEINSPECTIONCTION,,
REPLACEMENT, AND
REPLACEMENT, AND
MAINTENANCE
MAINTENANCE
4-2.5.1 4-2.5.1 GeneraGenerallAll inspections shall be
All inspections shall be performed by performed by designated per-designated per- son
sons.s. AnyAny defdeficiiciencenciesideniesidentifitifieded shashallll bebe exaexaminmineded andaanda de
detertermiminanatiotionn mamadede byby aa ququalalifiifieded pepersrsonon asas toto whwhetetheherr they constitute a hazard.
they constitute a hazard.
4-2.5.2
4-2.5.2 InspecInspectiontion
(a)
(a) FreqFrequent Inspectuent Inspectionion (1)
(1) All running ropes should be visually inspected All running ropes should be visually inspected once each working day.
once each working day. (2)
(2) Counterw Counterweight eight movemovemenment t roperopes, s, if if proprovidedvided,, should be visually inspected at least once a month. should be visually inspected at least once a month.
A visual inspection shall consist of observation of all A visual inspection shall consist of observation of all rope th
rope thatat can reacan reasonabsonably bely be expeexpected to be incted to be in use duruse duringing the day’s operations. These visual observations should the day’s operations. These visual observations should be
be concerned concerned with with discovering discovering gross gross damage, damage, such such asas listed below, which may be an immediate hazard. When listed below, which may be an immediate hazard. When such damage is discovered, the rope shall either be such damage is discovered, the rope shall either be removed from service or inspected as outlined in (b) removed from service or inspected as outlined in (b) below
below.. (-a)
(-a) disdistortortiontion ofof thethe rorope,pe, sucsuchh asas kinkinkinking,g, crucrush-sh- ing,
ing, unstrunstrandinanding,g, birdbirdcagincaging,g, mainmain strastrandnd displadisplacemecement,nt, or core protrusion; loss of rope diameter in a short rope or core protrusion; loss of rope diameter in a short rope length or unevenness of outer strands provide evidence length or unevenness of outer strands provide evidence that rope replacement should be considered
that rope replacement should be considered (-b)
(-b) general corrosion general corrosion (-c)
(-c) broken or cut strands broken or cut strands
(15) (15) (15) (15) - - - - ` ` , , ` ` , , ` ` , , ` ` , , , , ` ` , , , , , , ` ` ` ` ` ` , , , , ` ` , , , , , , ` ` ` ` ` ` , , , , , , ` ` ` ` - - ` ` - - ` ` , , , , ` ` , , , , ` ` , , ` ` , , , , ` ` - - - - - -
ASME B30.4-2015 ASME B30.4-2015
Fig.
Fig. 4-2.5.24-2.5.2-1 -1 CorCore Fe Failurailure in e in 1919 7 Rotation-Resistant Rope7 Rotation-Resistant Rope
Reduction of rope diameter Reduction of rope diameter
GENER
GENERAL NOTAL NOTE: E: Note the lenNote the lengtheningthening of lay and redug of lay and reduction of diamction of diametereter..
(-d)
(-d) numnumbeberr,, disdistritributibution,on, andand typtypee ofof visvisibliblee brbro-o- ken wires [see paras. 4-2.5.3(b)(1) and (b)(5) for further ken wires [see paras. 4-2.5.3(b)(1) and (b)(5) for further guidance]
guidance] (-e)
(-e) core core failurfailure e in in rotatirotation-ron-resistaesistant nt roperopes s (see(see Fig. 4-2.5.2-1)
Fig. 4-2.5.2-1) (3)
(3) Particular care shall be taken when inspecting Particular care shall be taken when inspecting boom
boom hoist hoist ropes ropes and and sections sections of of rope rope subject subject to to rapidrapid deterioration, such as flange points, crossover points, deterioration, such as flange points, crossover points, and repetitive pickup points on drums.
and repetitive pickup points on drums. (4)
(4) Particular care shall be taken when inspecting Particular care shall be taken when inspecting rotation-resistant ropes because of their susceptibility to rotation-resistant ropes because of their susceptibility to damage from handling and misuse and potential for damage from handling and misuse and potential for deterioration when used on equipment with limited deterioration when used on equipment with limited design parameters.
design parameters.
Internal deterioration of rotation-resistant ropes may Internal deterioration of rotation-resistant ropes may not be readily observable.
not be readily observable. (b)
(b) PeriodPeriodic Inspectioic Inspectionn (1)
(1) Inspection frequency shall be determined by a Inspection frequency shall be determined by a qualified person and shall be based on such factors as qualified person and shall be based on such factors as expected rope life as determined by experience on the expected rope life as determined by experience on the particular installation or similar installations, severity particular installation or similar installations, severity of environment, percentage of lifts at maximum rating, of environment, percentage of lifts at maximum rating, freq
frequencuency y rates of rates of operaoperation, and tion, and exposexposure to ure to shockshock loa
loads.ds. InsInspecpectiontionss neeneedd notnot bebe atat equequalal calcalendendarar inintertervavalsls and should be more frequent as the rope approaches and should be more frequent as the rope approaches the end of its useful life. However, this inspection shall the end of its useful life. However, this inspection shall be
be made made at at least least annuallyannually.. (2)
(2) These inspections shall cover the entire length These inspections shall cover the entire length of the rope. Any deterioration resulting in appreciable of the rope. Any deterioration resulting in appreciable loss of original strength, such as described below, shall loss of original strength, such as described below, shall be noted and
be noted and determination made as determination made as to whether furtherto whether further use of the rope would constitute a hazard.
use of the rope would constitute a hazard. (-a)
(-a) points listed in (a) above points listed in (a) above (-b)
(-b) rereduductictionon ofof roropepe didiamameteeterr duduee toto loslosss ofof cocorere support or internal or external corrosion
support or internal or external corrosion (-c)
(-c) severely corroded or broken wires at end severely corroded or broken wires at end connections
connections (-d)
(-d) severely corroded, cracked, bent, worn, or severely corroded, cracked, bent, worn, or improperly applied end connections
improperly applied end connections (3)
(3) Care shall be taken when inspecting rope sec- Care shall be taken when inspecting rope sec- tions subject to rapid deterioration, such as the tions subject to rapid deterioration, such as the following:
following: (-a)
(-a) sections in contact with saddles, equalizer sections in contact with saddles, equalizer sheaves, or other sheaves where rope travel is limited sheaves, or other sheaves where rope travel is limited
(-b)
(-b) sections of the rope at or near terminal ends sections of the rope at or near terminal ends where corroded or broken wires may protrude
where corroded or broken wires may protrude (-c)
(-c) sections subject to reverse bends sections subject to reverse bends
19 19
(-d)
(-d) secti sections of ons of rope that are rope that are normnormally hiddenally hidden during routine visual inspection, such as parts passing during routine visual inspection, such as parts passing over sheaves
over sheaves
4-2.5.3
4-2.5.3 Rope ReplRope Replacemeacementnt
(a)
(a) No precise rules can be given for determination of No precise rules can be given for determination of the
the exaexactct timtimee forfor roropepe rereplaplacemcemenent,t, sinsincece manmanyy vavariariableble factors are involved. Once rope reaches any one of the factors are involved. Once rope reaches any one of the sp
spececifiifieded crcriteiteriria,a, itit mamayy bebe alallowloweded toto opopererateate toto ththee enendd of the work shift, based on the judgment of a qualified of the work shift, based on the judgment of a qualified person. The rope shall be replaced prior to the next use person. The rope shall be replaced prior to the next use of the equipment.
of the equipment. (b)
(b) Removal criteria for rope replacement shall be as Removal criteria for rope replacement shall be as follows:
follows:
(1) Broken Wires (1) Broken Wires
(-a)
(-a) in running ropes, six randomly distributed in running ropes, six randomly distributed broken
broken wires wires in in one one lay lay or or three three broken broken wires wires in in oneone strand in one lay
strand in one lay (-b)
(-b) in rotation-resistant ropes, two randomly in rotation-resistant ropes, two randomly distributed broken wires in six-rope diameters or four distributed broken wires in six-rope diameters or four ran
randomdomlyly disdistritributbuteded brbrokeokenn wirwireses inin 30-30-roropepe diadiametmetersers (-c)
(-c) in in stanstandindingg roropespes,, thrthreeee oror mormoree brbrokeokenn wirwireses in one-rope lay anywhere in the wire rope
in one-rope lay anywhere in the wire rope (2)
(2) one outer wire broken at the contact point with one outer wire broken at the contact point with the core of the rope indicated by an externally protrud- the core of the rope indicated by an externally protrud- ing wire or loop of loose wire
ing wire or loop of loose wire (3
(3)) kinking, crushing, birdcaging, or any other kinking, crushing, birdcaging, or any other damage resulting in distortion of the rope structure damage resulting in distortion of the rope structure
(4)
(4) evidence of heat damage from any cause evidence of heat damage from any cause (5)
(5) rereduductioctionsns frfromom nomnominainall rorope dipe diameameterter ofof mormoree than 5%
than 5% (6)
(6) Attention shall be given to end connections. Attention shall be given to end connections. Upon development of two or more broken wires adja- Upon development of two or more broken wires adja- cent to a socketed end connection, the rope shall be cent to a socketed end connection, the rope shall be resocketed or replaced. Resocketing shall not be resocketed or replaced. Resocketing shall not be atte
attemptemptedd ifif thethe reresulsultingting roropepe lenlengthgth willwill bebe insinsuffufficieicientnt for proper operation.
for proper operation. (c)
(c) Broken wire removal criteria cited in this Volume Broken wire removal criteria cited in this Volume apply to wire rope operating on multilayer drums, apply to wire rope operating on multilayer drums, rega
regardlerdless of ss of sheasheave material. The ve material. The user shall user shall contacontactct the sheave, drum, or crane manufacturer or a qualified the sheave, drum, or crane manufacturer or a qualified person for broken wire removal criteria for wire ropes person for broken wire removal criteria for wire ropes operating on sheaves and single layer drums made of operating on sheaves and single layer drums made of material other than steel.
material other than steel. (d)
(d) Replacement rope and connections shall have a Replacement rope and connections shall have a strength rating at least as great as the original rope and strength rating at least as great as the original rope and
Copyright ASME International Copyright ASME International Provided by IHS under license with ASME
Provided by IHS under license with ASME Licensee=University of Alberta/5966844001, User=ahmadi, rozitaLicensee=University of Alberta/5966844001, User=ahmadi, rozita
- - - - ` ` , , ` ` , , ` ` , , ` ` , , , , ` ` , , , , , , ` ` ` ` ` ` , , , , ` ` , , , , , , ` ` ` ` ` ` , , , , , , ` ` ` ` - - ` ` - - ` ` , , , , ` ` , , , , ` ` , , ` ` , , , , ` ` - - - - - -
ASME B30.4-2015 ASME B30.4-2015
connections furnished by the manufacturer. Any devia- connections furnished by the manufacturer. Any devia- tion from the original size, grade, or construction shall tion from the original size, grade, or construction shall be specified
be specified by a by a rope manufacturerrope manufacturer, the , the hoist manufac-hoist manufac- turer, or a qualified person.
turer, or a qualified person. (e)
(e) RopRopes Not in es Not in RegRegulaular r UseUse.. All rope that has been All rope that has been