REPUBLIC OF KAZAKHSTAN SAFE WORK IN INDUSTRY SUPERVISION AND MINING SUPERVISION COMMITTEE (REPUBLIC OF KAZAKHSTAN GOSGORTECHNADZ GOSGORTECHNADZOR OR [GGTN])
REGULATIONS FOR CRANE DESIGN AND SAFE OPERATION
Binding for Ministries, Agencies, Industries, Associations, Companies (irrespective of their ownership types) and Individuals.
KRANENERGO SCIENTIFIC AND PRODUCTION ASSOCIATION ALMATY 1997
These Regulations have been developed on the basis of Crane Design and Safe th Operation Regulations approved by the USSR Gosgortechnadzor on the 30 of December 1969. Some amendments and additions introduced in the Russian Federation Crane Design and Safe Operation Regulations and approved by Gosgortechnadzor of Russia on the th 30 of December 1992, as well as comments and suggestions of the Republic of Kazakhstan Gosgortechnadzor (GGTN), the Republic of Kazakhstan Ministry of Housing Construction and Development of Areas (Minstroy), the Institute of Kaz Project Steel Structure and other concerned organisations and companies were taken into consideration in the course of the Regulations development development and editing. The Regulations have been reviewed and amended accounting for the experience of crane operation. Changes that have taken place on the engineering level of hoisting units, requirements of current Construction Standards and Regulations (SNIPS), Standards, legislative acts, resolutions and other regulatory documents were also taken into account. The compilers of the first revision hereof will appreciate any remarks and suggestions related to provision of crane safety during its operation to be received from ministries, industries, research and development, as well as designing institutions, companies, GGTN bodies, bodies, crane owners owners and individuals. individuals. Such comments will be considered considered in further revisions of the Regulations. These Regulations Regulations shall come into effect on 01.08.1994. 01.08.1994. The Crane Design Design and Safe Safe Operation Regulations approved by the USSR Gosgortechnadzor on the 30.12.1969 shall be invalid since the above date.
ISBN 5-620-01085-6
Republic of Gosgortechnadzor
Official Publication
Kazakhstan
Kranenergo State Owned Scientific and Production Association. Any reprint is prohibited
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TABLE OF CONTEXT 1. 2. 3.
General Provisions Engineering Requirements Cranes and Gripping Devices Production, Reconstruction, Reconstruction, Maintenance and Installation 4. Hoisting Equipment Design and Assemblage 4.1. Gripping Parts 4.2. Ropes 4.3. Chains 4.4. Drums, Blocks and Sprockets 4.5. Brakes 4.6. Running Wheels 4.7. Supporting Parts, Limit Stops and Bumpers 4.8. Counterweight and Ballast 4.9. Safety Instruments and Devices 4.10. Control Mechanisms and Devices 4.11. Control Cabins 4.12. Guarding 4.13. Galleries, Platforms and Ladders 4.14. Installation of Hoisting Equipment 4.15. Crane Track 5. Cable Type Cranes 6. Hoists and Winches to Lift People 7. Operation of Hoisting Equipment 7.1. Registration 7.2. Commissioning Permit 7.3. Technical Examination 7.4. Supervision and Servicing 7.5. Operation 8. Responsibility for Breaches of the Crane Design and Safe Operation Regulations 9. Emergency and Accident Investigation Investigat ion Procedures 10. Final Provisions Appendix 1. Terminology and Determinations Appendix 2. List of Regulatory Documents to be Applicable for Hoisting Equipment Designing, Fabrication, Maintenance and Operation Appendix 3. List of Head Organisations in Crane Production Appendix 4. Estimation of Tension in a Sling String Appendix 5. Crane Certificate Form Appendix 6. Chain Block Certificate Form Appendix 7. Maximum Permissible Deviations of Rail Tracks (Plane and Profile Views) from the Designed Position Appendix 8. Statement Form for a Crane Rail Track Acceptance at Commissioning Appendix 9. Work Permit Form (for the right of access to crane track and passage galleries of overhead travelling and mobile cantilever cranes to carry out maintenance and other types t ypes of work)
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Appendix 10. Standards to Reject Ropes of Hoisting Equipment Appendix 11. (Reference) International Standards ISO 4301/1, 4302, 4308/1, 4308/2, 4310 and 8087 Appendix 12. Threshold Standards of Load-Lifting Equipment Component Rejection Appendix 13. Standards for Rejection of Detachable Load-Gripping Devices Appendix 14. Knowledge Assessment Assessment Certificate Form for engineering and technical personnel responsible for supervision of load-lifting equipment safe operation, engineering and technical personnel responsible for load-lifting equipment maintenance in good serviceable conditions, and persons responsible for safe performance of work by cranes. Appendix 15. Threshold Standards to Reject Basic Components of Rail Tracks Appendix 16. Knowledge Assessment Assessment Certificate Form for operating personnel (crane operators, their assistants, mechanics, electricians, safety device adjusters, and slingers) Appendix 17. Shift Logbook of a Crane Operator Form Appendix 18. Recommended Signals when Moving Loads by Cranes Appendix 19. Form of a Work Permit for a Crane Operation Close to an Overhead Power Line List of Regulatory Documents Applicable to Facilities Supervised by the Regional State Mining and Technical Supervision Inspectorates (GGTN) of the Republic of Kazakhstan State Emergency Committee. Committee. (The Documents are Available at Kranenergo Research Research and Development Development Association)
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1. GENERAL PROVISIONS 1.1.
These Regulations shall set forth the requirements to hoisting machines and units, as well as load gripping devices, appliances and containers design, set-up, fabrication, installation, maintenance, reconstruction and operation.
1.2.
The Regulations shall be applicable for the following: a) Cranes of all types, including crane-manipulators; b) Power driven trucks (trolleys) travelling along ground rail tracks together with the control cabin; c) Cranes-excavators designed to operate with a hook on a steel line or electric magnet only; d) Power hoisting tackle; e) Winches to hoist loads or people; f) Removable gripping devices (hooks, clamshells, load-lifting electromagnets, etc.); g) Detachable load gripping appliances (slings, shackles, spreader bars, etc.); h) Load containers, with the exception of special containers applied in metallurgy (dippers, bowls, moulds, etc.), as well as at sea and river ports, requirements for which shall be provided by the industry standards and regulations.
1.3.
The Regulations shall not be applicable for the following: a) Hoisting units installed in mines, on sea and river boats and other floating structures, where specific requirements shall apply; b) Excavators designed designed to operate with earth-moving equipment or clam-shells; c) Cranes designed to operate with attached implements only (silent pile drivers, pile draw-out devices, cradle hoists, drilling equipment, etc.); d) Hoisting units for special purposes (e.g. floor, charging and planting machines, boom-cats, electric and combustion engine forklift trucks, pilers, tracklayers and bridge construction units, manipulators, etc.); e) Mounting polyspasts (block and tackle) and structures they are suspended on (masts, shavers, beams, etc.); f) Specific military hoisting units; g) Hand tackle units;
1.4.
Basic terminology and definitions used in the text hereof are described in Appendix 1. The list of standard documents and International standards applicable in Kazakhstan is given in Appendix 2.
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2. ENGINEERING REQUIREMENTS 2.1.
Designing and main research and development organisations (Appendix 3) shall develop standardising and regulatory documentation for hoisting units. Designing, research and development, and specialised organisations authorised (licensed) by Gosgortechnadzor (GGTN) shall develop designs of hoisting units to be fabricated.
2.2.
Designs, requirements specifications and other standard documentation for hoisting units to operate in explosive and inflammable environment shall be developed accounting for the requirements of Electric Unit Design Regulations (PUE) and the following standard documents: RD 24.090.96 and RD 24.090.91, Operation Safety Regulations and Safety Regulations. The design shall provide for arrangements to ensure safe working conditions of such hoisting units in the above environment. The ability of a hoist to operate in an explosive and inflammable environment (with the particular environment category stated) shall be noted both in the certificate and operation instructions.
2.3.
Hoisting units to operate in the areas with the design temperatures below -40 C shall be designed and produced in accordance with the HL (cold) type on the basis of GOST (State Standard) 115150. Hoisting units to operate in seismic areas (above 6 degrees) shall be designed and produced in accordance with SNIP 11-7, as seismic s eismic proof equipment.
2.4.
The company that carries out the corresponding work shall be held responsible for the quality of the design, production, installation, reconstruction and maintenance of a hoisting unit, removable gripping devices and detachable load gripping appliances, as well as for their compliance herewith.
2.5.
Hoisting mechanisms and their parts supplied from abroad shall comply with the requirements hereof. Prior to conclusion of a contract for any hoisting unit supply from abroad, a company (client) shall obtain the certificate of compliance herewith from the certification authority. authority. The certificate, certificate, instructions instructions and any other other operation documentation supplied with hoists shall be translated into the language of 1 international communication in Kazakhstan and comply with the requirements hereof. The client shall get all the possible deviations from these Regulations approved by the Republic of Kazakhstan Gosgortechnadzor prior to signing of the contract. Copies of the approval approval and certificate shall be attached attached with the Hoisting Unit Certificate.
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Russian.
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2.6.
The capacity and other characteristics, as well as the sizes shall comply with State Standards and specifications, and in case they are unavailable, such parameters shall be established in the requirements specifications or other documents in accordance with GOST 15.001.
2.7.
Hoisting units shall be designed in accordance with ISO 4301/1 and other standard documents.
2.8.
Self-propelled, railway and pull-type cranes with booms, cranes-excavators, tower and frame cranes shall be stable in both operating and stand-by stand-b y conditions. Stability of a crane shall be estimated under conditions of a test load, under the load (loaded stability), absence of load (inherent stability), sudden load removal and mounting (dismounting). If operation conditions of a crane require lowering of an unloaded boom in the horizontal position, the boom stability in such position shall be ensured. Stability of a crane shall be estimated in accordance with regulating documents developed by appropriate institutions and approved by the Republic of Kazakhstan Gosgortechnadzor. Gosgortechnadzor.
2.9.
The track gradient of a frame or cantilever crane truck (trolley) shall not exceed 0.003 at the worst position of the truck, and with the greatest operating load. The above rated gradient shall not refer to cranes, which the mechanism of the truck travelling is equipped with an automatic braking system of a closed type, or when the truck is moved with the help of cable haulage.
2.10.
The devices for load lifting and crane radius alteration shall be designed so as the load or boom are lowered with the help of the engine solely.
2.11.
Hoisting unit devices equipped with jaw, friction or other mechanical appliances to switch them on, or to switch over their operating speeds shall be designed in such a way that spontaneous switching or unclenching of the mechanism is impossible. In addition, the possibility of the drive disengagement disengagement without the brake application shall be eliminated for load and boom lifting winches. Application of friction and jaw actuating clutches shall be inadmissible in mechanisms designed to lift people, melted metal or slag, noxious and explosive substances, as well as in power driven mechanisms, with the exception of the following: a) Movement or turning mechanisms with several ranges of speeds to switch from one of them to another; b) The mechanism for a caterpillar crane movement, with a common drive for both tracks designed for their separate control. In cases stated in clauses "a" and "b", the brake shall have an uninterrupted kinematical link with the revolving section of the crane, caterpillar tracks or wheels.
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2.12.
Spline, keyed and bolted joints shall be applied in the assemblies of a hoisting unit that serve to transmit the torque.
2.13.
Spline, keyed and bolted joints of a hoisting unit shall be protected from arbitrary unscrewing or release. r elease.
2.14.
Provision for secure fixation for sliding structures of cranes with telescopic booms and towers shall be made.
2.15.
Lifting mechanisms of forging cranes shall be provided with damping devices.
2.16.
Cable and chain tackle and polyspasts of a hoisting unit shall be designed to eliminate spontaneous falling of the cable (chain) off the tackle, as well as the cable (chain) jam between the block and the pin (the sprocket and pin).
2.17.
Installation of an equalising block or balancer is required if a double polyspast is applied.
2.18.
Traction wheels of hoisting units with a hand drive shall be provided with guides to prevent the chains chains on them from from falling off. The traction chain chain shall be long enough for its lower part to be at the height of 500 mm from the surface, on which the worker operating the unit is located.
2.19.
Steel structures and steel parts of hoisting units shall be protected from corrosion. Arrangements to prevent moisture accumulation shall be provided in box and tubular steel structures of cranes operating in the open air.
2.20.
Safe access shall be provided to the mechanisms, protection devices, power equipment, steel structure components of hoisting units requiring maintenance. Galleries, platforms and and ladders shall be arranged arranged for the purpose. purpose. If there are no platforms and ladders to serve blocks and safety devices, the possibility of the boom lowering shall be provided.
2.21.
Power equipment of hoisting units, its installation, wiring and grounding shall comply with the requirements of the Power Unit Design Regulations (PUE). Power equipment of hoisting units shall be operated in accordance with the Consumer Power Unit Operation Regulations and Safety Regulations for Consumer Power Unit Operation.
2.22.
Automatic shutdown and fixation of mechanisms (the turning mechanism, those of the load and boom winches, boom and bracing jacks lifting, boom sections advancing) shall be provided for cranes with hydraulic drives, to be applied in case of a pipeline break or pressure pressure drop in the hydraulic system. The same shall be provided for crane-manipulators to be applied in case of flexible pipeline breaks.
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2.23.
The hydraulic system of cranes shall comply with the requirements of GOST R 50046 and provide the possibility of pressure control in each operating contour, as well as the possibility to replace hydraulic units, hoses and filters without any liquid discharge from the tank.
2.24.
Steel line slings shall be designed accounting for the number of the line strings and their incline to the vertical line angle (Appendix 4). In case of general-purpose slings with several strings modelling, the design angle between them shall be assumed as equal to 90 . When slings designed designed for a particular load is modelled, the actual angle may be taken as the basis for calculations. The strength margin factor for sling modelling shall be assumed as at least 6. The design of multiple-strand slings shall provide for uniform tension of all the strands.
2.25.
Slings of hemp, caperone and cotton ropes (tapes) shall be modelled accounting for the number of rope strings and the angle of their incline towards the vertical line. The strength margin factor in that case case shall be at at least 8.
3. CRANES AND GRIPPING DEVICES PRODUCTION, RECONSTRUCTION, RECONSTRUCTION, MAINTENANCE AND INSTALLATION 3.1.
All the hoisting units shall be designed and produced in compliance with these Regulations and standard documentation.
3.2.
Cranes and their elements shall be produced at plants with appropriate technical facilities and qualified personnel to provide their production in full compliance with the requirements of the Regulations, standards and specifications, and such plants shall possess a permit (license) for such production issued by Gosgortechnadzor Gosgortechnadzor bodies. The Republic of Kazakhstan Gosgortechnadzor Gosgortechnadzor shall be the authority to issue the above permits. The number and and the date of the permit permit for crane production, as as well as the description of the Gosgortechnadzor body issuing the permit shall be stated in the Crane Certificate. Production of hoisting units not liable for registration in accordance with clause 7.1.2 hereof requires no permit from f rom Gosgortechnadzor Gosgortechnadzor bodies.
3.3.
Executive officers and experts involved in production of cranes, steel structures for them and crane winches, as well as in crane installation and maintenance, shall pass their knowledge hereof assessment in accordance with the Regulations for the Knowledge of Standards and Guidelines Assessment issued by the Republic of Kazakhstan Gosgortechnadzor Gosgortechnadzor (GGTN).
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3.4.
A permit for a non-specialised plant to produce a hoisting unit for their own needs shall be issued by Gosgortechnadzor bodies in the order described below. The company shall submit the following documents for consideration: a) Assembly drawings of the crane and its basic units; b) Specifications for production approved in the established order; c) A certificate to confirm availability of welders attested in accordance with the Welders Attestation Regulations.
3.5.
The company shall submit the following documents to Gosgortechnadzor Gosgortechnadzor bodies in order to obtain a permit to produce designed crane steel structures, winches and safety devices made at the plant as separate elements (overhead beams, booms, etc.): a) Assembly drawings of units to be produced, cinematic, hydraulic and electric diagrams; b) Specifications for production approved in the established order; c) A certificate to confirm availability of welders attested in accordance with the Welders Attestation Regulations.
3.6.
Gosgortechnadzor Gosgortechnadzor bodies shall issue permits to produce cranes and their separate steel structures, winches and safety devices on the basis of the producer inspection results, revision of the documents submitted, and after successful testing of a pre-production pre-production model. Deviations from designs designs and other standard documents may be accepted on an agreement with the authority that has issued their approval. If it is the RoK Gosgortechnadzor Gosgortechnadzor that that has issued the approval, the deviations shall be agreed with that t hat particular body. The producer shall attach a copy of the agreement with the certificate of each crane.
3.7.
If a crane is assembled of units and parts produced at several plants, the assembling plant shall be made responsible for the quality of the product as a hole, and for compliance with these Regulations and State Standards, as well as for the documentation. documentation. The crane certificate certificate shall be compiled compiled on the basis of of the documents documents certifying separate separate units. Such documents documents shall be kept kept at the plant that assembles the crane.
3.8.
Welding quality control requirements and rejection parameters accounting for these Regulations and the procedure of units and the final product acceptance shall be provided by the requirements specifications for the crane or separate steel structures structures alongside with other conditions. conditions. The specifications specifications shall also include information about the material applied in production and welding materials.
3.9.
The producer shall carry out preliminary (mill), acceptance and recurring tests to control the quality of cranes and their compliance with regulations, standards
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and specifications. specifications. Every pre-production model of a crane crane shall undergo preliminary and acceptance testing. 3.10.
The producer shall arrange preliminary (mill) testing of the pre-production model in accordance with the programme and methods developed by the crane designers. Participation of the crane designers and Gosgortechnadzor representatives in crane testing shall be obligatory.
3.11.
Acceptance testing of the crane pre-production model shall be carried out in accordance with the programme developed by the designers, approved in the established order and agreed with the RoK Gosgortechnadzor.
3.12.
The programmes of the crane pre-production model mill and acceptance testing shall be be developed developed accounting for the requirements of ISO 4310. The programmes shall provide testing of cranes for their compliance with the certificates, visual inspection, static and dynamic testing, as well as testing of boom self propelled cranes for stability.
3.13.
The results of pre-production models preliminary and acceptance tests shall be presented in Minutes and Statements, where the Committees' suggestions and conclusions shall be stated.
3.14.
The producers shall carry out recurrent tests of stock-produced cranes in accordance with the programme they develop and get approved by Gosgortechnadzor. Gosgortechnadzor. Gosgortechnadzor's Gosgortechnadzor's representative shall participate in crane testing.
3.15.
The programme of recurrent tests shall provide for testing in compliance with the requirements hereof including visual inspection, idle stroke testing, static and dynamic tests, testing of safety devices and crane characteristics.
3.16.
One of stock-produced cranes shall undergo recurrent testing (once in 3 years).
3.17.
The results of recurrent crane tests shall be entered in a Statement including suggestions and conclusions of the Committee.
3.18.
Every produced crane or its units shall undergo acceptance tests at the QA/QC Department of the producer in accordance with a developed and approved programme. The testing results shall be entered entered in the Crane Certificate.
3.19.
The programme of acceptance testing shall provide for visual inspection, idle stroke testing, static and dynamic tests in compliance with the requirements hereof, testing of safety devices and crane characteristics, as well as testing of the crane running running gear. For cranes dispatched dispatched in the non-assembled non-assembled state, that that programme shall be developed in accordance with the standard documents.
3.20.
Every produced hoisting unit shall be supplied with the following:
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a) Certificate; b) Specifications; c) Operation instructions; d) Assemblage instructions (if required); e) Other documents provided for by appropriate state standards and requirements specifications. If separate steel structures, mechanisms and safety devices for cranes are produced, they shall be supplied with appropriate certificates. 3.21.
The producer shall record every newly produced hoisting unit in a production logbook and and provide it with a nameplate nameplate fastened at at a visible place. The nameplate shall state the name of the producer or its trademark, the capacity of the crane, the date of production, the serial number and other information in accordance with the documentation. documentation. The nameplate nameplate with the data shall be kept on the crane for the whole of its life l ife span. Cranes with a movable truck shall have such nameplates fastened either on the crane or on the truck; and jib, tower and frame cranes shall have the producer's trademark on each of the tower and boom sections in addition to the nameplate bolted at an easily seen place. pl ace. If separate steel structures and units are produced, their data shall be entered into a logbook.
3.22.
The Crane Certificate shall be compiled in accordance with the Form given in Appendix 5, and the certificate for a telpher shall be drawn up in accordance with the Form shown in Appendix 6.
3.23.
Hoisting unit operation guidelines shall be developed by a specialised organisation or producer in accordance with the requirements hereof and GOST 2.601. The Guidelines shall state the following: a) The frequency of units and mechanisms maintenance and service; b) Potential steel structure damages and the ways of their t heir repairs; c) The frequency and methods to test safety devices; d) Methods of brakes adjustment; e) The list of highly wearing-out parts and tolerances for their wear-out; f) The procedure of technical examination; g) The conditions of a clam-shell and magnet application for clam-shell and magnet cranes; h) A rail track for cranes set-up and operation requirements;
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i) The instructions to bring the crane into a safe position in stand-by conditions; j) Safety requirements in case of emergency; emergency; k) The criteria of the crane's threshold conditions to dispatch it to major repairs; l) The life-span of the crane; m) Other instructions on the crane maintenance and operation accounting for its design specificity. 3.24.
The producer shall take into account the deficiencies in a hoisting unit design and production revealed in the course of its operation and make arrangements to eliminate them. In cases, when when the deficiencies deficiencies revealed may impact the safety of a hoisting unit application, the producer must notify all the companies operating such units about the requirement and methods to eliminate such deficiencies. They shall shall also send technical technical documents and and materials, parts and and units required for the replacement. replacement. The body of Gosgortechnadzor Gosgortechnadzor that has issued the permit to produce the hoisting unit shall approve recommendations related to elimination of deficiencies.
3.25.
On identification of deficiencies in a hoisting unit in the course of its assembling or operation, or its incompliance with the requirements hereof, the owner shall send a complaint complaint letter to the producer. A copy of it shall be dispatched to the the certifying body and the Gosgortechnadzor Gosgortechnadzor body that has issued the permit for the unit production. If the hoisting units had been imported, the complaint letter shall be sent directly to the producer and the body that has issued the certificate.
3.26.
On receiving the complaint letter, the producer shall undertake to eliminate the deficiencies and incompliance herewith stated in the letter, if no permit of Gosgortechnadzor Gosgortechnadzor has been issued for related deviations from these Regulations. The producer shall maintain a special logbook of claims, where the information of the claimant, the unit serial number and the claim in brief shall be entered. The producer shall also record other notifications of crane design and production deficiencies in the same logbook.
3.27.
Production of detachable gripping devices and containers shall also comply with the standard documentation and assembly charts; and there must be a permit (license) of the local Gosgortechnadzor body available. If welding was applied during production, the production documents shall include information about it and its quality control.
3.28.
Detachable gripping devices (slings, chains, spreader bars, clamps, etc.) shall be tested at the producing plant after they are manufactured, and after their overhaul, the same shall be carried out at the factory having repaired them.
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Detachable gripping devices shall be visually inspected and tested with the load exceeding their rated capacity 1.25 times. ti mes. Containers for small items, loose and other loads shall be visually inspected after their manufacturing. Containers have no need need to be tested with loads. 3.29.
Information related to detachable gripping devices and containers manufacturing shall be entered into a logbook. logbook. The logbook shall state the description description of the device or container, its capacity, the number of the standard document (assembly chart), the number of the certificate of materials applied, welding quality control results and the results of the gripping device testing or container visual inspection.
3.30.
Detachable gripping devices shall bear a trademark or securely fastened metal labels, with the number, number, lifting capacity and and testing date stated stated on. Detachable gripping devices produced for other companies shall be supplied with a certificate in addition to the trademark (label).
3.31.
The purpose, number, dead weight and capacity shall be marked on containers.
3.32.
Companies with permits (licenses) from Gosgortechnadzor bodies may only carry out reconstruction of cranes with welding application, as well as safety device overhaul overhaul and adjustment. Permits for such work to be be carried out shall shall be issued in accordance with the procedure established by the Republic of Kazakhstan Gosgortechnadzor. Gosgortechnadzor.
3.33.
Crane reconstruction and maintenance shall be carried out in accordance with a design developed by a specialised company. The actual state of a crane (wear-out degree, damages, etc.) shall be taken into consideration while the design is developed. The tower or boom may be shortened without any design on an agreement with a specialised company if the crane certificate or its operation instructions do not provide for the possibility of such change. Special purpose equipment (excavators, boom-cats, etc.) may be reconstructed into cranes on a permission of Gosgortechnadzor bodies, given they comply with the requirements hereof. A specialised company shall confirm the possibility of special purpose equipment use as cranes.
3.34.
The company that repairs and reconstructs cranes shall be provided with requirements specifications including instructions on metals and welding materials to be applied, welding quality control methods, welded joint rejection rates and the procedure of separate units and items acceptance, as well as on paperwork procedures.
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3.35.
After the overhaul and reconstruction is completed, the company that has carried the work out shall state the character of work in the crane certificate and enter the information about materials applied into it stating the number of the certificate for the material. The documents certifying the quality of materials and welding applied shall be kept with the company, which has carried out the welding.
3.36.
A specialised company only may carry out repairs and reconstruction of steel structure load-bearing load-bearing members with welding application. application. The owner may be permitted to repair or reconstruct such crane steel structures on a permit of a Gosgortechnadzor Gosgortechnadzor body only.
3.37.
Repairs, assemblage or other work related to crane design or specifications modification shall be carried out on an approval of the producer or specialised company.
3.38.
Companies engaged in production, maintenance and assemblage of cranes and their units shall be certified in accordance with the Provisions of Hoisting Equipment Certification.
3.39.
Materials for production, maintenance and reconstruction of hoisting equipment and their units shall be applied in compliance with state standards and standard documentation developed by the main crane production organisations.
3.40.
Quality of materials applied in hoisting equipment production, reconstruction and maintenance shall be confirmed with a certificate provided by the supplier, and that of incoming quality qualit y control. If no certificate is available, materials may be applied after their testing in accordance with with standard documentation. documentation. Materials shall be selected selected accounting for the ambient air temperature lowest threshold values for operational and stand-by conditions, the extent of the elements being loaded and the aggressive character of the environment. environment. The data of the applied material type and the lowest threshold temperatures for operational and stand-by conditions shall be stated in the crane certificate.
3.41.
Cast iron with the quality of at least СЧ15 type in accordance with GOST 1412 may be applied to produce the following: a) Tooth gear, worm and running wheels of hoisting equipment with a hand drive; b) Worm wheels of hoisting units with mechanical drives designed for the classification (mode) group of at least M5, with the wheel peripheral speed not exceeding 1.5 m/sec; c) Worm wheels with bronze rims irrespective of the drive type and the hoisting unit mechanism classification (mode) group;
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d) Drums, bodies, reducers and blocks, with the exception of boom and tower crane blocks; e) Brake shoes, drum cantilevers and bearing housings. Mouldings with the quality of at least СЧ20 type in accordance with GOST 1412 may be applied to manufacture brake pulleys of hoisting equipment movement and turning mechanisms. Types of moulding are not regulated for counterweights and non-forced parts. 3.42.
Materials, which previously have not been applied to manufacture, reconstruct and repair hoisting equipment, may be used on the recommendation of a specialised company and approval of the RoK Gosgortechnadzor.
3.43.
Bearing elements of hoisting equipment steel structures shall be welded and welding joints quality shall be controlled in accordance with standard documentation developed by specialised companies.
3.44.
Welders certified in accordance with the Regulations of Welders Attestation only shall be allowed to weld and tack critical elements of steel structures, weld on platforms, railing and stairs of a crane.
3.45.
Welding shall be carried out in accordance with flow sheets developed by the producer or specialised company on the basis of state standards and standard documentation of main crane production organisations, and accounting for characteristics of the structures to be welded.
3.46.
Welding materials applied in crane structure welding shall ensure that mechanical properties (the ultimate stress limit, yield point, extension strain, flare angle and impact strength) of welding seam metal and that of welded joint are not below the lowest limit values of the same basic metal features established for the appropriate appropriate steel steel type in the state state standard or specifications. specifications. The requirement shall be also applicable for welding of railings, ladders and platforms. If steel of different types is applied in one joint, the mechanical properties of the weld metal shall correspond to the properties of the steel with the higher ult imate strength value. Types of additive materials, fluxing agents and protective gases shall be stated in specifications for crane fabrication, overhaul or reconstruction.
3.47.
All cutting methods may be applied to prepare structure elements out of sheets, section steel, pipes, etc. to provide quality in obtaining the shape and sizes of the elements required in accordance with shop drawings. Materials and half-finished products shall be cut in accordance with a technology that will ensure absence of cracks or will avoid deterioration of steel quality at the rims and within the areas of thermal impacts. i mpacts.
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3.48.
Precision of joints within the range of sizes and tolerances set forth in drawings and by process requirements shall be ensured in the course of structures assemblage for welding.
3.49.
Crane steel structures shall be welded inside covered areas to eliminate adverse impacts of weather conditions on the quality of welded joints. Welding in the open air may be permitted in accordance with a specific technology and on condition that appropriate arrangements are made to protect welding from precipitation and wind.
3.50.
The possibility of and procedure for welding at the ambient air temperature below 0C shall be established in the standard documents.
3.51.
Fabrication of welded steel elements with different welding methods application within one and the same unit may be accepted given it is provided for by specifications.
3.52.
Tacks made in the course of a structure assemblage may remain if they are completely melted during welding. Slag shall be removed from tacks prior to welding.
3.53.
Welded joints shall have a stamp or other mark on to identify the name of the welder. The method of welded joints marking marking shall not impair the items marked. Marks shall be applied by way of techniques that will ensure their preservation in the course of the crane crane operation. The technique and and location of the mark mark shall be stated on drawings.
3.54.
The requirement of post welding heat treatment for crane structure bearing elements shall be identified in requirements specifications for crane production, repairs or reconstruction. r econstruction.
3.55.
Welded joint quality control carried out by the QA/QC Department during crane production, assemblage, reconstruction and maintenance shall be performed by way of visual inspection and measuring, mechanical tests and NDT provided for by standard documents.
3.56.
The quality of welded joints shall be tested after their heat treatment (if it is required for the particular welded joint). Welded joint quality control results shall be recorded in appropriate documents (logbooks, charts, sheets, etc.).
3.57.
All the welded joints shall be visually inspected and measured in order to identify the following possible outer deficiencies: a) Ruptures or failures to achieve the perpendicularity of the connected section axes; b) Displacement Displacement of connected element rims;
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c) Deviations from drawings in seam dimensions and shapes (seam height, leg and width, regularity of intensification, etc.); d) Cracks of all types t ypes and directions; e) Bulges, cuts, burns through, non-welded dimples, porosity and other deficiencies. Prior to inspection, the surface of the seam and basic metal sections for at least 20 mm both ways adjoining the seam shall be cleaned from slag, drops and other contamination. Visual inspections of welded joints and their measurements shall be carried out from both sides along along the whole length length of the joint. If the inside surface of a weld is not available for inspection, it may be examined at the outer side only. 3.58.
Inspection of welded joints with the help of radiological methods shall be carried out in compliance with GOST 7512, and ultrasound testing shall be performed in accordance with GOST 14782. Welded joints at designed elements of steel structures shall be tested after elimination of deficiencies deficiencies revealed by visual inspection inspection only. The initial and the end parts of butt-joint seams at box-like beam, column, boom, and gooseneck gooseneck structures shall be inspected without fail. The summarised length of welded sections to be tested shall be established by standard documents, and shall be at least as follows: a) 50% of the joint length at each joint of a box-like or grid steel structure tensile chord; b) 25% of the joint or compression wall section length at each joint of a compression chord or at compression wall sections; c) 75% of the joint length at each joint of boom and gooseneck structures, and rack boxes of frame cranes; d) 25% of the joint length for all the other butt-joints not stated in clauses a), b) and c); e) 25% of the joint length for other welded joints tested with the ultrasound technique. Prior to X-ray or or gamma tests, tests, the appropriate appropriate sections of the welded joint shall be marked so that they may be easily identified at X-ray X -ray or gamma films.
3.59.
Welded joint quality estimation on the basis of visual inspection and NDT results shall be carried out in accordance with requirements specifications for crane production, production, assemblage, repairs repairs or reconstruction. The specifications specifications shall include the standards of welded joint quality estimation, which shall prevent production of defective units of reduced safety and operational reliability.
3.60.
The following deficiencies shall be unacceptable for welded joints:
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a) Cracks of all types and directions in the metal of the seam, along the fusion line and in the close to the seam area of basic metal including micro-cracks revealed by microscopic analyses; b) Faulty fusion (inadequate penetration) located at the surface along the cross section of the welded joint; c) Faulty fusion at the top (root) of angle and T- welded joints made without bevelling; d) Pores located as a continuous grid; e) Cuts and bulges f) Non-welded dimples; g) Blowholes; h) Non-welded burns-through burns-through in the metal of the seam; i) Burns-through and sub-melts of basic metals (in case of pipe contact butt welding); j) Rim bias above rated values provided by drawings. 3.61.
If NDT reveals unacceptable deficiencies in welded joints, the whole joint shall be inspected. inspected. Defective sections sections of welds identified shall be mechanically removed and welded anew.
3.62.
Mechanical tests shall be carried out to check welded joints for their compliance with the strength strength and plastic characteristics. They shall be made at control samples welded in conditions, which completely correspond to those of steel structure welding (the same basic and adding materials, the same welding techniques and welding positions).
3.63.
Mechanical tests at specialised plants fabricating, repairing and reconstructing cranes shall be carried out from time to time in accordance with specifications. When the above work is completed at a specialised plant, mechanical tests shall be carried out with control samples to be welded by each welder participating in crane steel structures structures assemblage. assemblage. The number of samples samples shall be at least two for each type of test (strain, bending).
3.64.
Mechanical properties of control sample welded joints shall be tested irrespective of the welded joint type by way of straining and bending of buttwelded joints. The results of mechanical testing shall be considered satisfactory if: a) The point of maximum load is not below the lowest value of that of the appropriate steel type provided by state standards or specifications; b) The bend angle of carbon steel types is at least 120 , of low-alloy types with the element thickness up to 20 mm - at least 80 , above 20 mm - at least l east 60.
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3.65.
The quality of welded joints shall be considered unsatisfactory if any type of inspection identifies inner or outer deficiencies exceeding the standards set forth hereby and by standard documentation for cranes production, assemblage, reconstruction and repairs.
4. HOISTING EQUIPMENT DESIGN AND ASSEMBLAGE 4.1. Gripping Parts 4.1.1. Forged and pressed load hooks shall be produced in accordance with the requirements of GOST 2105 and other standard documentation. The sizes and basic parameters of forged and pressed hooks shall depend on the hook type and the drive type of the hoisting unit in accordance with GOST 6627 and GOST 6628. Safety locks for single hooks of climatic type "V" according to GOST 15150 applied in general-purpose hoisting equipment (with the exception of hoisting units designed for operation in explosive environments) shall comply with the requirements of GOST 12840. Plate-type hooks shall be designed and manufactured in accordance with GOST 6619. 4.1.2. Steel forged and pressed hooks shall comply with standard documents. documents. 4.1.3. Hooks with the capacity of above 3 tonnes shall be installed on frictionless bearings, with the exception of hooks at specific purpose cranes. 4.1.4. A forged or pressed hook with the capacity of 5 and above tonnes, as well as a clevis of a plate-type hook in a spreader bar, shall be mounted so that spontaneous nut nut screwing is avoided. The nut shall be fixed with a locking plate for the purpose. Locking of nuts nuts with dowels, pins and and locking bolts bolts shall be unacceptable. 4.1.5. Load hooks of cranes and telphers shall be equipped with a safety lock to prevent the detachable detachable gripping device device from spontaneous spontaneous falling off. Hooks of cranes carrying melted metal or liquid li quid slag may be installed without safety locks. 4.1.6. Forged and pressed hooks for loads shall be marked in accordance with GOST 2105 or GOST GOST 12840. Marks on plate-type plate-type hooks shall accord accord with GOST 6619. If a plate-type hook is fastened on a spreader bar with a clevis, the latter shall be marked in the same way as the hook. 4.1.7. Hooks of specific design shall be supplied with a certificate, where the producer, hook number, capacity and material it is made of shall be identified.
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4.1.8. Rope grip buckets for bulk materials shall be manufactured in accordance with GOST 24599. 24599. They shall shall be designed designed so that spontaneous spontaneous opening and the possibility of ropes leaving block grooves are avoided. Clamshell capacity shall be estimated by way of material weighing after test scooping to be carried out by the clamshell owner prior to its application for a particular type (sort, kind) of load transhipment. 4.1.9. The clamshell shall be provided with a nameplate stating the producer, number, capacity, dead weight, and the type of material it is designed for and the maximum permissible weight of scooped scooped material. If such such nameplate is damaged, the owner shall restore it. Clamshells manufactured separately from cranes shall be provided with a certificate in addition to the nameplate. 4.2. Ropes 4.2.1. Steel ropes applied as load, boom, guy, track and hauling cables, and as material to fabricate slings shall comply with current State Standards and be supplied with a certificate of the cable producer or its copy certifying their successful testing in accordance accordance with GOST 3241 and GOST GOST 18899. Ropes manufactured manufactured in accordance accordance with ISO 2408 are also also acceptable. If ropes are received received without certificates, they shall be tested in accordance with the above Standards. Ropes without testing certificates shall not be accepted for operation. 4.2.2. Ropes shall be located and fastened on a hoisting unit in such a way that shall eliminate the possibility of their falling off drums and blocks, as well as minimise their abrasive wearing due to contacts with structure elements or ropes of other polyspasts. 4.2.3. A loop at the end of a rope to fasten it on a hoisting unit, as well as sling loops connecting them to rings, hooks and other parts shall be made with a thimble, with the free end plaited or clamped, a steel forged, pressed or cast bushing secured with a cotter, by way of cast moulding with fusible alloy or otherwise in accordance with standard documents. documents. Application of welded bushings bushings shall be unacceptable unacceptable (with the exception of a rope fastening in the t he bushing of a telpher). Housings, bushings and cotters shall have no sharp edges to wear the rope out. 4.2.4. The number of the rope punches with each strand while plaiting shall correspond to that of Table 1. Table 1 Humber of Rope Punches with Strands while Plaiting Rope Diameter, mm up to 15 from 15 to 28 from 28 to 60
Minimum Number of Punches with Each Strand 4 5 6
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The last punch with each strand shall be made with half of its wires (half section of the strand). The last punch punch may be made with a half of the rope strands. The number of clamps shall be be identified while designing, but but it shall be at least least three. The spacing between clamps and the length of the rope free end after the last clamp shall be equal to at least six rope diameters. diameters. Cramp irons shall be installed at at the free end of the rope. Hot (forged) installation of clamps shall be prohibited. 4.2.5. The rope shall be securely fastened to the drum providing rope replacement when required. If clamping bars are applied, applied, their number shall be at least two. The length of the free rope end from the last clamp on the drum shall be equal to at least two rope diameters. It shall be prohibited to bend the free end of the rope under the clamping bar or at the distance of less than three rope diameters away from the bar. 4.2.6. Steel ropes of hoisting units transporting melted or glowing metal and liquid slag shall be protected from the direct impact of radiant heat and metal drops with appropriate guarding. 4.2.7. Steel ropes to be applied as load, boom, guy, track and hauling cables, shall be selected in accordance with ISO 4308/1 and other standard documents, and those for boom self-propelled cranes shall be selected in accordance with ISO 4308/2. When designing, as well as prior to their installation of hoisting equipment, ropes shall be checked with the help of calculation utilising the following equation: F 0 SxZ p , where: F0 is the breaking strength of ropes in general (Н) taken from the certificate; Zp is the minimum factor of the rope usage (the minimum factor of the rope safety margin), to be identified from Tables 2 and 3; S is the maximum tension of the rope strand (Н) given in the crane certificate. If the testing certificate gives a summarised breaking strength of the rope threads, the value of F 0 maybe obtained by way of the summarised breaking strength multiplied by 0.83. Table 2 Minimum Factors of Rope Usage, Zp Unit Classification (Mode) Group ISO 4301/1 GOST 2583S M1
1М
Moving Ropes
Stationary Ropes Zp
3.15
2.5
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М2 МЗ М4 М5 М6 М7 М8
1М 1М 2М 3М 4М 5М 6М
3.35 3.55 4.0 4.5 5.6 7.1 9.0
2.5 3.0 3.5 4.0 4.5 5.0 5.0
Table 3 Minimum Factors of Rope Usage, Zp for Boom Self-Propelled Cranes Crane Classifi cation (Mode) Group Acc. to ISO 4301/21 (GOST 27553*)
А1 A3 А4
Moving Ropes Load lifting
Mechanism Classification (Mode) Group
Zp
МЗ М4 М5
3.55 4.0 4.5
Boom lifting / lowering Zp Mechanism
Classification (Mode) Group
М2 МЗ МЗ
3.35 3.55 3.55
Stationary Ropes Telescoping
Mechanism Classification (Mode) Group
М5 М2 M1**
Mounting Zp
3.15 3.35 3.15
3.05 3.05 3.05
Operation Mounting Zp
3.0 3.0 3.0
2.73 2.73 2.73
* - Classification (Mode) group "A3" is assumed for truck cranes, with the capacity up to 16 tonnes inclusive. ** - Without load. Classification (mode) group below M5 shall not be applied for operations in hazardous conditions (transportation of melted metal, slag, noxious substances and explosives). Z p shall be calculated as for classification (mode) group M8 for ropes on winches to lift people. 4.2.8. Hemp and cotton ropes used to make slings shall comply with GOST 483, GOST 1088 and other standard documents. 4.2.9. Loop plaiting in case of a hemp or cotton rope shall have at least two complete and two half punches, and shall be caged. 4.2.10. Application of synthetic and other materials to fabricate slings may be admitted in accordance with standard documents. 4.3. Chains 4.3.1. Leaf chains used used at hoisting equipment equipment shall comply with GOST 191. Welded and pressed chains applied as load lifting ones and to make slings shall comply with GOST 228 and other standard documents. Anchor chains chains may be applied applied either with spacer bars or without them.
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4.3.2. Chains used at hoisting units as slings shall be supplied with the producer's certificate about their testing in accordance with the State Standard applied in their production. If such certificate is not available, a sample of the chain shall be tested to assess the critical load and check its compliance with the State Standard. St andard. 4.3.3. The strength margin factor of leaf chains applied in crane units shall be at least 3 with respect to the breaking load value for classification (mode) groups of M1 and M2, and at least 5 for other groups of unit classification. Strength margin factors of welded load chains and chain slings with respect to the breaking load value shall be taken from Table 4. Table 4 Minimum Strength Margin Factors of Welded Chains Chain Purpose
Unit Classification (Mode) Group М1. М2 М3 - М8
Load Load cha chain in o erat eratin in on a smoo smooth th dru drum m Load chain operating on a sprocket calibrated For slings
3 3
6 8
5
5
4.3.4. Chains may be joined by way of electric welding of inserted links, or with the help of special special connecting links. When joined, the the new chain chain shall be tested tested with a load exceeding its designed tractive force 1.25 times for 10 minutes.
4.4. Drums, Blocks and Sprockets 4.4.1. The minimum diameter of drums, blocks and compensation blocks rounded with steel ropes shall be estimated in accordance with the following equation: D1h1 d , D 2 h 2 d , D 3 h 3 d ,
where:
d is the diameter of the rope, r ope, in mm; D1. D2. D3 - are the diameters of the drum, block and compensating block respectively at the centre line of the rope coiled, mm; h1. h 2. h 3 are factors of diameter selection for the drum, block and compensating block respectively (Table 5). Factor h1. may be changed, but not above two steps according to the classification group either way (see Table 5), with an appropriate compensation by way of the Z P. value (see Table 2) shifting to the same number of steps the opposite way.
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Table 5 Diameter Selection Factors for a Drum (h 1), Block (h2) and Compensation Block (h3) Unit Classification Group ISO 4301/1 M1 М2 МЗ М4 М5 М6 М7 М8
GOST 25835 1М 1М 1М 2М 3М 4М 5М 6М
Diameter Selection Factor h1 11.2 12.5 14.0 16.0 18.0 20.0 22.4 25.0
h2 12.5 14.0 16.0 18.0 20.0 22.4 25.0 28.0
h3 11.2 12.5 12.5 14.0 14.0 16.0 16.0 18.0
4.4.2. When operating on a sprocket, welded calibrated and leaf chains shall be in a complete clutch with at least two teeth of the sprocket at the same time. 4.4.3. The rope capacity of a drum shall provide that at the lowest possible position of the gripping device at least one and a half turns of the rope or chain remain coiled on the drum in addition to the turns t urns under the gripping device. 4.4.4. Hoisting equipment drums for one layer of wound rope shall be provided with helical grooves. Clamshell cranes, cranes, if the rope is wound in one layer, and special special cranes, if their operation is accompanied with jerks and rope slackening, shall have drums with a groove at least half of of the rope diameter diameter deep. deep. Otherwise they shall be equipped with a device ensuring proper winding of the rope on the drum. Drums with the smooth surface may be used in cases, when design purposes require many layers of rope to be wound on the drum, or if a chain is applied. 4.4.5. Smooth drums and grooved ones for many layers of rope shall be provided with ledges from both sides sides of the drum. drum. Grooved drums for for one layer of of two rope strings may have no ledges if the strings are wound from the sides of the drum towards its centre. There may be no ledge at the side where where the rope is fastened to the drum if one string of rope is wound wound on the drum with grooves. grooves. Drums of electric hoists (telphers) equipped with a device to prevent the rope from falling off the drum (a cable layer) may be produced without ledges. Ledges of a drum for rope shall rise over the top layer of the rope for at least two rope diameters, and for chains - at least for the width wi dth of the chain link. 4.4.6. If several layers of rope are laid on a hoisting unit drum, proper placing of each rope layer shall be ensured.
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4.4.7. Blocks of boom and load polyspasts shall be equipped with a device to prevent the rope from getting out of the block pass. The gap between the above device and the block ledge shall not exceed 20% of the rope diameter.
4.5. Brakes 4.5.1. Load lifting and crane radius changing mechanisms of hoisting units with a mechanical drive shall be equipped with brakes of the normally closed type automatically releasing at the drive actuation, with the exception of cases provided for by clause 4.5.2. Lifting mechanisms with a hand drive shall be equipped with automatically operating load thrust brakes. A device (check valve) to prevent the load or boom from going down if pressure in the hydraulic system drops shall be provided for the mechanisms of load lifting, radius changing and boom telescoping with a hydraulic cylinder. 4.5.2. Regulated normally closed brakes interlocked with the actuation coupling shall be applied for the mechanisms of load lifting and crane radius changing with regulated mechanism actuation couplings. The brakes shall prevent the load or boom from spontaneous going down. 4.5.3. Clamshell double-drum winches with separate electric drives shall have brakes installed on each drive. A treadle (button) to unbrake the mechanism when the engine is shut down may be installed on the drive of a support drum. In such case unbraking shall be possible after some continuous pressing of the treadle (button). If electric protection actuates or voltage is fed to the grid, the brake shall be automatically engaged even if the treadle (button) is pressed. 4.5.4. Load lifting and crane radius changing mechanisms shall be equipped with brakes, which shall have unbreakable unbreakable cinematic connection with drums. A torque-limiting clutch may be installed in cinematic circuits of chain and rope telpher lifting mechanisms. 4.5.5. The brake of load and boom lifting mechanisms, with the exception of cases stated in clause 4.5.8, shall provide a breaking torque accounting for the deceleration margin factor, which shall be taken from standard documentation, but shall be at least 1.5. To reduce dynamic loads at the boom lifting mechanism, two brakes may be installed, with the deceleration margin factor of one brake being at least 1.1, and that of the second being at least 1.25. The brakes shall be actuated automatically.
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4.5.6. Mechanisms of load lifting and crane radius changing for hoisting units to transport melted metal and slag, noxious substances and explosives shall be equipped with two brakes acting independently. Lifting mechanisms of specific metallurgical cranes (stripping, etc.) designed to transport glowing metal shall be also equipped with two brakes. 4.5.7. If two brakes are installed, they shall be mounted so that one of them is easily disengaged to check the efficiency of the other. 4.5.8. If two or more brakes are installed on a drive, the deceleration margin factor of each of them shall be at least 1.25. If a lifting mechanism has two simultaneously actuated drives, at least one brake with the same deceleration margin shall be installed at each drive. If each drive has two brakes, and there are two or more drives at the mechanism, the deceleration margin factor of each brake shall be at least 1.1. 4.5.9. If a load winch is equipped with two drives, the latter shall have rigid cinematic connection to prevent spontaneous lowering of the load if one of the drives fails. 4.5.10. A load thrust brake may be applied as the second one for telphers. In that case deceleration margin factor of the electromagnetic brake shall be at least 1.25. One of the brakes at lifting mechanisms with the classification (mode) group of M1 may be replaced with self-braking transmission. 4.5.11. Brakes shall be installed at movement mechanisms of hoisting units in the following cases: a) If the equipment is designed to operate in the open air; b) If the unit designed to operate indoors moves along a track laid on the floor; c) If the unit (truck) designed to operate indoors on a rail track moves with the speed above 32 m/min (0.53 m/sec.). Brakes on turning mechanisms shall be installed on all the cranes operating outdoors, as well as on cranes operating indoors (classification group M2 and above). 4.5.12. Brakes on turning mechanisms shall be installed on hoisting equipment of classification (mode) group M2 and above. 4.5.13. Breaks on movement and turning mechanisms of hoisting equipment shall be of the normally closed type and automatically disengaging when the drive is actuated. The exception will be movement mechanisms of truck and wheelmounted cranes, cranes on specific chassis and railway cranes, as well as turning mechanisms of tower and frame cranes.
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Hand brakes shall be installed on truck and wheel-mounted cranes, as well as on cranes mounted on specific automobile chassis the movement mechanism of which is equipped with a regulated brake of a normally open type. t ype. Brakes on the movement mechanism of railway cranes shall comply with the Republic of Kazakhstan Ministry of Transport and Communications standards. Regulated brakes of the normally open type may be installed on the mechanisms of tower, boom, with the tower and boom equipment, and frame cranes. In that case the brake shall be provided with a device to fix it in the closed position. Such device may be installed on brake regulating levers or treadles. 4.5.14. Brakes of movement and turning mechanisms may remain unlocked when the power engine is OFF if the wiring diagram provides for the possibility of braking with the help of the engine. In such case the diagram shall provide for the brake engagement (disengagement) with an additional device (button) when the controller is at the zero position. An additional drive for gradual braking may be installed at movement and turning mechanisms. In that case there may be no automatic locking of the brake. 4.5.15. Brakes at movement and turning mechanisms of the equipment operating outdoors shall ensure that the unit and the truck stop and remain motionless at the maximum possible wind speed taken for the operational condition of the crane from GOST 1451 accounting for the permissible gradient. 4.5.16. Worm gear cannot serve as the brake substitution of hoisting equipment mechanisms. 4.5.17. The weight locking a brake shall be fastened on a lever so that the possibility of its falling off or spontaneous shifting is eliminated. If springs are applied, the break locking shall be produced with the force of a compressed spring. 4.5.18. The brake shall be protected from moisture or oil getting directly on the brake pulley. 4.5.19. Cranes moving on rails outdoors shall be equipped with anticreep devices. Overhead cranes operating outdoors may have no anticreep devices if the value of movement mechanisms deceleration margin is at least 1.2 at the maximum possible wind speed taken from GOST 1451 for stand-by conditions of the crane. 4.5.20. If rail locks are applied as anticreep devices, their design shall allow securing of the crane at the whole length of its track. 4.5.21. Anticreep devices with mechanical drives shall be equipped with appliances to engage them by hand.
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4.6. Running Wheels 4.6.1. Running wheels of hoisting equipment and trucks movement mechanisms may be forged, rolled, pressed or cast. Forged wheels shall comply with GOST 28648. Wheels without ledges may be applied given there are devices preventing the wheels from coming off the rails. 4.6.2. One-ledge running wheels may be applied in the following f ollowing cases: a) If the track for cranes is not wider than 4 m and both track lines are located on the same level; b) If cranes move with each side on two rails given the wheel ledges on one rail are located opposite the ledges on the other rail; c) On support and suspended trucks; d) On suspended monorail trucks. If one-ledge wheels of support cranes are applied, the width of the rim less the ledge shall exceed the width of the rail top for at least 30 mm. The wheels of tower cranes on rails shall be of two ledges regardless of the track width.
4.7. Supporting Parts, Limit Stops and Bumpers 4.7.1. Hoisting equipment moving on rails shall be provided with supporting parts for the cases of wheels or axles failure. Supporting parts of monorail trucks with a towing cab shall be installed on the carriage of the cab. If the cab and lifti ng mechanism are suspended suspended on a common frame, supporting parts shall be installed on arch carriage. Supporting parts shall be installed at the distance not exceeding 20 mm from the rails the hoisting unit or truck moves on. They shall be designed for the largest possible load. 4.7.2. Supports or other devices to prevent the boom from falling back shall be installed on boom cranes with the alternating radius and flexible boom suspension. Such devices shall be installed on tower cranes if the angle between the horizontal line and the boom exceeds 70 at the maximum radius. 4.7.3. The force applied to raise (pull out) extension supports or their parts by hand shall not exceed 200 H. In case of a greater force, such supports shall be supplied with hydraulic, mechanical or other drives.
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4.7.4. Boom self-propelled cranes with cushioned running gear and non-outrigger characteristics shall be equipped with devices eliminating the action of elastic suspension and transmitting the load received by the crane directly to the carriage or extended supports. Such cranes shall be also equipped with a stabiliser of elastic suspension to allow the load be evenly transmitted to all the springs of one carriage axle and to provide their even sag. There may be no such devices installed on the front axles axl es of truck cranes with specific chassis. 4.7.5. Arresters shall be installed at the ends of rail tracks to prevent hoisting units from going off the rails. 4.7.6. Hoisting units with mechanic drives moving along rails and their trucks shall be equipped with elastic bumpers on appropriate heights to mitigate their possible impacts against arresters or each other. If operation documents provide for installation of shock-free dead-end arresters, bumpers are not installed. 4.8. Counterweight and Ballast 4.8.1. Components of crane counterweight and ballast shall be secured or enclosed in a casing to protect them from falling and prevent the weight designed from alteration. If small articles are used as a counterweight, it shall be placed in a steel box. The box design shall eliminate elimin ate precipitation penetrating into it, as well as loss of the load. Sand, gravel and crushed stone shall not be applied as counterweight. Inventory marked loads shall be provided as ballast at cranes of the boom type. They shall be produced and placed in accordance with the crane producer's drawings. 4.8.2. Movable counterweights shall be moved automatically with the change of the crane radius, or be provided with an easily visible indicator of the counterweight depending on the radius. 4.9. Safety Instruments and Devices 4.9.1. Cranes with mechanical drives shall be equipped with devices (limit switches) to stop automatically the following: a) The gripping device lifting mechanism in its extreme upper and lower positions. The limit switch of the t he gripping device lowest position may not be installed if operation conditions do not require lowering of the load below the level established by the design (certificate); b) The mechanism of the crane radius changing in the boom extreme positions; c) The mechanism of crane and its truck movement along rails (with the exception of railway ones) if the crane (truck) speed may exceed 0.5 m/sec at the time of its approaching the extreme position (movement mechanisms of tower and gantry cranes with the flight above 16 m and transhipment cranes shall be equipped with limit switches irrespective of their movement speeds);
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d) Movement mechanisms of gantry and cantilever cranes or their load trucks operating at one track. The above devices shall be also installed if the run of any other mechanism has to be limited, e.g. turning mechanisms, mechanisms of a hoisting unit telescopic part extension, mechanisms of the gripping device and cab lifting. 4.9.2. Limit switches installed on hoisting equipment shall be switched so that the possibility to move in the reverse way is provided. Further movement in the same direction may be admitted for the mechanism of an overhead crane movement, when it approaches a landing site or dead-end arrester with the lowest speed permitted by the wiring diagram of the crane control. 4.9.3. The limit switch of the lifting mechanism shall be installed so that after the gripping device stops, the clearance between the gripping device and the limit stop of the telpher is at least 50 mm during load lifting. For all the other hoisting units it shall be at least 200 mm. 4.9.4. The diagram of the lifting limit switch at clam-shell cranes with separate twoengine power drive for the clam-shell winch shall be designed in such a way that simultaneous disengagement of the lifting mechanism engine and the clam-shell locking engine is achieved, when the clam-shell reaches its utmost upper position. 4.9.5. The movement mechanism limit switch shall be installed in such a way that disengagement of its engine takes place at the distance from the stop of at least half decelerating way of the mechanisms. For tower, frame and gantry cranes, as well as transhipment cranes, it shall be at least one and a half-decelerating ways. If stop blocks for mutual run restraining are installed at overhead and cantilever mobile cranes operating at one track, the above distance may be reduced to 500 mm. The producer shall state the unit braking distance in the crane certificate. 4.9.6. Overhead cranes shall be equipped with a device to automatically cut off power from the crane, when people go out to its gallery. Power may not be cut off at trolley cables not exceeding 42 V if cranes operate indoors. The door leading to the gallery of an overhead crane shall be equipped with such interlink, if the entrance to the crane is provided through the gallery. 4.9.7. The door from the landing site to the cab of a crane control shall be equipped with an electric interlink, which will not allow the crane to start moving with the door open. If the cab is provided with an anteroom, such interlink shall be installed on the anteroom door. 4.9.8. The wiring diagram of magnetic cranes shall be designed so that if power is cut off from separate units by way of safety instruments and devices, it is not cut off from the load magnet.
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4.9.9. To prevent people from being squeezed between the non-turning and turning parts of tower cranes with a non-turning tower or frame cranes, where the cab is located at the turning part, a device to automatically cut the power engine of the turning mechanism off shall be installed. It shall be engaged till the personnel pass from the non-turning part to the turning one and to the cab. It shall also apply to metallurgical cranes with a turning cab. 4.9.10. Boom self-propelled, tower and frame cranes shall be equipped with a lifting capacity limit (load factor limit) to prevent them from falling backwards. The device shall automatically disengage load lifting and radius changing mechanisms if a weight exceeding the one for that particular radius by above 10% is being being lifted. For tower cranes cranes with the load load factor up to 20 tonnes x m and frame cranes the weight excess shall be above15%. Load lowering down or engagement of other mechanisms to reduce the load momentum shall be possible after the lifting li fting capacity limit actuation Cranes with two or more load lifting features shall apply a lifting capacity limit with a device to switch it over to operation in accordance with the feature selected. Access of the crane operator to the switch shall be prohibited at tower cranes. The protection board or relay (electronic) block of the lifting capacity limit shall be sealed. 4.9.11. Overhead cranes shall be equipped with lifting capacity limits (for each load winch) if the production process makes overloads possible. Cranes with lifting capacity varying along the length of the gantry shall be also equipped with such limits. The limit of an overhead crane shall not allow any overload above 25%. 4.9.12. Gantry and transhipment cranes shall be designed for maximum possible tilt forces occurring during movements, or equipped with automatic tilt limits. 4.9.13. Cranes with electric drives shall be provided with protection from load and boom falling down if any of the three feeding grid phases breaks. When the load or boom lifting power engine is disengaged, voltage shall be cut off from the coils of the electric magnet or winding of the hydraulic pusher engine. 4.9.14. Terminations of power crane safety devices and instruments (limit switches, manhole and cab door interlock, emergency switches, etc.) shall operate breaking the circuit. 4.9.15. Cranes with electric drives, lifting capacity of which changes with the radius, shall be provided with a lifting capacity indicator corresponding to the radius selected. The scale of the indicator shall be clearly seen from the operator's place.
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While calibrating the scale of the lifting capacity indicator, the radius shall be measured on a horizontal area with the load on the hook corresponding to that particular radius, and scale marks shall be made after the load is taken off. 4.9.16. Indicators of the crane tilt angle (inclinometers and annunciators) shall be installed in the cab and non-turning frame of boom self-propelled cranes. 4.9.17. Tower cranes with the height of above 15 m to the head top, gantry cranes with the flight above 16 m, frame and cable cranes and transhipment cranes shall be equipped with a device (anemometer) to automatically actuate a siren if wind speed reaches the value stated in the crane certificate. 4.9.18. Boom self-propelled cranes (with the exception of caterpillar ones) shall be equipped with protection from dangerous voltage during their operation close to overhead power lines. 4.9.19. Frame cranes shall be provided with a drum to automatically wind the cable feeding power to the end. 4.9.20. The wiring diagram of the hoisting unit power engines control shall eliminate the following: a) Self-starting of power engines after voltage supply resumes in the feeding grid; b) Power engines start with a wrong acceleration mode; c) Power engines start with safety device terminations (limit switch and interlink device contacts). 4.9.21. Voltage from the outer grid shall be supplied to the hoisting equipment through an input device provided with a hand or distant drive to cut voltage off. 4.9.22. The input device (protection board) of overhead and cantilever cranes shall be equipped with an individual contact lock with a key (mark-key). No voltage supply to the crane shall be possible without it. The input device and control board of tower cranes shall be equipped with a device to lock them. 4.9.23. An easily accessible switch shall be installed to feed power to the main trolley cables or flexible cable. The switch feeding the main trolley cables or flexible cable shall have a device to lock it in the disconnected position. position. 4.9.24. Lamps installed on tower cranes shall be switched on with an independent switch installed on the gantry. 4.9.25. Hoisting equipment controlled from the cab or control panel (in case of distant control) shall be equipped with a sound-signalling device. The sound shall be
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clearly heard within the movement locations and its tone shall differ from that of an automobile honk. 4.9.26. The control cabin and engine part shall be electrically lighted. Lighting at hoisting equipment with power drives shall remain connected, when power is cut off from electric equipment of the unit. Lighting and alarm grids connected prior to the input device shall be supplied with a separate switch. 4.9.27. Cranes shall be equipped with low voltage maintenance lighting system not exceeding 42 V. The maintenance lighting grid shall be fed from a transformer or battery installed on the crane. 4.9.28. Crane steel structures shall not be used as an operating current conductor to feed lighting, control and other grids with voltage above 42 V. 4.9.29. Electric heating appliances installed in the hoisting unit cab shall be fire safe, and their current conducting parts shall be guarded. Electric heating appliances shall be connected to the power grid after the input device. The body of the heating appliance shall be grounded. Installation of self-made heating appliances shall be prohibited. 4.9.30. Power engine starting resistors shall not be installed in the control cab of a hoisting unit. 4.9.31. All steel structures and metal parts (power engine and device housings, metal casing of conductors and cables, protection pipes, etc.) of cranes with electric drives fed from the outer grid shall be grounded in accordance with the Power Unit Design Regulations (PUE). The above parts are not included into the power grid, but may occur under voltage due to insulation failure. 4.9.32. The housing of a push-button device to control a power hoisting unit regulated from the floor shall be made of a dielectric material or grounded with at least two conductors. The line holding the pushbutton device may serve as one of the grounding conductors. 4.9.33. The gripping device of a rod removing crane and power equipment housing being under voltage conditioned by operation requirements shall not be grounded. In such case they shall be insulated from grounded parts of the unit with at least three stages of insulation. Resistance of each insulation stage shall be at least 10 MOhm after the assemblage of a newly produced crane or a crane after major repairs. Power equipment and wiring wirin g insulation shall be designed for the case of load tension being applied, when the stages of protection insulation are damaged or blocked.
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4.9.34. Safety valves shall be installed on the discharge line of each pump at cranes with hydraulic drive. The valves shall be adjusted for pressure exceeding the operating one by not more than 10%. The lines of fluid supply and discharge shall be designed in such a way that fluid leaks are eliminated during operation or stand-by periods. Flexible hoses applied in the hydraulic drive shall be reliable and protected from possible mechanical damage. The system of operation fluid supply shall provide for devices to completely remove the fluid while repairing, the possibility of main line purging and cleaning the fluid from contaminants. 4.10. Control Mechanisms and Devices 4.10.1. Control devices of a hoisting unit shall be manufactured and installed so that control is easy and does not impede observation of the gripping device and load. The direction of handles, levers and hand wheels operation shall be reasonable and shall correspond to the direction the executive mechanisms and units move. Conventional signs shall be installed on such mechanisms and devices to show the directions of movements caused. Such signs shall be preserved during the whole period of their operation. Separate positions of control handles, levers and hand wheels shall be fixed and be marked. The fixation force in the zero position or in OFF position sh all exceed that of the intermediate position. Buttons for each mechanism reverse starting shall be interlinked to prevent simultaneous engagement of reverse contactors. 4.10.2. Manual control starting devices applied at hoisting equipment controlled from the floor shall have devices for self-reset into the zero position. If contactors are used in such cases, their retention in the ON position shall be possible by way of continuously pressing the start button only. Control devices shall be suspended on a steel line with such length that it shall enable the person operating the mechanism remain at a safe distance from the load lifted. The control device shall be located at the distance from 1000 mm to 1500 mm from the floor. 4.10.3. Engagement Engagement of the protection board contactor at hoisting units with power drives shall be possible in case all the controllers are in zero position only. Terminations of the zero interlink of magnetic controllers with the individual zero protection may be excluded from the protection board (input device) contactor circuit.
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In such case, light signals shall be installed in the control cab to inform of the magnetic controller engagement or disengagement. disengagement. 4.10.4. If several control stations are arranged for a hoisting unit (with the exception of manipulator cranes), an interlink preventing the unit from being controlled from separate stations simultaneously shall be provided. 4.11. Control Cabins 4.11.1. The control cab or panel shall be located at such place, where the operator could observe load gripping, as well as the load and gripping device during the whole cycle of the crane operation. An exception may be made for tower, boom, with tower and boom equipment, and frame cranes. 4.11.2. The control cab of a boom crane shall be located so that the load cannot strike the cabin during usual crane operation with the shortest radius. Crane mechanisms shall not be located directly above the cab. 4.11.3. The cab of an overhead crane and movable cantilever crane shall be located under the gantry (cantilever) gallery and be connected connected to it with a ladder. Overhead cranes may have the cab suspended to the frame of the load truck. In that case the exit from the cab to the gallery shall be arranged through the truck deck or railed outer catwalk. 4.11.4. An overhead crane cab shall be suspended from the side opposite the one, where the main trolley cables are located. Exclusions may be made in cases, when trolley cables are not accessible for any accidental touch from the cab, landing site or ladder. 4.11.5. The control cab shall have the following minimum size: 2000 mm high, 900 mm wide and 1300 mm long, the minimum volume shall be 3 m . The height may be reduced to 1600 mm in cabs with a non-vertical front part in the cross section going through the centre of the operator's seat. The size of boom self-propelled crane cabs shall be taken from GOST 22827. Equipment located in the cab shall be easily accessible. 4.11.6. Cabs of hoisting equipment designed for operation outdoors shall have an uninterrupted enclosure from all sides and uninterrupted upper cover to protect the operator from adverse weather conditions. Fenestration in the cab shall be covered with safety (shatterproof) glass. Open cabs of double-beam overhead and movable cantilever cranes may be enclosed for the height of at least 1000 mm from the floor. Cabs in one-beam overhead cranes designed for seated work may be enclosed for the height of 700 mm.
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If the cab is enclosed with safety (shatterproof) glass for the height of 1000 mm, an additional metal grid will be required. There may be no upper cover at open cabs of cranes operating indoors. 4.11.7. Cabs of overhead and movable cantilever cranes, in cases, when the distance between the back wall of the cab and the items it moves in relation to is below 400 m, shall be provided with an uninterrupted enclosure from the back and lateral sides for the height of at least 1800 mm. The back wall enclosure shall cover the whole width, and the sides shall have covers for the width of at least 400 mm from the side adjoining the back wall. 4.11.8. Glass shall be installed in the cab in the t he way that makes it easy to clean the glass from both inside and outside, or a device to clean glass shall be provided. Lower glasses, the operator may stand on, shall be provided with a grid to bear his weight. Sun protection screens shall be installed in cabs of cranes operating outdoors. 4.11.9. The door to enter the cab may be of a swinging or sliding type, and shall be equipped with a lock from the inside. A swinging door shall open to the inside of the cab, with the exception of boom self-propelled cranes and if there is an anteroom or platform with appropriate railing at the entrance to the cab. In those cases the door may open to the outside. Cranes operating outdoors shall be provided with a device to lock the door from the outside when the operator leaves the working place. Entrance to the cab through a manhole in the floor shall be prohibited. 4.11.10. The floor in the cab of a hoisting unit with power drive shall be covered with planking of non-metal materials to prevent sliding and covered with a dielectric rubber rug. If a cab floor area is big, rubber rugs with the size of at least 500 x 700 mm may be only laid at places, where the operator works with power equipment. 4.11.11. Crane cabs shall be equipped with a stationary seat for the operator. It shall be designed and located so that he may control crane devices and observe the cargo seating. The seat shall be adjustable vertically and horizontally to make work and control devices operation convenient. In cases provided by standard documents, operator's seat at control boards or the whole cab shall be rotating. 4.11.12. The crane cab shall be designed and equipped so as appropriate temperature conditions and ventilation are provided in accordance with standard documents. The producer shall install a heating device in t he cab.
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4.11.13. Design and equipment of hoisting unit cabs operating in hot chemical or other shops, where dust and hazardous gases are emitted shall comply with the requirements of standard documents. 4.12. Guarding 4.12.1. Easily accessible movable parts of a hoisting unit, which may cause an accident, shall be enclosed with securely fastened steel detachable guarding. The guarding shall be easily examined and oiled. The following shall be provided with guarding: a) Tooth, chain and worm gear; b) Couplings with prominent bolts and pins, as well as other couplings located in the passageways; c) Drums located close to the operator's working place or in the passageways. At the same time guarding shall not impede the view of the rope winding on the drum; d) The shaft of overhead crane movement mechanisms, with the rotation speed of 50 and above r/min (if the speed is below 50 r/min, the shaft shall be guarded at the location of the manhole leading to the gallery). Shafts of other mechanisms shall be also guarded if they are located at places designed for the operating personnel passage. 4.12.2. Running wheels of cranes moving on rails (with the exception of railway cranes) and their trucks shall be equipped with screens to prevent foreign objects from getting under the wheels. The clearance between the screen and the rail shall not exceed 10 mm. 4.12.3. All non-insulated conductors of a hoisting unit including switches, contactor panels and resistor boxes shall be guarded if they are located in such places, where people in the cab, on the gallery, on catwalks or close to the unit may accidentally touch them. Non-insulated conducting parts of switches supplying power to the main trolley cables or feeding cable shall be also guarded. Contactor panels and resistor boxes may remain unguarded if power is automatically cut off when people enter the places of their location, as well as if they are installed in special appliance cabs locked for the period of the hoisting unit operation. 4.12.4. The main trolley cables located along the crane track and their current collectors shall not be accessible for an accidental touch from the crane gantry, stairs, landing sites and other places, where people may turn up. The above shall be ensured with the help of the cables and current collectors appropriate location or guarding. 4.12.5. Trolley cables located on a hoisting unit and not cut off with the hatch interlink device (cables of a load electric magnet, trolley cables with t he voltage above 42
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V at cranes with a movable cab) shall be guarded or located among the gantry frames at the distance inaccessible for the operating personnel. Trolley cables shall be guarded along their whole length and at the butts. 4.12.6. Adequate protection shall be installed at places, where load ropes may contact main or ancillary trolley cables of an operating crane or other crane located a layer below. Trucks of overhead cranes installed on open sites shall be protected from precipitation. 4.13. Galleries, Platforms and Ladders 4.13.1. Overhead and movable cantilever cranes, with the exception of those stated in clause 4.13.4, shall be equipped with galleries or platforms with convenient entrances and access to all the mechanisms of the crane and its power equipment. The galleries and platforms are required for safe and easy servicing of equipment and devices located outside the cab. 4.13.2. Tower, gantry and frame cranes shall be provided with easy entrances from the ground to the crane and into the cab. Overhead cranes shall also have a safe exit to the truck. 4.13.3. Frame cranes shall be equipped with a safe entrance from the gantry stairs to the platform located around the gantry cap (head) at any position of the rotating part p art of the crane. The height from the deck of the platform to the lowest prominent elements of the turning part shall be at least 1800 mm. The turning part of the crane shall be accessible from the gantry at any position it is in. 4.13.4. Platforms and galleries are not necessary at one-beam overhead cranes with a hand or mechanic drive, as well as at double-beam suspended cranes, if maintenance platforms are available. 4.13.5. The width of a free passageway along the gallery of overhead and movable cantilever cranes designed for power equipment and mechanisms servicing shall be as follows: a) At least 500 mm on cranes with transmission drives; b) At least 400 mm on cranes with non-transmission or hand drives. The width of the passageway between the railing and devices supporting trolley cables and current collectors on the same cranes if their galleries are used to locate them shall be at least 400 mm. 4.13.6. Galleries shall be installed in bays of buildings with overhead cranes of classification (mode) A6 and above in accordance with ISO 4301/1 in the bays to provide passages along crane tracks at both sides of the bay.
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Galleries arranged as passages along the crane track shall be provided with railing from the bay side, and the opposite side if there is no wall there. A gallery on an open trestle may be provided with railing from the outer side only (opposite of the bay). The width of the passageway (clear distance) along the gallery shall be at least 500 mm, and the height at least 1800 mm. At column locations, a passage at least 400 mm wide and 1800 mm high shall be arranged at the side of a column or through the column. Every gallery section near columns shall be enclosed. If a passageway is arranged through a column, the width of the passage in the gallery shall be reduced to that of the passage through the column at the distance of 1000 mm from it. Every gallery shall be provided with exits to stairs at least every 2000 m. 4.13.7. Maintenance platforms shall ensure safe and convenient access to mechanisms and power equipment. If the distance between the floor of the maintenance platform and the lowest parts of the crane is below 1800 m, the door of the maintenance platform shall be equipped with a lock and automatic interlink to cut off power from the main trolley cables of the maintenance section. Movable platforms may be arranged instead of stationary maintenance ones. 4.13.8. Overhead cranes controlled from the cab (except for one-beam ones) shall be equipped with cabs (platforms) to service the main trolley cables and current collectors if they are located below the deck of the crane gallery. A manhole to enter the cab from the deck to service the main trolley cables shall be provided with a lid and a device to lock it. The cab to service the main trolley cables shall be enclosed with railing at least 1000 mm high covered completely at the top for the height of 100 mm. 4.13.9. If a manhole is arranged in the maintenance platform deck, its size shall be at least 500 x 500 mm. The manhole shall be provided with an easily opening lid. The angle between the manhole lid in the open position and the deck shall not exceed 75 . 4.13.10. A landing site (platform) with stationary stairs shall be arranged to enter a control cabin of an overhead, movable cantilever crane or an electric truck moving on rails on the ground. The distance from the floor of the landing platform to the lowest parts of the overhead cover or prominent parts of structures shall be at least 1800 mm. The floor of the platform shall be located on the same level with the floor of the cab or anteroom if any. The clearance between the landing platform and the door
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(anteroom) threshold shall be at least 60 mm, but not exceed 150 mm, when the crane stops at the landing platform. A landing platform may be arranged below the cab floor level, but not exceeding exceeding 250 mm in cases, when the clearance of 1800 mm in height cannot be achieved if the platform is at the same level with the cab floor. It may be also done in cases when the landing platform is located at the butt of the building and the established clearance between the cab threshold and the platform cannot be achieved. If a landing platform is arranged at the end of the crane track below the cabin floor level, an overlap of the cab and platform is acceptable, but not exceeding 400 m when bumpers are fully compressed. In such case the clearance between the platform and the lowest part of the cab (vertically) shall be within 100-250 mm, that between the cab and the platform railing shall be within 400450 mm, and from the side of the entrance to the cab - 700-750 mm. 4.13.11. An entrance to the control cab of an overhead crane may be arranged through the gantry in cases, when direct getting into the cab is impossible due to design or operation reasons. In such case the entrance to the crane shall be arranged in a specially allocated place through a door in the gantry railing equipped with an electric interlink in i n compliance with clause 4.9.7 hereof. No entrance to the control cab of magnetic cranes through the gantry shall be acceptable. The exception may be made for the cases, when trolley cables feeding the load electric magnet are enclosed or located in a place inaccessible for accidental touching and the power is cut off by the interlink of the crane entrance door. 4.13.12. Galleries, platforms, passageways and stairs shall be designed in accordance with the requirements hereof. 4.13.13. Decks of galleries, platforms and passageways shall be metal or made of other solid materials if they comply with fire requirements. The deck shall be laid along the whole length of the gallery or platform. A metal deck shall prevent any sliding (steel grooved, punched sheets, etc.). if expanded or punched metal is applied, no hole shall exceed 20 mm. 4.13.14. Galleries, platforms, passages and stairs arranged in places, where trolley cables or non-insulated conductors under voltage are located shall be equipped with guarding to prevent accidental touching of trolley cables or conductors irrespective of entrance interlink existence. 4.13.15. Platforms and galleries located at hoisting units, end beams of overhead cranes and platforms and galleries designed to service hoisting equipment shall be enclosed with railing 1000 mm high, with complete cover at the bottom for the height of 100 mm and an intermediate link at the height of 500 mm. Railing and cover at the bottom shall be also installed at the butt ends of overhead crane trucks, and if there is no gallery, along the crane gantry and at the lengthwise sides of the truck.
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The height of railing may be reduced to 800 mm at the truck of an overhead or movable cantilever crane and at the end beam of such cranes if the dimensions of the building do not allow railing 1000 mm high. Posts on a landing platform the railing or fastening structures of the platform are secured to shall be located at least 400 mm away from the cab if they are at the height of 1000 mm from the platform deck. 4.13.16. Stairs from the floor to the platform and galleries shall be at least 600 mm wide. The width of stairs located on the crane itself, with the exception of those not exceeding exceeding 1500 mm in height, height, shall be at least 500 mm. Stairs lower than 1500 mm located on the crane, as well as stairs leading from the cab to the gallery of overhead or movable cantilever cranes may be at least 350 mm wide. 4.13.17. The distance between steps shall not exceed 300 mm for vertical stairs, 250 m for inclined stairs and 200 mm for inclined stairs of tower cranes. The spacing of steps shall be the same for the whole staircase. Steps of vertical stairs shall be at least 150 mm away from the crane steel structures. 4.13.18. Stairs leading from the floor to landing and maintenance platforms and galleries to pass along the crane track shall be located so as squeezing of people on them by the moving crane or its cab is prevented. Such landing stairs shall be inclined, with the angle of the incline to the horizon not exceeding 60 . 4.13.19. Inclined stairs shall be railed from both sides to the height of at least 1000 mm from the steps and have flat steel steps at least 150 mm wide eliminating the possibility of slipping. 4.13.20. Guarding in the shape of arcs shall be installed on vertical stairs starting from 2500 mm from the staircase bottom. The arcs shall be located at the distance not exceeding 800 mm from each other and connected with at least four longitudinal bands. The distance from the staircase to an arc shall be at least 700 mm and shall not exceed 800 mm with the radius of 300-400 mm. There is no need to install the arc guarding if a staircase is located inside a lattice column with the cross section not exceeding 900 x 900 mm or a tubular tower with the diameter not exceeding 1000 mm. Arrangement of vertical stairs above manholes shall be unacceptable. unacceptable. If a staircase is above 10 m high, platforms shall be provided on them every 6-8 m. If a staircase is located within a tubular tower, such platforms are not required.
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4.14. Installation of Hoisting Equipment 4.14.1. Overhead cranes in buildings, tower, frame and cable cranes on open sites, in ports and other permanent operation locations shall be installed in accordance with a design developed by a specialised company. 4.14.2. Hoisting equipment shall be installed in such a way that when a load is lifted, it is not required to drag it with the load ropes being inclined, and there is an opportunity to transport the load lifted for at least 500 mm above equipment, cargo piles, vehicles, etc. While cranes controlled from the floor or on the radio are being installed, an easy passageway for the worker controlling the crane shall be provided. Installation of hoisting units with an electric magnet as a gripping device above industrial and other rooms shall be prohibited. 4.14.3. Installation of cranes, load trucks and movable tackle above industrial premises to lift and lower loads through a hatch in the floori ng may be allowed in the only case if one room is located directly above the other. The hatch in the flooring shall be provided with stationary guarding at least 1000 mm high with complete cover at the bottom for 100 mm and mandatory arrangement of light signals (lit lettering) to warn people of both the load above the hatch and lowering of the load. It shall be also provided with signs prohibiting staying of people under the load moved. Installation of stationary tackle or winches to lift loads through a hatch in the flooring shall be prohibited. 4.14.4. Hoisting units moving along rails on the ground shall be installed in compliance with the following requirements: a) The distance from the hoisting unit upper point to the ceiling of the building, the lowest belt of the roof truss or articles fastened to it, as well as to the lowest point of another hoisting unit operating one level above, shall be at least 100 mm; b) The distance from the deck of platforms and galleries of an overhead crane, with the exception of end beam and truck decks, to the roofing, the lowest belt of the roof truss or articles fastened to it, as well as to the lowest point of another hoisting unit operating one level above, shall be at least 1800 mm; c) The distance from prominent parts in the crane butts to the building columns and walls and railing of galleries shall be at least 60 mm. Such distance shall be established at the symmetric position of the crane wheels relative to the rail; d) The distance between the lowest point of a hoisting unit (not including the gripping device) to the floor of the shop or platforms, where people may be working during the crane operation (with the exception of the crane maintenance platforms) shall be at least 2000 mm. The distance between the
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lowest point of the crane cab and the floor level shall be at least 2000 mm or (in grounded cases) within the range from 500 mm to 1000 mm; e) The distance between the lowest prominent parts of a hoisting unit (not including the gripping device) to equipment located within the area of its operation shall be at least 400 mm; f) The distance between the lowest prominent parts of a control cab and trolley cables servicing cab to a wall, equipment, pipelines, prominent parts of the building, columns, roofs of ancillary facilities and other objects the cab moves relatively to shall be at least 400 mm. 4.14.5. The horizontal distance from the prominent parts of a crane moving along rails on the ground to buildings, cargo piles and other objects located at the height of up to 2000 mm above the ground surface level or platforms shall be at least 700 mm, and at the height above 2000 mm - at least 400 mm. The vertical distance from the counterweight cantilever or counterweight located under the cantilever of a tower crane to platforms with possible location of people shall be at least 2000 mm. 4.14.6. Installation of cranes, suspended electric trucks and tackles with automatic or semi-automatic control, when the operator does not accompany the hoisting unit shall ensure that the load does not impact the building elements, equipment, cargo piles, etc. Presence of people shall be eliminated along the way of such a unit movement. Safety covering (mesh, etc.) capable of sustaining falling loads shall be installed above the carriageways and passageways for people. 4.14.7. Cranes for construction and installation work shall be mounted in accordance with the design of work to be carried out by cranes developed by a company licensed by Gosgortechnadzor. Gosgortechnadzor. 4.14.8. The line owners shall approve installation of cranes moving on rails within the protection zone of overhead power lines. The permit of such installation for construction purposes shall be kept together with the work design, and in other cases with the crane certificate. 4.14.9. Boom self-propelled cranes shall be mounted on a levelled and prepared ground accounting for its characteristics and category. Cranes shall not be mounted on newly backfilled and non-compacted ground, as well as on a site with an incline exceeding the value stated in the crane certificate. 4.14.10. A boom self-propelled crane shall be installed in such a way that during its operation the distance between the rotating part of the crane and buildings, cargo piles and other objects is at least 400 mm at any position of the crane. 4.14.11. If there is a requirement to install a boom self-propelled or railway crane on extended supports, it shall be mounted on all the extended supports available. Firm and stable pads shall be laid under supports. The pads under additional crane supports shall be included in its inventory.
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4.14.12. Boom self-propelled cranes may be mounted at the edge of a pit (trench) batter on condition all the distances stated in Table 6 are complied with. Iv the distances are not possible to comply with, the slope shall be stabilised in accordance with the design. Table 6 Minimum Distances (in mm) from the Pit (Trench) Batter to the Nearest Crane Supports with Solid (not Backfilled) Ground Pit (Trench) Depth, m 1 2 3 4 5
Ground Sand and Gravel 1.5 3.0 4.0 5.0 6.0
Sandy Loam 1.25 2.4 3.6 4.4 5.3
Loam 1.0 2.0 3.25 4.0 4.75
Clay 1.0 1.5 1.75 3.0 3.5
Dry Loess 1.0 2.0 2.5 3.0 3.5
4.15. Crane Track 4.15.1. Rail tracks for a hoisting unit (with the exception of railway crane tracks) shall be constructed in accordance with a design developed by a specialised company or crane producer. Prior to crane installation on its rail track the latter shall be tested for the load. The rail track of a railway crane shall be constructed and maintained in accordance with the standards of the RoK Ministry of Transport and Communications. 4.15.2. The following basic data shall be included into the design for a crane rail track: a) The rail type; b) The type and length of cross ties; c) The distance between ties; d) The technique of rails fastening to cross ties ti es and to each other; e) The requirement of pads between the rails and cross ties; f) The clearance between the rails; g) The material and size of the t he ballast layer; h) The minimum permissible radius of the curve at the curved track section; i) Maximum permissible values of the general longitudinal incline, subsidence under the wheels and tolerances for the gauge width and the difference in the railhead levels; j) Dead-end arresters design; k) Rail track grounding design.
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4.15.3. Crane tracks (with the exception of those for tower and railway cranes) and tracks of suspended load trucks equipped with points or turn-tables, as well as crossings serving to move the hoisting unit or its t ruck from one track to another, shall comply with the following fol lowing requirements: a) Uniform motion shall be ensured at places, where the hoisting unit or its truck moves from one track to t o another; b) To prevent two close rails of the crane track from splitting, locks with an electric interlink shall be installed to lock the close rails securely and prevent the hoisting unit or its truck from moving if the lock is not locked. It also applies to the rail of the crane track and the rail of the point or turn-table. Electrical interlink may be replaced by mechanical for mechanisms with a hand drive; c) Sections of the track to be disconnected, as well as the rails of points and turn-tables shall be equipped with automatic locks to prevent the hoisting unit or its load trucks from going off the t he rail track; d) A point or turn-table shall be switched with the help of a special mechanism controlled from the ground of control cab of the hoisting unit; e) Power shall be fed to tthe he hoisting unit trolley cables, point regulating devices and power interlink devices with the help of one switch. 4.15.4. Crane rails and load truck rails shall be installed in such a way that their lateral and longitudinal shift is avoided during the hoisting unit movement and operation. If rails are secured with welding, the possibilit y of their thermal strain shall be eliminated. 4.15.5. Vehicles and forklifts may cross the tracks of gantry and tower cranes in exceptional cases only, if no by-pass is possible. The owner of the crane shall develop safety measures accounting accounting for the intensity of its operation and traffic. 4.15.6. Crossings of gantry, tower and frame crane tracks with rail tracks of the plant traffic may be admitted in separate grounded cases on an approval of Gosgortechnadzor bodies and after arrangements to prevent operating cranes from crashing with the rolling rol ling stock are developed. A crossing of a frame crane track with a railway track shall be constructed in accordance with a design developed by a specialised company and approved by both the owners of the crane and the owners of the railway. 4.15.7. Tolerances for the gauge size, linearity and horizontality of the track and permissible values of rail elastic subsidence under the crane wheels shall be taken from standard documents. If such data are not available in standard documents, the values of tolerances shall be identified in accordance accordance with Appendix 7. 4.15.8. A section for the crane stand-by location shall be stated in the rail track design.
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4.15.9. If there exist buried engineering lines laid previously without accounting for a rail track construction above them, an estimation shall be carried out t o eliminate the possibility of causing damage to the lines and their cover designed if required. 4.15.10. A rail track being ready for operation shall be certified with an Acceptance Statement Statement (in accordance accordance with Appendix 8). The results of the track transversal and longitudinal profiles survey and the gauge size testing shall be attached to the Statement. 4.15.11. The rail track condition inspection and its grounding resistance testing shall be carried out in i n accordance with the standard documentation. 5. CABLE TYPE CRANES 5.1.
Requirement set forth by Chapters 1-4 and 7 with amendments and additions provided for by this Chapter shall be applicable to cable cranes (with bearing ropes).
5.2.
The stability factor of movable solid crane supports (non-swing bearing) each way accounting for all the basic and additional loads (inertia forces, wind load, snow weight, etc.) shall be at least 1.3 at their worst combination. The stability factor of swing bearings in the plane perpendicular perpendicular to bearing ropes shall be at least 1.3.
5.3.
Cranes shall be equipped with a device to automatically stop support movement mechanisms in case one of them moves farther than another one for a distance exceeding the designed value, and an indicator of such difference value installed in the operator's cab.
5.4.
Cranes shall be equipped with lifting limits li mits actuating at lifting capacity excess of 25%. Load lowering only shall be possible after the lifting limit actuation.
5.5.
Cranes with movable supports shall be equipped with anemometers sending a sound signal when wind speed exceeds the value stated in the crane certificate.
5.6.
A movable crane shall be secured with hand grips when operating at one place. If operation of a crane requires its frequent relocation, the crane may remain ungripped, but they shall be secured with grips after the end of work.
5.7.
Indicators of the gripping device position according to its height and along the span, as well as an indicator of the clamshell open or closed position shall be installed in the operator's cab. Such indicators shall be adjustable to remove errors accumulated. accumulated.
5.8.
The lifting mechanism and clam-shell closing mechanism of clam-shell cranes shall be equipped with devices (limit switches) to automatically stop them:
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a) When lifting if the distance between the bumpers of the gripping device and the load truck reaches 1 m; b) When lowering if at least three rope wraps remain on the drum; 5.9.
The load truck movement mechanism shall be equipped with a device (limit switch) to automatically stop it at the distance of at least 5 m from the support site or a polyspast truck. Further movement of the load truck may be allowed to the support sites or polyspast truck with a lowered speed.
5.10.
A load truck shall be designed so that its fall in case of failure or running wheels going off the carrying rope (ropes) is impossible.
5.11.
The load truck from the bottom and the gripping device (hook, clam-shell blocks) from the top shall be equipped with wooden or other bumpers, which will not allow the gripping device to rest against the truck equipment.
5.12.
The load truck moving mechanism shall provide for inspection speed not exceeding 0.5 m/sec to examine and oil ropes.
5.13.
The movable load truck brake shall provide for the breaking torque accounting for the deceleration margin factor of at least 1.25.
5.14.
If the moving mechanism of a truck has a rope-driving sheave, the diameter of the sheave shall be at least 60 rope diameters. The traction factor of the rope and the sheave shall be at least 1.5 calculated for the static load, and at least 1.25 accounting for dynamic loads.
5.15.
Maintenance personnel only may go by a load truck. Such work shall be carried out on the basis of a work permit to be issued in accordance with the form given in Appendix 9.
5.16.
The engine department of a crane shall comply with the following requirements: r equirements: a) The height of the department shall be designed accounting for the location of hoisting means (cranes and tackles) above the main equipment; b) The distance from the department walls to winches and between the winches shall be at least 800 mm. The distance between the wall and a winch may be reduced to 200 m on condition a safe passage is provided to the winch parts requiring servicing; c) The size of the door to the department shall ensure movement of the largest inseparable parts of the equipment. The height shall be at least 1800 mm.
5.17.
The engine department, operator's cab and crane tower heads shall be equipped with telephones allowing for a simultaneous conversation among all the locations.
5.18.
Plates with the crane lifting capacity, its number and the date of the next testing shall be placed in the crane engine department, operator's cab and on supports.
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5.19.
Load trucks shall be supplied with platforms to examine bearing ropes and supports in the crane span. The platforms shall be at least 750 mm wide, with the railing 600 mm high, two intermediate longitudinal connections (rods) and with an uninterrupted enclosure at the bottom 100 mm high. Entrances to the platform shall be equipped with rigid barriers and locks eliminating their t heir arbitrary opening.
5.20.
Crane supports shall be provided with platforms to tighten bearing ropes, maintain the equipment and enter the load truck. The width of such platforms shall be at least 1000 mm, and their railing shall comply with the requirements hereof.
5.21.
Cranes with swinging supports shall be equipped with special platforms and installation blocks to set the counterweight of the swinging tower. The platforms shall be designed for the weight of the support with bearing ropes detached.
5.22.
Bearing ropes shall represent an enclosed structure and made of one piece. Multistrand ropes with a steel core may be applied at cranes with hooks designed for installation work.
5.23.
Double-spin ropes with the core of a fibre material shall be applied for lifting and haulage ropes. Regular lay ropes shall be applied as lifting ones. Long lay ropes may be applied if the rope untwisting or polyspast branches spinning are eliminated. Application of long lay ropes is preferable for haulage ropes to move the truck and supports.
5.24.
The device to fasten a bearing b earing rope on supports shall be a hinged one to regulate the rope tension. If several bearing ropes are applied, their uniform tension shall be ensured.
5.25.
A bearing rope shall be fastened in a coupling with a cotter or cast moulded with a metal alloy. The rope may be fastened with clamps on cranes with a variable span. In such case the hold shall be designed for a force equal to the breaking strength of the whole rope
5.26.
The diameter of the drum and guiding blocks for load, haulage and clam-shell (both supporting and closing) ropes shall be estimated according to the following equation: D h d , where: D is the diameter of the drum or block measured along the rope centre line, mm; d is the diameter of the rope, r ope, mm; h is the factor of the drum or block diameter selection to be identified from Table 7.
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Table 7. Minimum Zp and h Factors Rope Purpose Bearing Lifting: Hook installation
Hook transshipment
Clam-shell transshipment
haulage: load truck moving driving support movement crane (support) moving Crane (support) retention from movement by wind in stand-by conditions For bearing ropes anchoring polyspasts For cam supports suspension For mast and support guying For power cables suspension Installation: With a hand drive With a mechanic drive
h -
Zp 3.0
30 40 50 30 40 50 30 40 50
5.0 4.5 4.0 5.5 5.0 4.5 6.0 5.5 5.0
30 30 30 30
4.0 4.0 4.0 2.5
30 -
6.0 3.0 3.0 3.0
12 20
4.0 4.0
* It is assumed that the weight of the clamshell with material is evenly distributed to all the ropes. 5.27.
Lifting, haulage ropes and ropes to suspend cables shall be intact. Rope splicing may be accepted in separate cases. The length of the sections spliced shall be at least 1000 rope diameters.
5.28.
Bearing ropes of an enclosed design, as well as double-spin ropes shall be rejected in accordance with the criteria given in Appendix 10. If a crane with a swing support is shut down due to bearing ropes wear-out, the support shall be mounted on the installation foundation.
5.29.
Static testing of a crane shall be carried out with a load exceeding its lifting capacity by 25%. In that case the load truck shall be placed in the middle of the span, the load shall be lifted to the height of 200-300 mm and kept there for 30 minutes. After that, the conditions of ropes in the couplings and the general condition of the crane shall be inspected.
5.30.
The following shall be carried out during the crane dynamic testing: a) Rotating lifting and lowing of a load stopping at various heights; b) Rotating movement of the load truck stopping at various points within the span;
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c) Rotating movement of the crane in different directions to different distances; d) Rotating lifting and lowing of a load, with simultaneous movement of the load truck. 5.31.
The following shall be attached to the crane certificate in addition to documents enumerated in clause 7.1.3 for its registration at Gosgortechnadzor: a) Steel Structure Acceptance Statements (at the producer's or installation sit e). b) The Steel Structure Testing Statement if such testing is provided by the design; c) The crane track design; d) The Statement of Crane Track and Foundations Acceptance with survey marks and adjustments; e) The Statement of Ropes Fixation in Couplings; f) The Statement of Bearing Ropes Sagging Measurements; g) The Statement of Tension in Support Guys Measurements; Measurements; h) The Statement of the Swing Support Position Inspection. The sag of the bearing rope shall be measured with the truck being in the middle of the span and with the maximum operation load. The actual sag value shall not differ from the designed one for more than the tolerance established. The check of the swing support position compliance with the designed one shall be carried out with the empty truck being at the non-swinging support. When crane tracks are inspected, the angle of inclined crane tracks shall be measured, the linearity and horizontality, the distance between the track of one support and the tracks of opposite supports. Inspections of the track conditions, rope fixation in couplings and support guys tension, as well as inspections of rope sag compliance with the design and the swing support position in the course of operation shall be carried out during each certification of a cable crane. 6. HOISTS AND WINCHES TO LIFT PEOPLE
6.1.
Requirement set forth by Chapters 1-4 and 7 with amendments and additions provided for by this Chapter shall be applicable to hoists on tower cranes and winches to lift people.
6.2.
Hoists at tower cranes and methods of their testing shall comply with the standard documentation for tower cranes manufacturing developed by companies specialised in crane production.
6.3.
Winches with hand drives shall be equipped with safe handles, their design shall provide for lifting or lowering by way of uninterrupted force application to the handle. The speed of lowering shall not exceed 0.33 m/sec.
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6.4.
Winches with power drives shall be equipped with normally closed brakes, which shall automatically close with the engine disengagement. The deceleration margin factor shall be at least 2.
6.5.
The shaft of the engine shall be connected to the shaft of the drum with the help of tooth or worm gear. Belt and friction gear, friction and cam clutches shall not be applied for the purpose.
6.6.
Winches shall be secured on foundation or provided with ballast to ensure their stability at double operational load.
6.7.
The method of the cradle and platform for people suspension shall eliminate the possibility of their falling over. Cradles and platforms shall be equipped with railing at least 1200 mm high. Workers shall be fastened with safety belts when lifted in cradles seated (without railing). Arrangement of doors in the railing is prohibited. If cradles are suspended on a hook, the latter shall be equipped with a safety clamp to eliminate falling of the cradle.
6.8.
In cases, when a cradle or a platform may hit against prominent building parts, structures, or when their speed exceeds 0.33 m/sec, rigid or flexible guides shall be installed and arrangements made to protect people lifted from their possible hitting prominent building or structure parts.
6.9.
Measures shall be taken to provide smooth stopping of a cradle or platform if the lifting or lowering speed of winches with power drives exceeds 0.33 m/sec.
6.10.
Stationary winches with power drives shall be equipped with automatic switches to disengage the engine when the cradle approaches the upper position.
6.11.
Stationary power winches shall be controlled from cradles or platforms by way of continuous pushing of the control button. The winch shall stop when pushing is ceased.
6.12.
Winches shall undergo complete examination before commissioning and every 12 months.
6.13.
Static testing of winches shall be carried out with the help of a load 1.5 times exceeding their tractive force when lifting, and dynamic testing - with the load exceeding it 1.1 times. 7. OPERATION OF HOISTING EQUIPMENT 7.1. Registration
7.1.1. The following hoisting units shall be registered at Gosgortechnadzor bodies: a) Cranes of all types, t ypes, with the exception of those stated in clause 7.1.2; b) Excavators designed designed to operate with a hook or electric magnet;
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c) Load power trucks with a control cab moving along rail tracks on the ground. 7.1.2. The following hoisting units do not require registration at Gosgortechnadzor bodies: a) Crane of all types with hand driven mechanisms and cranes that alongside hand driven movement mechanisms a pneumatic or hydraulic cylinder is applied as a lifting mechanism; b) Overhead cranes and movable or rotating cantilever crane with the lifting capacity up to 10 tonnes inclusive controlled from the floor with a pushbutton device or from a stationary panel; c) Boom cranes with the lifting capacity up to 1 tonne inclusive; d) Boom cranes with the permanent radius or having no rotation or moving mechanism; e) Adjustable cranes to install masts, towers, pipes adjusted on the structure being installed; f) Overhead cranes and tower cranes mounted on training grounds for training purposes; g) Cranes mounted on excavators, crushing and loading, and other process equipment to be applied for such equipment maintenance only; h) Telphers and winches to lift loads and/or people. 7.1.3. Hoisting equipment shall be registered at Gosgortechnadzor bodies on a written application of the owner and his submission of the equipment certificate. The application shall state availability of engineers and technicians in the company (whose knowledge hereof has been assessed) to supervise safe operation of hoisting equipment, and availability of trained personnel to service the crane. It shall also confirm that technical conditions of the crane allow its safe operation. If the owners have no required experts available, they shall submit an agreement with a specialised company for supervision and servicing. If an overhead crane, tower or frame crane are registered, a statement certifying that the crane has been mounted in accordance with the instructions and signed by an authorised representative of the installation company. If an overhead crane is registered, the drawing of its installation i nstallation shall be attached with the certificate indicating locations of the main trolley cables and the l anding platform to enter the crane. The drawing shall show actual dimensions regulated in clauses 4.13.10 and 4.14.4. When a hoisting unit moving along a rail track on the ground is registered, a certificate confirming that the track has been designed for that particular unit operation shall be submitted. The designing company or the owners of the crane shall give the certificate stating that the track is in line with the loads of the crane with reference to the design.
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If the counterweight and ballast plates for tower and frame cranes have been made by the owners of the cranes, the Plates Acceptance Statement shall be submitted stating the actual weights of the plates. If cranes are installed on wharfs, a certificate shall be submitted stating that cranes on them are acceptable. If a crane is registered after having operated the rated life-span through, a resolution of a specialised company shall be submitted stating the possibility of its further operation. When imported cranes are registered, resolutions of the certification body shall be attached. If boom self-propelled cranes (with the exception of caterpillar ones) are registered, Gosgortechnadzor shall make a note on the owners' application to register it at the road police department (State Automobile Inspectorate). 7.1.4. In case a hoisting unit is not supplied with the producer's certificate, it may be registered at Gosgortechnadzor on the basis of the certificate compiled by a specialised company. In addition, the certificate of a hoisting unit shall include the following data: a) A conclusion made on the basis of the unit and its separate elements lifting capacity correspondence to the effective lifting capacity (confirmation of the effective lifting capacity may be also given on the basis of the unit basic designed elements comparison with the same elements of another hoisting unit of the same type); b) A laboratory certificate of chemical analyses and mechanical properties of the steel structure material, with the closest analogue of local steel identified; c) The hook design and calculations if it does not correspond to the State Standard or is not provided with the producer's stamp; d) The Statement of steel structures and welded joints quality testing. 7.1.5. Hoisting units shall be re-registered after: a) Reconstruction; b) Maintenance if a new certificate was made for the unit; c) Transfer to other owners; d) Installation of an overhead crane at another location. 7.1.6. If a hoisting unit is registered after reconstruction, a new certificate compiled by the company that carried out the reconstruction shall be submitted, or the old one, with the t he following documents attached:
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a) The certificate of the reconstruction character signed by the specialised company, which had worked out the design of the reconstruction; b) New crane characteristics and the drawings of its overall view with the basic dimensions if they have changed; c) The principle wiring and hydraulic diagrams if they have changed; d) Cinematic diagrams of mechanisms and rope reeving diagrams if they have changed; e) Copies of certificates (extracts from certificates) for metal applied in the hoisting unit reconstruction; f) Specifications of the adding material (built-up metal testing results or welding rods certificates copies); g) Data of steel structures welding quality control. 7.1.7. If a hoisting unit registration is denied, the reasons of it shall be stated in writing with reference to appropriate clauses hereof and standard documents. 7.1.8. If a crane is dispatched for operation to other regions for a period of above 3 months, the owners shall notify the Gosgortechnadzor body, where the crane is registered, about it stating the registration number of the crane, the new location and the period of operation. On the crane arrival to the place of destination, the work supervisor shall register it temporarily in the local Gosgortechnadzor body and obtain a permit for the crane operation. In that case documents regulating the procedure of preventive inspection and maintenance, the design of construction and installation work to be carried out and memorandums assigning assigning persons in charge and servicing personnel shall be submitted. 7.1.9. A hoisting unit shall be taken out of registration in the foll owing cases: a) When it is written off; b) When transferred to other owners; c) When transferred into the category of those not liable to registration, a hoisting unit shall be taken out of registration by Gosgortechnadzor bodies on a written application of the owners and with entering the reasons into the certificate. 7.1.10. Hoisting units not liable to registration at Gosgortechnadzor bodies, as well as detachable gripping devices shall be provided with individual numbers, such shall be entered in the t he hoisting unit and gripping device record log. 7.2. Commissioning Permit 7.2.1. A Commissioning Permit for a hoisting unit subject to registration at Gosgortechnadzor bodies shall be obtained from the above bodies in the following cases:
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a) Prior to commissioning of a newly registered hoisting unit; b) After installation due to the hoisting unit relocation (except for boom selfpropelled cranes); c) After a hoisting unit reconstruction provided for by clause 3.333; d) After steel structure design elements or parts maintenance or replacement with welding; e) After a frame crane installation at a new location. 7.2.2. A Commissioning Permit for a hoisting unit subject to registration shall be issued by a Gosgortechnadzor Inspector on the basis of an examination carried out by the owners. The owners shall inspect the conditions of the hoisting unit and the crane track. The system of units supervision and servicing arrangement in the company shall be also checked. The owners shall notify Gosgortechnadzor (Inspector) about the coming hoisting unit commissioning within at least 5 days. 7.2.3. A commissioning permit for caterpillar and wheel-mounted cranes after their relocation shall be issued by an engineer in charge of safe crane operation assigned by the owner's memorandum. It shall be issued after the hoisting unit conditions examination and when safe operation is ensured. 7.2.4. A commissioning permit for a newly manufactured boom crane supplied to the owners assembled shall be issued by Gosgortechnadzor on the basis of the crane mill test results and technical examination (without testing under load) carried out by the owners. An appropriate entry shall be made in the certificate. 7.2.5. A commissioning permit for hoisting units not subject for registration at Gosgortechnadzor shall be issued by an engineer in charge of safe crane operation on the basis of the crane producer's documents and technical examination. 7.2.6. A commissioning permit for a hoisting unit subject to registration at Gosgortechnadzor shall be entered in its certificate by a Gosgortechnadzor Inspector, and for other hoisting units - by an engineer in charge of safe crane operation. A commissioning permit for detachable gripping devices and containers shall be entered in the recording log by the person who issues the permit. 7.3. Technical Examination 7.3.1. Hoisting units and detachable gripping devices shall undergo complete technical examination prior to their commissioning. commissioning. Hoisting units liable to registration at Gosgortechnadzor shall be examined prior to their registration.
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Technical examination shall be carried out in accordance with the instructions on the hoisting unit operation developed accounting for ISO 4310 (texts of basic International Standards are given in Appendix 11). If the above Instructions give no appropriate guidelines, the examination shall be carried out in accordance herewith. 7.3.2. Hoisting units in operation shall be examined from time to time: a) Partially - at least once every 12 months; b) Completely - at least once every 3 years with the exception of rarely operating units (cranes to serve motor halls of power plants and pumping stations, compressor units and other hoisting equipment used during equipment maintenance only). Seldom operated hoisting units shall undergo complete examination at least once every 5 years. The owners shall identify cranes as seldom operating ones on coordination with Gosgortechnadzor. Gosgortechnadzor. 7.3.3. An extraordinary complete examination of a hoisting unit shall be carried out after the following: a) Installation due to a hoisting unit relocation; b) A hoisting unit reconstruction; c) A hoisting unit steel structure repairs, with design elements or parts replacement; d) Installation of removable boom equipment or boom replacement; e) The load (boom) winch major repairs or replacement; f) The hook or hook suspension replacement (static testing only); g) Bearing or guy ropes replacement at cable cranes; h) A frame crane installation at a new location; i) On a request of a Gosgortechnadzor Inspector or a person in charge of supervision. 7.3.4. After the replacement of worn out load or other ropes and in all the cases of rope re-reeving, their new reeving and rope end fastening, as well as rope stretching with operating load shall be checked. An engineer in charge of the hoisting unit operating conditions shall enter the results in the crane certificate. 7.3.5. The owners shall carry out technical examinations of hoisting equipment, with the exception of cases set forth in clause 7.3.6. An engineer in charge of supervision and safe hoisting equipment operation shall carry out technical examinations, with participation of an engineer in charge of crane operating conditions.
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Testing after a hook or hook suspension replacement at night may be assigned by a shop memorandum to shift engineering personnel at metallurgical and other plants with a continuous process. 7.3.6. Hoisting units manufactured at a producing or specialised maintenance plant and transported to the site assembled shall be completely examined at the plant prior to their shipment to the owner. The date of such examination and its results shall be entered into the crane certificate. Prior to the start-up, the owner shall partially examine the crane and enter the results into the crane certificate. 7.3.7. Technical examinations have the objective to identify that: a) The hoisting unit and its installation comply with the requirements hereof, the certificate and the documents submitted for registration; b) The hoisting unit is in good working condition ensuring its safe operation; c) The arrangement of the hoisting unit supervision and maintenance comply with the requirements hereof. 7.3.8. In case of a complete technical examination a hoisting unit shall undergo the following: a) Visual inspection; b) Static testing; c) Dynamic testing. In case of partial technical examination, neither static nor dynamic testing is carried out. 7.3.9. Technical examination of a hoisting unit shall include visual inspection and testrunning of its mechanisms and power equipment, safety devices, brakes, running wheels and control appliances, as well as checking of lighting and overall dimensions regulated hereby. While checking the operation of the hatch leading to the crane gantry interlink contact, it is required to make sure that power is not supplied to trolley cables located on the crane. In addition, the following shall be checked during the examination: a) The condition of the hoisting unit steel structures and its welded (riveted) joints (absence of cracks, displacements, wall thickening due to corrosion, loosening of riveted joints and other deficiencies), as well as the cab, stairs, platforms and railing; b) The condition of the hook, running wheels, blocks, drums, braking elements. In case of hoisting units transporting melted metal and liquid slag, forged and pressed hooks and their suspension parts shall be tested by the plant laboratory in accordance with the instructions on NDT application. The
58
conclusion of the laboratory shall be kept together with the crane certificate. Non-destructive testing shall include checking for cracks in the threaded part of the forged (pressed) hook, cracks in the threaded part of the plate-type hook and in the axle of the plate-type plate-t ype hook connection connection to the fork or spreader bar. Such examination shall be carried out at least once every 12 months. The owner shall establish the requirement to inspect suspension parts and the frequency of such inspections. c) The actual distance between the hook suspension and the stop at the lifting mechanism limit switch actuation; d) The condition of cables and grounding insulation at a power crane, and assessment assessment of their resistance; e) Compliance of the counterweight and ballast weights with the values stated in the crane certificate for a boom crane; f) The condition of the crane track and its compliance with the requirements hereof, design and operation instructions; g) The condition of ropes and their fastening. The limits to reject elements of a hoisting unit shall be given in operation instructions. If the instructions do not contain them, elements shall be rejected on the basis of recommendations given in Appendixes 10 and 12. Work provided by clauses "a", "b" and "d" of this Article may be carried out before the technical examination. In such case the results of visual inspections and tests shall be recorded in a statement signed by the inspecting and testing person. 7.3.10. Static testing of a hoisting unit shall be carried out with a load exceeding its lifting capacity by 25% in accordance with methods provided by the crane operation instructions. Such testing is targeted at checking the durability of the unit. 7.3.11. Static testing of an overhead crane and movable cantilever crane shall be carried out as follows further. The crane shall be installed above the supports of the crane track, and its truck (trucks) shall be installed in the position corresponding to the greatest sag. The hook or device substituting it shall grip the load and lift it to the height of 100-200 mm, where it shall be kept for 10 minutes. The load shall be lowered in 10 minutes and the crane gantry checked for residual deformation. Static testing of a gantry crane and transshipment crane shall be carried out in the same way as that of an overhead crane. Each cantilever of a cantilever crane shall be tested separately. In case of residual deformation resulting from the crane test, such crane shall not be accepted for operation till a specialised company identifies the causes of the deformation and estimates the possibility of the crane further operation.
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7.3.12. Recurrent or extraordinary testing of a boom crane with one or several lifting characteristics shall be carried out in the position corresponding to the highest lifting capacity of the crane. Cranes with removable boom equipment may be tested with the equipment installed on them for operation. After removable boom equipment has been installed on a crane, the test shall be carried out in the position corresponding to the crane highest load capacity with the equipment installed. Boom cranes without any mechanism to change the radius (the boom is supported with a guy line) shall be tested with the radius established for the crane. Further operation of the crane shall be permitted with that very radius given the results of testing t esting are satisfactory. 7.3.13. When boom cranes are statically tested, the boom shall be installed in the position corresponding to the crane lowest designed stability relative to the running platform. The load shall be lifted to the height of 100-200 mm. 7.3.14. The crane shall be considered having passed the static test satisfactorily if the load lifted does not lower down to the ground within 10 minutes, and no cracks, residual deformation or other damage to steel structures and mechanisms are found. 7.3.15. Dynamic testing of a hoisting unit shall be carried out with a load exceeding its lifting capacity by 10%. Such testing is targeted at checking the functioning of mechanisms and brakes. Dynamic testing shall include numerous lifting and lowering of the load, as well as checks of other mechanisms in combinations of movements provided by the operation instructions. 7.3.16. If a hoisting unit is equipped with two or more lifting mechanisms, each of them shall be tested. 7.3.17. If a hoisting unit is applied to lift and lower loads only (lifting of water gates at a hydraulic power plant), its dynamic testing may be carried out without moving the unit itself or its truck. 7.3.18. Static and dynamic testing of overhead cranes operating at hydraulic and thermal power plants and sub-stations may be carried out with the help of specific devices allowing creation of the testing force without load application. The device shall allow for dynamic testing of a mechanism under load within at least one revolution of the drum. Testing of the movement mechanism under load is not necessary. The crane owners or specialised company shall develop additional instructions to test cranes with specific devices.
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7.3.19. Testing of a crane with several removable gripping devices may be carried out with the device installed on the crane at the time of testing. Testing of magnetic and clamshell cranes may be carried out with a magnet or clam-shell accordingly. 7.3.20. If operation conditions do not require a crane application (with the exception of a boom self-propelled one) with its rated capacity, complete examination of such crane may be based on its reduces lifting capacity. In that case an entry shall be made in the crane certificate that the capacity is reduced. Appropriate changes shall be made in the t he nameplate on the crane and operator's instructions. 7.3.21. Technical examination of cranes that have operated through their rated life span shall be carried out after their inspection made by a specialised company in accordance with methodological guidelines developed by specialised companies and approved by the RoK Gosgortechnadzor. 7.3.22. The owners shall ensure availability of a set of testing loads with their weights marked for crane resting purposes. 7.3.23. The technical examination results shall be entered into the crane certificate by the person, who has carried out the examination. The time of the next testing shall be also stated. When a newly mounted crane is examined, the entry in its certificate shall confirm that the crane has been assembled and installed in accordance with the Regulations and operation instructions, and that it has passed tests satisfactorily. The entry of an operating crane undergoing a recurrent examination shall certify that the crane complies with the requirements hereof, is in good condition and has passed tests satisfactorily. The permit for further operation of the crane shall be issued in that case by the safe crane operation supervising engineer. 7.3.24. Recurrent visual inspections and maintenance of hoisting units, as well as repairs and alignment of crane tracks shall be carried out in accordance with the producer's instructions and within the terms provided by the preventive maintenance schedule. schedule. The schedule shall be developed accounting for the crane actual operating time and its condition. The owners of hoisting equipment shall ensure compliance of the above work with the schedule and timely elimination of deficiencies found. Crane operation after the time rated for inspection and maintenance is prohibited. 7.3.25. The results of visual inspections and maintenance, information of hoisting equipment repairs shall be entered into a log. Information of a hoisting unit repairs requiring its extraordinary technical examination shall be entered into its certificate.
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7.3.26. The results of removable gripping devices and containers visual inspections shall be entered into a log. 7.3.27. After having operated the rated life span through a hoisting unit shall be inspected by a specialised company licensed by Gosgortechnadzor Gosgortechnadzor bodies. The procedure of a permit (license) for crane inspection issuing is set forth by the standard documentation of the RoK Gosgortechnadzor. 7.3.28. Owners shall inspect removable gripping devices and containers from time to time in the course of their operation. The frequency shall be as follows: Spreader bars of tongs, other grips and containers - every month; Slings (except for those applied seldom) - every 10 days; Seldom applied removable gripping devices - before application. Slings and containers shall be inspected in accordance with the instructions developed by a specialised company. The instructions shall identify the procedure and methods of inspection, rejection criteria and methods to eliminate damage found. If the instructions are not available, slings shall be rejected on the basis of recommendations given in Appendixes 10 and 13. Damaged removable gripping devices identified in the course of inspection shall be immobilised. 7.4. Supervision and Servicing 7.4.1. Company managers and private owners of hoisting units, containers, removable gripping devices and crane tracks, as well as managers of companies operating cranes shall provide their good working conditions and safe operation conditions by way of proper inspection, examination, maintenance, supervision and servicing arrangement. The following shall be done for the purpose: a) An engineer to supervise safe operation of hoisting equipment, removable gripping devices and containers, an engineer in charge of keeping hoisting equipment in good working conditions and a person in charge of safe crane operation shall be assigned; b) Maintenance service and the procedure of recurrent r ecurrent inspections, maintenance and repairs shall be established to provide good working conditions of hoisting units, crane tracks, removable gripping devices and containers; c) Personnel training and knowledge assessment procedures shall be established as required hereby for people servicing hoisting units, as well as the procedure of engineering personnel knowledge hereof assessment; d) Instructions for persons in charge and service personnel, work diagrams, flow charts, specifications for handling, load slinging and piling patterns, and other regulations of hoisting unit safe operation shall be developed;
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e) Distribution of hoisting unit safe operation regulations, job descriptions and guidelines among engineers, and operation instructions among the personnel shall be ensured; f) Compliance of engineers herewith and servicing personnel with the instructions shall be provided. 7.4.2. The owners shall assign engineers to supervise hoisting equipment safe operation after their knowledge hereof assessment by a Committee, with a Gosgortechnadzor Gosgortechnadzor Inspector participation, and issue of appropriate certifications certifi cations in accordance with the form given in Appendix 14. Knowledge of engineers supervising hoisting equipment safe operation shall be assessed every 3 years. The numbers of the supervision service and its structure shall be established by the hoisting equipment owners accounting for the number of units and their operation conditions, and shall be approved by Gosgortechnadzor. 7.4.3. The engineer supervising hoisting equipment safe operation shall: a) Supervise the conditions and safe operation of hoisting units, removable gripping devices, containers and crane tracks, and make arrangements to prevent breaches of safety regulations; b) Inspect hoisting equipment and issue permits for its operation in cases provided hereby, as well as keep records of and inspect hoisting units and removable gripping devices not subject to registration at Gosgortechnadzor if no one else is made responsible r esponsible for that; c) Control implementation of improvement notices issued by Gosgortechnadzor, Gosgortechnadzor, compliance with the schedules of hoisting equipment and crane tracks recurrent inspection and maintenance and terms of removable gripping devices and containers visual inspections; d) Check compliance with the work permit procedure established herein for workers operating and servicing hoisting equipment, participate in committees attesting servicing and maintenance personnel and assessing their knowledge, committees assessing knowledge of engineers in charge of keeping of hoisting equipment in good working conditions and persons in charge of crane safe operation; e) Control availability of operation instructions and compliance of servicing personnel, engineers (experts) in charge of keeping of hoisting equipment in good working conditions and persons in charge of crane safe operation with the above instructions; f) Check implementation of safety regulations, work charts and process schedules during hoisting equipment operation. Special attention shall be paid to correct application of load slinging methods, compliance with load piling overall sizes established, accuracy of boom self-propelled cranes installation, application of proper working and personal protection techniques. He shall also check compliance with the system of work permits
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when operating close to overhead power lines and on crane tracks of overhead and movable cantilever cranes; g) Control compliance with the procedure of boom self-propelled cranes allocation and dispatch to the sites procedure established by the owners. 7.4.4. If faults or breaches hereof are revealed in the course of hoisting equipment operation and maintenance, the engineer supervising hoisting equipment safe operation shall take measures to eliminate them, and shut down the unit if required. The engineer supervising hoisting equipment safe operation shall prohibit a unit operation if: a) Faults of brakes, blocks, ropes and their fastening, chains, hooks, winches, running wheels, interlink devices and safety devices, as well as incompliance of the crane wiring with the design are found; b) There are cracks and displacements in bearing steel structures; c) Faults in the crane track are revealed (Appendix 15); d) The term of technical inspection or rated life span of the unit have expired; e) It is serviced by non-attested operators and slingers, engineers in charge of keeping of hoisting equipment in good working conditions and persons in charge of crane safe operation have not been assigned; f) The crane certificate or information of its registration at Gosgortechnadzor are not available; g) Removable gripping devices and containers appropriate for the weight and character of loads are not available or faulty; h) Improvement notices issued by him or Gosgortechnadzor are not implemented; i) Grounding or power equipment are faulty. 7.4.5. The responsibility for keeping of hoisting equipment in good working conditions shall be imposed on an adequately qualified engineer after his knowledge hereof assessment by a committee including a Gosgortechnadzor inspector, and on his reception of an appropriate certificate and job description. The personnel (except for slingers) servicing the crane shall report to him. Such engineer's knowledge shall be assessed every 3 years. The number and date of the memorandum of the person in charge assignment, his position, name, identity card number and signature shall be included in the hoisting unit certificate. Such information shall be entered in the certificate prior to the unit registration at Gosgortechnadzor, and also every time a new person in charge is assigned.
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For the period of such person's annual holidays, business trip, sick leave or in other cases of his absence, his responsibilities shall be imposed on the person substituting him in his position. The latter shall be of appropriate qualification and after his knowledge hereof are assessed (without entering of his name into the unit certificate). The owner shall create conditions for the person in charge to carry out his obligations. 7.4.6. The engineer in charge of keeping hoisting equipment in good working conditions shall provide the following: a) Keeping of hoisting units, removable gripping devices, containers and crane tracks in good working conditions (if working condition of the latter is not the duty of another service) by way of recurrent inspections, maintenance and repairs within the time set forth by schedules. Regular control of accurate inspection log maintenance and timely elimination of deficiencies found, as well as personal inspection of hoisting units, crane tracks, removable gripping devices and containers within the time scheduled. b) Maintenance of hoisting equipment by trained and attested personnel with adequate knowledge and skills to carry out their duties. He shall also ensure recurrent assessment of the servicing personnel knowledge; c) Compliance of the operators and maintenance personnel with operation and maintenance instructions; d) Timely preparation of hoisting equipment for technical examination, as well as preparation of cranes, which life-span has expired; e) Shut down of hoisting equipment for scheduled maintenance; f) Compliance with the mark-key system in overhead cranes operation; g) Compliance with the established procedure of servicing and other workers access to crane tracks of overhead and movable cantilever cranes for maintenance and other work; h) Proper keeping of certificates and specifications for hoisting units and removable gripping devices, containers and crane tracks, as well as maintenance of personnel recurrent knowledge assessment logs; i) Implementation of improvement notices issued by Gosgortechnadzor and the engineer in charge of safe hoisting equipment operation. Good working conditions of removable gripping devices, containers and crane tracks may be imposed on another expert of appropriate qualification. 7.4.7. A person responsible for crane safe operation shall be assigned in every shift at every shop, construction site or other site, where hoisting equipment operates. Such person is a foreman, crew leader l eader or section foreman.
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Storekeepers may be assigned as persons in charge of crane safe operation at warehouses on Gosgortechnadzor approval. Such persons shall be appointed after their knowledge of appropriate sections hereof, job descriptions and those for crane operators and slingers is assessed. A committee including a Gosgortechnadzor inspector shall carry out such assessment and issue certificate and instructions to those who pass the assessment satisfactorily. The knowledge of such persons shall be assessed at least every 12 months. 7.4.8. The person in charge of crane safe operation shall: a) Arrange crane operation in accordance with the safety regulations, work design, specifications and process schedules; b) Instruct crane operators and slingers about safe work methods paying attention to hazardous factors, specific conditions at the site, non-admission of the crane overload, accuracy of slinging and gripping, accuracy of boom self-propelled cranes installation, safety requirements while unloading railway cars, platforms and trucks and personal safety of slingers; c) Eliminate access of untrained and non-attested personnel to crane operation, estimate the number of slingers required and the requirement of signalmen during operation; d) Eliminate application of removable gripping devices and containers if they are unmarked, faulty or inappropriate according to their lifting li fting capacity; e) Show crane operators and slingers the place, order and overall sizes of load piling; f) Directly supervise operations of railway cars loading and unloading, load handling with several cranes, close no overhead power lines, above overhead coverings with industrial or ancillary rooms under them, where people may be present, cases when loads without slinging patterns are handled and in all other cases provided for by designs or process schedules; g) Show crane operators the locations to install boom self-propelled cranes when close to power lines and issue work permits entering it into a shift log; h) Control compliance with the mark-key system in overhead cranes operation; i) Eliminate operations without work permits in cases provided by these Regulations; j) Provide workers with required implements and means for safe work; k) Look after the operator and slingers' compliance with instructions, work designs and process schedules. 7.4.9. At companies with a small number of hoisting units (up to three registered cranes), where all the persons in charge provided hereby can not be appointed, the duties of the engineer in charge of hoisting equipment working conditions
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and the person in charge of safe crane operation may be imposed on one engineer or (under a contract) an expert of a specialised company. Gosgortechnadzor Gosgortechnadzor shall approve it. 7.4.10. If the owner of a hoisting unit has no opportunity to assign persons in charge provided hereby, their duties may be imposed on employees of a specialised company under a contract and on an approval by Gosgortechnadzor. Gosgortechnadzor. 7.4.11. The owners shall assign crane operators and mechanics to control and maintain hoisting equipment and electricians in addition to them for units with power drives. 7.4.12. An assistant of a crane operator shall be assigned in cases provided for by the crane operation instructions if required by local conditions. 7.4.13. A driver may be assigned to control a crane truck after his training for a crane operator and assessment by a qualification committee. 7.4.14. Slingers shall be appointed to sling loads to the crane hook, with the exceptions of cases stated in clause 7.4.15. Other workers (riggers, etc.) may be accepted as slingers if they are trained t rained for a position requiring slinging operations. An entry shall be made in i n the certificates of such workers about their t heir assignment as slingers. 7.4.15. Workers of basic positions trained additionally as slingers according to a shortened programme may be permitted to hang loads on a hoisting unit hook without its preliminary slinging (loads with eyes, frames, trunnions or those being in various containers). They may also do it in cases when the load is gripped with a semi-automatic gripping device. The same requirements hereof as those for slingers shall be applicable to such workers. 7.4.16. In cases, when the area served by a hoisting unit is not entirely seen from the operator's cab and there is neither radio nor telephone communication between the operator and slingers, one of the slingers shall be appointed a signalman. si gnalman. 7.4.17. Workers at least 18 years old may be assigned as crane operators, operator assistants, mechanics, electricians and slingers. 7.4.18. Crane operators, their assistants and maintenance personnel shall pass medical examination prior to their assignment to estimate if their health complies with the requirements for the positions. 7.4.19. Crane operators, their assistants, slingers, mechanics, electricians and safety device setters shall be trained and attested at vocational schools and at courses and technical schools for workers. Technical schools and courses may be established at companies and construction sites possessing an adequate base for theoretical and practical training and a permit (license) of Gosgortechnadzor.
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Training of workers for the above positions shall be carried out in accordance with programs developed at training centres and approved by the RoK Gosgortechnadzor. 7.4.20. Crane operators and their assistants, when transferred from cranes of one type to cranes of other types (e.g. from a tower crane to an overhead one), shall be trained and attested in the order established hereby. Training in such cases may be carried out on the basis of a shortened program approved by Gosgortechnadzor. If crane operators and their assistants are transferred to a crane of the same type, but another model, index or with another drive, they shall be familiarised with the peculiarities of such crane operation and maintenance and pass a probation. Such workers may be admitted to independent work after their knowledge and skills assessment. The owner of the crane shall establish the procedure of training, probation and skills assessment. 7.4.21. Crane operators and their assistants shall be assessed by a committee appointed by the crane owner after a break in their work for more than a year. If the assessment results are satisfactory, they may be admitted for probation to restor e the skills required. 7.4.22. The qualification committee shall assess recurrently knowledge of the servicing personnel (crane operators, their assistants, mechanics, electricians, safety device setters and slingers) as follows: a) Recurrently at least every 12 months; b) When workers are transferred to another working place; c) On a request of the engineer supervising crane safe operation or Gosgortechnadzor Gosgortechnadzor Inspector. Recurrent knowledge assessments shall be carried out within the scope of instructions. Inspector's participation in such assessments is not required. 7.4.23. The results of attestation and servicing personnel recurrent knowledge assessment shall be stated in Minutes and entered into certificates. 7.4.24. Gosgortechnadzor representative's participation in the work of the crane operators qualification committee is mandatory. Gosgortechnadzor (inspector) shall be notified of the examination date within at least 10 days. The qualification committee of the company or training company may attest other workers serving hoisting equipment without Gosgortechnadzor inspector's participation.
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In separate cases, Gosgortechnadzor participation in attestation of slingers.
may
require
its
representative's
7.4.25. On passing their exams workers shall be given certificates in accordance with the form established (Appendix 16) signed by the Committee Chairman, and in case of crane operators and their assistants they shall be signed by the Chairman and Gosgortechnadzor Gosgortechnadzor representative. Types and indices of cranes the crane operator is permitted to work at shall be stated in his certificate. Certificates of crane operators and slingers shall bear their photos. They shall have their certificates with them at work. 7.4.26. Work permits for crane operators, their assistants, mechanics, electricians, safety device setters and slingers shall be issued as a memorandum (order) of the crane owners. 7.4.27. Workers of basic professions (machine operators, riggers, etc.) may operate a hoisting unit from the floor or stationary panel and hook loads on such units after an appropriate induction and operation and slinging skills assessment according to a procedure developed by the crane owners. Workers qualified for crane operators and having appropriate certificates may control cranes by radio. 7.4.28. Attested slingers only may work as signalmen. The person in charge of crane safe operation shall appoint signalmen. 7.4.29. Workers of basic professions servicing cranes cranes controlled from the floor or with a stationary panel and hooking loads shall have recurrent inductions every 3 months. 7.4.30. For cranes to be served properly, the owners shall provide crane operators, their assistants, mechanics, mechanics, electricians and slingers with instructions identifying their rights, duties, safe work procedures and responsibilities. The instructions shall be distributed among the above workers (against receipt) before their work permit. 7.4.31. The owners of hoisting equipment, removable gripping devices and containers shall establish procedures for the persons in charge of the equipment servicing (crane operators, their assistants, electricians and mechanics) to look after it by way of visual inspections and test running, and maintain it in good working conditions. Crane operators shall inspect hoisting units before commencing work, and the owners shall allocate a certain time period for it. The results of the operators' visual inspections and checking shall be entered into the shift logbook (the form is given in Appendix 1).
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Slingers shall visually inspect removable gripping devices and containers before their application. 7.5. Operation 7.5.1. Hoisting units may be permitted to lift and handle only such loads, which weight does not exceed the lifting capacity of the unit. In case of boom self-propelled and railway cranes, the position of extended supports, and in case of cranes with travelling counterweights, the position of the counterweight shall be accounted for. Requirements stated in the certificate of a hoisting unit and in its operation instructions shall not be infringed during its operation. 7.5.2. Hoisting units equipped with a clamshell or magnet may only be admitted to operation given specific directions for the purpose stated in producer's instructions are implemented. 7.5.3. A hoisting unit equipped with a magnet may handle a one-piece load (slabs, ingots) solely if its transloading is eliminated. 7.5.4. Hoisting units with lifting mechanisms equipped with friction clutches or cam clutches can not be applied to lift and handle melted metal, noxious substances and explosives, and pressure vessels. 7.5.5. Load handling above overhead coverings with industrial or ancillary rooms under them, where people may be present shall be unacceptable. In separate cases, on an approval of Gosgortechnadzor, loads may be handled above overhead coverings with industrial or ancillary rooms under them, where people are present after special arrangements are developed to provide safe operation. 7.5.6. Load handling by several cranes may be permitted in separate cases. Such work shall be carried out in accordance with the design or process chart, where load slinging and handling patterns shall be stated, operational sequence and positions of load ropes noted. They shall also include the requirements for the track conditions and other instructions on safe operations. If several cranes handle loads, the load proportion for each crane shall not exceed its capacity. The person in charge of safe crane operations shall directly supervise the work of load handling by several cranes. 7.5.7. Operating hoisting units shall be provided with nameplates, with the registration number, lifting capacity and the date of the next partial or complete inspection clearly marked. 7.5.8. Hoisting units, removable gripping devices and containers, which have not undergone technical technical examination shall not be admitted to operation. Faulty removable gripping devices and devices without nameplates (stamps) shall not be kept at operation sites. Unmarked and damaged containers shall be also removed from such locations.
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7.5.9. A mark system shall be employed in operation of overhead cranes controlled from the cab. Such system s ystem means that solely the crane operator, who receives the mark-key completing the electric circuit of the crane control may control the crane. 7.5.10. An easy access shall be provided for the person controlling the unit if it is controlled from the floor. 7.5.11. Exits to the tracks and galleries of overhead and movable cantilever cranes shall be locked if the cranes ate in operation. Access of crane servicing personnel and other workers to the track and passage galleries of operating overhead and movable cantilever cranes for maintenance or any other work shall be arranged on the basis of a work permit stating the conditions of safe operation. The crane owners shall develop the procedure of work permit issue and induction of workers. Crane operators of all the shifts in the workshop span, where work is to be carried out, and if necessary operators of adjoining spans shall be notified about it with the help of an entry in the shift log. 7.5.12. The procedure of the crane operator's safe descending from the cab shall be developed in every workshop (span) with overhead or movable cantilever cranes not equipped with passage galleries along the crane track. It shall be done for the case of the crane emergency halt away from the landing platform. The descending procedure procedure shall be stated in the operator's instructions. 7.5.13. At the owner's discretion, overhead cranes may be applied for painting and other work from platforms on the crane. Such work shall be carried out on the basis of work permits identifying safety arrangements to prevent falling off the crane, electric shocks, clashes of cranes, movement of the crane and its truck. Load handling with people carrying out work on the t he gantry shall be unacceptable. 7.5.14. The owners of hoisting units shall develop the methods of accurate load slinging and hooking to be taught to slingers. Graphic presentation of the slinging and hooking methods shall be distributed among the slingers and operators, or placed at work locations. The owners shall also develop the methods of slinging for machine parts and units handled during installation, dismantling and repairs. Appliances and methods of safe load canting shall be also mentioned if such operation is carried out with a crane. Graphic presentation of the slinging and canting methods, as well as the list of gripping devices applied shall be given in process pr ocess schedules. schedules. Handling of loads without slinging patterns shall be carried out under the supervision of the person in charge of safe crane operation.
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The management of sea and river ports shall ensure that load handling operations with hoisting equipment are carried out in accordance to process charts approved. 7.5.15. The owners of hoisting units, together with operating companies, shall: a) Develop and dispatch to crane operation sites construction and installation work designs, process charts for load storage, handling loads from the rolling stock and other process schedules; b) Familiarise (against receipt) persons in charge of safe crane operation, operators and slingers with the designs and process schedules; c) Provide slingers with distinction signs, tested and marked removable gripping devices and containers corresponding to load weight and character; d) Place the list of basic handled loads and their weights at the work location. The same list shall be handed to crane operators and slingers servicing boom self-propelled cranes during construction and installation; e) Provide for recurrent testing of the lifting limit of the crane with the help of a precisely weighed load within the terms stated in the operation instructions or device certificate; f) Establish the order of boom self-propelled cranes allocation to sites on the basis of applications, and provide compliance with it; g) Establish the procedure of tower crane protection board sealing and locking, as well as lifting limit relay rel ay block on boom self-propelled cranes sealing; sealing; h) Identify the areas for load storage, equip them with attachments and accessories required (racks, pyramids, shelving, ladders, stands, supports, pads, spacers, etc.) and instruct operators and slingers about piling procedures and overall sizes; i) Ensure implementation of work designs and other process schedules during hoisting equipment operation; j) Ensure good working conditions of tower cranes being at the site as stand- by equipment. Disconnect the crane from the power source and make arrangements to eliminate movement of the crane by wind after the client's notification about work completion (prior to dismantling commencement). commencement). k) Ensure good conditions of crane tracks. 7.5.16. The owner of a hoisting unit shall establish the pattern of signals exchanged by the operator and slingers. The system recommended is given in Appendix 18. When buildings and structures above 36 m are constructed, a two-way radio communication system shall be applied. The signalling system and signals applied in radio communication shall be recorded in the instructions for the operator and slingers. 7.5.17. The site of crane operation shall be lighted in accordance with the design or standard documents.
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7.5.18. Crane operation shall be halted if wind speed exceeds the limit of that particular crane, in case of a snow fall, rain or fog, as well as in other cases, when the operator scarcely distinguishes the signals of slingers of the load being handled. 7.5.19. If boom self-propelled cranes operate at the distance below 30 m from their lifted (expanded) part at any position, or from the load to the vertical plane formed by the projection to the ground of the closest overhead power conductor under the voltage of 42 V and above, the work shall be carried out on the basis of a work permit. The latter shall specify the conditions of safe operation (the form is given in Appendix 19). The procedure of work arrangement close to overhead power lines, a work permit issue and induction of workers shall be established by the orders of the crane owner and superintendent of work. Safe conditions specified in the work permit shall comply with GOST 12.1.013. The issuing company shall establish the period of the t he permit validity. The work permit shall be handed to the crane operator prior to work commencement. The operator shall not install the crane near an overhead power line himself, the prohibition shall be entered into his way ticket. Crane operation close to a power line shall be carried out under direct supervision of the person in charge of safe crane operation. Such person shall show the operator the location to install the crane at, provide compliance with the conditions stipulated in the work permit and make an entry in the shift log of the t he crane about his permission to work. If work is to be carried out within the protection zone of a power line, or within openings provided by the High Voltage Power Line Protection Regulations, the work permit may be issued if there is a permit of the line operating company only. If boom self-propelled cranes operate at existing power plants, substations and power lines, and if hoisting work is carried out by the personnel operating the power units while the crane operators are in the staff of the power company, the work permit for operations close to conductors and equipment under voltage shall be issued in accordance with the requirements of the industry. Self-propelled cranes may operate under urban transport contact wires if the distance between the boom and the wire is at least 1000 mm. A stop (arrester) shall be installed to prevent the above distance from being reduced when the boom is lifted. The line owners shall establish the procedure of a crane operation close to a power line utilising flexible cable. Work permits are not required in that case. 7.5.20. The owners of cranes and the company that carries out work shall ensure compliance with the following requirements to provide safe load handling:
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a) Persons without direct relation to the operations shall be denied access to the load handling site and the crane; b) People shall enter and descend overhead and movable cantilever cranes through a landing site (platform), or in separate cases through passage galleries; c) The knife-switch of the input device shall be disconnected if there is a need to examine or repair crane mechanisms, power equipment, or examine and repair steel structures. The same requirement shall be complied with if there is a necessity to go out to the gantry of an overhead crane; d) If rails of a load truck are located at the level of an overhead crane gallery deck, the truck shall be placed in immediate proximity to the exit from the cab on to the deck before the servicing personnel goes out to the gallery; e) Construction and installation work shall be carried out in accordance with the work design, which shall provide for the following: -
conformity of cranes with the construction and installation work as related to their lifting capacity, lifting height and radius (crane lifting characteristics);
-
provision of safe distances from power grids and overhead lines, urban transport and pedestrian routes, as well as safe distances from cranes to buildings and parts and materials storage grounds;
-
crane installation and operation close to slopes and pits safe conditions;
-
safety conditions for several cranes operating on the same track or parallel tracks;
-
the list of gripping devices applied and graphic presentation of load slinging;
-
load storage locations and overall sizes, access roads, etc.;
-
arrangements of safe operations accounting for particular conditions at the crane site (fencing of the construction site, installation area, etc.);
The person in charge of safe crane operation, operators and slingers shall be familiarised with the design (against receipt) prior to the work commencement; f) Load handling and piling with cranes at bases, warehouses and sites shall be carried out in accordance with process charts worked out accounting for the requirements of GOST 12.3.009 and approved in the established order; g) Loads shall not be lowered on a truck or lifted if there are people in the cab or body. Stationary racks or suspended platforms for slingers shall be arranged at the locations, where trucks or railway cars are loaded/unloaded. Railway cars shall be loaded/unloaded with hook cranes in accordance with the technology approved by the crane owners. It shall s hall specify the locations of slingers during loads handling and their ways to racks and suspended platforms. Presence of people in cars when they are loaded/unloaded is unacceptable;
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h) Loads shall not be handled with people beneath. A slinger may stay close to the load during its lifting or lowering if the load is lifted to the height not exceeding 1000 mm from the platform level; l evel; i) Loads shall be slinged in accordance with slinging patterns. Slings shall conform with the weight and character of the load lifted. The number of strings and their incline angles shall be accounted for. General purpose slings shall be selected so that the angle between their strings does not exceed 90 ; j) Small-piece loads shall be handled in specially designed containers. Pieces falling out of such containers shall be eliminated. Bricks may be lifted on pallets without enclosure when loaded on or unloaded (on the ground) from hauling units; k) Loads of unknown weights shall be handled after their actual weights are identified only; l) A load or gripping device shall be lifted 500 mm above objects in the t he way to move them horizontally; m) When a boom self-propelled crane moves with a load, the boom position and the loads on the crane shall be assumed in accordance with the crane operation instructions; n) A load handled may be lowered on the place assigned for the purpose only. Such location shall eliminate falling, overturn or sliding of the load. Appropriate spacers shall be placed at the location for the slings to be easily and without damage drawn from under the load. Loads shall not be placed at locations not designed for it. Loads shall be stacked up and unstacked evenly, not disturbing overall sizes established and jamming passageways. Loads shall be stowed in railway card and on platforms in accordance with the RoK Transportation and Communication Ministry standards and on the consignee's approval. Loads shall be placed on trucks and other haulers so that its easy and safe slinging sli nging is ensured when unloading. Railway cars, platforms, trucks and other hauling units shall be loaded and unloaded without disturbing their equilibrium. o) Presence of people and any work shall be prohibited within the range of cranes with clamshells or magnets operation. Shiftmen servicing such cranes may be admitted to carry out their duties solely during breaks in the crane operation and after the clamshell or magnet is lowered to the ground. Locations of such cranes operation shall be fenced and marked with warning signs. p) A clamshell shall not be used to lift people or carry out ant work it is not designed for. q) On work completion, or during a break, no load shall be left suspended, the knife-switch in the operator's cabin or gantry shall be put in the t he OFF position and locked. On completion of a tower, frame, overhead, gantry and transhipment crane operation, the control cabin shall be locked, and the crane shall be secured with all available means against unauthorised movement.
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r) Loads may be canted with cranes at canting areas or specially provided places. Such work may only be carried out in accordance with a process developed in advance. It shall describe the sequence of operations, slinging methods and safe work instructions; s) If cranes operate being installed on several layers, the upper layer cranes shall be able to move above the lower ones without loads and with the hook lifted to the upper working position only; t) When a load is lifted, it shall first be lifted to the height not exceeding 200300 mm to check the accuracy of slinging and reliability of brakes; u) When a load is lifted close to a wall, column, stack, railway car, machine or other equipment, people (including those hooking the load) shall not remain between the load lifted and the above parts of the building or equipment. The same requirement shall be strictly complied with when lowering loads. 7.5.21. The following shall be unacceptable during a hoisting unit operation: a) Admission into the hoisting unit cab during its it s movement; b) Presence of people close to an operating boom self-propelled or tower crane to eliminate their jamming between the turning and non-turning parts; c) Handling of a load being in unstable position or hooked with one arm of a double hook; d) Movement of people or a load with people on it. People may be lifted with cranes in exceptional cases only, in a specially designed cage and after specific safety arrangements are worked out. Such work shall be carried out in accordance with specific instructions i nstructions approved by Gosgortechnadzor. Gosgortechnadzor. e) Lifting of loads covered with soil or frozen to the ground, covered with other loads, fastened with bolts or concrete, as well as lifting of metal or slag hardened in the furnace or stuck after being poured out; f) Load dragging on the ground, floor or rails with the crane hook, load ropes being tilt without guiding blocks application to provide the vertical position of load ropes; g) Crane application to release slings, ropes or chains pinched with a load; h) Pulling a load aside during its lifting, movement or lowering; Hooks or guys of appropriate lengths shall be applied to turn long and bulky loads when handling them; i) Aligning of the load being dandled by hand and correction of slings when hanging; j) Feeding of loads through windows or on balconies without special receiving platforms or appliances; k) Application of limit switches as tools to stop mechanisms automatically, with the exception of the case, when an overhead crane approaches the landing site arranged in the butt wall of the building;
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l) Operation with disengaged or faulty fault y safety devices and brakes; m) Starting of crane mechanisms when people are on the crane outside the cab (in the engine department, on the gallery, boom, tower, counterweight, etc.). an exception can be made for people examining and adjusting mechanisms and power equipment. In such case the mechanisms shall be started on a signal of the examining person; n) Load lifting immediately from its location (ground, stack, etc.) with the boom winch; 7.5.22. The engineer in charge of hoisting equipment good working conditions shall be the person to shut down a crane for maintenance in accordance with the schedule approved by the owners. A work permit shall be issued in accordance with the established order for the maintenance of overhead and movable cantilever cranes. The work permit shall describe measures to be taken to create safe maintenance conditions. In particular, arrangements shall be made to prevent electric shocks, falls of people down from height, operating cranes colliding with the repaired one and access of the maintenance personnel to the tracks of operating cranes. The date and time of a crane shut down for maintenance, as well as the name of the person in charge of it shall be entered into the work permit and the shift log of the operator. Preventive examination, examination, servicing of the crane and elimination of defaults on t he operator's request may be carried out without a work permit. If several crews carry out repairs at an overhead crane, a work-permit shall be issued for each of them. Crane operation during its repairs is prohibited. 7.5.23. The engineer in charge of the hoisting equipment good working conditions shall issue the permit for a crane to operate after repairs, with the exception of cases set fort by clause 7.2.1. Such permit shall be recorded in the shift log. 8. RESPONSIBILITY FOR BREACHES OF THE CRANES DESIGN AND SAFE OPERATION REGULATIONS 8.1.
These Regulations shall be binding for all the managers and professionals of companies engaged in hoisting equipment design, production, maintenance, reconstruction, installation, operation and diagnosing irrespective of their ownership and the industry they refer to, and also for physical persons owing cranes.
8.2.
Managers, professionals and physical persons responsible for breaches hereof shall be held responsible for the infringements committed in accordance with
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current legislation regardless weather it results in an emergency or accident. Such persons shall be also held responsible for infringements hereof committed by their subordinates. 8.3.
If officers issue orders forcing their subordinate employees to infringe these Regulations and instructions, without authorisation resume operations suspended by Gosgortechnadzor representatives, and also in case such officers fail to make arrangements aimed at elimination of infringements of the Regulations and instructions, such officers shall be held responsible in accordance with current legislation.
8.4.
Workers (crane operators, slingers, mechanics and electricians) trained and attested in the established order, and supplied with operation instructions shall be responsible for infringements of directions provided by t hem.
8.5.
Depending on the character and consequences of infringements, persons indicated in clauses 8.2, 8.3 and 8.4 may be held administratively, disciplinarily or criminally responsible in accordance with the legally established procedure. 9. EMERGENCY AND ACCIDENT INVESTIGATION INVESTIGATION PROCEDURES
9.1.
Investigation of incidents occurring during hoisting equipment operation and liable to registration at Gosgortechnadzor shall be carried out in accordance accordance with the procedures established by the RoK Gosgortechnadzor.
9.2.
In case of an incident, the owner of the unit subject to registration shall notify Gosgortechnadzor within 1 day and provide preservation of the incident set-up until a representative of Gosgortechnadzor arrives if it does not present risk for the health and lives of people. Notifications about incidents shall be sent to organisations concerned in accordance with the current provisions of industrial accidents investigation. 10. FINAL PROVISIONS
10.1.
Due to these Regulations coming into force, the requirement and deadlines for existing hoisting equipment reconstruction shall be established by the equipment producers and owners on an approval of Gosgortechnadzor. Gosgortechnadzor.
10.2.
Managers and experts of companies, as well as physical persons engaged in hoisting equipment design, production, maintenance, reconstruction, reconstruction, installation, operation and diagnosing shall pass their knowledge hereof assessment within the time periods approved by Gosgortechnadzor.
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APPENDIX 1 (to Section 1.4) TERMINOLOGY AND DEFINITIONS DEFINITIONS Ref. #
Terms Load Lifting (Hoisting) Unit
Definitions A cyclic-operation hoisting device, with a reciprocating motion of the load gripping part.
Diagrams -
1. TYPES OF CRANES 1.0
Crane
A cyclic-operation hoisting device designed to lift and spatially move loads suspended with a hook or held with other load gripping device. Design Based Crane Classification
1.1
Overhead travelling type crane
A crane that has a load gripping part suspended on a load trolley, chain block or boom crane that travels along a bridge.
1.1.1
Overhead travelling crane
A crane that has bearing structural components rested directly upon the crane track.
1.1.2
Gantry crane
A crane that has bearing structural components rested upon the crane track with the help of two supporting stanchions.
1.1.3
Semi-gantry crane
A crane that has bearing structural components rested upon the crane track directly on one side, and with the help of a supporting stanchion on the other.
1.1.4
Berth transhipment crane
A crane with one or two cantilevers that has bearing structural components rested upon the crane track with the help of a portal.
Cable type crane
A crane that has a load gripping part suspended on a load trolley that travels along bearing lines fastened on two supports.
1.2
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1.2.1
Cable crane
A crane, with cable lines as bearing components that are fastened at the tops of supporting masts (towers).
1.2.2
Overhead travelling cable crane
A crane, with cable lines as bearing components that are fastened at the ends of a bridge installed on supporting stanchions.
1.3
Boom type crane
A crane that has a load gripping part suspended on a boom or trolley travelling along a boom.
1.3.1
Portal crane
A travelling crane rotating on a portal that is designed to let railway cars or trucks through.
1.3.2
Semi-portal crane
A travelling crane swinging on a halfportal that is designed to let railway cars or trucks through.
1.3.3
Boom crane
A rotary crane that has a boom or tower and boom equipment fastened on a turning platform, which is located directly upon the running gear.
1.3.3.1 Self-propelled boom crane
A boom type crane that may be equipped with tower and boom equipment and may travel both loaded and unloaded on a motor vehicle chassis maintaining balance and stability due to gravity force.
1.3.4
Tower crane
A rotary crane, with a boom installed in the upper part of a vertical tower.
1.3.5
Railway crane
A crane installed on a platform travelling along a railway track.
1.3.6
Floating crane
A crane on a self-propelled, or nonself-propelled pontoon designed for crane installation and movement.
1.3.7
Marine boom crane
A rotary crane installed on a deck of a watercraft and designed to load and unload the craft.
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1.3.8
Derrick pole
A rotary crane, with the boom fastened with a hinge on a derrick that has lower and upper supports.
1.3.8.1 Guyed derrick pole
A derrick pole, with the top of the derrick fastened with the help of guy lines.
1.3.8.2 Stiff-leg derrick pole
A derrick pole, with the top of the derrick fastened by way of stiff tension bars.
1.3.9
Cantilever crane
A boom-type crane, with a load gripping part suspended on a rigidly fastened cantilever (boom), or a trolley travelling along a cantilever (boom).
1.3.9.1 Cantilever crane on a column
A cantilever crane, with a potential to swing on a pillar that has its base fastened to a foundation, or fastened to a pillar that may rotate in a bearing installed in the foundation.
1.3.9.2 Wall-track jib crane
A stationary crane attached to a wall, or travelling along a ground crane track fastened to a wall or bearing structure.
1.3.9.3 Wheeled column crane
A cantilever crane that travels along the ground rail track held with a guide at the top.
1.3.10
A boom crane installed on a truck chassis and serving for its loading and unloading.
Cranemanipulator
Crane Classification on the Basis of the Load Gripping Part 1.4
Hook crane
A crane equipped with a hook as a load-gripping device.
1.5
Clamshell crane
A crane equipped with a clamshell as a load-gripping device.
1.6
Magnetic crane
A crane equipped with an electric magnet as a load-gripping device.
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1.7
Charging boxmagnet crane
An overhead travelling type crane equipped with an electric magnet as a load-gripping device, and with a device to transfer moulds.
1.8
Charging boxclamshell crane
An overhead travelling type crane equipped with a clamshell as a loadgripping device, and with a device to transfer moulds.
1.9
Turnaround charging crane
An overhead travelling type crane equipped with an overarm to grip moulds.
1.10
Rod removing crane
An overhead travelling type crane equipped with a gripping device to remove rods from electrolytic baths.
1.11
Stacker (piler) crane
An overhead travelling type crane equipped with a vertical pillar and a device to stack (pile) load.
1.12
Pouring crane
An overhead travelling type crane equipped with tools to lift and tilt a foundry ladle.
1.13
Block transport crane
An overhead travelling type crane equipped with a turnaround pillar that has horizontal tongs in its lower part to grip metal blocks and feed them into a furnace.
1.14
Forging crane
An overhead travelling type crane equipped with a device to lift, transport and turn forged pieces.
1.15
Ingot-stripping crane
An overhead travelling type crane equipped with a device to push ingots out of moulds.
1.16
Pit crane
An overhead travelling type crane equipped with a tong grapple and designed to serve pit furnaces
Crane Classification on the Basis of Travelling Capacities 1.17
Stationary crane
A crane that is fixed on its foundation or other immobile base.
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1.18
Self-elevating (climbing) crane
A crane installed structures of a building under construction, and climbing with the help of its own devices as the building grows.
1.19
Adjustable jib
A crane, which is installed on a base, and may be moved from one location to another manually or utilising other hoisting equipment.
1.20
Radial crane
A crane that may move while operating in relation to one stationary support.
1.21
Mobile crane (jenny)
A crane that may be moved during operation.
1.21.1
Trailed crane
A mobile crane that has no selfpropelling equipment and is towed with a tractor (hauler).
1.21.2
Self-propelled crane
A mobile crane that has selfpropelling equipment to move during operation and/or transportation.
Crane Classification on the Basis of Running Gear (Chassis) 1.22
Crawler (caterpillar) crane
A self-propelled crane equipped with caterpillar tracks for re-location.
1.23
Crane on wheels
A self-propelled crane equipped with wheels for re-location.
1.23.1
Truckmounted crane (picker truck)
A crane mounted on a serial production truck chassis.
1.23.2
Specific chassis crane
A crane mounted on a specific truckt rucktype chassis.
1.23.3
Pneumatic wheel crane
A crane mounted on a pneumatic wheel chassis.
1.23.4
Short-base crane
A crane mounted on a short-base chassis.
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1.24
Track-riding crane
A crane travelling on a rail track.
Crane Classification on the Basis of the Drive Type 1.25
Manual crane
A crane, with a hand drive for its gear.
1.26
Electric crane
A crane, with a power drive for its gear.
1.27
Mechanical crane
A crane, with a mechanical drive for its gear.
1.28
Hydraulic crane
A crane, with a hydraulic drive for its gear.
Crane Classification on the Basis of the Rotation Degree 1.29
Rotary crane
A crane that may swing (horizontally) its rotating part with a load against the supporting part.
1.29.1
Partially rotating crane
A rotary crane that may swing its rotating part from one limit position to another at an angle below 360 degrees.
1.29.2
Full-rotating crane
A rotary crane that may swing its rotating part from one limit position to another at an angle of 360 degrees and above.
1.30
Non-rotating crane
A crane that cannot swing a load (horizontally against the supporting part.
Crane Classification on the Basis of the Manner of Support 1.31
Supporting crane
An overhead travelling crane that is rested upon the ground crane track.
1.32
Suspended crane
An overhead travelling crane that is suspended on the lower flanges of the crane track.
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2. PARAMETERS Loads 2.1
Effective lifting capacity
A load, with the weight of mPL, lifted by the crane and suspended with the help of removable load gripping devices, or in the absence of such, suspended directly on stationary load gripping devices. devices. If cranes are applied to lift gates at hydraulic power plants or lift loads from the water surface, effective lifting capacity may include efforts caused by water suction or cohesion due to suction.
2.2
Removable load gripping device
Any equipment (with the weight of
2.3
Net loadlifting capacity
mNA) connecting a load that conforms
Refer to the Diagram in Section 2.1
to the effective load-lifting capacity with the crane, and being neither a part of the crane nor the the load. The removable load-gripping device is easily removed from the hoisting unit, and disconnected from the load. A load, with the weight of mNL lifted by a crane and suspended by way of stationary load-gripping devices. The
Refer to the Diagram in Section 2.1
weight of mNL is a summarised value of the load weight corresponding to the effective load-lifting capacity
(mPL), and removable load-gripping devices (mNA): mNL = mPL + mNA 2.4
Stationary load-gripping device
Any equipment (with the weight of
mFA) to suspend a load that
Refer to the Diagram in Section 2.1
corresponds corresponds to the net load-lifting capacity, and which is permanently fastened to the lower end of the hoisting unit. Stationary loadgripping device form an integral part of the hoisting unit.
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2.5.
Interim loadlifting capacity (on ropes)
A load with the weight of mHL, which is lifted by a crane and is suspended to the lower end of the hoisting unit.
Refer to the Diagram in Section 2.1
The mHL weight is a summarised value of the load weight corresponding corresponding to the effective load-
(mPL), removable load-gripping devices (mNA), and
lifting capacity
stationary load-gripping devices (mFA): mNL = mPL + mNA + mFA 2.6
Lifting device
Ropes, chains or any other oth er equipment, with the weight of mNM that hangs from the crane, load trolley or boom tip and is driven with a winch to lift or lower down a load suspended to the lower end of the lifting device. Lifting devices form a part of the hoisting unit.
2.7
Gross lifting capacity
A load with the weight of mGL, which is suspended directly on the crane, load trolley or boom tip. The weight weight is a summarised value of the load weight corresponding to the effective
Refer to the Diagram in Section 2.1
Refer to the Diagram in Section 2.1
load-lifting capacity (mPL), removable and stationary loadgripping devices ( mNA and mFA), and the lifting device (mNM):
mGL = mPL + mNA + mFA + mNM 2.8
Load momentum: M=LxQ
2.9 Tilting load momentum: MA = A x Q 2.10
Design weight (Gk )
The product of the crane radius value (L), multiplied by the corresponding lifting capacity (Q). The product of the radius from the tilt edge value (A), multiplied by the corresponding corresponding lifting capacity (Q).
The crane weight without ballast and counterweight counterweight in non-serviced state, i.e. without fuel, oil, lubricants and
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water. For boom cranes, the value is assumed as an assembly with the main boom and counterweight in a nonserviced state. 2.11
Total weight (G)
A complete weight of a crane in the serviced state, with the ballast and counterweight.
2.12
Load on a wheel (P)
The value of the maximum vertical load transmitted by one running wheel onto the crane track or axel. Crane Linear Parameters
2.13
Crane radius (L)
A horizontal distance from the rotation axis of the rotating part to the vertical axis of the load-gripping part, without any load, while the crane is installed on a horizontal area.
2.14
Radius from the tilt edge (A)
A horizontal distance from the tilt edge to the vertical axis of the loadgripping part, without any load, while the crane is installed on a horizontal area.
2.15
Cantilever radius (l)
The largest horizontal distance from the axis of the closest to the cantilever crane support to the axis of the loadgripping part located on the cantilever.
2.16
Clearance (C)
The minimum horizontal distance from the crane rail axis to the vertical axis of the load-gripping part.
2.17
Rear clearance limit (г) (г)
The maximum radius of the crane rotary unit from the side opposite to the boom.
2.18
Lifting height (H)
A vertical distance from the level of the crane location site to the loadgripping part located in its uppermost position: for hooks and forks, up to their seating surfaces; for other load-gripping
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devices, up to their lowest point (in the closed position). The lifting height of an overhead crane shall be measured from the floor surface. The lifting height shall be measured without a load, while the crane is installed on a horizontal hori zontal area. 2.19
Lowering depth (h)
A vertical distance from the level of the crane location site to the loadgripping part located in its lowest position: for hooks and forks, down to their seating surfaces; for other load-gripping devices, down to their lowest point (in the closed position). The lowering depth of an overhead crane shall be measured from the rail level. The lowering depth shall be measured without a load, while the crane is installed on a horizontal hori zontal area.
2.20
Lifting range (D)
A vertical distance between the upper and lower operating positions of the load-gripping part (see Sections 2.18 and 2.19).
2.21
Crane track height (HQ)
Vertical distance from the floor (ground) level to the level of the crane track railheads. Operation Movement Speeds
2.22
Load lifting (lowering) speed (Vn)
The speed of vertical load relocation r elocation under steady movement conditions.
2.23
Landing speed (Vm)
The minimum lowering speed of the maximum operating load during installation or laying down under steady movement conditions.
2.24
Rotation frequency (angle speed (w))
The angle speed of the crane rotary part rotation under steady movement conditions. It is estimated at the largest radius with the operating load, while the crane is installed on a
88
horizontal area, and the wind speed does not exceed 3 m/sec at the height of 10 m. 2.25
Crane travelling speed (Vk )
2.26
Trolley travelling speed (Vt)
Crane travelling speed under steady movement conditions. It is estimated while the crane is travelling with the operating load along the horizontal track, with the wind speed not exceeding 3 m/sec at the height of 10 m. The travelling speed of the load l oad trolley under steady movement conditions. It is estimated while the trolley is travelling with the maximum operating load along the horizontal track, with the wind speed not exceeding 3 m/sec at the height of 10 m.
2.27
Radius alteration speed (Vr)
The average speed of operational load horizontal relocations under steady movement conditions. It is estimated, when the radius is changed from the t he largest to the smallest value, while the crane is installed on a horizontal hori zontal track, with the wind speed not exceeding 3 m/sec at the height of 10 m.
2.28
Time of radius alteration
The time required when changing the radius from the largest to the smallest value. It is estimated while the radius radius is changed under load equalling to the load-lifting capacity for the largest radius, and while the crane is installed on a horizontal track, with the wind speed not exceeding 3 m/sec at the height of 10 m.
2.29
Inspection speed
A low speed of the t he cable-type crane load trolley travelling under steady movement conditions used to inspect track cables and units of the crane.
2.30
Transportation speed (Vo)
The highest speed of a crane movement in transportation position
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that is ensured by its own drive. 2.31
Operating cycle time
The time required to carry out one established operating cycle. Parameters Related to the Crane Track
2.32
Crane location level
The horizontal surface of the foundation or the surface of railheads, upon which the non-rotary part of the crane is supported. For cranes that have supports located at different heights, the location level is assessed on the basis of the lower crane support location.
2.33
Span (S)
The horizontal distance between the crane track rail axes for overhead travelling cranes.
2.34
Track (K)
The horizontal distance between the track rail axes or running gear wheels for boom-type cranes. For load trolleys, the distance between rail axes the trolley travels tr avels along.
2.35
Base (B)
The distance between the crane support axes measured along its longitudinal centreline.
2.36
Outrigger base (Bo)
The distance between the outrigger vertical axes measured along the longitudinal centreline of the crane.
2.37
Distance between outriggers (Kc)
The distance between the outrigger vertical axes measured across the longitudinal centreline of the crane
2.38
Track gradient
The gradient, on which crane operation is acceptable. acceptable. The gradient gradient is estimated utilising the ratio of i=h/B that corresponds to the difference of levels of two points located from each other at the distance of B, which equals to the crane crane base. The value of of level difference is measured, when there is no load on that particular
90
section of the track. 2.39
Climbable gradient
A gradient (i=h/B) that a crane may overcome with its constant transportation speed.
2.40
Supporting contour
The contour formed by horizontal projections of the lines connecting vertical axes of the crane supporting components (wheels or outriggers).
2.41
Curve radius (Rk )
The smallest radius of the inner rail axis curve at a curved section of the track.
2.42
The smallest radius of the turn
The radius of a circumference circumscribed by the crane outer front wheel when changing the movement direction. General Parameters
2.43
Classification group (operating conditions)
Crane characteristics that account for its application on the basis of loadlifting capacity and time, as well as operation cycles.
2.44
Clearance to obstructions
The area determined by safety requirements during the crane operation close to structures. The load gripping part only may go outside the clearance area during operations.
2.45
Braking margin factor
The ratio of the momentum created by the brake to the maximum momentum at the brake shaft due to static loads applied: the maximum operating load (for the lifting gear) boom weight, counterweight, the maximum operating load, wind in the operating conditions (for the radius alteration unit)
2.46
Characteristics
Load lifting characteristics of a self-
91
without outriggers
propelled crane, when operating without outriggers installed. 3. BASIC NOTIONS Movements
3.1
Load lifting (lowering)
Vertical relocation of the load.
3.2
Smooth landing of the load
Lowering of the load with the minimum speed while its installation or laying.
3.3
Boom lifting (lowering)
Angle boom movement in the vertical plane.
3.4
Radius alteration
Movement of the load-gripping part by way of boom lifting, lowering or relocation, or by way of load trolley relocation.
3.4.1
Load horizontal movement
Alteration of the radius performed by lifting of the boom, when the load automatically moves along the curve, which is close to a horizontal line.
3.5
Travelling of the crane
Movement of the whole crane in the t he operating position.
3.6
Travelling of the load trolley
Movement of the load trolley along the overhead bridge, cable, boom or cantilever.
3.7
Turn
An angle movement of the overhead travelling or boom-type crane rotary part in the horizontal plane. Crane Stability
3.8
Crane stability
Capacity of the crane to withstand tilting forces.
3.9
Load stability
Capacity of the crane to withstand tilting forces, which are formed by load weight, inertia forces, wind load in the operating conditions, and other factors.
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3.10
Inherent stability
Capacity of the crane to withstand tilting forces in both operating (including without a load) and standby conditions. Testing
3.11
Static testing
Crane testing by way of static load application to the load-gripping unit. The load shall exceed the crane loadlifting capacity by X%.
3.12
Dynamic testing
Crane testing by way of conducting routine operations operations under under load. The load shall exceed the crane loadlifting capacity by Y%. 4. UNITS
4.1
Lifting gear
A drive unit to lift and lower loads.
4.2
Crane travelling gear
A drive unit to move the crane.
4.3
Trolley or chain block travelling gear
A drive unit to move the trolley or chain block.
4.4
Radius alteration gear
A drive unit to change the radius by way of changing the angle of the boom and/or gooseneck incline.
4.5
Rotation gear
A drive unit to swing the rotary part of the crane in the horizontal plane.
4.6
Boom extension gear
A drive unit to change the length of the crane boom.
4.7
Winch
Gear, which traction force is transmitted by way of a flexible component (cable, rope) from the drive drum. Winch types: - drum-type - with cable driving pulleys - capstan winch.
4.8
Chain block
A load lifting gear assembled in one
93
housing with the drive. 4.9
Running gear
The crane base to install the rotary platform or tower that includes a drive unit to move the t he crane.
4.10
Portal
A structure that has an elevated running frame supported with the help of posts, or resting directly on the crane track.
4.11
Equalising trolley
A supporting structure equipped with wheels or rollers, and provided with a hinged joint to equalise load transmission to wheels or rollers.
4.12
Bridge
A bearing structure of overhead travelling cranes designed to provide travelling of a load trolley, or a structure between supports of a gantry or semi-gantry crane.
4.13
Load trolley (carrier)
A structure designed to move suspended loads.
4.14
Supportturning table (unit)
A unit to transmit loads (load momentum, vertical and horizontal forces) from the rotary part of the crane to the non-rotating one, and to rotate the rotary part. The unit may also include the gear to rotate the table.
4.15
Turning platform
A turning crane structure to locate gear units.
4.16
Tower
A vertical crane structure that supports the boom and/or turning platform and provides the required elevation to locate the boom support.
4.17
Column
A vertical structure that supports the turning boom with the operating load and provides the required elevation for load lifting.
4.18
Boom
A crane structure that provides the required radius and/or elevation to lift
94
the load-gripping device. 4.19
Tower and boom equipment
Removable equipment equipment of a boom selfpropelled crane that consists of a tower, boom with or without a gooseneck, and required devices.
4.20
Swinging mounting
A cable crane support that can change the angle to the horizontal line as forces change in bearing cables.
4.21
Stable mounting
A cable crane support that cannot change the angle to the horizontal line as forces change in bearing cables.
4.22
Counterweight
Loads adjusted to the counterweight cantilever or turning platform to balance weights of operating loads and/or separate crane parts during operations.
4.23
Ballast
A load adjusted to the frame or portal to provide stability of the crane.
4.24
Brake
A device designed to lower the speed of movement or to stop and/or keep the gear motionless.
4.25
Block (cable)
A rotating component with one or several grooves to guide cables.
4.26
Equalising block
A block that serves to equalise loads in two cable branches.
4.27
Cable guiding sheave
A rotating cable sheave with grooves (a groove) that serves to drive one or several cable branches by way of friction forces occurring between the sheave and cable.
4.28
Polyspast (block and tackle)
A block and cable system that serves to change the force and speed of cable movements.
4.29
Duplex polyspast
A polyspast, with both cable ends fixed on one or two drums.
4.30
Hook
A system of blocks located on a
95
suspension
frame, which is equipped with a hook.
4.31
Load-gripping part
A unit (hook, clamshell, electric magnet, fork, etc.) to grip and move loads.
4.32
Cinematically non-releasing link
A mechanical link between the engine and the drum that is implemented by way of: direct connection of the engine with the reducer, and the reducer with the drum utilising non-releasing couplings, with the help of the gear shift mechanism (in the case, when no spontaneous spontaneous starting or declutching of the mechanism is possible, or unless no normally closed brake is engaged).
4.33
Outrigger
A device designed to enlarge the crane support contour in the operating conditions.
4.34
Ladder
A structure including a row of steps to climb up.
4.34.1
Boarding ladder
A ladder providing access to the crane, with the gradient to the horizontal plane up to 60 inclusive.
4.34.2
Inclined ladder
A ladder, with the gradient to the horizontal plane being from 60 to 75 inclusive.
4.34.3
Vertical ladder
A ladder, with the gradient to the horizontal plane above 75 .
4.34.4
Rigging ladder
A simplified structure, without railing, designed for workers admitted to work at elevated locations (steeplejacks), or to be used in case of emergency.
4.35
Gallery
A long narrow structure with horizontal flooring, which is designed to provide free passage.
4.36
Catwalk
A structure in the form of a bridge, with horizontal or inclined flooring, fl ooring,
96
whish is designed to provide passage during crane servicing or maintenance. 4.37
Platform
A horizontal surface designed to locate a person during crane servicing or maintenance. 5. LIMITERS AND INDICATORS Load and Movement Limiters and Indicators
5.1
Limiter
A device that shall cause a stop, limit movements or functions of the crane. The majority of such devices actuate automatically, when the appropriate movement or function reach their threshold conditions.
5.2
Crane function limiter
A limiter that causes a stop to or limits operational functions of a crane.
5.3
Load limiter
-
5.3.1
Load-lifting capacity limiter
-
5.3.2
Load momentum limiter
-
5.3.3
Bumper
A device to mitigate impacts.
5.4
Limit stops
-
5.4.1
Operating movement limiter
5.4.2
Lifting elevation limiter
-
5.4.3
Lowering elevation limiter
-
a limiter that causes a stop to and/or limits specified movements of the crane.
97
5.4.4
Rotation limiter
-
5.4.5
Travelling limiter
-
5.4.6
Trolley travelling limiter
-
5.4.7
Boom pitch limiter
-
5.5
Indicator
A device that provides visual and/or sound information to the crane operator for proper crane operation.
5.6
Operating parameter indicator
A device that provides visual and/or sound information about operating parameter values to the crane operator
5.7
Load indicator
-
5.7.1
Lifting capacity indicator
-
5.7.2
Load momentum indicator
-
5.8
Movement indicator
-
5.8.1
Radius indicator
-
5.8.2
Boom pitch indicator
-
Function Limiters and Indicators 5.9
Function limiter
5.9.1
Bridge tilt distortion limiter
-
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5.9.2
Cable winding limiter
-
5.9.3
Cable unwinding limiter
-
5.9.4
Rotation frequency limiter
-
5.9.5
Lifting (lowering) speed limiter
-
5.9.6
Travelling speed limiter
-
5.9.7
Trolley travelling speed limiter
-
5.9.8
Safety valve (in hydraulic systems)
-
5.9.9
Anticreep grapple
5.10
Function indicator
5.10.1
Bridge tilt distortion indicator
5.10.2
Crane tilt angle indicator
5.10.3
Drum rotation indicator
5.10.4
Cable slack indicator
A device to prevent the crane from travelling along the rail track, tr ack, when impacted by wind in stand-by conditions.
99
6. TYPES OF WORK, ORGANISATIONS AND PERSONS RELATED TO CRANES 6.1
Regulatory documentation (standards, specifications)
Documents containing safety requirements (approved by the Republic of Kazakhstan Gosgortechnadzor), Gosgortechnadzor), regulations, general principles, and characteristics related to particular types of operations or their results, and available to a wide range of customers (users).
6.2
Maintenance (overhaul)
Restoration of damaged, worn out or becoming worthless for any other reason crane units, and bringing the crane to serviceable conditions.
6.3 Reconstruction
Changing of the crane design, which leads to the requirement of entering changes into its certificate (e.g., changing of the drive type, boom length, tower height, lifting capacity, and stability), crane alteration and other modifications that cause redistribution and alteration of loads.
6.4
Compliance certification (certification)
Confirmation of hoisting equipment or production compliance with the requirements of domestic and/or international regulatory documents, which is conducted by an independent organisation.
6.5
Specialised organisation (company) for cranes
An organisation (company) (company) that has a permit (license) issued by the Republic of Kazakhstan Gosgortechnadzor Gosgortechnadzor (GGTN) (on the basis of a resolution by a Head Organisation as related to design work) to carry out the following: - full-scale or partial designing in relation to crane fabrication, overhaul and/or reconstruction; - crane fabrication, assemblage, overhaul, reconstruction, and/or adjustment of safety devices; - crane operation; - inspection of cranes with overdue
100
service period. 6.6
Head Crane Fabrication Organisation
An organisation authorised by the Republic of Kazakhstan GGTN to: - carry out research on safe hoisting equipment operation; - implement full-scale functions of a specialised organisation; - develop regulatory documents in relation to hoisting equipment; - perform expert analyses of newly developed and upgraded cranes (prior to acceptance testing); - participate in acceptance testing of hoisting equipment; - participate in certification of hoisting equipment and producing companies; - perform expert analyses of hoisting equipment, including imported units; - inspect hoisting equipment, including units with expired service life periods.
6.7
Engineering Centre for Safety (Engineering Centre)
An organisation authorised by the Republic of Kazakhstan GGTN to carry out work related to practical assistance to organisations, companies, and individuals in the field of safety provision during hoisting equipment operation, maintenance and overhaul.
6.8
Certification Body
A company authorised by the Republic of Kazakhstan GGTN to arrange and carry out certification of hoisting equipment and its production, and issue compliance certificates.
6.9
Crane Operator
A person permitted to operate a crane and performing his/her duties.
6.10
Operating personnel
Persons operating a crane that is controlled from the floor, or operating a crane with automatic control system. s ystem.
6.11
Crane owner
A company, association, partnership, or other organisations, irrespective of their ownership, that have the hoisting
101
equipment on their balance sheets, or co-operators, farmers, or other individuals having hoisting equipment as their property, as well as lessees that undertake functions of crane owners on in accordance with a contract.
102
APPENDIX 2 (to Section 1.4) LIST of Regulatory Documents to be Applicable for Hoisting Equipment Designing, Fabrication, Maintenance and Operation GOST 2.601-68 GOST 12.1.013-78 GOST 12.27058-81 GOST 12.3.009-76 GOST 12.4.026-76 GOST 15.001-73 GOST 15.001-88 GOST 191-82 GOST 228-79 GOST 483-75 GOST 1088-71 GOST 1412-85 GOST 1451-77 GOST 1575-87 GOST 2105-75 GOST 2688-80 GOST 3241-80 GOST 6619-75 GOST 6627-74 GOST 6628-73 GOST 7512-82 GOST 7665-80 GOST 7667-80 GOST 7668-80 GOST 7669-80 GOST 12840-80 GOST13556-91 GOST 14782-86
ESKD. Operation Documents. SSBT. Construction. Electrical Safety. General Requirements. Safety. Cranes. Colour Indication of Hazardous Parts. SSBT. Load Handling Work. General Safety Requirements. SSBT. Colour Signals and Safety Signs. Product Development and to Putting in Production. Product Development and to Putting in Production System. Industrial Purpose Products. Lifting Leaf Chain. Specification. Chain Cable, with Spacers. General Specification. Hemp Ropes. Specification. Sisal Ropes. Specification. Cast Iron, with Lamellate Graphite for Moulding. Cranes. Wind Loads. Standards and Determination Methods. Cranes. Series of Basic Parameters. Forged and Extruded Hooks. Specification. Double Spin Rope, of the LK-R Type, Design 6x19 (1+6+6/6)+1. Assortment. Steel Cables. Specification. Leaf Hooks, Single- and Double-Armed. Specification. Single-Armed Hooks. Rough Workpieces. Types. Design and Sizes. Double-Armed Hooks. Rough Workpieces. Types. Design and Sizes. Non-Destructive Testing. Welded Joints. Radiographic Method. Double Spin Rope, of the LK-3 Type, Design 6x25 (1+6; 6+12)+1. Assortment. Double Spin Rope, of the LK-3 Type, Design 6x25 (1+6; 6+12)+7x7(1+6). Assortment. Double Spin Rope, of the LK-RO Type, Design 6x36 (1+7+7/7+14)+1. Assortment. Double Spin Rope, of the LK-RO Type, Design 6x36 (1+7+7/7+14)+7x7(1+6). Assortment. Safety Locks for Single-Armed Hooks. Types and Sizes. Tower Cranes for Construction. General Specification. Non-Destructive Testing. Welded Joints. Ultrasonic Methods.
103
GOST 15150-69
GOST 16765-87 GOST 18899-73 GOST 22045-89 GOST 22827-85 GOST 22584-88 GOST 24599-87 GOST 25546-82 GOST 25573-82 GOST 25835-83 GOST 27584-88 GOST 27913-88 GOST 27914-88 GOST 27555-87 GOST 27551-87 GOST 27552-87 GOST 27553-87 GOST 28609-90 GOST 28648-90 GOST 29266-92 ISO 2408 ISO 4301/1 ISO 4306/1 ISO 4308/1 ISO 4308/2 ISO 4309 ISO 4310 ISO 7363-86
Machines, Instruments and other Industrial Purpose Products. Design for Various Climatic Regions. Regions. Categories, Storage and Transportation Conditions in Relation to Impacts of Ambient Weather Conditions. Boom Self-Propelled Cranes, General Purpose. Acceptance and Testing Methods. Steel Cables. Enclosed Bearing Cables. Specification. Overhead Travelling Cranes, Electric, Single Support Beam. Specification. Boom Self-Propelled Cranes, General Purpose. Specification. Electric Cable Block and Tackle. Specification. Cable Clamshells for Bulk Loads. General Specification. Cranes. Operating Conditions. Cable Load Slings for Construction. Cranes. Unit Classification on the Basis of Operating Conditions. Electric Overhead Travelling and Gantry Cranes. General Specification. ISO 7752/1. Cranes. Control Units. Locations and Characteristics. Part 1. General Principles. ISO 8087-85. Self-Propelled Cranes. Dimensions of Drums and Blocks. ISO 4306/1-85. Cranes. Terminology and Definitions. ISO 7752/2-85. Self-Propelled Boom Cranes. Control Units. General Requirements. ISO 4306/1-85. Self-Propelled Boom Cranes. Terminology and Definitions. ISO 4301/2-85. Self-Propelled Boom Cranes. Classification on the Basis of Operating Conditions. Cranes. Basic Provisions for Modelling. Crane Wheels. Specification. ISO 9373-89. Cranes. Requirements for Accuracy of Parameter Measurements while Testing. Steel Wire Ropes of General Purpose. Characteristics. Cranes. Classification. Hoisting Equipment. Glossary. Load Lifting Cranes. Wire Rope Selection. Load Lifting Cranes. Steel Cable Selection. Part 2. SelfPropelled Boom Boom Cranes. Cranes. Usage Ratio. Cranes. Wire Ropes. Standards and Regulations for Inspection and Discarding. Cranes. Testing Regulations and Methods. Cranes and Hoisting Devices. Specifications and Acceptance Documents. Power Unit Design Design Regulations. Consumer Power Power Unit Operation Operation Regulations. Regulations. Safety Regulations for Consumer Power Unit Operation. Operation. Traffic Rules.
104
SNiP 2.01.01-82 — 7-81 SNiP II — 7-81 SNiP III-4-80 SNiP 3.08.01 OST 34-62-81 OST 22-115-70 OST 24.090.63-87 OST 24.090.85-88 RD 22-25-79 RD 22-145-85 RD 22-166-86 RD 22-205-88 RD 22-207-88 RD 22-317-91 RD 22-318-91 RD 22-319-92
RD 24.090.52-90 RD 24.090.90-89 RD 24.090.91-89
TP RD 24.090.95-89 TP RD 24.090.96-89 RD 24.225.03-90 MU 34.22.2002-92 34.22.2002-92
Construction Climatology and Geophysics. Geophysics. Design Standards. Construction in Seismic Regions. Safety in Construction. Mechanisation in Construction Industry. Rail Tracks of Tower Cranes. Load Lifting Equipment. General Requirements. Blocks for Steel Cables. Load Lifting and Transportation Equipment. Requirements for Fabrication of Welded Steel Structures. Electric Drives of Load Lifting Cranes. Calculation Standards. Self-Propelled Boom Cranes of General Purpose. Guidelines for Certificate Preparation. Self-Propelled Boom Cranes. Standards for Calculation of Stability against Tilting. Tower Cranes for Construction. Calculation Standards. Ultrasonic Flaw Detection of Welded Joints in Cranes. Load-Lifting Equipment. General Requirements and Standards for Production. Temporary Regulatory Documents for Polyamide Application to Fabricate Blocks. Tower Cranes. Methodological Directives for Inspection of Cranes with Expired Service Life Period. Self-Propelled Boom Cranes of General Purpose. Methodological Methodological Directives for Inspection of Cranes with Expired Service Life Period Conditions. Load Lifting and Transportation Equipment. Materials for Welded Steel Structures. Hoisting Equipment. Basic Requirements for Technical Documents for Reconstruction. Hoisting Equipment. Basic Requirements for Reconstruction for Further Application in Fire Hazardous Areas. Hoisting Equipment for Explosive Areas. Basic Requirements for Designing. Hoisting Equipment for Fire Hazardous Areas. Basic Requirements for Designing. Self-Propelled Boom Cranes. Steel Structures. Calculation Standards. Methodological Methodological Directives for Inspection of Cranes with Expired Service Life Period to Assess the Potential of their Further Operation. Operation. Methodological Methodological Directives for Inspection of Cranes, with the Purpose to Assess the Potential of their Further Operation. Operation. The Fourth Issue, Revised and and Supplemented. Supplemented. Guidelines for for Incoming Control of Metal Quality for Crane Overhaul, Fabrication and Reconstruction. Reconstruction.
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APPENDIX 3 (to Section 2.1) LIST of Head Organisations in Crane Production Organisation Equipment Assortment Description Kazsteelconstruction Kazsteelconstruction Cranes of overhead travelling and cable types, portal, cantilever, railway cranes, telphers. Specific installation cranes. Tower cranes, cranes, timber loading cranes, movable and derrick pole cranes, , boom cranes on rail tracks.
Organisation Address (illegiblein the original) Dzhandosov St., 480070 Almaty.
106
APPENDIX 4 (to Section 2.24) ESTIMATION OF TENSION IN A SLING STRING A load with the weight of Q is suspended on a hook by way of a sling rope or chain with n strings that are inclined to the vertical line at the t he angle of . When the load weight (Q t) is known, the tension of S (kN) occurring in each string shall be calculated in accordance with the following foll owing equation: S = 10Q__ = M 10Q__ ncos n where the M factor at
= 0, 30 and 45 will be equal to 1, 1.15 and 1.42 accordingly.
107
APPENDIX 5 (to Section 3.22) CRANE CERTIFICATE FORM A Certificate shall be issued with a hard hard cover on sheets of the 210x297 210x297 mm format. A certificate published at a printing-house shall have the format of 218x290 mm. Certificate Cover ______________________________________________________________________ (Crane Description)
______________________________________________________________________ (Crane Index)
CERTIFICATE* ______________________________________________________________________ (Certificate Description)
* This Certificate is a specimen to serve as the basis for producers to develop their own Certificates accounting for the types of cranes they produce in accordance with the regulatory documents of the Head Organisation, and to select from the list contained in the specimen only the data that refer to the particular type of crane to be i ncluded in their Certificates. If required, a Certificate Certificate may include additional data, which which will characterise the specific specific character of a produced produced crane. The Certificate shall be prepared in Russian. Front Page The crane is liable to registration with Gosgortechnadzor Bodies prior to its putting into operation (the caption shall be included for cranes liable for registration only). The place for the producer’s trademark (logotype). ______________________________________________________________________ ______________________________________________________________________ (Company Name)
______________________________________________________________________ (Crane Type and Description)
______________________________________________________________________ (Crane Index)
CERTIFICATE ______________________________________________________________________ (Certificate Description)
______________________________________________________________________ (Registration Number)
108
If the crane is transferred to another owner or leased with transference of the owner’s functions, this Certificate shall be handed over together wit h the crane. Front Page Reverse Side 1.
The owner of the crane or organisation (a company, co-operative, joint stock company, company, partnership or individual) that rents the crane with the owner’s functions shall permanently keep this Certificate.
2.
A permit for crane operation shall be obtained in accordance with the procedure provided by the Crane Design and Safe Operation Regulations.
3.
A list of permits issued by Gosgortechnadzor Gosgortechnadzor for deviations from the Regulations (copies) shall be attached to the Certificate.
4.
_____________________________________________________________ (other details for the crane owner
______________________________________________________________ to pay special attention to)
______________________________________________________________
Page 1 Page for the drawing of the crane general view in the operating position, and with w ith the basic sizes identified. Format 210x297 (218x290) mm.
Page 2 Permit (License) for production No. __________ of _______________ _______________ (Date)
______________________________________________________________________ (The title and address of the Gosgortechnadzor Body
______________________________________________________________________ that has issued the permit
______________________________________________________________________ for the crane production)
______________________________________________________________________ 1. General Information 1.1 1.2 1.3 1.4 1.5
The Crane producer’s title and address ______________________ ________________________________ __________ The crane type ___________________________________________________ The crane index __________________________________________________ Serial number ____________________________________________________ Year of production ________________________________________________
109
1.6 1.7 1.7.1
1.8
The purpose of the crane ____________________________________________ Crane classification (conditions) group _______________________ _________________________________ __________ Unit classification (conditions) groups ____________________________ _________________________________ _____ Main lifting ______________________ _________________________________ _____________________ _____________________ ___________ Auxiliary lifting ______________________ _________________________________ _____________________ __________________ ________ Radius alteration ____________________ ________________________________ ______________________ __________________ ________ Crane travelling ______________________ ________________________________ _____________________ ___________________ ________ Trolley travelling _____________________ ________________________________ _____________________ __________________ ________ Turning __________________________________________________________ Drive type _______________________________________________________ (for self-propelled boom cranes, the type of locomotion gear drive, and the drive type of the gear located on the turning platform shall be identified)
1.9
Ambient conditions of the environment, in which the crane may be operated: The highest
above 0
Temperature _______________________ ___________________________ ____ C _______________________ The lowest
1.10
below 0
Relative air humidity ______________________ _________________________________ _____________________ ______________ ____ Explosion hazard __________________________________________________ Fire hazard _______________________________________________________ Other features of the environment as required ____________________________ ____________________________ ________________________________________________________________ Permissible wind speed, m/sec.: For operating conditions (accounting for wind gusts) corresponding to the action threshold of the wind indicator (anemometer) installed on the crane __________ For operating conditions of a crane, which is i s not equipped with a wind indicator (anemometer), at the height of 10 metres ______________________ _______________________________ _________ For stand-by conditions of the crane, at the height of 10 metres ______________ ________________________________________________________________ (For modular cranes, data for particular combinations
________________________________________________________________ shall be indicated)
1.11
1.12
1.13 1.14
1.15
A permissible gradient of the area, on which a self-propelled boom crane may m ay be installed, % (degrees): When operating with outriggers _____________________________ ______________________________________ _________ When operating without outriggers ______________________________ ____________________________________ ______ Requirements for the site, where crane relocation with a load may be permitted: 2 Ground pressure (specific), Pa (kg-force/cm ) ___________________________ Gradient, % (degrees) ______________________ _________________________________ _____________________ _____________ ___ Limitation of simultaneous performance of operations _____________________ _____________________ Type of electric current, voltage, and the number of phases Power circuit _____________________________________________________ Operational lighting circuit ____________________ ______________________________ _____________________ ____________ _ Maintenance lighting li ghting circuit _____________________ _______________________________ ____________________ __________ Basic engineering requirements, regulations and guidelines of Gosgortechnadzor, Gosgortechnadzor, International and National standards, in accordance with which the crane has been manufactured (code and description) ______________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________
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2. Basic Specifications of the Crane 2.1
2.2
Basic crane specifications : Maximum lifting capacity for the main lifting, t (tonnes) ___________________ ___________________ Maximum lifting capacity for the auxiliary lifting, t _____________________ _______________________ __ Load lifting capacity at the maximum radius, t ___________________________ ___________________________ Maximum load momentum, t x m _____________________________________ Maximum lifting height, m _____________________ _______________________________ _____________________ ___________ Lifting height at the maximum radius, m ____________________________ _______________________________ ___ Lowering elevation, maximum, m __________________ _____________________________ __________________ _______ Maximum radius, m _______________________________________________ Radius at the maximum load lifting capacity ________________________ ____________________________ ____ Minimum radius, m ____________________ ______________________________ _____________________ __________________ _______ Crane span, m ____________________________________________________ Cantilever radius, m _______________________ _________________________________ _____________________ _______________ ____ Load-lifting and height characteristics (to be compiled for any operating condition combinations and crane designs, at which its operation is envisaged). Load-lifting characteristics: Tables, diagrams and graphs of the crane load -lifting characteristics.
Height characteristics: Tables, diagrams and graphs of load-lifting elevations.
2.2.1
2.2.2
2.3
The maximum weight of a load, for which a boom section may be extended, tonnes (the boom design shall be indicated – indicated – telescopic, telescopic, telescopic with an extension, with mechanical extension; and also operation with or without outriggers shall be noted) _____________________ ________________________________ _____________________ ____________ __ ________________________________________________________________ The maximum weight of a load, for which relocation of a self-propelled boom crane may be admitted, tonnes (the site condition, speed of movement, and the boom position versus the relocation axis shall be indicated) _________________ _________________ ________________________________________________________________ Crane geometrical parameters: Base, m __________________________________________________________ Outrigger base, m __________________________________________________ Track, m _________________________________________________________ Rear dimensions, m ________________________________________________ (to be indicated with advanced and retracted counterweight)
Turning radius, m __________________________________________________ The smallest radius of the inner rail axis curve at a curved section of the track, m ________________________________________________________________
Data for particular combinations shall be indicated for modular cranes, data for the main boom shall be given for self-propelled boom cranes.
111
Crane diagram and tables showing values of the basic crane dimensions and parameters of its manoeuvring 2.4
Speed ___________________________________________________________ (For units with several speeds, all the values or the range of their changes shall be indicated)
Load Lifting, Lowering and Landing Speeds, m/sec. (m/min) Polyspast Main Lifting Speed Auxiliary Lifting Speed Multiplicity Rated Landing Rated Increased** Landing Increased
Locomotion speed, m/sec (m/min or km/hr): Of the crane with a load on its hook _____________________ ________________________________ ______________ ___ Of the crane without load (operating) ______________________________ __________________________________ ____ t he maximum) (The whole range of speeds shall be indicated from the minimum to the Of the crane transportation (trailed by b y a tractor) ________________________ __________________________ __ Of the boom section extension/retraction __________________________ _______________________________ _____ Radius alteration (average) ______________________ ________________________________ ____________________ __________ Rotation frequency, rad./sec. (rev/min) ____________________ ______________________________ _____________ ___ (To be indicated for any design of operating equipment)
2.5
2.6 2.7
Time for complete radius change (for the main boom): From the maximum to the minimum, mi nimum, sec. (min) _____________________ _________________________ ____ From the minimum to the maximum, sec. (min) _________________________ _________________________ Turning angle, rad (degrees) _______________________________ _________________________________________ __________ Climbable road gradient, rad (degrees) __________________________ _________________________________ _______ (Values for any transportation options or their range shall be indicated)
2.8
Control location: During operation _______________________ ___________________________________ ______________________ _______________ _____ During assemblage and testing _______________________________________ During a self-propelled boom crane locomotion _________________________ __________________________ _ In operating conditions ______________________ _________________________________ _____________________ ____________ __ In transportation conditions _____________________ _______________________________ _____________________ ___________ For outriggers _____________________________________________________
2.9
Control method (methods of control shall be indicated): Mechanical, electric, hydraulic, pneumatic, pneumatic, etc. as related to a particular unit (gear) or a group of units _____________________ _______________________________ _____________________ _____________ __ Power supply to the crane and units ___________________________________ Stability characteristics ______________________ _________________________________ _____________________ ____________ __
2.10 2.11
Shall be mandatory for self-pr opelled boom cranes. Conditions, at which operation with increased speed is permitted (or provided), shall be indicated.
112
Load Momentum, kN x M (t x m)
Stability with Load
Inherent Stability
Holding Momentum, Mh (with the radius of), m Tilting Momentum, Mt*** (with the radius of), m 2.12
2.13 2.14
Weight of the crane and its main parts, tonnes: The design weight (to be indicated together with the main boom for a selfpropelled boom crane) ______________________________________________ ________________________________________________________________ The total weight of the crane (to be indicated together with the main boom and in a fully full y serviced state for a self-propelled boom crane) ___________________ ___________________ Counterweight ____________________________________________________ Ballast weight _______________________ _________________________________ _____________________ ___________________ ________ Weight of the main assembly parts of the crane that are transported separately ________________________________________________________________ Weight of the t he crane in the transported condition __________________________ __________________________ Design load of the running wheel on the rail, kN (t/sec) ____________________ ____________________ Load of the chassis axels on the base in transported conditions
Crane Design Total \
2.15 2.16
Load, kN (t/sec) Front axel
Rear axel
Average specific ground pressure, Pa (for ( for caterpillar cranes) ________________ Other data as required (e.g., data related to metal, ballast drawings, etc.) ______ ________________________________________________________________ ________________________________________________________________ Specifications and Characteristics of Assemblies and Parts
3.1 3.1.1
Engines of power units and gear ______________________________________ Internal combustion engines (parameter values at the sea level): _____________ _____________ ________________________________________________________________ Purpose __________________________________________________________ Type and symbolic notation _______________________ _________________________________ ___________________ _________ Rated capacity, kW (HP) ____________________________________________ Rotation frequency, rad/sec (rev/min) _____________________ _______________________________ _____________ ___ Maximum torque, N x m (kg-force x m) ________________________________ Rotation frequency, rad/sec (rev/min) _____________________ ________________________________ _____________ __ Specific fuel consumption, g/kW/hr ____________________ _______________________________ _______________ ____ Start-up device, type and symbolic notation _____________________ _____________________________ ________ Capacity, kW (HP) _____________________ ________________________________ _______________________ _________________ _____ Air filter, type _______________________ _________________________________ _____________________ ___________________ ________ Capacity of the fuel tank, litres li tres ____________________________ ______________________________________ ___________ _
Momentum values shall be indicated, which characterize inherent stability and that under load for operating equipment and at the boom position (radius) of M, when the ratio of momentums is closest to one.
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Batteries: Type and symbolic notation __________________________________________ Voltage, V _________________________________________________ Rated capacity, ____________________________________________ Quantity ___________________________________________________ Specific power consumption for an hour of the crane operation, kW-hr/hr _____ Type of engine connection to transmission: Type ______________________________________________________ Notation ___________________________________________________ Service meter, notation ____________________ _______________________________ _____________________ ______________ ____ 3.1.2
Generators and power engines
Parameters
Electric Engine of a Power Unit
Generators
Electric Engine of a Gear Drive
Purpose (the gear, the engine is installed for) Type and symbolic notation Type of current Voltage, V Rated current, A Frequency, Hz Rated power, kW Rotation frequency, rad/sec (rev/min), % per 10 minutes Protection level in accordance with GOST 17494 Type of engine connection to transmission – transmission – the type description and notation.
3.1.3 3.1.4
Cumulative rated power of the electric engine, kW ___________________ _______________________ ____ Hydraulic pumps and hydraulic monitors Parameters
Hydraulic Pumps
Hydraulic Monitors
Purpose Quantity Type and symbolic notation Limit momentum (for hydraulic monitors) Rated consumed power, kW (for hydraulic pumps) Rated pressure of the operating medium – medium – 2 discharge pressure, Pa (kg-force/cm ) Rated capacity (flow rate), litre/min Rotation frequency, rad/sec (rev/min) Direction of rotation
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3.1.5
3.2 3.2.1
Hydraulic cylinders: Purpose __________________________________________________________ Quantity _________________________________________________________ Type and symbolic notation __________________________________________ Cylinder diameter, mm ____________________ ______________________________ _____________________ _______________ ____ Piston stroke, m _____________________ _______________________________ _____________________ ____________________ _________ 2 Rated pressure of the operating medium – medium – discharge discharge pressure, Pa (kg-force/cm ) ________________________________________________________________ Liquid type _______________________________________________________ Diagrams ________________________________________________________ Wiring schematic diagram ____________________ ______________________________ _____________________ _____________ __ Room for the diagram
3.2.1.1 List of power equipment components Legend
Description Descripti on and Brief Specification
Type
Qty.
Notes
3.2.1.2 Wiring drawings Room for the wiring drawing 3.2.2
Schematic diagram for hydraulics Room for the schematic diagram
3.2.3
Schematic diagram for pneumatics Room for the schematic diagram
3.2.4
Cinematic diagram (the cinematic diagram shall include the diagram of bearing installation, and their list shall be attached as a specification to the diagram). Room for the diagram
3.2.4.1 Characteristics of tooth gear Position on the Diagram No.
Notation on the Drawing
Part Description
Module, mm
Number of Teeth
Material, Type
Thermal Treatment (teeth hardness)
3.2.4.2 Characteristics of Chain Gear Sprockets
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Position on the Diagram No.
Standard No., or Notation on the Drawing
Description
Spacing, mm
Number of Teeth
Material
Thermal Treatment (teeth hardness)
3.2.4.3 Reducer characteristics Position on the Diagram No.
Description, Type
Notation on the Drawing
Transmission Ratio
3.2.4.4 Brake characteristics: The unit, where the brake is installed ___________________________ ______________________________________ _____________ __ Number of brakes ________________________________________________________ The type and system (automatic, controlled, normally open or closed, block brake, disk brake, etc.) _____________________________________________________________ Brake pulley of the disk diameter, mm _______________________ _________________________________ ________________ ______ Braking margin factor of: The load winch __________________________________________________________ The boom winch ________________________________________________________ Brake drive: Type __________________________________________________________________ Effort, N _______________________________________________________________ Effector stroke, mm ______________________ _________________________________ _____________________ _____________________ ___________ Unit braking distance _____________________________________________________ 3.2.5 Reeving diagrams and characteristics of ropes and chains (reeving diagrams for load polyspasts of the main and auxiliary lifting, boom, gooseneck, etc. lifting polyspasts; the diagrams shall indicate sizes of drums and blocks, and also methods of cables and chains fastening) Room for diagrams 3.2.5.1 Cable characteristics (to be filled in on the basis of certificates provided by the cable producers): Cable purpose (main or auxiliary lifting, boom, etc.) ______________________ ______________________ Cable design and standard notation _______________________________ ____________________________________ _____ Diameter, mm _______________________ _________________________________ _____________________ ___________________ ________ Length, m ________________________________________________________ 2 Temporary resistance of wires to break-up, N/mm _______________________ General strength of the t he cable, N ______________________________ ______________________________________ ________ Design tension of the cable, N ______________________________ ________________________________________ __________ Utilization factor (strength margin factor): Designed ________________________________________________________ Standard _________________________________________________________ Wire surface coating (in accordance with GOST) ____________________ _________________________ _____ ________________________________________________________________
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3.2.5.2 Chain characteristics (to be filled in on the basis of certificates provided by the chain producers): Chain purpose and notation on the diagram _____________________________ _____________________________ Chain design and standard notation ____________________________________ Link diameter (calibre), or roller diameter, mm __________________________ __________________________ Chain spacing, mm ________________________________________________ Chain length, m ___________________________________________________ Strength of the chain, kN ____________________________________________ Design tension, kN _________________________________________________ Strength margin factor: Designed ________________________________________________________ Standard _________________________________________________________ 3.3 Load-gripping devices devices (to be filled in i n on the basis of the certificate provided by the load-gripping device producer) 3.3.1 Hooks: Design __________________________________________________________ Type (single-armed, double-armed, forged, leaf, etc.)
________________________________________________________________ Rough workpiece of the hook according to the t he Standard and Standard notation ________________________________________________________________ Rated load-lifting capacity, t _______________________ _________________________________ __________________ ________ Serial No. (Certificate, year of production) _____________________ ______________________________ _________ ________________________________ ___ Crane Crane producer’s QC Department stamp _____________________________ ________________________________________________________________ 3.3.2
3.3.3
Clamshells: Type ____________________________________________________________ 3 Bucket capacity, m ________________________________________________ Type of materials to be handled with the clamshell, and their maximum bulk 3 weight, kN/ m ____________________________________________________ Clamshell weight, t _____________________ ________________________________ _____________________ ________________ ______ Weight of material scooped by the clamshell, t ___________________________ ___________________________ Serial No. ________________________________________________________ Producer’s QC Department stamp ______________________________ _____________________________________ _______ Electric magnets: Type ____________________________________________________________ Power, kW _______________________________________________________ Feed current: Type of current ____________________________________________________ Voltage, V _______________________________________________________ Weight of the electric magnet, t _____________________ ________________________________ __________________ _______ Lifting force, kN ______________________ ________________________________ _____________________ __________________ _______ When lifting the following materials: Shavings ________________________________________________________ Scrap metal ______________________________________________________ Cast iron ingots ___________________________________________________ Maximum temperature of handled load, C ______________________________ Serial No. ________________________________________________________
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3.3.4 3.4 3.4.1
Producer’s QC QC Department stamp ____________________ ______________________________ _________________ _______ Other load-gripping devices (spreaders, automatic grapples, etc.). Instruments, safety devices devices and alarm systems. systems. Protection devices. devices. Limit switches
Type – lever, spindle, etc. switch (wiring diagram)
3.4.2
3.4.3
Gear, the limit switch is functionally related to (installation location)
Distance from the crane gripping devices, and the trolley to the limit at the time the engine is shut down (m, degrees, revolutions, etc.)
3.4.5
Quantity
Position No. on the schematic wiring diagram
Load lifting limiter: Gear shut down with the limiter _____________________ _______________________________ _________________ _______ Notation (type, modification, and the serial No.) _______________________ _________________________ __ ________________________________________________________________ System __________________________________________________________ Maximum overload, at which the limiter actuates, % ______________________ ______________________ Availability of sound and light warning signals __________________________ __________________________ Overload, at which warning signals actuate_________________________ actuate______________________________ _____ Safety contacts
Installation location (the cabin, remote control panel, etc.)
3.4.4
Interlink
Type
Purpose
Position No. on the schematic wiring diagram
Arresters and bumpers: Units ____________________________________________________________ Design (rigid, spring, hydraulic, etc.) _______________________________ __________________________________ ___ Maximum stroke, mm (for spring, hydraulic, etc. bumpers) _________________ _________________ Other safety devices
Description Anemometer (wind indicator) Anticreep devices Parking brake Arresters of caterpillar trolleys
Type, type of drive
Purpose
For self-propelled boom cranes, the table shall be compiled accounting for all types and designs of operating equipment supplied with the crane.
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Tilting limiter of a gantry crane Other safety devices 3.4.6
Indicators
Description Load-lifting capacity and radius indicator Crane tilt indicator Load on the crane gripping device indicator Other information purpose indicators 3.4.7
Type
Purpose
Signalling and communication devices Description
Type, notation, and system of the device
Purpose, actuation conditions
Radio station Alarm signal of hazardous overhead power line (under voltage) approach Sound signal Overall size light signals Other devices 3.5
Cabins Location _________________________________________________________ Purpose __________________________________________________________ Type, design solution
________________________________________________________________ (open, enclosed, etc.)
3.6
Number of seats ___________________________________________________ Type and characteristics of glass ______________________________________ Insulation characteristics (thermal, acoustic, etc.) ______________________ _________________________ ___ Characteristics of systems applied to establish micro-climate in t he cabin (ventilation, hating, air conditioning, etc.) ______________________ _______________________________ _________ Other equipment (screen wipers, fire extinguishes, etc.) ____________________ ____________________ ________________________________________________________________ Data related to the metal utilised in the t he main structures of the crane (to be filled in on the basis of certificates provided by material vendors)
Unit and component descriptions and notations
Type and thickness of rolled metal, standard
Material type, category, group, and strength class
Standard for the material type
Certificate No.
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4. Acceptance Statement (Certificate) The crane ______________________________________________________________ (description, type, index, design)
Serial No. ______________________________________________________________ has been fabricated in compliance with engineering standards _____________________ _____________________ ______________________________________________________________________ The crane has passed testing in accordance with the programme __________________, __________________, and has been accepted as fit for operation with the parameters stated in the Crane Certificate _____________________________________________________________ Warranted service life li fe is ____________________ ______________________________ ____________ __ months Service life at 1.5-shift operation in the Certificate specified conditions shall be ______ years. Resources till the first overhaul shall make up ________ motor-hours.
____________________________ Signature
Chief Engineer of the Company
Stamp _______________________ Date
____________________________ Signature
Head of the QA/QC Department
5. Documentation to be Supplied by the Producer 5.1
5.2
Documents to be included into the Crane Certificate: a) A diagram of ballast and counterweight counterweight installation, with weight allowance and plate gravity centres disconnection, warning painting and lettering on plates to be stated therein; b) Ballast and counterweight drawings. Documents to be supplied with the Crane Certificate: a) A Certificate (guidelines) of the load lifting (load momentum) limiter, and a diagram of its operation; b) A Certificate of the automobile chassis; c) A Certificate of the internal combustion engine; d) A Certificate (guidelines) of safety instruments and devices. e) A crane operation manual; f) Guidelines for rail track construction; g) A set of drawings for wearing out parts; h) A bill of spare parts, tools and appliances;
To be filled in for the cases, when the producer ships a crane in an assembled state, or if the plant performs a complete assemblage of the crane.
120
i) j)
A set of wiring diagrams (as required); Other documents (as required)
Information of the crane location* Name of the company (organisation) owning the crane, or the name and initials of an individual owner
Crane location (owner’s address)
Date of installation (delivery)
___________________________
* At least 2 pages Information about assignment of engineering and technical staff to be responsible for crane safe and serviceable conditions* No. and Date of the Assignment Memorandum, or a Contract with the Company
Person’s Person’s Name
Position
Certificate No. and Validity Period
Signature
___________________________
* At least 5 pages Information about steel structure overhauls and replacements of units, and load-gripping device cables* Date
Details of the Overhaul and Crane Component Replacement Replacement Character
Details of the Crane Acceptance after the Overhaul (date, document No.)
Signature of the Engineer Responsible for the Crane Safe and Serviceable Conditions
___________________________
* At least 5 pages Note: Documents certifying quality of newly installed units, cables and other crane components, as well as applied materials (rolled metal, welding r ods and wire, etc.), and also the conclusion of welding quality shall be kept with the Crane Certificate. Records of technical inspection results* Inspection Date
Inspection Results
Time of the Next Inspection (complete and partial)
___________________________
* At least 32 pages
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Note: Results of a specific crane inspection, when it has operated through its it s designed service life period (technological lifespan), shall be also i ncluded herein. Registration (a separate page) The crane has been registered r egistered with the No. of ______________________ ________________________________ ____________ __ ______________________________________________________________________ (State the registering body)
The Certificate contains ____ numbered pages and totally ______ stringed sheets, including drawings on ______ sheets. Stamp _____________________ Date
________________________ (Signature and position) _________________________ (Name and initials of the registering person)
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APPENDIX 6 (to Section 3.22) CHAIN BLOCK CERTIFICATE FORM Producer’s Trade Mark (Logotype)
A Certificate shall be issued with a hard cover on sheets of the 210x297 mm format. A certificate certificate published at a printing-house may have the format of 145x218 mm. Certificate Cover
CERTIFICATE* ______________________________________________________________________ (Chain Block Description)
______________________________________________________________________ (Chain Block Notation)
Registration No. ______________ ______________ If the chain block is transferred to another owner, this Certificate shall be handed over together with the chain block. ______________________________________________________________________ (Place Name of the Chain Block P roduction)
Page 1 Permit (License) for production No. __________ of _______________ _______________ (Date) ________________________________________ (The title and address of the Gosgortechnadzor Body
________________________________________ that has issued the permit for the chain block production)
1. General Information 1.1 1.2 1.3 1.4 1.5 1.6
The chain block producer’s p roducer’s title and address ____________________________ _____________________________ _ ________________________________________________________________ The chain block type _______________________________________________ Serial number _____________________________________________________ Year of production _______________________ _________________________________ _____________________ ________________ _____ Classification group ______________________ __________________________________ ______________________ ______________ ____ Drive type _______________________________________________________
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1.7
Ambient conditions of the environment, in which the chain block may be operated: The highest
above 0
Temperature _______________________ ___________________________ ____ C _______________________ The lowest
1.8
below 0
Relative air humidity ______________________ _________________________________ _____________________ ______________ ____ Explosion hazard __________________________________________________ Fire hazard _______________________________________________________ Other features of the environment as required _________________________ ____________________________ ___ Basic engineering standards, in accordance with which the chain block has been manufactured 2. Basic Specifications and Characteristics Characteristics
2.1
2.2
2.3
2.4
General data: Load-lifting capacity, t _______________________ __________________________________ _____________________ ____________ __ Lifting height, m _____________________ ________________________________ _____________________ __________________ ________ Rated lifting speed, m/sec ___________________________________________ Type of current in the power circuit: Voltage, V _______________________________________________________ Frequency, Hz ____________________________________________________ Type of current in the control circuit: Voltage, V _______________________________________________________ Frequency, Hz ____________________________________________________ Method of power supply to the chain block _____________________________ Type and profile of the track tr ack ___________________________ ______________________________________ ______________ ___ Minimum radius of a track curve, m _______________________ _________________________________ ____________ __ Load on a wheel, N ________________________________________________ Dead weight, kg ___________________________________________________ Steel cables: Cable design and standard notation ____________________________________ Diameter, mm _______________________ _________________________________ _____________________ ___________________ ________ Length, m ________________________________________________________ 2 Temporary resistance of wires to break-up, N/mm _______________________ ________________________________________________________________ General strength of the cable, N _______________________________ ______________________________________ _______ Strength margin factor ______________________ _________________________________ _____________________ _____________ ___ Wire surface coating _______________________________________________ Hook: Standard notation _________________________________________________ Hook No. according to Standard ______________________________________ Load-lifting capacity, t ______________________ ________________________________ _____________________ ______________ ___ Power engines:
Parameters Type and symbolic notation Voltage, V
Lifting Gear
Travelling Gear
124
Rated current, A Frequency, Hz Power, kW Rotation frequency, rev/min Starting time, % per 10 minutes Number of start-ups per 1 hour Design Level of protection 2.5
Brakes Parameters
Lifting Gear
Travelling Gear
Type Number of brakes Deceleration (braking) margin factor Brake drive: Type Effort, N Effector stroke, mm 2.6 2.6.1
Safety devices Limit switches
Type
2.6.2 2.7
Gear the Switch is Designed to Stop
Distance from the Chain Block Hook Suspension to the Stop after the Gear id Stopped
Quantity
Other safety devices ________________________________________________ ________________________________________________________________ Control devices Description
Type
Purpose
3. Acceptance Statement (Certificate) The chain block ______________________________ ______________________________ Serial No. __________________ __________________ has been fabricated in compliance with the requirements of GOST __________ (or TU _________________) _________________) and the Crane Design and Safe Operation Regulations. The chain block has passed testing in accordance with ____________________ __________________________, ______, ______________________________________________________________________ (Description of the Regulatory Document)
and has been accepted as fit for operation with the parameters stated in the Certificate. Warranted service life li fe is ____________________ ______________________________ ____________ __ months
125
____________________________ Signature
Chief Engineer of the Company
Stamp _______________________
____________________________
Date
Signature
Head of the QA/QC Department 4. Documentation to be Supplied by the Chain Block Producer with the Certificate A Certificate (guidelines) of the load lifting limiter (if available), and a diagram of its operation; A chain block operation manual; Guidelines for the chain block installation; Guidelines for rail track construction; A list of chain block parts and assembly units, with noted related to their r outine maintenance (if required) A bill of spare parts, tools and appliances; Other documents (as required) Information of the chain block location* Name of the chain block owner
Chain block location
Date of installation
___________________________
* 1 page 6. Information about assignment of engineering and technical staff to be responsible for the chain block safe and serviceable conditions* No. and Date of the Assignment Memorandum
Person’s Name and Position
Signature
___________________________
* 1 page Note: Documents certifying quality of newly installed units, cables and other crane components, as well as materials applied in the overhaul, shall be kept in a separate file. 7. Records of technical inspection results* Inspection Date
Inspection Results
Time of the Next Inspection (complete and partial)
___________________________
* At least 8 pages
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APPENDIXES TO THE CERTIFICATE Appendix A General View (1 page) A drawing with the general view shall be attached stating overall and installation dimensions. Appendix B Schematic Wiring Diagram (1 page) A drawing with the schematic wiring diagram shall be attached including a table to interpret notations. Appendix C Cinematic Schematic Diagram (1 page) A drawing with the cinematic schematic diagrams of the chain block lifting and travelling gear, as well as the diagram of cable reeving and fastening f astening shall be attached.
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APPENDIX 7 (to Section 4.15) Maximum Permissible Deviations of Rail Tracks (Plane and Profile Views) from the Designed Position
Deviation
Graphical Representation of the Deviation
Overhead Travelling
Cranes Tower Gantry
Portal
Difference in elevations of railheads in the cross section (P1), mm (S is the size of the track, m)
40
45-60 (for S=4.56 m)
40
40
Trans ship ment 50
Difference in rail elevations at neighbouring columns (P2), mm
10
-
-
-
-
Narrowing or widening of the rail track (rail horizontal deviation from the design position), (P3), mm
15
10
15
15
20
Mutual displacement of joined rail butts both horizontally and vertically (P4), mm
2
3
2
2
2
Gaps in rail butt joints (at the temperature of 0C, and the rail length of 12.5 m) (P 5), mm
6
6
6
6
6
Difference in railhead elevations at the rail track section of 10 m (total) (P6), mm
-
40
30
20
30
Notes: 1. Maximum permissible values of deviations shall be complied with in operation. Construction allowances shall be identified in design documents for the rail track. 2. P1 and P3 deviations shall be measured at the whole length of the crane potential travelling area, at the intervals of at least 5 m. 3. If the ambient temperature changes by 10 C, allowance for P 5 gap shall be amended by 1.5 mm. E.g., the gap allowance allowance shall be reduced by 3 mm at the temperature of 20C. 4. Deviation allowances for rail tracks of gantry cranes with the span above 30 m shall be taken as those for transhipment cranes.
128
APPENDIX 8 (to Section 4.15.10) STATEMENT FORM for a Crane Rail Track Acceptance at Commissioning ______________________________________________________________________ (Company)
Date: ______________________ ______________________ Facility address: _________________________________________________________ Crane type, serial and registration numbers _____________________ ________________________________ _______________ ____ ______________________________________________________________________ Rail Track Length of the rail track ______________________ _________________________________ _____________________ ___________________ _________ Availability of design documentation ___________________________ ______________________________________ _____________ __ ______________________________________________________________________ (Design Developers)
Compliance of constructed rail track with design documents ______________________ ______________________ ______________________________________________________________________ Availability of the ground bed for f or the upper rail track structure Acceptance Statement _ ______________________________________________________________________ Rolling smooth of the rail track has been carried out with the crane runs: Without load _____________________________________________________ With the maximum operating load _______________________________ ____________________________________ _____ Measurement Measurement Results: Track width, mm ________________________________________________________ Straightness, mm ________________________________________________________ Longitudinal gradient _____________________________________________________ Cross slope _____________________________________________________________ Resilient trim, mm ____________________ ______________________________ _____________________ _____________________ ______________ ____ Availability and serviceability of stop blocks _____________________ ________________________________ _____________ __ Availability and serviceability of bumping posts ______________________ _______________________________ _________ Track Grounding Grounding design ________________________________________________________ Grounding location and length _______________________ _________________________________ _____________________ ____________ _ ______________________________________________________________________
129
Description, type and No. of the instrument applied to measure grounding resistance. __ ______________________________________________________________________ Measurement location ____________________________________________________ Weather during the last three days and at the day of measurement __________________ __________________ ______________________________________________________________________ Grounding resistance, Ohm _______________________________________________
Track Grounding: Complies with the requirements ____________________________ ________________________________________ _______________ ___ Does not comply with the requirements _____________________________________ Rail track grounding has been installed by ___________________________________ (Company,
_____________________________________________________________________ name, position, signature)
Rail track grounding resistance has been measured by ___________________________ (Company,
_____________________________________________________________________ name, position, signature)
Work on crane rail track construction has been carried out and handed over by _______________ (Company,
________________________________________ name, position, signature)
Crane rail track has been accepted for operation by by ________________________________________ (Company,
________________________________________ name, position, signature)
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APPENDIX 9 (to Section 5.15) WORK PERMIT FORM for the right of access to crane track and passage galleries of overhead travelling and mobile cantilever cranes to carry out maintenance and other t ypes of work. 1. Issued on ________________ (Date) at _____ hours ________ minutes 2. The responsible person ________________________________________________, (Name)
with a crew consisting of ________ persons, is charged to carry out the following work: ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ 3. Work location (workshop, span) _____________________________ _______________________________________ _____________ ___ ______________________________________________________________________ 4. To ensure safety during preparation to and carrying out of the work you shall implement the following precautions: a) to prevent electric shocks __________________________ _____________________________________ _______________ ____ ________________________________________________________________ b) to prevent falls from elevated locations ________________________ _______________________________ _______ ________________________________________________________________ c) to prevent injuries by operating cranes ___________________________ _______________________________ ____ ________________________________________________________________ d) to prevent access to crane tracks of operating cranes and cranes of adjoining spans ___________________________________________________________ ________________________________________________________________ e) crane operators of all shifts within the span (shop) and crane operators of adjoining spans have been notified, and appropriate entries have been made in the shift logbook ______________________ _________________________________ _____________________ _________________ _______ ________________________________________________________________ The Crew includes: Members of the Crew (full Signatures of Crew members after name, position) being familiarised with work conditions and safety measures
________________________________________ (Signature of the Workshop Superintendent or Fore man that supervises the work of the maintenance crew)
6. Work shall commence at ____ hours ____ minutes on ___________________ ___________________ (Date)
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7. The Work-Permit is issued by: ______________________ ________________________________ _____________________ ___________ (Signature of the Workshop Superintendent or his Deputy for Equipment)
8. Briefed on the work conditions and received the Work-Permit __________________ __________________ (Signature of the Responsible Person)
Note: A Work-Permit for the right of access to crane track and passage galleries galleries of overhead travelling cranes to carry out maintenance and other t ypes of work shall be issued on the basis of a Memorandum to the Work Supervisor (Workshop or Area Superintendent, or Foreman that supervises the work of the maintenance crew).
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APPENDIX 10 (to Section 5.28) STANDARDS TO REJECT ROPES OF HOISTING EQUIPMENT 1.
Rejection (discarding) of ropes applied in operating hoisting equipment shall be performed in accordance with the Guidelines on the hoisting unit operation (Operation Manual), which shall be developed on the basis of ISO 4309 requirements. If there is no appropriate section in the Operation Manual, rejection of ropes of a hoisting unit shall be carried out in accordance with this Appendix. The following criteria shall be applied to assess safety of the rope application: a) The nature and number of wire breaks (Figures from 1 to 3), including presence of wire at rope terminations, t erminations, presence of wire break accumulations, the intensity of the wir wiree break number increase;
Figure 1. Breaks and displacements of wires in a rope of a regular lay. la y.
Figure 2. Combination of wire breaks with wear-out: a) in a regular lay rope; b) in a long lay rope
Figure 3 Wire breaks within the area of an equalising block: a) in several rope strands; b) in two strands in combination with local wear-out.
b) c) d) e)
A brake of a strand; Surface and internal wear-out; Surface and internal corrosion; Reduction of the rope diameter, including a break of the core;
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f) Reduction of the rope wires cross section area (loss of internal cross section); g) Displacement Displacement in the form of corrugation, wage shape, extrusion of wires and strands, squashing of strands, breaks, bends, etc.; h) Damage resulting from temperature impacts or electric arc discharges.
Figure 4. Wear out of external wires in a regular lay rope: a) small flat spots on wires; b) increased length of flat spots on separate wires; c) lengthening of flat spots on separate wires, with a visible reduction of the wire diameters; d) flat spots on all the wires, reduction of the rope diameter; e) intensive wear-out of all external wires of the rope (wire diameters decrease by 40%)
Figure 5. Surface corrosion of wires in a regular lay rope: a) initial oxidation of the surface; b) general oxidation of the surface; c) visible oxidation; d) high oxidation; e) intensive corrosion.
Table 1 Number of Wire Breaks, with the Presence Presence of Which Double Lay Ropes Operating with Steel and Cast Iron Blocks shall be Rejected
Number of bearing wires in external strands, n
Typical examples of rope designs
n 50
6x7(1+6)+1x7(1+6) 6x7+1 8x6(0+6)+9
51 n 75
6x19(1+9+9)+1
Group of the unit classification (conditions) M1, M2, M3 and M4 M5, M6, M7 and M8 Regular lay Long lay Regular lay Long lay At a section with the length of 6d 30d 6d 30d 6d 30d 6d 30d 2 4 1 2 4 8 2 4
3
6
2
3
6
12
3
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6
76 n 100 101 n 120
121 n 140
141 n 160 161 n 180
181 n 200 201 n 220 221 n 240 241 n 260 261 n 280 281 n 300 300 < n
6x19(1+9+9)+7x7(1+6) 6x25(1+6; 6+12)+1 6x25(1+6; 6+12)+ 7x7(1+6) 6x19(1+6+6/6)+ 7x7(1+6)* 6x19(1+6+6/6)+1 6x16(0+5+11)+9 18x7(1+6)+1 8x19(1+6+6/6)+1 6x30(0+15+15_+7 6x30(6+12+12)+1 6x31(1+6+6/6+12)+1 6x31(1+6+6/6+12)+ 7x7(1+6) 6x36(1+7+7/7+14)+1 6x36(1+7/7+14)+ 7x7(1+6) 6x37(1+6+15+15)+1 18x19(1+6+6/6)+1*
4
8
2
4
8
16
4
8
5
10
2
5
10
19
5
10
6 6 6 7
11 13 13 14
3 3 3 7
6 6 6 7
11 13 13 14
22 26 26 29
6 6 6 7
11 13 13 14
8
16
4
8
16
32
8
16
8
18
4
9
18
38
9
18
10 10 11 12 0.04n
19 21 22 24 0.08n
5 5 6 6 0.02n
10 10 11 12 0.04n
19 21 22 24 0.08n
38 42 45 48 0.16n
10 10 11 12 0.04n
19 21 22 24 0.08n
Notes: 1. 2.
3.
4.
2.
n is the number of bearing wires on external strands of a rope; d is the rope diameter, in millimetres. Filling wires are not considered bearing ones, thus are not liable to accounting. In ropes with several layers of strands, wires of the visible external layer are accounted accounted only. In ropes with a steel core, the latter is considered as an internal strand, and hence is not accounted. The number of visible breaks in strand design ropes shall be calculated in accordance with established equations. The obtained value shall be rounded rounded to a whole number towards the larger one. For ropes with different diameters of outer wires in external strands, the design class has been reduced in the Table and marked marked with an apteryx. If a rope operates only or partially with with blocks of synthetic materials or metal blocks with synthetic lining, a considerable number of wire brakes inside the rope prior to occurrence of visible break indications or intensive wear out of the external surface is more characteristic [ further text is illegible].
Ropes that operate with steel and cast iron blocks shall be rejected on the basis of the number of wire breaks in accordance with Table 1. Ropes of hoisting equipment designed to lift people, as well as those applied to transport melted or glowing metal, fl ammable and toxic substances, shall be rejected if the number of wire breaks is twice less.
3.
If the rope diameter decreases due to surface wear-out (Figure 4) or corrosion (Figure5) by 7% and more as compared with the rated diameter, the rope shall be rejected even if there are no visible wire breaks. If the rope diameter di ameter decreases due to damage caused to the core, e.g., internal wear-out, squashing, squashing, break, etc. (by 3% of the rated diameter for non-whirling ropes, and by 10% for other ropes), the rope shall be rejected even if there are no visible wire breaks (Figure 6).
135
Figure 6. Local rope diameter decrease at the location of the organic core damage. If a rope reveals surface wear-out or corrosion of wires, the number of brakes serving as an indication for rejection shall be reduced in accordance with data of Table 2 Table 2 Standards for Rejection on the Basis of Surface Wear-out or Corrosion Wire Diameter Decrease Due to Surface Surf ace Wear-out or Corrosion, % 10 15 20 25 30 and more
Number of Wire Breaks at a Lay Pitch, % of those stated in Table 1 85 75 70 60 50
If the original diameter of external wires decreases by 40% and more as a result of wear-out (Figure 4) or corrosion (Figure5), the rope shall be rejected. Wear-out and corrosion of wires on the basis of their diameter shall be identified utilising a micrometer or other instrument, which provides analogous accuracy. If the number of wire breaks is below the values specified in Table 1, as well as if the wire surfaces are worn out without breaks, a rope may be accepted for operation provided that its condition is thoroughly monitored and periodically inspected, and the results results are recorded in the inspection inspection logbook. The rope shall be replaced as the wear-out level l evel specified in Table 2 is achieved. If loads are suspended on two ropes, each of them shall be inspected and rejected separately, and replacement of only one rope, the mostly mostl y worn-out one, may be accepted. 4.
To assess conditions of internal wires, i.e., to control the loss of the metal part of the rope cross section (loss of internal cross section), which may be caused by breaks, mechanical wear-out and corrosion of wires in internal layers of strands (Figure 7), the rope shall undergo undergo flaw detection along its whole length. length. If a flaw detector identifies a loss l oss of wire metal cross section, s ection, which reaches 17.5% and above, the rope shall be rejected.
Figure 7. Decrease of the wire cross section area (intensive internal corrosion)
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5.
If one or several broken strands are identified in a rope, the rope shall not be accepted for further operation.
Figure 8. Corrugation of a rope (see the text for description). 6.
Rope corrugation is characterised by the pitch and direction of its coil (Figure 8). If the direction of the corrugation coil and that of the t he rope lay coincide, and the pitch of the corrugation coil (H в) and that of the rope lay (H k ) are equal, the rope shall be rejected at d в1.08dk , where dв is the diameter of the corrugation coil, and dk is the rated diameter of the rope. If the directions of the corrugation coil and rope lay do not coincide, and the pitch of the corrugation coil and that of the rope lay are unequal, the rope shall be rejected at d в4/3dk . The length of the rope section under under inspection inspection shall not exceed 25 d k .
7.
Ropes shall not be accepted for further operation if the following is found: -
basket-shaped basket-shaped displacement (Figure 9); core extrusion (Figure 10); strand extrusion or separation (Figure 11); local increase of the rope diameter (Figure ( Figure 12); local decrease of the rope diameter (Figure (Fi gure 6); squashed areas (Figure 13); kinks (Figure 14); breaks (Figure 15); bends (Figure 16); damage resulting from temperature impacts or electric arc discharges.
Figure 9. Basket-Shaped Basket-Shaped Displacement
Figure 10. Core Extrusion
Figure 11. Strand Wires Extrusion a) in one strand; b) in several strands
137
Figure 12. Local Increase of the Rope Diameter
Figure 13. Rope Squashing.
Figure 14. Kink
Figure 15. Rope Break
Figure 16. Rope Bend
138
APPENDIX 11 (Reference) INTERNATIONAL STANDARDS STANDARDS ISO 4301/1, 4302, 4308/1, 4308/2, 4310 and 8087 INTERNATIONAL STANDARD ISO 4301/1 (CRANES AND LIFTING UNITS. CLASSIFICATION. CLASSIFICATION. PART 1. GENERAL PROVISIONS). Introduction Load-lifting Load-lifting cranes (hereinafter ―cranes‖) are applied to lift and relocate loads, weights of which do not exceed exceed their rated load-lifting capacities. Cranes of one type (e.g., (e.g., overhead travelling ones) and cranes of different types (e.g., a t ower crane for construction and a port crane with a considerable lifting capacity) may have different operating conditions. conditions. Crane designing shall shall account for conditions of operation operation to ensure the required level of safety and durability that will comply with the requirements of the customer. Classification is a system that is used as as a tool to establish an effective basis to design structures and machines, and as a basis to develop relations between the Customer and Producer. Producer. The Classification will assist in selecting selecting a particular crane for the envisaged type of work. The Classification reviews such operating conditions only that are not dependent on the crane type and the ways ways of its control. Further International Standards Standards will establish the portions of the classification line that will be applicable to various crane types (i.e., overhead travelling, self-propelled, tower, etc.). This International Standard establishes crane classification and forms a part of ISO 4301 International Standard. A complete list of ISO 4301 parts is as follows: Part 1. General Provisions. Part 2. Self-Propelled Boom Cranes. Part 3. Tower Cranes. Part 4. Portal and Pedestal Cranes. Part 5. Overhead Travelling and Gantry Cranes. 1. Purpose and Scope of Application This International Standard establishes crane classification on the basis of operating cycles performed during an expected period of the crane service, and th e load distribution factor, which represents rated loading conditions. This Standard does not assume that the same method of load modelling or testing method will be applicable to all types of devices included into ISO/TK 96 assortment.
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2. Application of the Classification In practice, the Classification may have two ways of application that may be considered separately. 2.1.
General Classification of a Lifting Unit The first application of the Classification will allow the crane Purchaser and Producer to achieve an agreement about operating conditions of that particular crane. Hence, it is a contractual and and technical reference matter, and and is used for designing. The classification method method is represented represented in Section 3. 3.
2.2.
Classification for Designing Purposes The second application of the Classification will allow the Designer to analyse the project on its basis, and prove that the crane under his design is able to operate during a certain service period in certain operating conditions established for that particular type t ype of application. The Designer will receive the data of load distribution submitted by the Customer or provided by the Producer (in case of serial equipment designing), include them into initial data, on which his analysis will be based, and considers the factors that govern sizes of the crane parts. The form of load distribution requisition, on the basis of which the required data may be identified, is to t o be developed in one of future International Standards. 3. Crane Classification Groups in General
To identify a group the crane refers to, it is required to consider the class of application and loading conditions. 3.1.
Application Class. The Customer expects that during the service period the t he crane will perform a certain number of operating cycles, which is one of the main parameters for classification. In specific types of work (e.g., (e.g., in bulk unloading by way of a gripping device), the number of cycles may be obtained if the summarised number of operating hours and the number of operating cycles per hour are known. In other cases, cases, e.g., when self-propelled cranes cranes are considered, considered, the total number of operating cycles is more difficult to obtain, as such cranes are used in various conditions; in this case appropriate values shall be obtained by experiment. The total number of operating cycles cycles is a sum of all operating cycles per a certain period of the crane service. Economic and engineering factors, influence of the environment and obsolescence obsolescence shall be taken into account when identifying a crane service life.
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The total number of operating cycles c ycles depends on the frequency of the crane usage. For the sake of classification, classification, the whole range of potential operating operating cycle numbers has has been divided into ten application application classes (Table 1). 1). The operating cycle commences, commences, when a load l oad is ready for lifting, and completes, when the crane is ready to lift the next load. Table 1. Class of Crane Application Application Class U0 U1 U2 U3 U4 U5 U6 U7 U8 U9 3.2
Maximum Number of Operating Cycles 1.6x10 4 3.2x10 4 6.3x10 5 1.25x10 5 2.5x10 5 5x10 6 1x10 6 2x10 6 4x10 6 above 4x10
Notes Irregular usage
Regular usage in easy conditions Regular usage with intervals Regular intensive usage Intensive usage
Loading Conditions. Another basic parameter parameter of classification is that of loading conditions. conditions. Loading conditions are related to the number of load lifts, while the load is of a particular weight expressed in parts parts of the crane load lifting capacity. Table 2 shows the rated values of load distribution factors for a crane (K p), and each of them characterises a corresponding loading condition. Table 2 Nominal Factors of Load Distribution for Cranes
Loading Condition Q1 – Q1 – easy easy
Rated Factor of Load Distribution 0.125
Q2 – Q2 – moderate moderate
0.25
Q3 – Q3 – heavy heavy
0.50
Q4 – Q4 – rather rather heavy
1.00
Notes Cranes that systematically lift light loads, and rarely nominal loads. Cranes that systematically lift average loads, and rather often nominal loads. Cranes that systematically lift heavy loads, and often nominal loads. Cranes that systematically lift loads close to nominal.
If numbers and weights of loads that are lifted during the crane service life are not available, selection of the appropriate loading class shall be agreed between the Producer and Customer.
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If exact information about the numbers and weights of loads that are lifted during the crane service life is known, the ratio of load distribution for the crane may be modelled in the following way: The load distribution factor for the K p crane shall be obtained utilising the following equation:
where Ci is the average number of operating cycles, with particular levels of the load weight, = C1, C2, C3, …, Cn; CT, is the total number of operating cycles with all the l oads: = CT, = C1, + C2, + C3, + …, + Cn; Pi are values of separate load weights (load levels) for a typical t ypical application of the particular crane: Pi = P1, P2, P3, …, Pn; Pmax is the weight of the largest load (nominal, rated load) that is acceptable for the crane to lift; m=3 Detailed, equation (1) shall look as follows:
The rated value of the load distribution factor for a crane shall be established on the basis of Table 2 (the closest larger value shall be assumed). 3.3
Identification of the Crane Classification Group in General After identification of the application class in accordance with Table 1 and the loading conditions on the basis of Table 2, the Classification Group of the t he particular crane may be established utilising Table 3. Table 3 Crane Classification Groups in General
Loading Conditions Q1 – Q1 – easy easy Q2 – Q2 – moderate moderate
Load Distribution Factor 0.125 0.25
Application Class and Maximum Number of Operating Cycles for the Particular Unit U0 U1 U2 U3 U4 U5 U6 U7 U8 U9 A1 A2 A3 A4 A5 A6 A7 A8 A1 A2 A3 A4 A5 A6 A7 A8
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Q3 – Q3 – heavy heavy Q4 – Q4 – rather rather heavy
0.5 1
A1 A2
A2 A3
A3 A4
A4 A5
A5 A6
A6 A7
A7 A8
A8
Application of classification groups to model separate types of cranes will be developed in future International Standards. 4. Gear Classification Groups in General 4.1.
Class of Gear Application A class of gear application is characterised by envisaged total duration of their operation in hours, and rated classes shown in Table 4. Table 4 Class of Gear Application
Application Class T0 T1 T2 T3 T4 T5 T6 T7 T8 T9
Total Duration of Testing, hrs 200 400 800 1600 3200 6300 12500 25000 50000 100000
Notes Irregular usage
Regular usage in easy conditions Regular usage with intervals Regular intensive usage Intensive usage
The maximum total duration of operation may be obtained on the basis of envisaged daily time of application in hours, the number of working days per year, and the expected service life in years. In this Classification, it was assumed that the time of gear operation is understood as the time, during which the t he gear is moving. The values of total duration of application shall be only viewed as theoretical, conventionally assumed, assumed, and serving as initial data to design gear parts, for which application time is the criteria for selection (e.g., ball bearings, toothed gear wheels, and shafts). shafts). They cannot cannot be considered as guaranteed guaranteed values. 4.2.
Loading Conditions Loading conditions determine relative duration, with which gear will be exposed to maximum or lowered loads. Table 5 gives rated loading conditions. Table 5
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Nominal Factors of Load Distribution for Gear (K m) Loading Condition L1 – L1 – easy easy
Rated Factor of Load Distribution 0.125
L2 – L2 – moderate moderate
0.25
L3 – L3 – heavy heavy
0.50
L4 – L4 – rather rather heavy
1.00
Notes Gear that is systematically exposed to light loads, and rarely to the highest loads. Gear that is systematically exposed to moderate loads, and rather often to the highest loads. Gear that is systematically exposed to heavy loads, and often to the highest loads. Gear that is systematically exposed to the highest loads.
The load distribution factor for Km gear shall be calculated on the basis of the following equation:
where ti is the average duration of the gear application, with particular levels of the load, = t 1, t2, t3, …, tn; tT is the total duration with all the particular levels of the load: = tT, = t1, + t2, + t3, + …, + t n; Pi are values of separate loads (load levels) typical t ypical for that particular gear application: Pi = P1, P2, P3, …, Pn; Pmax is the largest load that may be applied to the gear; m=3 Detailed, equation (3) shall look as follows:
Rated values of the load factor for gear shall be established on the basis of Table 5 (the closest larger value shall be assumed). 4.3.
Identification of the Gear Classification Group in General
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The Classification Group of the particular gear shall be established on the basis of Table 6 after identification of the application class and the loading conditions. Table 3 Gear Classification Groups in General Loading Conditions L1 – L1 – easy easy L2 – L2 – moderate moderate L3 – L3 – heavy heavy L4 – L4 – rather rather heavy
Rated Load Distribution Factor, m 0.125 0.25 0.5 1
T0
M1 M2
T1
T2
Gear Application Class T3 T4 T5 T6
M1 M2 M3
M1 M2 M3 M4
M2 M3 M4 M5
M3 M4 M5 M6
M4 M5 M6 M7
M5 M6 M7 M8
T7
T8
T9
M6 M7 M8
M7 M8
M8
Application of classification groups to model separate types of gear will be developed in future International Standards.
INTERNATIONAL INTERNATIONAL STANDARD ISO 4301/2 (LIFTING UNITS. CLASSIFICATION. CLASSIFICATION. PART 2. SELF-PROPELLED BOOM CRANES). Introduction This International Standard establishes crane classification and forms a part of ISO 4301 International Standard. A complete list of ISO 4301 parts is as follows: Part 1. General Provisions. Note: Part 1 is to be developed on the basis of current ISO 4301. Part 2. Self-Propelled Boom Cranes. Part 3. Tower Cranes. Part 4. Portal and Pedestal Cranes. Part 5. Overhead Travelling and Gantry Cranes. 1. Purpose and Scope of Application This International Standard establishes classification of self-propelled boom cranes and appropriate crane gear on the basis of the number of operating cycles performed during an expected period of a self-propelled boom crane or gear service, and the load l oad distribution factor, which characterises characterises rated loading conditions. The Standard shall be applicable to the basic types of self-propelled boom cranes and gear in accordance with ISO 4306/2. 2. References ISO 4301. Lifting Units. Classification
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ISO 4306/2. Lifting Units. Glossary. Part 2. 2. Self-Propelled Boom Cranes. ISO 4308. Cranes. Wire Cable Selection. 3. Classification. Classification of self-propelled boom cranes and their gear into groups on the basis of operation conditions is represented in Table 1. Table 1 Classification of Self-Propelled Boom Cranes into int o Groups* Crane Operating Conditions Groups Cranes for general load-lifting operations, with a hook, not A1 applied for continuous operation. Cranes equipped with a clamshell, grapple or magnet. A3 Heavy conditions, e.g., container loading/unloading loading/unloading and A4 general operations in docks. * Corresponding lines of Q factors (loading conditions) and U (application class) are given in ISO 4301. 4. Classification of Gear into Groups Classification of self-propelled boom crane gear into groups is represented in Table 2. Table 2 Classification of Gear into Groups (Refer to the Note) Gear Purpose
Crane Operating Conditions A1 A3 A4 M3 M4 M6 M2 M3 M4 M2 M3 M3 M1 M2 M1*
Load lifting Crane rotation Boom lifting and lowering Telescoping Crane locomotion (within the site only): wheel-mounted crane M1 M1 caterpillar crane M1 M2 * The function of telescoping is not performed with suspended loads.
M1 M2
Notes. 1. Refer to Table 6, ISO 4301 2. Appropriate lines of L factors (loading conditions) and T (application class) stated in Table 6, ISO 4301 are applicable for M1, M2, M3, M4, and M5. 3. The above Classification shall not refer to values of Z p for cables and values of h for the ratio of drum and block diameters (see ISO 4308).
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INTERNATIONAL STANDARD ISO 4308/1 (CRANES AND LIFTING UNITS. WIRE CABLE SELECTION. PART 1. GENERAL PROVISIONS). Introduction This International Standard is a part of ISO 4308 International Standard related to the issue of steel wire cable selection for cranes and lifting equipment. A complete list of ISO 4308 parts is as follows: Part 1. General Provisions. Part 2. Self-Propelled Boom Cranes. Part 3. Tower Cranes. Part 4. Portal and Pedestal Cranes. Part 5. Overhead Travelling and Gantry Cranes. 1. Purpose and Scope of Application This International Standard establishes two methods of wire cable selection for hoisting units, types of which are set forth in ISO 4306/1 and listed in Appendix A. This Standard establishes minimum requirements for wire ropes that shall have an acceptable margin of stress and operational features accounting for their design, application and maintenance. The Standard gives the potential to select a wire cable utilising one of the two methods; one of them is based on accounting for the value of the cable selection factor (C), and the other accounts for the value of the utilisation factor (Z p). Table 1 shows the values of the above factors.
2
Table 1
Values of ZP and C Factors (for R 0=1570 N/mm , and K’=0.2948) Gear Classification Group M1 M2 M3 M4 M5 M6 M7 M8
Zp 3.15 3.35 3.35 4.0 4.5 5.6 7.1 9.0
C, mm/N 0.085 0.087 0.090 0.095 0.100 0.112 0.125 0.140
Note: Equation (1) gives exact ratio between the C and Z p factors. The values of C and and Zp are adjusted and correspond to numbers of the Renard’s series.
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For a particular crane type t ype (self-propelled boom, overhead travelling, gantry, etc.), classification groups groups shall be selected in accordance accordance with ISO 4301/1. Cable selection shall account for values of C and Z p factor s (or their design equivalents) only. 2. References ISO 2408. 2408. Steel Wire Cables of General Purpose. Purpose. Specifications. ISO 4301/1. Cranes and Lifting Units. Units. Classification. Part 1. General Provisions. ISO 4306/1. Lifting Units. Glossary. Part 1. General Terminology. ISO 4309. Wire Cables for Lifting Units. Methods of Inspection Inspection and and Discarding. Discarding. 3. Cable Type A wire cable to be used shall comply with the requirements of ISO 2408. A steel cable that is i s not specified in ISO 2408 may be applied; in such cases the Vendor shall confirm to the Customer that the cable complies with the minimum requirements provided by the appropriate section of ISO 4308 Standard. 4. Operating Conditions Classification of lifting unit gear shall be made accounting for operating conditions specified in ISO 4301/1. 5. Cable Selection Procedure 5.1.
Calculation of the cable selection factor (C). The value of C is a function of Z p, and shall be calculated I accordance with the following equation:
where C is the cable selection factor (minimum); K’ is an empirically determined factor of the minimum breaking load of a particular design cable (see Table 2 of ISO 2408); 2 R0 is the minimum ultimate tensile strength limit of the cable wires, N/mm ; Zp is the minimum actual utilisation factor. 5.2.
Values of the utilisation factor (Zp). Table 1 shows shows values of the Zp factor that shall be applied for each gear classification group to comply with the minimum requirements of the appropriate ISO 4308 Section, and design values of the C
2
6
2
1 N/mm = 10 N/m = 1 MPa.
148
factor, which correspond to, e.g., a cable with a particular tensile strength (R 0 = 157o N/mm), and empirical factor (K’ = 0.2948). For cables with other than stated above ultimate tensile strength limit (R 0) and empirical factor (K’), values of the C factor may be calculated utilising utilising equations (1) and (2). 5.3.
Calculations of the minimum cable diameter. The minimum cable diameter (d) in millimetres shall be identified in accordance with the following equation:
where C is the cable selection factor, and S is the maximum cable tension in Newtons, accounting for the following: a) b) c) d) e)
5.4.
the rated operating load of the unit; the weight of the tacking and/or other lifting device; multiplicity of reeving (the polyspast transmission ratio); the polyspast efficiency; the weight of the hanging portion of the load rope (if the lifted load is more than 5 metres below the turning gear of the lifting device).
Estimation of the minimum breaking tension. The minimum breaking tension shall be identified in accordance with the following equation: F0 = S x Zp
(3)
Examples of a cable selection are given in Appendix B 6. Drum and Block Diameters The minimum diameter of drums, blocks, and equalising blocks measured along the centreline of a wound cable shall be calculated on the basis of the cable minimum diameter, which is provided by Section 5.3, utilising utili sing appropriate values of h 1, h2, and h3 factors that depend on the gear classification group (Table 2): D1 h1d
(4),
or D2 h2d
(5),
or D3 h3d
(6)
where D1 is the diameter of the drum on the centre line of the wound cable; D2 is the diameter of the block on the centre line of the wound cable; D3 is the diameter of the equalising block on the centre line of the wound cable; D is the minimum diameter of the cable (Section 5.3);
149
h1 is the drum diameter selection factor (the ratio of the drum diameter along the centre line of the wound cable to the design cable diameter); h2 is the block diameter selection factor (the ratio of the block diameter along the centre line of the wound cable to the design cable diameter); h3 is the equalising block diameter selection factor (the ratio of the equalising block diameter along the centre line of the wound cable to the design cable diameter). Table 2 Factors of h1, h2, and h3 Selection Gear Classification Group M1 M2 M3 M4 M5 M6 M7 M8
Drum (h1) 11.2 12.5 14.0 16.0 18.0 20.0 22.4 25.0
Diameter Selection Factors Block (h2) Equalising Block (h3) 12.5 11.2 14.0 12.5 16.0 12.5 18.0 14.0 20.0 14.0 22.4 16.0 25.0 16.0 28.0 18.0
For particular cases of hoisting equipment applications, e.g., self-propelled boom cranes, it is recommended that a single line of h factor values should be selected irrespective of the gear classification group. 7. Stationary Cables Stationary cables are fastened at both ends, and are not used for winding on drums. Such cables are selected in accordance with the requirements of Section 5.4, utilising adjusted values of Z p factor specified in Table 3. The maximum tension tension of the cable cable (S) shall be specified by the gear producer, and it shall account for both static forces, and wind and dynamic loads. Table 3 Zp Factor Value for Stationary Cables Gear Classification Group
M1 M2 M3 M4 M5 M6 M7 M8
Zp Factor Value 2.5 2.5 3.0 3.5 4.0 4.5 5.0 5.0
8. Hazardous Conditions In case of operation in hazardous conditions (operations with liquid metal):
150
a) b)
No classification group below M5 shall be applied; When the cable is selected, the value for 25% Z p shall be considered up to the maximum 9.0, or the value of C shall be taken for a higher classification group.
9. Steel Wire Cable Inspection, Maintenance and Rejection Wire cable inspection, maintenance and rejection standards in accordance with ISO 4309 are recommended for application.
INTERNATIONAL STANDARD ISO 4308/2 (CRANES AND LIFTING UNITS. WIRE CABLE SELECTION. PART 2. SELF-PROPELLED BOOM CRANES. UTILISATION FACTOR). Introduction This International Standard is a part of ISO 4308 International Standard related to the issue of steel wire cable selection for cranes and lifting equipment. A complete list of ISO 4308 parts is as follows: Part 1. General Provisions. Part 2. Self-Propelled Boom Cranes. Utilisation Factor. Part 3. Tower Cranes. Part 4. Portal and Pedestal Cranes. Part 5. Overhead Travelling and Gantry Cranes. 1. Purpose and Scope of Application This International Standard establishes minimum values of taken from practice utilisation factor (Zp), which is specified in ISO 4308/1 for usual and non-spinning cables applied at self-propelled boom cranes. This Standard shall be applicable for all self-propelled cranes (see ISO 4306/2). 2. References ISO 4301/1. Cranes and Lifting Units. Units. Classification. Part 2. Self-Propelled Boom Cranes.
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ISO 4308/1. Cranes and Lifting Units. Wire Wi re Cable Selection. Part 1. General Provisions. ISO 4306/2. Lifting Units. Glossary. Part 2. Self-Propelled Boom Cranes. 3. Utilisation Factor 3.1.
General-purpose cables. Minimum values of the utilisation factor (Zp) for general-purpose cables are shown in Table 1 in accordance with the classification of cranes and lifting gear specified in ISO 4301/2.
Table 1 General-Purpose General-Purpose Cables Moving Cables Crane Operating Conditions
General Continuous Continu ous Heavy
Crane Classification
A1 A3 A4
Load Lifting Gear Clas sifica tion M3 M4 M5
Zp
3.55 4 4.5
Boom Lifting/Lowering, Telescoping Gear Zp in Zp Clas Ope during sifica ration Insta tion llation M2 3.55 3.05 M3 3.55 3.05 M3 3.55 3.05
Stationary Cables In Ope During ration Insta llation
3 3 3
2.73 2.73 2.73
Note. It is assumed that cable safety during operation is based on selection of cable inspection and rejection criteria. 3.2.
A non-spinning non-spinning cable is a cable that has eight or more more strands in the external layer laid along a spiral in the direction opposite to the direction of the underlying layer. Minimum values of the utilisation factor (Zp) for non-spinning cables are shown in Table 2 in i n accordance with the classification specified in ISO 4301/2. Table 1 General-Purpose General-Purpose Cables
Crane Operating Conditions General
Crane Classification A1
Moving Cables for Load Lifting, Zp 4.5
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Continuous Heavy
A3 A4
5.6 5.6
Note. The Table shows ―conventional‖ types of non-spinning non -spinning cables. cables. As new types types of non-spinning cables appear appear resulting from future researches, researches, other values of utilisation factors will be obtained.
INTERNATIONAL STANDARD STANDARD ISO 4310 (CRANES, REGULATIONS AND METHODS OF TESTING) 1. Purpose and Scope of Application This International Standard establishes contents and methods of testing that are required to check whether cranes comply with their specified characteristics, as well as to check their capacity to lift rated loads. If stability determines the value of a rated load, load, then a testing method and a testing load shall be established, which will allow the stability margin to be easily tested. This Standard shall be applicable for the following types of cranes: a) b) c) d) e) f) g) h)
overhead travelling; gantry; portal; self-propelled boom and excavator cranes; tower; railway; cable cranes; other types of cranes that may m ay be included into the list additionally.
2. Methods and Scope of Testing 2.1.
a) b) c)
2.2.
Three types of testing shall be applied to achieve objectives specified in this International Standard: Testing for a crane compliance with the data specified in its certificate (Section 3.1); External inspection of the crane (Section 3.2); and Testing to check if the crane is adequate for operations (Sections 3.4, 3.5, and 3.6); Each crane shall pass the tests, methods of which are stated above. In case of large-scale production, the number of cranes to be tested (Section 2.1) shall be established on a mutual agreement between the Seller and the Buyer
Legal Parties that have executed a contract: the Seller is the Party to supply the crane, and the Buyer is the Party receiving the crane.
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2.3
Cranes supplied from producing plants ready for operation shall have been tested at the plant prior to their their shipment. Cranes that are are installed or finally assembled assembled at their operation locations shall be tested at such locations unless otherwise has been provided by agreements between the Seller and the Buyer. 3. Content and Methods of Testing
3.1.
Testing for a crane compliance with the data specified in its certificate. Testing for a crane compliance with the certificate data shall be carried out in accordance with their load characteristics to check the following parameters: -
3.2.
Weight of the crane (if practical); Distance from the rotation axis to the stability edge; Height of the load lifting; Speed of the load lifting; Speed of landing; Speed of the crane locomotion; Speed of the trolley travelling; Rotation speed; Time for radius modification; Time for telescoping; Time for one cycle (if required); Operation of limiting devices; Operating characteristics of the power drive parameters, e.g., current intensity in electric engines under conditions of testing l oads application.
Visual inspection. A visual inspection shall include a check for the crane compliance with the certificate data and/or a check for conditions of all the critical elements, such as: -
gear, electric equipment, safety devices, brakes, control devices, lighting and signalling systems;
-
steel structures and their joints, ladders passage ways, cabins and platforms;
-
railing;
-
the hook or other load gripping device and their suspension parts;
-
cables and their fastening locations;
-
blocks, axels and details of their fastening, as well as components of the boom suspension system.
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No disassembling of any assembled parts shall be included into the visual inspection. Visual inspection includes includes a check of leads for for their normal opening in the course of standard operation, e.g., lids of limit switches. The objective of the visual inspection i nspection is to examine and check compliance with all the specified requirements for cranes. 3.3.
Testing during operations with loads. Tests for the crane adequacy for operation include i nclude the following: -
3.3.1
Static testing; Dynamic testing; Testing for stability (if required).
Static testing.
3.3.1.1.
Static tests shall be carried out with the purpose to check the design adequacy of the crane and its assembly units. Tests shall be considered successful if during their performance no cracks, residual deformation, paint peeling or damage that may influence the crane operability and safety are identified, and no joint retention loss or damage occurs.
3.3.1.2.
Static tests shall be also carried out for each load-lifting unit, if it is provided by the crane certificate, at simultaneous operation of load lifting units in positions and design options that shall be selected so that tensions in cables, as well as mending momentums and/or axial forces in the basic crane components components were the highest. highest. A testing load shall be gradually increased, increased, lifted to the height of 100-200 mm from the ground surface and held in that position during the time, which is required to carry out the test, but at least 10 minutes.
3.3.1.3.
The testing load (P) for all cranes shall be at least 1.25, unless a higher value is required in accordance with National Standards or cable positions. Components of the P value are as follows: a)
b)
Load on the lifting gear, including the weight of the effective load, as well as the weight of the hook unit and rigging devices (for self-propelled cranes); The rated load-lifting capacity for the equipment established by the producer. The rated load-lifting capacity capacity shall not include include any lifting devices being a permanent part of the crane in operating position (for other cranes).
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3.3.2. Dynamic testing. 3.3.2.1.
Dynamic tests shall be carried out with the purpose to inspect operation of the crane gear and brakes. The crane shall be considered as having successfully passed the test if it is established that the above mentioned components perform their functions, and if further visual inspection reveals no damage to the gear or structural elements, and no joint retention loss occurs. The crane shall be controlled during the tests in accordance with requirements specified specified in the crane documentation. documentation. Attention shall be paid in the course of the described tests to prevent accelerations and speeds from exceeding the values specified for the crane operation.
3.3.2.2.
Dynamic tests shall be carried out for each gear or, if it is provided by the crane certificate, at simultaneous operation of the gear in positions and design options that correspond to the maximum loading l oading of the gear. Testing shall include a re-start and a stop at each movement within the whole range of such movement, and shall continue for at least 1 hour, while complying with that particular operation cycle. Testing shall include gear start-up from the intermediate position, with suspended test test load. In such case no no reverse movement with the test load shall occur.
3.3.2.3.
The testing load (P) shall be at least 1.1.
3.3.3. Testing for stability. 3.3.3.1.
Tests for stability under load shall be carried out with the purpose to check the crane stability. stability. The crane shall be considered considered as having successfully successfully passed the test if no tilt til t of the crane occurs, when a static load is applied to the hook.
3.3.3.2.
In case of self-propelled boom cranes, the testing load for stability tests shall be established utilising the following equation: 1.25P +0.1Fi
(1)
where Fi (F1 or F2) is the weight of the crane boom (G), or the weight of the gooseneck (g) adjusted to the head of the boom or gooseneck. If the weight of the boom (G) is small, and the gooseneck gooseneck is designed for relatively small loads, testing for stability shall not be carried out in accordance with equation (1), with the test load lifted on the gooseneck gooseneck head.
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In such case requirements to stability shall be checked by way of calculations. Note: The value of 1.25P may vary in cases, when higher values are required. A drawing below shows a side view of a typical t ypical crane, with the described parameters identified: L and l are lengths of the boom and gooseneck (for telescopic booms it is the length of the boom under discussion); X, Y and x, y are coordinates of the boom and gooseneck gravity centres; centres; j and k are radii of the boom and gooseneck; m and n are gravity centre radii for the boom and gooseneck; Fi shall be calculated in accordance with the following equation:
Designation of Parameters to Estimate Loads for Stability Testing
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For cranes equipped with a boom only, k=n=g=0, and
For cranes equipped with both a boom and a gooseneck, if the load is lifted on the boom head, k=0, and
if the load is lifted on the gooseneck head,
Note: Values of P, G, g and the centre of gravity coordinates X, Y and x, y shall be established in the crane documents for each value of L and l. 3.3.3.3.
No special tests for stability shall be carried out for all cranes, with the exception of self-propelled ones.
3.3.3.4.
Tests shall be carried out at such positions and design options within a specified operating area, area, at which the crane stability is minimum. If different loads are established for different positions or operating areas, stability testing shall be carried out to select such conditions.
3.4.
A Testing Statement. On completion of testing in accordance accordance with Section 2.1, a Statement shall be drawn out, which shall shall include conclusions and and testing results. The Statement shall state the serial No. of the tested crane, the date and testing location, and the name of Testing Supervisor. Supervisor. Exact loads, positions, positions, design options, methods methods and testing results shall be also specified for each separate case. With reference to cranes that comply with the requirements of Clause 2.1 b only, the Statement may be drawn in a shortened shortened form. Such Statement shall shall contain the crane No., the date and location locat ion of testing, the Supervisor’s name and testing results for each parameter.
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4. Testing Conditions 4.1.
To carry out testing, the crane shall be equipped with operating equipment for the rated load in accordance with the crane documentation.
4.2.
Cranes travelling along a rail rail track track shall be tested on the track, which shall be constructed and laid in accordance with specifications stated in the crane certificate.
4.3.
Air-tyred or caterpillar cranes shall be tested on a horizontal site with hard cover, which will have a deviation from the horizontal line of 0.5%.
4.4.
Wind speed during the testing period shall not exceed 8.3 m/sec (30 km/hr). The crane position shall correspond to the mostly favourable conditions (wind speed) unless it is provided by the Contract.
4.5.
When air-tyred cranes are tested without outrigger application, pressure in the tyres shall not differ from the pressure set by the producer for more than 3%, and all the wheels shall be oriented along the crane centre line. Note: Conditions of the overhead travelling crane bridge support shall be agreed with the requirements of the t he producer.
4.6.
If a crane is tested with outriggers, outriggers, it shall shall be be located with the deviation from the horizontal line not exceeding 0.5%.
4.6.1. If an air-tyred crane is tested with outriggers, outriggers, it shall be located so that its wheels are not in contact with the ground, and are relieved from the crane weight, unless there are other instructions of the Seller. 4.6.2. If a caterpillar caterpillar crane is tested with outriggers, outriggers, it shall be located so that reliable support of outriggers on the bearing surface is ensured. 4.6.3. Cranes of other types shall be located located as specified in National Regulations Regulations or contracts. 4.7.
The fuel tank shall be filled for one or two thirds of its capacity. Cooling liquid, oil and hydraulic mixtures shall be filled up to the level specified by the Seller.
INTERNATIONAL INTERNATIONAL STANDARD ISO 88087 (SELF-PROPELLED CRANES. SIZES OF DRUMS AND BLOCKS 1. Purpose and Scope of Application This International Standard establishes the minimum ratio of the drum and block diameter to the rated diameter of the cable used for lifting and lowering.
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The rated diameter of a cable is an initial value, which utilisation provides for universality of application, as it is not limited by the crane gear, while self- propelled cranes are designed for various purposes, such as load lifting with a hook, clamshell or electric magnet. This International Standard shall be applicable to the main types of self-propelled cranes in accordance with ISO 4306/2. 2. References ISO 4301/1. Cranes and Lifting Units. Classification. ISO 4306/2. Lifting Units. Glossary. Part 2. Self-Propelled Boom Cranes. ISO 4308. Cranes and Lifting Lifting Units. Wire Cable Selection. Selection. ISO 4309. Wire Cables for Lifting Units. Standards and and Regulations for Inspection and Rejection. 3. Sizes of Drums and Blocks The minimum ratio of the drum and block diameter to the rated diameter of a cable is shown in the table below. Taking into account that self-propelled cranes are often designed for versatile application, only one group of ratios is given. Thus, the values represented have no dependence on the classification of crane gear. The Minimum Ratio of the Diameter* to the Rated Diameter of a Cable Component The Drum of a Load-Lifting Winch A Load Block (in Movable Tacking) An Equalising Block: Lifting Lowering A Boom-Lifting Drum A Boom Lifting Block
Minimum Ratio 16.0:1 18.0:1 14.0:1 12.5:1 14.0:1 16.0:1
* The diameter shall be measured on the centre line of the wound cable.
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APPENDIX 12 (to Section 7.3.9) THRESHOLD STANDARDS OF LOAD-LIFTING EQUIPMENT COMPONENT REJECTION Component Description Running Wheels of Cranes and Trolleys
Defects that Serve as Criteria for the Component Rejection 1. Cracks of any sizes. 2. Wear-out of the flange surface for up to 50% of the original thickness. 3. Wear-out of the roll surface that reduces the original wheel diameter by 2%. 4. A difference in the diameters of wheels that are related cinematically, by above 0.5%.
Blocks
1. Wear-out of the block groove for above 40% of the original groove radius.
Drums
1. Cracks of any sizes. 2. Wear-out of the drum groove along the cross section for above 2 mm.
Hooks
1. Cracks and tears on the surface. 2. Wear-out of the hook opening for above 10% of the original height of the hook vertical cross section.
Brake Sheaves
1. Cracks and breaks that penetrate operating and mounting surfaces. 2. Wear-out of the rim working surface for above 25% of the original thickness.
Brake Lining
1. Cracks and breaks that penetrate to openings under rivets. 2. Wear-out of the brake lining along its thickness up to appearance of rivet heads, or for above 50% of the original thickness.
* For gear with the central drive.
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APPENDIX 13 (to Section 7.3.28) STANDARDS FOR REJECTION OF DETACHABLE LOAD-GRIPPING DEVICES Rejection of operating removable load-gripping devices shall be carried out in accordance with regulatory documentation, which identifies the rejection procedure, methods and rejection criteria. If the owner has no regulatory documents available, rope or chain slings shall be rejected in accordance with recommendations recommendations specified in this Appendix. A rope sling is liable for rejection if the number of visible breaks in the rope outer wires exceeds the values shown in the Table below. Double Lay Rope Slings
Number of Visible Wire Breaks within A Section of a Rope Sling, with the Length of: 3d 6d 30d 4 6 16
Note: d is the rope diameter in millimetres. mil limetres.
A chain sling is liable for rejection if a chain link is extended for above 3% of its original size (Figure 1), and if the chain link cross section diameter is reduced by above 10% due to its wear out (Figure 2).
Figure 1. Elongation of the Chain Link: L0 is the original length of the link, in mm.; L1 is the increased length of the link, in mm.
Figure 2. Reduction of the Chain Link Cross Section Diameter: d0 is the original diameter, mm; d1, d2 are actual link cross section diameters measured in mutually perpendicular orientations, mm.
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APPENDIX 14 (to Section 7.4.2) Knowledge Assessment Assessment Certificate Form for engineering and technical personnel responsible for supervision of load-lifting equipment safe operation, engineering and technical personnel responsible for load-lifting equipment maintenance in good serviceable conditions, and persons responsible for safe performance of work by cranes. ______________________________________________________________________ (Description of the Company, Organisation, Facility)
Issued to: ______________________________________________________________ (Full Name)
Position: _______________________________________________________________ Place of Work: __________________________________________________________ To certify that he/she has passes Knowledge of ______________________ ________________________________ __________ ______________________________________________________________________ ____________________________________________________________ Assessment. (State the Safety Regulations)
Basis: Minutes No. ____________ of __________________________________ (Date) Chairman of the Examination Board ____________________________ ______________________________________ ____________ __ Board Members ____________________________ ______________ ____________________________ ________________________ __________ ____________________________________________________ ____________________________________________________ ____________________________________________________ Stamp Information about Recurrent Examinations Position: _______________________________________________________________ Place of Work: __________________________________________________________ To certify that he/she has passes Knowledge of ______________________ ________________________________ __________ ______________________________________________________________________ ____________________________________________________________ Assessment. (State the Safety Regulations)
Basis: Minutes No. ____________ of __________________________________ (Date) Chairman of the Examination Board ____________________________ ______________________________________ ____________ __ Board Members ____________________________ ______________ ____________________________ ________________________ __________ ____________________________________________________ ____________________________________________________ ____________________________________________________ Stamp Position: _______________________________________________________________ Place of Work: __________________________________________________________
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To certify that he/she has passes Knowledge of ______________________ ________________________________ __________ ______________________________________________________________________ ____________________________________________________________ Assessment. (State the Safety Regulations)
Basis: Minutes No. ____________ of __________________________________ (Date) Chairman of the Examination Board ____________________________ ______________________________________ ____________ __ Board Members ____________________________ ______________ ____________________________ ________________________ __________ ____________________________________________________ ____________________________________________________ ____________________________________________________ Stamp Position: _______________________________________________________________ Place of Work: __________________________________________________________ To certify that he/she has passes Knowledge of ______________________ ________________________________ __________ ______________________________________________________________________ ____________________________________________________________ Assessment. (State the Safety Regulations)
Basis: Minutes No. ____________ of __________________________________ (Date) Chairman of the Examination Board ______________________________ ________________________________________ __________ Board Members ____________________________ ______________ ____________________________ ________________________ __________ ____________________________________________________ ____________________________________________________ ____________________________________________________ Stamp Position: _______________________________________________________________ Place of Work: __________________________________________________________ To certify that he/she has passes Knowledge of ______________________ ________________________________ __________ ______________________________________________________________________ ____________________________________________________________ Assessment. (State the Safety Regulations)
Basis: Minutes No. ____________ of __________________________________ (Date) Chairman of the Examination Board _____________________________ _______________________________________ ___________ _ Board Members ____________________________ ______________ ____________________________ ________________________ __________ ____________________________________________________ ____________________________________________________ ____________________________________________________ Stamp Note: The Certificate shall be issued with a hard cover on sheets of the 110x80 mm format.
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APPENDIX 15 (to Section 7.4.4) THRESHOLD STANDARDS TO REJECT BASIC COMPONENTS OF RAIL TRACKS Track Description A rail track of seating load-lifting equipment
Rail Defects 1. Cracks of any sizes. 2. Indents in a railhead or rail base. 3. Vertical, horizontal or adjusted (vertical plus half of horizontal) wear out of the railhead for above 15% of the value of the appropriate non-worn out profile size. 4. Rail track deviations horizontally and vertically above the values specified in Appendix 7.
A rail track of suspended load-lifting equipment
1. Cracks and dents of any sizes. 2. Reduction of the rail belt width due to wear out: B 0.05B 3. Reduction of the rail seat thickness due to wear out: 0.2, with a simultaneous seat bend: f 1 0.15 4. A bend of the rail seat (f 1 > 0.25), with its simultaneous wear out: 0.1 (ref. to the Drawing)
Locations of the rail track profile basic defects in case of suspended load-lifting equipment: B is the initial belt width; t is the wall thickness;
f 1 is the seat bend; is the original thickness of the seat at the distance of (B-t)/4 from the edge; is the reduction of the seat thickness due to wear out.
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APPENDIX 16 (to Section 7.4.25) Knowledge Assessment Assessment Certificate Form for operating personnel (crane operators, their assistants, mechanics, electricians, safety device adjusters, and slingers) __________________________________ (Personal Signature)
Photograph
Issued on _____________________ _____________________ (Date) Stamp of the Training Institution
CERTIFICATE No. ____________ Page 2 Issued to: ______________________________________________________________ (Full Name)
to certify that he/she completed __________________________ _____________________________________ ___________________ ________ (Description, No. and location of the
______________________________________________________________________ (Training Institution)
______________________________________________________________________ on __________________________ (Date) specialising in __________________________________________________________ ______________________________________________________________________ Page 3 By the Examination Board Resolution ______________________________________________________________________ (Full Name)
is qualified as __________________________________________________________ ______________________________________________________________________ and is permitted to operate _________________________________________________ ______________________________________________________________________ (the Crane Type)
Page 4 The basis - the Examination Board Minutes No. ___________________ of _________________________________ (Date) Gosgortechnadzor Inspector ______________________________________________ (Inspector’s stamp and signature)
Director of the Training Institution __________________ _____________________________ _____________________ ____________ __ (Signature)
Note: The Certificate shall be issued with a hard cover on sheets of the 110x80 mm format.
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Page 5 (Insert) TO CERTIFICATE No. ___________ ___________ Recurrent Knowledge Assessment Assessment was carried out Minutes No. __________ of _____________________ (Date) Examination Board Chairman ___________________________ (Signature)
Page 6 The reason of a withdrawal COUPON No. 1 __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ (Position of the person
__________________________________ who withdraws the Coupon)
___________________________ (Date) _________________________________
To be recorded and kept by the Safety and Labour Protection Service COUPON No. 1 To Certificate No. __________________ __________________ The Holder: ______________________ _______________________ _ __________________________________ who has infringed safety standards and regulations (operational guidelines) at ___ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________
(Signature)
Page 7 The Coupon shall be withdrawn in case the Certificate Holder infringes safety standards and regulations.
__________________________________ __________________________________ __________________________________ __________________________________ (Position of the person
__________________________________ who withdraws the Coupon)
___________________________ (Date) _________________________________ (Signature)
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Page 8 The reason of a withdrawal COUPON No. 2 __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ (Position of the person
__________________________________ who withdraws the Coupon)
___________________________ (Date) _________________________________
To be recorded and kept by the Safety and Labour Protection Service COUPON No. 2 To Certificate No. __________________ __________________ The Holder: ______________________ _______________________ _ __________________________________ who has infringed safety standards and regulations (operational guidelines) at ___ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________
(Signature)
Page 9 The Coupon shall be withdrawn in case the Certificate Holder infringes safety standards and regulations. regulations. After the third infringement the Holder shall be deprived of the Certificate and suspended from equipment operation. operation. He/she has has the right to pass his/her Safety Knowledge Assessment Assessment within 3 months.
__________________________________ __________________________________ __________________________________ __________________________________ (Position of the person
__________________________________ who withdraws the Coupon)
___________________________ (Date) _________________________________ (Signature)
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APPENDIX 17 (to Section 7.4.31) Shift Logbook of a Crane Operator Form Date _______________________________ Shift ______________________________ Crane Operator __________________________________________________________ Crane Inspection Results Ref. #
Unit, Geer and Part Description
1
Steel structure
1
Brakes of: The load lifting winch The boom lifting winch Travelling gear Trolley Rotation Crane locomotion gear
3
Safety devices: Load lifting limiter Limit switches Interlink contacts Indicators Signalling devices
4
Power equipment
5
Ropes Load lifting Boom lifting Boom guys Trolley
6
Hook suspension
7
Lighting, heating
8
Crane track
9
Counterweight, ballast
10
Grounding
11
Other deficiencies revealed in the course of operation
Inspection Findings
Last Name and Initials of the Person, who Eliminates the Deficiency
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Shift received by: ________________________________________________________ (Last name, initials and signature of the crane operator)
Shift handed over by: _____________________________________________________ (State the crane condition)
______________________________________________________________________ (Last name, initials and signature of the crane operator)
Results of the crane inspection by: Mechanic ______________________________________________________________ Electrician _____________________________________________________________ Engineer or Technician responsible for maintenance of load lifting equipment in good serviceable conditions ____________________________________________________
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APPENDIX 18 (to Section 7.5.16) RECOMMENDED SIGNALS WHEN MOVING LOADS BY CRANES Operation Lift the load or hook
Picture
Signal An abrupt movement of the arm upwards at the waist level, the palm is pointing up, the arm is bent in the elbow.
Lower the load or hook
An abrupt movement of the arm downwards in front of the chest, the palm is pointing down, the arm is bent in the elbow.
Relocate the crane (bridge)
A movement with a stretched arm, the palm points to the direction of the required movement.
Relocate the trolley
A movement with an arm bent in the elbow, the palm points to the direction of the required trolley movement.
Swing the boom
A movement with an arm bent in the elbow, the palm points to the direction of the required boom movement.
The recommended closes of a slinger: the vest and hardhat yellow, the shirt light blue, and the ar mband red.
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Lift the boom
A movement upwards with a stretched arm, which has been previously lowered to the vertical position, the palm is open.
Lower the boom
A movement downwards with a stretched arm, which has been previously lifted to the vertical position, the palm is open.
Stop (stop lifting or locomotion).
Caution (to be applied prior to one of the above listed signals if there is a necessity of a small relocation)
An abrupt movement of the arm right and left, the palm points down.
Hands are positioned with palms facing each other an a small distance apart, arms ate lifted.
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APPENDIX 19 (to Section 7.5.19) FORM OF A WORK PERMIT for a Crane Operation Close to an Overhead Power Line ______________________________________ (Description of the Company
______________________________________ and Ministry)
Work Permit No. ___________ The Work Permit shall be issued for operations to be carried out at the distance below 30 m from the outermost conductor of an overhead power line, with the voltage above 42V. 1. To the Crane Operator _________________________________________________ (Full Name)
of ____________________________________________________________________ (Crane Type, Registration No.)
2. Assigned for work _____________________________________________________ (The Company Allocating the Crane)
3. At the site of __________________________________________________________ (The Company the Crane is Allocated to,
______________________________________________________________________ Work Location, Construction Site, Warehouse, Workshop, etc.)
4. Voltage of the overhead line _____________________ _________________________________ ______________________ ____________ __ 5. Work conditions _______________________________________________________ (Any requirement to cut off voltage
______________________________________________________________________ from the overhead power line, the minimum horizontal
______________________________________________________________________ distance permitted for the crane operation
______________________________________________________________________ from the outermost conductor to the closest crane parts,
______________________________________________________________________ load movement methods, and other safety precautions)
6. Crane relocation conditions ____________________ _______________________________ _____________________ _______________ _____ (Boom positions and other
______________________________________________________________________ safety precautions)
7. Work commencement commencement at ______ hours ______ minutes on _______________ _______________ (Date) 8. Work completion at ______ hours ______ minutes on ___________________ ___________________ (Date)
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9. The Person Responsible for Safe Operations ________________________________ ________________________________ ______________________________________________________________________ (Position, Full Name, the Date and No.
______________________________________________________________________ of the Assignment Memorandum)
10. Slinger _____________________________________________________________ (Full Name)
______________________________________________________________________ (Certificate No., and the Date of the Last Safety Knowledge Assessment)
11. Permit for the crane to operate in the power line protection zone ________________ (The Company
______________________________________________________________________ that Issues the Permit, Permit No. and Date)
12. The Work Permit iiss issued by the Chief Engineer (Electrician) _________________ _________________ ______________________________________________________________________ (Company, Signature)
13. Required safety actions specified by b y Section 5 have been taken ________________ ______________________________________________________________________ The Person Responsible for Safe Operations ____________________ ______________________________ ______________ ____ ______________________________________________________________________ ____________________________ ______________ _______________ _ ____________________________ ______________ _______________ _ (Date) (Signature)
14. The instructions have been received by the Crane Operator ____________________ ____________________ (Signature)
_______________________ (Date) Notes: 1. The Work Permit shall be issued in two copies: the first one shall be given to the Crane Operator, and the second shall be kept by the company performing the work. 2. Section 11 hereof shall be filled in if the crane is to operate within the power line protection zone. 3. Branch lines shall also refer to overhead power lines. 4. Work close to overhead power lines shall be carried out in the presence and under supervision of the Person Responsible for Load Handling by Cranes.
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List of Regulatory Documents Documents Applicable to Facilities Supervised by the Regional State Mining and Technical Supervision Inspectorates Inspectorates (GGTN) of the Republic of Kazakhstan State Emergency Committee. (The Documents are Available at Craneenergo Craneenergo Research and Development Association) 1. 2. 3.
4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
18. 19. 20. 21. 22. 23. 24. 25. 26.
Labour Protection and Safety Manual for Gosgortechnadzor Gosgortechnadzor Inspectors. Standard Safety Regulations for Blasting. Methodological Methodological Directions for Servicing and Maintenance of Steel Structures and Electric Equipment of Cranes (Suspended, Overhead Travelling, Gantry, etc.). RD-01-93 Regulations for Welder Certification. Welding, Thermal Treatment and Testing of Boiler Piping Systems and Pipelines. RD-04-07-94. Safety Regulations for Gas Systems. Regulations for Lift Design and Safe Operation. Provisions for the Procedure of the Vessel Service Life Extension in the Republic of Kazakhstan. RD-03-94. Standard Safety Regulations for Mineral Crushing, Sorting, and Concentration. Standard Safety Regulations for Mineral Resources Development Development by Open Pit Mining. Regulations for Crane Design and Safe Operation. Regulations for Pressure Vessel Design and Safe Operation. Regulations for Steam and Water Boiler Design and Safe Operation. Regulations for Steam and Hot Water Pipeline Design and Safe Operation. Methods of Vessels and Equipment with Overdue Service Life Conditions Diagnostics within the Republic of Kazakhstan. RD-04-94. Methodological Methodological Directions for Inspection and Certification of Kotlonadzor (Boiler Supervision) Supervised Facilities. Typical Provisions for Engineering and Technical Staff Responsible for Supervision of Load-Lifting Equipment, Removable Gripping Devices and Containers Safe Operation. Typical Provisions for Engineering and Technical Staff Responsible for Maintenance of Load-Lifting Equipment in Good Serviceable Conditions. Typical Provisions for a Person Responsible for Safe Performance of Work by Cranes. Typical Guidelines on Safe Work Methods for Tower Crane Operators. Typical Guidelines on Safe Work Methods for Self-Propelled Boom Crane Operators. Typical Guidelines on Safe Work Methods for Overhead Travelling Crane Operators. Typical Guidelines for Slingers Servicing Cranes. List of Regulatory Documents for Cranes and Load-Lifting Structures (GOST, OST, TU, RD) current in i n the Republic of Kazakhstan (as of 01/02/96). Methodological Methodological Directions for Inspection and Certification of Vessels, Tanks, Drums and Cylinders Operating Under Pressure. Typical Provisions for Engineering and Technical Staff Responsible for Supervision of Pressure Vessel Conditions and Operation.
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27. 28.
29.
30. 31. 32. 33.
34. 35. 36.
37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50.
Typical Provisions for Engineering and Technical Staff Responsible for Pressure Vessel Good Serviceable Conditions and Safe Operation. Provisions for the Procedure of Expert Analyses and Inspections of Companies (Organizations), Irrespective of their Ownership and Industrial Reference, to Issue a Resolution of the Republic of Kazakhstan Gosgortechnadzor Gosgortechnadzor (GGTN) to Permit such Companies to Carry out Work at Boiler and Gas Facilities, LoadLifting Equipment and in the Bread Producing Industry. Provisions for the Procedure of Knowledge of Safety Regulations, Standards and Guidelines Assessment Assessment and Examination of Managerial Staff and Experts of Companies, Organisations and Facilities Supervised by the Republic of Kazakhstan Gosgortechnadzor. Gosgortechnadzor. Regulations for Stationary Compressor Unit Design and Safe Operation. Regulations for Operation of Stationary, Container and Mobile Filling Stations. Regulations for Electrode Boilers and Power Boiler Houses Design and Safe Operation. Regulations for Steam Boilers, with the Steam Pressure of 0.07 MPa (0.7 kg2 force/cm ), Water Heating Boilers and Water Heaters, with the Heating Temperature not Exceeding 388 C (115 C), Design and Safe Operation. Regulations for Hoist (Rig) Design and Safe Operation. Regulations for Municipal Heating Boiler House Operation. Amendment No. 1 to RD-04-07-94, Methodological Directions for Welding, Thermal Treatment and Testing of Boiler Piping Systems and Pipelines in Cases of Power Plant Equipment Installation and Maintenance. Provisions for the System of Steam and Water Heating Boiler Diagnostics in Industrial Power Generation. Typical Provisions for Engineering and Technical Staff Responsible for Steam and Water Heating Boilers Good Serviceable Conditions and Safe Operation. Load-Lifting Slings, General Purpose. Requirements for Design and Safe Operation. Regulations of Non-Destructive Testing Expert Certification. Specification, TU 640 RK 02495141-002-96, 02495141-002-96, Cranes. Requirements for Welded Steel Structure Fabrication and Maintenance. Methodological Methodological Directions for Inspection and Certification of Stationary Compressor Units Operating under Pressure of Compressed Air or Inert Gas. Methodological Methodological Directions for Inspection of Boiler Houses and Certification of Steam and Water Heating Boilers. Typical Guidelines for Boiler House Personnel. Guidelines for Supervision of Facilities Supervised by Kotlonadzor (Boiler Supervision) Fabrication, Installation and Maintenance. Provisions for Preliminary Supervision of Gas Supply System Construction and Reconstruction. Guidelines for Supervision of Lifting Structure Fabrication, Installation and Maintenance. Guidelines for Supervision of Gas Supply System Facilities Fabrication, Construction, Installation, Commissioning and Maintenance. Maintenance. Operation Regulations and Safety Requirements for Gas Supply Systems. Typical Provisions for Engineering and Technical Staff Responsible for Steam and Hot Water Pipelines Good Serviceable Conditions and Safe Operation.
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51.
52.
53.
54. 55. 56. 57. 58.
Methodological Methodological Directions for Inspection of Cranes with Expired Service Life (Tower Cranes) with the Purpose to Identify the Potential of their Further Safe Operation. Methodological Methodological Directions for Inspection of Cranes with Expired Service Life (Self-Propelled Boom Cranes) with the Purpose to Identify the Potential of their Further Safe Operation. Methodological Methodological Directions for Inspection of Cranes with Expired Service Life (Overhead Travelling Type Cranes, Cable Cranes, Railway Cranes, Column Cranes, Cantilever Cranes, Portal Cranes, and Transhipment Cranes) with the Purpose to Identify the Potential of their Further Safe Operation. Regulations of Overhead Travelling Crane Tracks Design and Safe Operation. Rail Tracks of Gantry Cranes. General Specification and Standards of Design and Safe Operation. Typical Guidelines for Persons Responsible for Maintenance of Hoists (Rigs) in Good Serviceable Conditions. Methodological Methodological Directions for Inspection of Hoists (Rigs) with Expired Service Life. Guidelines for Inspection and Certification of Buried Tanks for Liquefied Gas Storage.
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CRANEENERGO CRANEENERGO RESEARCH AND DEVELOPMENT ASSOCIATION To everyone, who wishes to cooperate with Cranenergo R&D Association and receive the latest regulatory documents related to operation, installation, maintenance and diagnostics of Gosgortechnadzor supervised equipment and facilities. Specialisation and basic types of activities: -
-
-
Scientific research and introduction of its results, laboratory analyses, designing, fabrication, upgrading, overhaul, reconstruction, servicing, inspection, maintenance and testing of cranes and lifting structures, process boilers, and vessels of various types t ypes and designs; Expert analyses of design and cost estimate documentation, expert conclusions c onclusions on designed work related to designing, maintenance, reconstruction, overhaul and fabrication of crane structures, boilers and other supervised by Gosgortechnadzor Gosgortechnadzor equipment and facilities; Development of standards, regulations, guidelines, methodological directions and other regulatory documents, information services; Personnel training and professional skills improvement training; Certification of lifting equipment and structures, steam and water heating boilers, pressure vessels and pipelines for steam and hot water.
We invite you to mutually beneficial cooperation!
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