Page 114 - Alex Ruscuklic - Complete Works

Major Inspections
Major inspections are part of the following preventative maintenance program as outlined in the AS 2550 standards (for full details, refer to the relevant parts of the standard):
1. Pre-operational inspection
2. Routine inspection & maintenance
3. Periodic inspections
4. Major inspections
5. Third party inspections.
AS 2550.1 clause 7.3.5 requires the following cranes to be subjected to a major inspection:
Cranes that have reached the end of their design life or, where this is unknown, after a maximum of 10 years
of service for the mechanical components and 25 years for the structure.
Old cranes which are to be re-commissioned and that do not have previous records.
Cranes that are to be upgraded or modified.
The major inspection is comprehensive and includes inspecting for wear, fatigue and cracking of all components of the crane critical to its safe operation and use. The inspection includes attention to structural and mechanical (etc.) anomalies, based on strip-down inspection and non-destructive examination. Guidance on what items should be included in an inspection is provided in AS 2550.1 “Appendix B”.
Operators of cranes should schedule major inspections well in advance to avoid disruptions to production. The planning process should allow for consequential repairs of the particular crane and should also consider alternative measures, such as the hire of a stand-by unit.
Crane owners may choose not to conduct a single event major inspection by incorporating the requirements of the 10-year major inspection into the comprehensive periodic inspections. In such cases, the crane owner must:
Ensure that the periodic maintenance regime is developed by a competent person supervised by a professional engineer, and includes all safety critical components, normally stripped down at the major inspection; and
Keep all maintenance and repair records in order to be able to verify adherence to the maintenance regime.
Where the 10-year major inspection requirements have been incorporated into the periodic inspection program, the owner of the crane should, when the 10-year major inspection would normally have become due, undertake a hazard identification and risk assessment in accordance with the Plant Regulations. This process provides the owner opportunity to identify any components that would normally have been inspected under the 10-year major inspection program, that have not been satisfactorily covered by the periodic inspections, and allows corrective action to be carried out.
Reasons for 10 and 25-year periods
The reasons for the specification of 10 years for the major inspection of mechanical parts and 25 years for structures include:
• Plant and components likely to be designed to Australian or overseas standards are based on a 10 and 25-year design life (e.g. AS 1418.1 clause 2.2).
• 10 years is regarded as a maximum period for checking wear limits of mechanical parts and verifying design assumptions.
• 10 years is regarded as a minimum period for the first signs of fatigue to appear in mechanical parts.
A period of 10 years for a major inspection of mechanical parts should be used as a default where no other evidence of history of the crane is available and a hazard identification, risk assessment, or risk control process does not identify a shorter time interval. (This is often the case with imported second-hand plant.)
SAFETY FIRST . . . ALWAYS
SAFETY FIRST . . . AL
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