PRESENTATION ON TESTING OF

EOT CRANES
 DUTY CLASSIFICATION
CRANE STRUCTURES ARE CLASSIFIED IN FOUR
CLASSES ACCORDING TO THE FREQUENCY OF
APPLICATION,VARIATION OF MAGNITUDE OF
LOAD AND THE EFFECT IMPACT AS PER THE
TABLE.
DUTY CLASSIFICATION WORKING EFFECTIVE LOAD DYNAMIC
PERIOD EFFECT

1 SHORT LOW LOW

2 LONG LOW LOW

2 SHORT HIGH LOW

2 SHORT HIGH HIGH

3 LONG HIGH LOW

3 LONG LOW HIGH

3 SHORT HIGH HIGH

4 LONG HIGH HIGH

THE WORKING PERIOD OF ANY CRANE SHALL
BE CONSIDERED, SHORT - IF IT OPERATES FOR
LESS THAN 500 HRS. PER ANNUM.
LONG - IF IT OPERATES FOR MORE THAN 500
HRS. PER ANNUM.
THE TERM “OPERATES” SIGNIFIES THAT THE
CRANE IS ACTUALLY UNDER LOAD OR IS IN
MOTION OR BOTH.
THE EFFECTIVE LOAD OF ANY CRANE SHALL
BE CONSIDERED TO BE LOW UNLESS IT
LIFTS LOADS GREATER THAN 2/3 OF ITS
SWL ON MORE THAN 1000 OCCATIONS PER
ANNUM.THE EFFECTIVE LOAD SHALL
OTHERWISE BE CONSIDERED TO BE HIGH.
• THE DYNAMIC EFFECT MAY BE CONSIDERED TO BE
LOW - IF THE SPEEDS OF TRAVELLING OF BOTH
TROLLEY AND CRANE OF HOIST ARE EACH LESS THAN
100 MTRS./ MIN.
HIGH – IF THE CRANE OR ANY MOTION IS USED FOR
ANY PURPOSE OR IN ANY MANNER LIKELY TO
PRODUCE GREATER SHOCK EFFECTS THAN THOSE
CAUSED BY TRAVELLING ON STEEL TRACK RAILS AT
THE AFORESAID SPEEDS.
MANUFACTURING
• RAW MATERIALS ARE RECEIVED WITH MILL T.C’s
(STRUCTURALS,CASTINGS,ALLOYSTEELS -
BAR/ FORGINGS)
IF MILL T.C’s ARE NOT AVAILABLE, THEN TO CHECK TEST AS
PER RESPECTIVE IS/BS STANDARDS/ SPECIFICATIONS IN
ANY NABL (NATIONAL ACCREDIATION BOARD OF
LABORATORIES) APPROVED LABORATORY UNDER WITNESS
OF 3rd PARTY INSPECTION AGENCY/ CLIENTS
REPRESENTATIVE AS PER APPROVED Q.A.P.
• AFTER MATERIALS ARE ACCEPTED, FABRICATION OF
MAJOR STRUCTURAL ITEMS SUCH AS GIRDERS, END
CARRIAGES, TROLLEY & ROPE DRUMS ARE STARTED
& SETUP IS INSPECTED BY 3rd PARTY INSPECTION
AGENCY/ CLIENTS REPRESENTATIVE AS PER
APPROVED Q.A.P.
• WELDING OF LOAD CARRYING MEMBERS ie. MAJOR
STRUCTURAL ITEMS SUCH AS GIRDERS, END
CARRIAGES, TROLLEY & ROPE DRUMS ARE TO BE
CARRIED OUT ONLY BY QUALIFIED WELDERS.
• WELDERS ARE QUALIFIED BY 3rd PARTY INSPECTION
AGENCY/ CLIENTS REPRESENTATIVE AS PER
APPROVED Q.A.P.
• MAJOR STRUCTURAL ITEMS SUCH AS
GIRDERS, END CARRIAGES, TROLLEY BOXES
ARE INSPECTED BY 3rd PARTY INSPECTION
AGENCY/ CLIENTS REPRESENTATIVE AS PER
APPROVED Q.A.P. AFTER INSIDE WELDING
BUT BEFORE CLOSING OF BOX SECTIONS.
VISUAL & N.D.T.(D.P. TESTING) IS BEING
DONE AS PER APPROVED Q.A.P.
• IN CASE OF GIRDERS BOTTOM HALF IS
COMING IN TENSION ZONE, HENCE ALL
BUTT WELDS IN THE TENSION ZONE ARE
SUBJECTED TO 100% RADIOGRAPHY
TESTING.AFTER ACCEPTANCE OF
RADIOGRAPHY TESTING BY 3rd PARTY
INSPECTION AGENCY/ CLIENTS
REPRESENTATIVE FURTHER CLEARANCE IS
GIVEN BY 3rd PARTY INSPECTION AGENCY/
CLIENTS REPRESENTATIVE.
• ROPE DRUM BEING THE MAJOR LOAD
CARRYING MEMBER, ALL BUTT JOINTS ARE
IOO% RADIOGRAPHY TESTED.
• AFTER COMPLETE FABRICATION, STESS
RELIEVING IS DONE AS PER DESIGN
REQUIREMENTS.( eg. ALL ROPE DRUMS &
GEAR BOX CASINGS ARE STRESS RELIEVED).
STESS RELIEVING IS DONE TO RELEASE THE
THERMAL STRESSES DEVELOPED DURING
WELDING OPERATION.
• GENERALLY SR IS DONE
- LOADING AT 300 DEGREE
CENTIGRADE
- HEATING UPTO 600-650 DEGREE
CENTIGRADE AT HEATING RATE OF 100
DEGREE CENTIGRADE/ HOUR.
- SOAKING AT 600-650 DEGREE
CENTIGRADE UPTO 1 HOUR/INCH
THICKNESS.
 - COOLING RATE 80 TO 100
DEGREE CENTIGRADE / HOUR UPTO
300 DEGREE CENTIGRADE AND THERE
AFTER STILL AIR COOLING.
• ALL MACHINING INVOLVED IN
ITEMS BEING STRESS RELIEVED TO BE DONE
ONLY AFTER STRESS RELIEVING.
• CARE TAKEN DURING ASSEMBLY
- ENSURING ALL FASTENERS ARE
TIGHTENED TO THE REQUIRED TORQUE.
- ENSURING FITMENT OF
WHEEL/AXLE,PINS,GEAR/ PINION,
BRAKE DRUM,COUPLINGS,BEARINGS ARE AS
PER THE REQUIRED FITS/ TOLERANCES.
TESTING
 TESTING ON STAND

• DIMENSIONAL MEASUREMENT AS PER REPORT

( SPAN,DIAGONAL, SKEW,ETC.)
• ACTUAL TESTING
- IDLE RUNNING OF LT,CT,HOIST
- LOAD TESTING OF CT, HOIST
- LOAD TESTING OF LT IS GENERALLY DONE AT
SITE.
 BREAK SETTING

Braking Path
The braking path of the crane motions shall be within the distance as
calculated from the following formula with all the brakes applied simultaneously
unless required otherwise by the purchaser:
v
S= ------------
Cb x Cdf
where
s = braking path in metres
v = speed of motion .in metres/minute
Cdf = co-efficient for group classification and type of motion as defined in 7.4.3
Cb = 80 for hoisting motions,
=20 for travel motions
.
 - AFTER SUCCESSFUL COMPLETION
OF LOAD TEST CRANE TO BE
SUBJECTED TO OVER LOAD TEST
WITH 125% OF SWL TO ASCERTAIN THE
FOLLOWING,
- THE FUNCTIONING OF BRAKES,
TRIPPING OF LIMIT SWITCHES &
OVER LOAD RELAYS.
- THE CRANE MECHANISMS AND
STRUCTURALS ARE CAPABLE OF
WITHSTANDING OVERLOAD.
- THERE IS NO PERMANENT SET IN
THE GIRDER WHEN THE CRANE IS
SUBJECTED TO THE OVERLOAD.
 PRECAUTIONS TO BE TAKEN WHILE TESTING

• ALL GEAR BOXES ARE FILLED WITH SUFFICIENT QUANTITY

OF GEAR OIL..
• FILL UP BRAKE OIL IN THE THRUSTOR BRAKES.
• TO CHECK FOR PROPER SETTING OF ALL BRAKES.
• TO ENSURE ALL LOAD SLINGS ARE PROPERLY LOCKED.
• TO ENSURE ALL HAND RAILINGS, LADDERS, TOE
GUARDS,CHEQUERED PLATE ON TROLLEY FRAME,
COUPLING/ FLOATING SHAFT COVERS ARE FIXED BEFORE
START OF TESTING.
• TO KEEP SUFFICIENT DISTANCE FROM ROTATING PARTS
WHILE TAKING TRIALS.
 INSPECTION OF ELECTRICAL ITEMS

• INCOMING BOUGHTOUTS
- JUNCTION BOXES
- LIGHT FIXTURES
- MISC. ELECTRICAL ITEMS
- CABLE ACCESSORIES
• INSPECTION AT VENDOR
- MOTORS
- PANELS (FUNCTIONAL,SIMULATION OF
SAFETY INTERLOCKS,HIGH VOLTAGE
TESTS,INSULATION RESISTANCE
TEST(MEGGERING)
• INSPECTION AT SHOP
- CHECKING EARTHING
- MEGGERING OF CABLES (IR TEST)
- PERFORMANCE
- NO LOAD TEST
• YARD STICK TO CONFIRM BETTER PERFORMANCE
- MOTOR NO-LOAD CURRENT(10-15% HIGHER
THAN IDLE TEST RESULT OF MOTOR AT THE
SUPPLIERS END)
- VIBRATIONS
- DB LEVELS
- FULL LOAD TESTING – MOTOR CURRENT
SHOULD NOT EXCEED FULL LOAD CURRENT ON
NAME PLATE.
• IF HIGH VOLTAGE TEST IS DONE ONCE ON THE
EQUIPMENT, THEN FOR THE NEXT TIME IT IS
DONE AT 80% OF EARLIER VOLTAGE.(THIS IS
TO BE DONE TWICE ONLY)