CRANES

CRANE
A large, tall machine used for moving heavy objects by
suspending them from a projecting arm or beam.
OR
A crane is a tower or derrick that is equipped with cables and
pulleys that are used to lift and lower material.
 Types of Cranes
• Cranes are generally divided on the basis of power source.

• a/ Mechanical Crane

• b/ Electrical Crane

• c/ Hydraulic Crane

• d/ Hybrid (Electro-Hydraulic) Crane

 Type of Cranes- Mostly Used
• Mobile Cranes
The most basic type of crane consists of a steel truss or
telescopic boom mounted on a mobile platform, which could be
a rail, wheeled, or even on a cat truck. The boom is hinged at
the bottom and can be either raised or lowered by cables or
hydraulic cylinders.
• Telescopic Crane
This type of crane offers a boom that consists of a number of
tubes fitted one inside of the other. A hydraulic mechanism
extends or retracts the tubes to increase or decrease the
length of the boom.
• Tower Crane
The tower crane is a modern form of a balance crane. When
fixed to the ground, tower cranes will often give the best
combination of height and lifting capacity and are also used
when constructing tall buildings.
• Truck Mounted Crane
Cranes mounted on a rubber tire truck will provide great
mobility. Outriggers that extend vertically or horizontally are
used to level and stabilize the crane during hoisting.
• Rough Terrain Crane
A crane that is mounted on an undercarriage with four rubber
tires, designed for operations off road. The outriggers extend
vertically and horizontally to level and stabilize the crane when
hoisting. These types of cranes are single engine machines
where the same engine is used for powering the undercarriage
as it is for powering the crane. In these types of cranes, the
engine is normally mounted in the undercarriage rather than
in the upper portion.
• Loader Crane
A loader crane is a hydraulically powered articulated arm fitted
to a trailer, used to load equipment onto a trailer. The
numerous sections can be folded into a small space when the
crane isn’t in use.
• Overhead Crane
Also referred to as a suspended crane, this type is normally
used in a factory, with some of them being able to lift very
heavy loads. The hoist is set on a trolley which will move in
one direction along one or two beams, which move at angles
to that direction along elevated or ground level tracks, often
mounted along the side of an assembly area.
• Offshore Pedestal Crane
An offshore crane is defined as a pedestal-mounted elevating
and rotating lifting device used to transfer materials or
personnel to or from marine vessels, barges and structures,
according to API Spec 2C, a set of standards used to
manufacture marine cranes.
Offshore Pedestal Cranes
• Generally two types of Offshore Pedestal Cranes are used.
• 1/ Lattice Boom Crane
• 2/ Box Boom Crane
 Inspection Of Cranes
• Thorough Inspection of cranes is usually divided into three categories.
• 1/ Visual Inspection
Visually inspect the each part of crane for condition &
proper operation like boom & column structure, blocks, hooks, cabin,
hydraulic/mechanical/electrical system, gauges, SLI, wire ropes,
sheaves, lights, AC/Heater, safety signs/signals, emergency equipment
etc.
• 2/ Function Test
Operate all powered components to their travel limits
to check for prop­er limit switch operation like Boom cut off, Hoist cut
off, emergency stop, emergency load lowering, horn. SLI, gauges,
cooling system, level indicators, warning signals & alarms etc.

• 3/ Non Destructive Testing (NDT )

Inspection critical components by NDT like MT, ET, UT
etc. of hooks, boom, Pedestals, dead end terminations etc.
Visual Inspection
• Technical Data-
- Serial Number of Crane
- Type of Crane
- Year of Manufacture
- Manufacturer
- SLI Type & Manufacturer
- Length of Boom/Jib & Length of Extension Jib/Flying Jib
- Type of Boom
- Rated capacity/ Load chart
- Date of Last Load test & Thorough Inspection
• Wire Ropes-
Main Line wire rope, Whip/Auxiliary Line wire rope,
Boom Line wire rope, Pennant Line wire rope if applicable.

- Visually inspect the wire rope for any type of broken

wires, crush, twist, permanent kink, strand displaced, bird
caging, heat affected, dead end opening, corrosion, core
protrusion, mechanical damage etc.
- Dimensionally inspect the wire rope through out the
length for localized wear & increase in diameter due to
corrosion
- Verification of wire rope’s construction as per
manufacturer recommendation
• Wire rope defects
• Dimensional Inspection of wire ropes
• Inspection of Main Block & Auxiliary Blocks with Hook

- Inspect for clearly marked with serial number & rated

capacity to trace their certificates
- Inspect for hook nut, swivel, excessive play in sheaves,
groove condition, any visible damage/crack, side plates etc.
Hooks
• Boom Inspection-

- Visually inspect the boom for corrosion, paint condition,

lattice bent, crack, mechanically damage, wear etc.
- Check for proper chord connection & weld connection
for any type of visible crack, wear, damage etc.
• Boom Butt & Foot Pad Eyes
- Inspect boom butt weld areas for sign of corrosion,
wear, damage etc.
- Inspect boom foot pad eyes weld area for sign of
corrosion , wear , visible crack etc.
- Check for proper securing of lock plates & nut bolts.
- Check for proper alignment of boom if there is any
side wear on foot pad eye.
- Check for wear on foot pins if applicable.

Boom Butt Area

• Gantry sheaves, Boom Tip sheaves & Floating sheave
Inspection-

- Check for proper lubrication & motion of sheaves.

- Check for excessive play in sheave.

- Check for any visible crack, damage, cut, wear, groove

abrasion, rope marking /rope printing in grooves.

- Check for proper installation & securing of sheaves,

shaft & side plates.
Visual & Dimensional Inspection of sheaves
• Dead End Inspection-
- Visually inspect the dead end terminations for correct
installations & correct rating of wedge socket.
- Inspect for any type of visible crack/damage, body bent ,
stretched, wear at holes, pin bent, wear on pin etc.
- Inspect dead end pad eyes for wear, bent , damage, welds for
sign of corrosion etc.
• Winch Inspection-

- Inspect winch for proper drum guard, flange, drum

condition, anti jump bar etc.
- Check welds for sign of corrosion & visible crack/damage
etc.
- Check for proper spooling of wire rope on drum and
should not .be rub the drum flange.
- Check condition of mounting bolts for loose & damage
bolts .
- Inspect for proper attachment of drivers and drive
motors and Brake assembly
• Crane Operator Cabin Inspection-

- Check sheet metal work for corrosion and damage

- Check the seals, latches and hinges of doors for correct
operation
- Check all windows are in place and free from damage
- Check the windshield wipers are in working order
- Check the driver’s seat is in good condition
- Check the heater / air conditioning is in good working
order
- Check for overhead protection
- Warning signals/ alarms
• Column Group / Pedestal-

- Inspect circumferential and vertical welds of column

structure
- Inspect welds on platform assembly and holding
platform to column
- Inspect for missing, loose or broken bolts
- Examine Access ladder for damage structure, welds
for crack or corrosion
- Warning signs - rotating equipment / authorized
personnel only
- Inspect swing gearbox mounting
- Inspect swing bearing and gear for loose, broken or
missing bolts
• Engine House –

- Check general condition of doors and hatches,

ensuring the seals, latches and hinges are in good condition
- Check radiator shutters and operating cylinders for
correct operation.
- Check condition of central lubrication system, ensure
grease is distributed to all intended locations
- Check all fluid levels are being maintained: fuel,
hydraulic fluid, engine oil, coolant, gear oils etc.
- Last overhauled date and hours
- Check the engine mounting bolts are free from
corrosion and are securely fastened.
- Check the engine exhaust silencer for corrosion.
Ensure the self-closing flaps are operating correctly and that
condensate drains are clear
• Boom Accessories-

-Inspect Boom accessories like anti two blocks, rollers.

Wooden bumpers, lights, cables, platform etc. are properly
installed and secured with secondary retention to avoid drop
object.
- Inspect all items for proper operation and any sign of
corrosion & damage.
Function Test of Crane
• Operate all powered components to their travel limits to check for prop­er limit
switch operation

• Check load moment indicator for proper operation

• Check all controls for proper operation, Boom upper and lower limit switch

• Check all lighting for proper operation. (Include

• helicopter warning light if appli­cable)

• Check all brakes for proper stopping action

• Function test the emergency stop, Emergency load lowering & swing if
applicable

• Check the windshield wipers are in working order

• Operation of the boom camera if applicable

• Check function of Horn / warning devices

NDT of Crane
• Non Destructive Testing-

There are four type of NDT techniques are used in periodic

inspection of cranes.

1/ Magnetic Particle Testing

2/ Eddy Current Testing

3/ Ultrasonic Testing

4/ Liquid Penetrant Testing

Magnetic Particle Testing in Crane

• Magnetic particle testing is used to inspect Crane Hooks &

Wedge sockets
Eddy Current Testing in Crane

• Eddy Current testing is used to inspect Crane Pedestals (Main

deck ,Lower and upper pedestal)
• Boom Butt & Foot pad Eyes weld areas
• Floating Sheave & Bridle plate assembly
• Dead End Pad eyes
• Pennant Line pad Eyes at Boom tip
• Gantry sheaves weld areas and boom tip weld areas
• Boom lattice & Chord welds 20 per cent of boom
• A Frame base weld & Chassis weld if applicable
 Eddy Current Inspection

A-Frame Floating Sheave Assembly

Main Deck Pedestal Upper & Lower Pedestal

Liquid Penetrant Testing in Crane

• Liquid Penetrant testing is used to inspect Crane load link

plates & pins if applicable. It is for non ferrous material or you
can use eddy current inspection also.
Ultrasonic Testing in Crane

• Ultrasonic testing is used to inspect Crane boom chord &

lattice thickness.
 Document Verification
The documents need to be verified during inspection are-

1. Last Load test Certificate

2. Last Thorough Inspection Report
3. Wire Rope Certificates
4. Wedge Socket Certificates
5. Main and Auxiliary Block Certificates
6. Monthly & Weakly checklist
7. Oil Analysis Report
8. Last Engine Overhaul Report
9. Wire Rope installation date procedure
10. SLI calibration Certificate if applicable