| Test items | Item Number | Inspection content and requirements | Inspection method and category |
|---|---|---|---|
| 1 Design information | 1 | The crane manufacturer shall provide valid design information and type test report. | Type B: access to data, prove the name and number of the data. |
| 2 | Manufacturing inspection standards should comply with national standards and industry standards. | Type B: Check information and prove the main body's standard number. | |
| 3 | Non-destructive testing standards should meet the design requirements | ||
| 2 purchase | 4 | The crane manufacturer shall provide the procurement documents, including the technical requirements for the purchased materials (such as technical conditions, processing drawings, etc.) and the factory inspection and verification regulations (including sampling methods, inspection items, technical indicators, etc.). For important purchased materials (such as steel, welding materials, castings, forgings, standard parts and other purchased parts), the manufacturing unit shall provide the detailed technical requirements of the materials specified in the contract and the quality certification list provided at the time of delivery. |
Type B: Check information, check the physical object and verify and approve. |
| 3Metal structure | 5 | The manufacturing unit provides the relevant production process change materials with the material substitution license materials verified by the technical person in charge. | Type B: Check information, and verify and approve. Material substitution should be approved by the design unit when it is necessary. |
| 6 | The material surface of the main force-bearing member should be stamped with a steel stamp at a suitable position or a table or card should be used to prove the transplantation of the material label. | Type A: Check the data or check the steel seal, the transplanted label should be traceable. | |
| 7 | The person in charge of welding technology of the manufacturing unit shall provide technical information such as welding procedure qualification and welding production technology. GB985, GB986. | Type B: Check the data, the supervisory inspector verifies on the data, and records the name and number of the data. | |
| 8 | The person in charge of welding technology of the manufacturing unit shall provide data on weld repair (number of times, location and inspection) and weld repair process data. | Type B: Check information, and verify and approve. | |
| 9 | The manufacturing unit provides a non-destructive test report (NDT), the radiographic is qualified according to GB3323, not less than level II, and the ultrasonic is qualified according to JB1152, not less than level I. The flaw detection ratio of welds and the non-destructive testing of dangerous parts shall meet the requirements of the design drawings. |
Category B: Radiographic NDT, supervisory inspector review not less than 30% of the corresponding weld film, and fill in the review report. Ultrasound NDT, review the ultrasound NDT report, and verify and approve. | |
| 10 | The welding joint defects of the main stressed components are classified according to GB6417, and the shape and size are tested according to GB985 and GB986. Special joints should be marked on the drawings, and there must be no obvious defects visible by visual inspection. | Type A: Use a weld gauge to measure, magnify 3-5 times, and visually inspect with a magnifying glass with a mirror diameter ≧100mm. | |
| 11 | The butt welds of the flange plate and the web should not be on the same section, and the spacing should not be less than 200mm; the transverse stiffeners should be separated from the parallel butt welds of the web, and the spacing should not be less than 200mm. | Type A: Measure with tape measure. | |
| 12 | Force-bearing components: the camber of the main girder of bridge and gantry cranes (including electric hoist bridges and gantry) cranes is (0.9-1.4) S/1000, and the camber of gantry cranes is (0.9-1.4) L1/350 ; The camber of the main girder of the electric single girder and electric suspendus monopoutre grue is (1-1.4)S/1000. After the load test, the camber of the bridge and gantry crane shall not be less than 0.7S/1000, and the upturn shall not be less than 0.7L1/350; the camber of the main girder of the electric single-beam and electric single-girder suspension crane shall not be less than 0.8S/1000 . | Type A: Box girder crane detects the upper flange plate of the main girder, truss crane detects the track, and the I-track detects the center of the lower flange. The specific method is as follows: 1. Steel wire method: use 0.49-0.52mm steel wire to pull on the main beam, one end is fixed, one end is pulled with a 150N spring scale, and the contour block H is placed between the middle steel wire of the end beam and the end beam to measure The distance h between the steel wire and the main girder at the reinforcement plate in the mid-span S/10 range, and the camber of the main girder is F=Hh-Δ. Δ is the correction value of the steel wire's own weight influence (see attached table) 2．Level method: Place the level in the proper position, level it, and measure the elevations of the S/10 ribs in the middle of the main beam, the center of the end beam (legs), and the end of the cantilever for calculation. |
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| 13 | There should be no serious unevenness in the web of the main beam, and the local flatness should be no more than 0.7δ within H/3 of the flange plate of the compression zone and no more than 1.2δ in the rest of the area. | Type A: Visual inspection, if necessary, use a 1m flat ruler on the web, use a steel ruler to measure the distance between the flat ruler and the web, and take the maximum value. | |
| 14 | The structure of the cab must have sufficient strength and rigidity. The connection between the driver's cab and the crane should be firm and reliable. | Type B: Visual inspection. | |
| 15 | Appropriate fire extinguishers, insulated floors and acoustic signals outside the driver’s compartment should be installed in the driver’s compartment, and a locking device must be installed on the door. The machine room should have a good view. The headroom inside the driver's compartment is generally not less than 2m, the bottom area is not less than 2m, and the door opening direction should meet the requirements of relevant standards. | Type A: Visual inspection, if necessary, conduct a power-on test for the audio signal of the company. Visual inspection, if necessary, measure with steel tape. |
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| 16 | Railings, ladders and walking platforms should meet the requirements of GB6067. | Type B: Visual inspection, if necessary, use steel tape measure and force measuring device to measure. | |
| 4 wheels and tracks | 17 | The limit deviation of the gauge of the normal track box girder and the semi-off track box girder of less than 50t: ±2mm at the end, in the middle of the span, when S≤19.5m, it is +1～+5 mm, when S>19.5 m, it is +1～+7 mm, other beams shall not exceed ±3 mm. | Type A: Measured with steel tape measure. |
| 18 | The height difference of the trolley rail joint d≦1mm, the lateral misalignment f≦1mm, and the joint gap e≦2mm. The length of the shortest track at both ends should be greater than 1.5m, and stoppers should be added at the end of the track. | Type B: Visual inspection, when necessary, use steel ruler and feeler gauge to measure visual inspection, and use steel tape measure when necessary. | |
| 5 institutions | 19 | The work level, utilization level, and load status should be consistent with the manufacturer's data and factory data. | Type B: Check information, and verify and approve. |
| 20 | The selection of technical parameters such as the capacity of the hoisting motor should conform to the design drawing and the requirements of GB3811. | Type B: Check information, and verify and approve. | |
| twenty one | The selection of technical parameters such as the number of sets of the lifting brake and the safety factor shall meet the requirements of the design drawing and GB3811. | Type A: Check information, and verify and approve. | |
| twenty two | The selection of technical parameters such as operating motor capacity should conform to the design drawings and the requirements of GB3811. | Type B: Check information, and verify and approve. | |
| twenty three | The braking torque of the operating mechanism brake plus the running frictional resistance (excluding the frictional resistance between the wheel flange and the side of the rail head) should be able to make the crane or trolley under unfavorable conditions stop within the required time (the required time is based on the crane Working conditions are determined). | Type B: Check information, and verify and approve. | |
| 6 parts | twenty four | The quality assurance information of the hook is complete. The structural type and size of the selected hook should meet the requirements of the design drawings and the requirements of GB10051. The surface of the hook should be smooth and clean, and there should be no defects such as cracks, folds, and burns. There shall be no defects such as cracks, white light and over-limit inclusions inside the hook. | Type B: Look up information and verify and approve visual inspection. |
| 25 | The quality assurance information of the wire rope is complete. The structural type and size of the selected hook should meet the requirements of the design drawings. | Type B: Check information, and verify and approve. | |
| 26 | The pulley's warranty information is complete. The selection of pulley diameter should meet the requirements of the design drawings, and meet D0min (D0min=h2·d) should not be less than the value specified in GB3811, Table 32. The pulley should have a device to prevent the wire rope from falling out of the groove, and it should be reliable and effective. The pulley should rotate well, and there should be no defects such as cracks and broken rims that damage the wire rope. | Type B: Check information, and verify and approve. Visual inspection, if necessary, measure with a steel ruler. |
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| 27 | The quality assurance information of the reel is complete. The selection of diameter should meet the requirements of the design drawing, and the selection of D0min (D0min=h1·d) should not be less than the value specified in GB3811, Table 32. For the multi-layer winding drum, the end should have a flange that is 2 times the diameter of the wire rope higher than the outermost wire rope. | Type B: Check information, and verify and approve. Visual inspection, if necessary, measure with tape measure. |
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| 28 | The quality assurance information of the open gear is complete, and the meshing should be smooth, without cracks, and without defects such as broken teeth. | Type B: Visual inspection, and verification and approval. | |
| 29 | The wheel must not have cracks, and the tread and the inner side of the rim have no defects that affect the performance. | Type B: Check information, and verify and approve. | |
| 30 | The maximum deceleration allowed by the buffer is 4m/s. The buffer shell should be able to withstand the maximum impact force that occurs when the crane collides with the rated speed. | Type B: Check information, and verify and approve. Verification inspection can be carried out when necessary. | |
| 31 | The reducer shall meet the design requirements, the anchor bolts of the reducer and the connecting bolts of the shell shall not be loosened, and the bolts shall not be damaged. | Type B: Visual inspection. | |
| 32 | The torque transmitted by the coupling should conform to the design drawing and the requirements of GB3811. There is no defect in the coupling parts, and the concentricity and clearance of the connection should meet the requirements. | Type B: Visual inspection, experimental observation. Verification calculations can be performed when necessary. |
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| 33 | The rope guide should effectively lay the rope in the entire working range, and there should be no defects such as jamming. | Type B: Visual inspection. | |
| 34 | The selection of the chain should meet the requirements of the design drawings. The chain should not have defects such as cracks, welding, etc. | Type B: Appearance inspection, access to information. Use a caliper to measure if necessary. |
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| 7 Electrical | 35 | The transmission control scheme adopted by the electric control of the crane should be an approved and mature scheme. If the existing plan cannot meet the actual needs and other plans proposed by the user need to be adopted, the user’s manufacturer shall reach a special agreement in advance or apply for a supplementary plan review. | Type B: Consult electrical schematic diagrams or related materials. |
| 36 | The composition of the crane drive control scheme must include the following necessary protection links: a. At least one level of short-circuit protection. b. Loss of pressure protection. c. Emergency stop switch or device. d. The necessary limit protection. |
Type B: Review electrical schematic diagrams or related materials. | |
| 37 | The composition of the crane transmission control scheme varies with the specific schemes to be built, and the following protection links need to be added: a. Controller zero protection. b. The mechanical and electrical interlock between the positive and negative contactors and other contactors that are closed at the same time will cause a short circuit accident. c. Overcurrent protection set separately according to the motor: three-phase wound asynchronous motors can be set with overcurrent protection in the two phases, and the system protected by the protective box should be equipped with the total overcurrent protection of the third phase of all motors. The main contactor is disconnected. d. Overspeed protection: The hoisting mechanism adopts AC stator thyristor voltage regulation, eddy current brake speed regulation, dynamic brake speed regulation, frequency conversion speed regulation, DC thyristor speed regulation and DC unit power supply speed regulation and other transmission control schemes should be set to overspeed Protection, other places where the consequences of overspeeding are particularly serious (such as cranes such as steelmaking, casting, quenching, etc.) should also be equipped with overspeed protection, and the DC separately excited motor should be equipped with loss-of-excitation protection. |
Type A: Review the electrical schematic diagram and check the electronic control components. | |
| 38 | A multi-strand single-core wire of no less than 1.5mm or a multi-strand multi-core wire of 1mm (except for electronic devices) must be used on the crane. | Type A: Information access, visual inspection. | |
| 39 | The cables used for moving on the crane shall be nitrile and PVC flat flexible cables, rubber flat flexible cables, heavy-duty rubber sheathed flexible cables or marine flexible cables. | Type B: Check drawings and materials, and check the actual objects. | |
| 40 | The wires on the crane should be laid in a wire trough or metal pipe. Where the wire trough or metal pipe is inconvenient to lay, metal hoses can be worn, and the cables are allowed to be laid directly. | Type B: Visual inspection. | |
| 41 | Single-core wires (or cables) with an AC current carrying current of more than 25A are not allowed to pass through the metal pipe alone. | Type B: Visual inspection. | |
| 42 | Wire carrying capacity ≥ wire load current. | Type B: Check drawings and documents, and visual inspection. Check calculations when necessary. | |
| 43 | The two ends of the wire should be made of cold-pressed steel ends that will not fall off, and the connection between the wire and the end must be pressed tightly by cold-pressing pliers. | Type B: Visual inspection | |
| 44 | Both ends of the wire should have permanent identification marks consistent with the circuit diagram or wiring diagram. | Type B: Check electrical schematic diagrams and check electrical installations. | |
| 45 | The AC side power cord of the electromagnetic lifting magnet should be connected from the inlet end of the main power contactor to ensure that the lifting electromagnet is continuously energized when the main power contactor cuts off the main power supply due to various reasons inside the crane. Where a sudden power failure may cause an accident, the electromagnetic lifting electromagnet can be equipped with a backup power supply. | Type A: Visual inspection power-on test | |
| 46 | There are indication signs next to various joysticks, switches and signal devices; the operating direction of the operating handle is the same as that of the mechanism; the linkage console should have a zero-position self-locking link. | Type A: Visual inspection, action test if necessary. | |
| 47 | Portable control device: a. The control power supply voltage adopts a safe low voltage; b. The control device must have an emergency switch capable of disconnecting the main power supply. C. In general, the control device should adopt an insulated casing. |
Type B: visual inspection. When necessary, use an electrical instrument to measure its voltage should not be greater than 50V | |
| 48 | The driver’s cab, passage, electrical room, and machine room of the crane should have proper lighting. When the power supply is cut off, the lighting must not lose power. When lighting the work surface on the crane, anti-vibration measures should be considered. The power supply voltage of the fixed lighting device shall not exceed 220V. When there is no dedicated working neutral line, the 220V AC power supply for lighting should be obtained from the isolation transformer. It is strictly forbidden to use metal structure as the loop of the lighting circuit (except for the system with a single battery power supply and the voltage does not exceed 24V). The power supply voltage of the portable lighting device should not exceed 36V, the AC power supply should use a safety isolation transformer, and it is forbidden to use an autotransformer to supply power directly. | Type A: Visual inspection, and electrical meter measurement if necessary. | |
| 49 | The status of the main power switch of the crane should be clearly indicated in the driver's cabin. The crane (except the flashlight door control) should be equipped with warning sound signals, and should be clearly heard within the crane working site. | Type A: Check the configuration and operate the test. | |
| 50 | Grounding of electrical equipment: The whole metal structure is allowed to be used as the grounding trunk line on the crane, and the metal structure must be a whole conductor with reliable electrical connection. If the metal structure is connected with a non-welded part, another grounding trunk or jumper should be provided. All electrical equipment on the crane should be normally non-charged metal shell, transformer core and metal isolation layer, threaded metal pipe groove, cable metal sheath There should be a reliable ground connection with the metal structure. |
Type A: Visual inspection, and electrical meter measurement if necessary. | |
| 51 | When the rated voltage is not greater than 500V, the insulation resistance of the electrical circuit to the ground is not less than 0.8MΩ in a general environment, and not less than 0.4 MΩ in a humid environment. | Type A: power off, artificially make all the contactors and switches on the crane closed, so that all the electrical circuits of the crane are turned on, connect the L end of the 500 megohmmeter to the electrical circuit, and connect the E end to the metal structure or grounding electrode of the crane , Measure the insulation resistance value. When the above methods are difficult, the method of segmented measurement can be used. The electronic components that are easy to break down should be short-circuited during measurement. | |
| 8 Safety devices and safety accessories | 52 | The lifting mechanism should be equipped with lifting height limiters, and the lifting mechanism for lifting hot metal should be equipped with two sets of height limiters to meet the requirements of the two sets of switch actions. Different circuit breakers should be controlled and different ones should be used as much as possible. Structure type. | Type A: Check the configuration, and carry out actual results if necessary. |
| 53 | Large and trolley operating mechanisms should be equipped with stroke limiters (except for electric hoist single beams, trolleys that suspend cranes, and manual crane operating mechanisms). | Type B: Check the configuration, and carry out actual results if necessary. | |
| 54 | Except for special maintenance cranes, cranes with a rated lifting capacity of bridge type greater than 20t and gantry type greater than 10t should be equipped with lifting capacity limiters. | Type B: Check the configuration, and carry out actual results if necessary. | |
| 55 | The trolley running mechanism and the trolley running luffing mechanism and their track ends shall be provided with buffers and end stops respectively. Perform actual effect tests. The buffer should be well connected to the end stop or the buffer of another crane operating mechanism. The end stop should be firmly fixed, and both sides should be in contact with the buffer at the same time. | Type B: Check the configuration and enter if necessary | |
| 56 | Cranes working in the open air should be equipped with wind-proof devices such as rail clamps, anchoring devices or iron shoes. | Type B: Check the configuration, and carry out actual results if necessary. | |
| 57 | Anti-tipping device: Single-beam cranes that drop hooks on one side of the main beam should be equipped with anti-tipping safety hooks. | Type B: Visual inspection, steel ruler or feeler gauge measurement. | |
| 58 | Track sweeping plate: When the truck track is set on the working surface or the ground, the heavy machine should be equipped with a track sweeping plate; the distance between the track sweeping plate and the track should not be greater than 10mm. | From category B: visual inspection, if necessary, measure with a steel ruler. | |
| 59 | The crane must be equipped with an emergency power-off switch. In an emergency, it should be able to cut off the main power supply of the crane. The emergency power-off switch should not be automatically reset, and should be located in a place that is convenient for the driver to operate. | Type A: Check drawings and objects, and conduct operational tests when necessary. | |
| 60 | Interlocking protection of passageway: The door entering the crane and the door from the driver's cab to the bridge frame must be equipped with electrical interlocking protection devices. When any door is opened, all the crane mechanisms should not work. | Type A: Check drawings and objects, and conduct operational tests when necessary. | |
| 61 | Simultaneous operation interlock protection: The crane that can be operated in two places should be equipped with interlock protection device. | Type A: Check drawings and objects, and conduct operational tests when necessary. | |
| 62 | Slip line protection board: The conductive slip line protection board should be installed at the position of the operator or the spreader that is easy to touch the slip line. | Type B: Visual inspection of the setting of the protective plate and whether the protection is effective. | |
| 63 | Protective cover: All movable parts exposed on the crane that may hurt people should be equipped with a protective cover. The electrical equipment of the crane operating in the open air should be equipped with a rain cover. | Type B: Visual inspection settings and protection are effective. | |
| 9 trials | 64 | The rated load test is to verify the performance of the crane's various mechanisms, brakes and safety protection devices under various working conditions. Each mechanism operates normally, without gnawing or three legs. The static rigidity requirements are as follows: for A1～A3 grades not greater than S/700; for A4～A6 grades not greater than S/800; for A7 grades not greater than S/1000; cantilever end not greater than L1/350 or L2/350. After the test, check that the crane should not have cracks, loose connections, damage to components and other defects that affect the performance and safety of the crane. | Class A: When the conditions are available on site, the rated load is hoisted and the static rigidity is measured, the trolley is located in the middle of the span. From the actual supply value, the downward deflection value of the trolley when it is located in the middle of the span is measured. Stick a ruler in the middle of the main beam (or cantilever), and measure the difference before and after the hoisting with a level or theodolite or an arch tester. |
| 65 | Lift the rated load, 100～200mm from the ground, and gradually load to 1.25 times the rated load, hang in the air for no less than 10 minutes, check the permanent deformation after unloading, and repeat it for three times. There should be no more permanent deformation. At this time, the camber of the main beam is not less than 0.7S/1000 (electric single beam, suspension crane is not less than 0.8S/1000), and the cantilever end is not less than 0.7L1/350 or 0.7L2/350. The crane should not have defects such as cracks, loose connections, damaged components, etc., which affect the lifting performance and safety. | Type A: When the conditions are available on site, park the trolley at the mid-span and the cantilever end, the lifting mechanism is loaded at 1.25 times the rated load, and the test and inspection are carried out according to the inspection content and requirements. After the inspection, the connection of the lifting weight limiter or its connection must be restored. Action value. | |
| 66 | When lifting 1.1 times of the rated load, both mechanisms should be activated at the same time, so that the lifting and running mechanisms can perform repeated starting, running, forward and reverse actions according to the cycle time of their working level, and the cumulative time is ≥1 hour. After testing, each mechanism should be sensitive, work smoothly and reliably, and its performance should meet the design requirements. Each limit switch and safety protection interlocking device should operate accurately and reliably. There are no cracks and loose connections in all parts, and electrical equipment is overheated. | Class A: When the conditions are available on site, lift 1.1 times the rated load to check the flexibility of the crane's various mechanisms and the reliability of the brake. The test for each working condition shall not be less than three times, and the next start shall be carried out after each movement is stopped, and care must be taken to limit the acceleration, deceleration and speed within the normal working range of the crane. After unloading, the inspection mechanism and structural components are loose and damaged. After inspection, the connection of the lifting weight limiter or its operating value must be restored. | |
| 10 other | 67 | Refers to special requirements and items that the inspectors think should be added that do not conform to national standards or safety regulations. |
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