SECTION 10.

0 CRANE INSPECTIONS
The following text provides information on suggested work scopes for each of the inspection
categories previously discussed.
10.1 Pre - Use Inspection
Pre-use inspections (performed by a qualified crane operator or qualified inspector) should include,
but are not limited to, the following actions.
a) Perform a walk - around visual examination of the crane boom and support structure to verify
that no visible damage exists.
b) Check all fluid levels of prime mover to include the following, where applicable:
• engine oil
• radiator coolant
• hydraulic reservoir
• diesel fuel reservoir
• auxiliary hydraulic reservoir
c) Verify control mechanisms including brakes and clutches for proper operation.
d) Visually check for lubricant oil leakage on hoist(s) and all gear boxes. In hoists where a sight
glass is provided, also check the fluid level.
e) Visually check for leakage or damage to the air and non - mechanical systems.
f) Check the following devices, for proper operation where applicable:
• boom hoist pawl
• helicopter warning light
• crane hook latch
• boom hoist limit
• anti - two-block device operation
• safe load indicators (if installed).
g) Verify the correct load - rating chart for the configuration in use is visible to the crane
operator at the primary control station.
h) Visually check wire rope for evident deterioration and damage, or improper reeving.
i) Visually check for loose, missing, or corroded bolts, pins, keepers, or cotter pins.
j) Visually check rigging gear to be used, such as slings, sling hooks, and shackles.
k) Lubricate components and correct deficiencies as required based on the results of these
inspections.
10.2 Monthly Inspection Annex B3.3
Monthly Inspections (performed by a qualified crane operator or qualified inspector) shall include all
the elements of a pre - use inspection and should include, but are not limited to, the following
actions.
a) Further check all control mechanisms for proper function, and contamination by foreign matter.
b) Check appropriate electrical apparatus for proper function.
c) Verify the boom hoist limit and anti - two - block devices are functioning properly. Care
should be exercised to prevent damage to crane components.
d) Lubricate components and correct deficiencies as required based on the results of these
inspections. Document these results.
10.3 Quarterly Inspection Annex B3.4
Quarterly Inspections (performed by a qualified inspector) shall include all the elements of a pre -
use inspection and a monthly inspection and should include but are not limited to the following
actions.
a) Boom should be inspected for bent chord members, missing or broken lacing, and cracked
welds on critical members. Boom section end connections should be inspected for cracked
welds, deformation, and corrosion.
b) Check boom angle/radius indicators over full range for accuracy.
c) Sheaves should be inspected for wear, cracks, and rope path alignment and bearing condition.
d) Check power plants for proper performance compliance with safety requirements
e) Check belts and chains for proper adjustment.
f) Visually check crane hooks for deformation, and discard if deformations exceed those
manufacturer’s recommendations.
g) Inspect wire rope in accordance with company’s written policy.
h) Check lubricant level in all hoists and slew drives, including those not fitted with sight glasses.
i) Lubricate components and correct deficiencies as required based on the results of these
inspections. Document these results.
Oil sample analysis, as suggested by the hoist manufacturer, is intended primarily to
evaluate its mechanical integrity. Oil sample analysis need not necessarily mean a laboratory
analysis. It can be effectively achieved by qualitative tests performed in the field by a
qualified inspector or crane operator (such as cheesecloth, smell, and texture tests).
10.4 Anual Inspection
10.4.1 Preliminary Survey
• Check the Manufacturer’s Plate to ensure that the identification number is clearly displayed,
and that the Load Radius Charts for all duties are available in the Operators Cabin.
• Check previous Platform Inspection and Maintenance records to ensure that everything is
up-to- date for the crane that will be used. This logbook should be kept current
at all times and include maintenance, repairs, and other details specific to the
equipment. A review of the logbook should communicate an accurate condition
of the crane.
• Establish what work has been carried out since the last Statutory Inspection, and what
problems have been identified.
• When ropes or other components which require separate certification have been fitted check
that the certification is available, correct and updated
• Visually survey the crane from a distance, observe it operating and listen for any unusual noises.
Note !! Some defects are more easily seen from a distance than under close inspection (ie)
a bent or twisted boom.
• The inspection should be carried out methodically in stages, as the crane may not be available
for an uninterrupted period.
• If the crane is shut down for helicopter movements or due to weather, that time should be used
to carry out the inspection at rest (ie) inside the pedestal or inspecting the boom.
• Use Check Sheets to ensure you do not miss out on any part of the examination and supply
the client with a copy of the check sheet.
Annual inspections (performed by a qualified inspector) shall include all the elements of a pre -
use, monthly, and quarterly inspections, as well as inspections of any other critical crane
components and weight indicator systems to verify their accuracy, where applicable.
10.4.2 Inspection of Critical Crane Components
The annual inspection of critical components appropriate for an individual machine will differ,
depending on the crane type and design of the individual components
A basic guideline for inspection of critical crane components should consider but not be limited to
the following.
Hoist Assemblies
Annual Inspection and maintenance of the hoist should be determined by the crane owner as a
function of the hoist type, past and anticipated duty cycle, and condition.
The quality of the hoist lubricant is considered a primary indicator of the mechanical integrity of the
hoist.
Brakes should be tested by stalling the drive. Consult the crane manufacturer or other qualified
source for the best applicable procedures for testing the hoist and swing parking brakes.
Main Hoist Rope & Hook Block

• Raise the load hook to the highest position slowly when nearing the top in case the over-hoist
limit switch does not function properly, and to prevent the hook block fouling the boom head
sheaves.
• Lower the hook block slowly and inspect the rope coming off the drum until the hook reaches
its lowest point. This may be determined by the over - lower limit switch, by reaching sea level
or even the length of rope if it has been shortened.
• Ensure that there is sufficient rope fitted to the crane to allow it to operate safely, and still have
a minimum of at least 3 dead turns on the drum when the over - lower limit switch operates.
• Check the rope anchorage on the drum, and the termination at the hook block or boom head
to ensure that they are in good condition, with all pins, split pins in place.
• Ensure that socket & wedges are of the correct size and are fitted correctly with looped tail and
bulldog grips.
• Check rope for correct reeving and routing ensuring that the rope is not fouling on the crane
structure.
• The hook block should be inspected. All sheaves, should be checked for free movement and
signs of wear or cracking, worn bushes or bearings. Side plates and spacers, locking plates
and pins should also be inspected.
• The load hook should rotate freely, be securely fitted and be undamaged. Check the hook
shank thread and securing nut for undue movement, which may indicate wear or corrosion.
Ensure the retaining nut is restrained from slacking off by a locking plate or screws.
• Check condition of any weights, chains or shackles fitted, and ensure that they are in good
condition and securely fitted.

Auxiliary Hoist Rope & Hook Block

Requirements are as per Main Hoist Rope and Hook Block above
Foundation
• Inspect condition of Pedestal from bearing flange right down to the base of the pedestal.
Examine for fracture, deformation and corrosion.
• Check all bracings and connections to the platform for damage, distortion, cracks in welds or
loose bolts (where applicable).
• Check all internal and external platforms and ladders to ensure that they are in good condition.
• Check condition of all steelwork for corrosion and cracked paintwork.
• Check inside the base of the pedestal for any signs of water / oil / fuel. Check for other debris
(ie) rags, paper, scaffold boards etc. which contribute to a fire hazard.
Superstructure
• Check the condition of all steelwork, bracings, connections, ladders, handrails and platforms
for damage, distortion, cracks or deterioration.
• Where there are box or tubular sections this should be brought to the client’s attention and a
suitable scheme put in place to monitor for internal corrosion.
• If you are concerned with the integrity of any welds, anchorages or connections, arrange for an
NDE to be carried out.
Swing Circle Assembly
The swing circle assembly is the connecting component between the crane revolving upper
structure and the pedestal. Consequently, regular inspections are paramount to ensure a long and
safe operational life.
As stated previously there are 3 main types of swing circle assemblies typically used on pedestal
mounted cranes:
1) Ball / Roller Bearing
2) King Post
3) Hook and Roller Assembly
The inspection procedure for each varies significantly and should be tailored, not only to fit the type
of swing circle assembly, but also for the physical and operational environment of each particular
crane and platform.
Regardless of the type of swing circle assembly, the objective of any inspection is to determine and
monitor wear, fatigue, corrosion, and the overall operational condition.
The crane and swing circle assembly manufacturers are the best sources for information in
developing the inspection program. The following are suggested inspection guidelines for each
type of swing circle assembly.
Ball / Roller Bearings
This type of swing circle assembly is either bolted and/or welded to the pedestal and rotating crane
turntable, as illustrated below.

The three major inspections that should be performed are for:

i) bearing wear,
ii) crane / bearing connection integrity, and
iii) operating characteristics
i) Bearing Wear
The wear in the bearing shall be monitored to determine its expected service life. The wear
measurement may be performed in a number of ways. Some of which are as follows:
a) Wear assessment by grease sample analysis --- wear may be monitored by periodic
grease sample analysis as describe in the following slides.

Grease samples should be collected every twelve months as a minimum and the results
of the analysis recorded; this period should be shortened if obvious metal or
contaminants are present.
 b) Annual Ball Ring Grease Sampling Analysis Method.

1) Preparation

• Clean the raceway to minimize contamination of the sample.

• Position the crane boom at the minimum radius to allow a full 360° rotation.
• Use grease that is recommended by the crane manufacturer
2) Collection of Sample

• Pump grease while slowly rotating the crane 360°.

• A sufficient bead of grease should be observed all the way around the lip seal.
• Select eight points equally spaced to obtain a sufficient sample
• Collect the sample in a clean container, such as a clear plastic bag, sample jar,
etc.
• Clean off excess grease after taking the sample
3) Evaluation of Sample

• Take a small portion of the sample and spread it out on a light coloured material
such as a white cotton cloth, coffee filter, etc.
• Dilute the grease sample with a solvent to expose any contaminates
• Inspect the sample looking for metal particles, sand, nylon, rust, water, etc.
Note: Special attention should be given to metal particle size, shape, and
quantity.
• The crane manufacturer, appropriate supervisory personnel, or experienced
engineer should be consulted if the sample is questionable and further
evaluation is required.
c) Tilt Method

In order to perform this procedure, it shall be possible to fully tilt the bearing forward and
rearward using the counterweight of the crane, jacks, boom luffing cylinder, etc.
The objective is to measure the total internal bearing raceway to rolling element clearance
with no substantial moment on the bearing that could cause elastic deformation.
It is strongly recommended the tilt procedure be performed at a minimum of four locations
every 90° around the circumference of the bearing
This procedure involves positioning a dial indicator between the rotating and non - rotating
bearing races.
The crane boom is positioned to fully tilt the bearing forward using a light hook load if
necessary.
The dial indicator is either positioned under the boom or under the rear of the crane in line
with the boom centreline and zeroed.
 The boom is then raised to its highest position to fully tilt the bearing rearward. The
bearing clearance is then measured on the dial indicator, as illustrated below.

The bearing should again be tilted forward to its original position to verify the accuracy of
the measurement by the dial indicator again reading zero.
CAUTION This tilt procedure can only be used if the crane has sufficient counterweight
to fully tilt rearward when the boom is raised to its highest position. If the
crane
/ bearing is not tilted fully, highly inaccurate and misleading clearance
measurements will result
For cranes with insufficient counterweight, jacks may be used to fully tilt the bearing
rearward or on box boom cranes, the luffing cylinder may be used to lightly power down
against an adequate support to tilt the bearing rearward.
d) Depression Measurement Method

This system involves the monitoring of bearing wear by periodically measuring the
distance between two machined surfaces on the front or rear of the crane with the bearing
fully tilted forward with no excessive moment load
In order for the procedure to be accurate, the measurements shall be taken between the
exact same surfaces at the exact same point each time with the boom at the same
position with the same moment load.
The first measurement shall be performed when the bearing is new, and the crane is first
put into service to obtain a base value for subsequent repeat measurement comparisons.
Without having this base value, the depression measurement method cannot be used to
determine the total wear in the bearing as the bearing is never lifted tilted rearward. See
figure below
e) Rotation Method

When the Tilt Method cannot be used due to insufficient crane counterweight and when
no base value reading was ever taken for use with the Depression Measurement Method,
a third method shall be used. One possible third method is the Rotation Method.
The Rotation Method is based on the fact that a bearing may be fully tilted forward in the
direction of the boom and the tilt will follow the rotation of the crane.
A dial indicator, with a magnetic base, may be fixed to the crane or pedestal with the
needle of the indicator positioned on a clean, rust free, machined horizontal surface of the
bearing or crane. The dial indicator is positioned in the front or rear of the crane in line
with the boom.
The boom shall be positioned such that the bearing is fully tilted forward with no excessive
moment load.

After the indicator is zeroed, the crane is slowly rotated 360° with the dial indicator reading
recorded every 45° of crane rotation. The dial indicator should return to zero when the
crane is rotated 360° back to its original position. See figure below.
The dial indicator should be repositioned every 90° in order to perform four individual
tests.
 This method may not be as precise as the tilt and depression measurement methods as
the machined surface of the bearing opposite where it contacts the crane and pedestal
flange may not be machined perfectly true to the rolling element raceway diameter.
However, the rotation method does produce reasonably accurate results when performed
on a periodic, consistent basis and may be the only method that can be used.
ii) Crane / Bearing Connection Integrity

The crane/bearing may be connected using bolts, welding or combinations of the two. The
integrity of this connection is crucial to the life of the swing circle assembly. The crane and/or
swing circle assembly manufacturer should be contacted for guidance when developing the
inspection procedures, as each crane is unique.

Bolts shall be correctly preloaded to function properly, and the crane manufacturer may be
the only source for proper torque / preload procedures and values.
General purpose bolt torque charts may not be applicable due to the various bolt materials,
plating, surface finishes, joint designs, etc. found in use. A loose or incorrectly preloaded
mounting bolt is one of the major causes of swing circle assembly failure.
iii) Operating Charateristics

The operating characteristics of a bearing are another factor to be considered in an inspection.

The crane should be rotated 360° in each direction at slow, intermediate, and full speed and
the smoothness of rotation monitored.
Any irregular, jerky, bumpy, etc. motions should be recorded, and further inspection may be
necessary.
Kingpost
A more secure method used by some manufacturers is the Kingpost, illustrated below.

In this method the slew bearings are relocated to either the top of the A - Frame (Kingpost) or to a
position inside the Pedestal (Kingpin).
As can be seen in the diagram, if the slew bearing failed the crane would come to rest against
either the post or the pedestal.
Bearing areas of the crane should be inspected to ensure that there is no significant wear or
damage to either the rotating or stationary load bearing members, which left uncorrected, might
result in a loss of structural integrity of the mounting system.
The King Post crane inspection procedure will depend on the design of the crane being inspected
and should be done in accordance with the manufacturer’s recommendations.
The inspection should include, but not limited to the details below:
a) Upper thrust bearing
b) Upper radial bearing
c) Lower thrust bearings or radial bearings
d) Kingpin wear and condition
e) Lower king post radial bearings.
The radial bearings condition is critical as it protects the king post from the lower thrust rollers
or radial bearings. On cranes not equipped with wear bearings or wear material, the wear zone
on the king post shall be carefully monitored to ensure the structural integrity of the king post.
f) King post - to - platform structural connection.
Hook & Roller Assemblies (illustrated below)

• Were originally designed and fitted to mobile cranes.

• May be found on converted cranes fitted to offshore pedestal cranes.
• Strong enough to withstand stability loads but can fail when overloaded on a fixed base (ie)
pedestals.
Hook Roller clearance is critical on these types of offshore cranes, hence they should be
inspected at regular intervals
Usually there are three or four assemblies used. Two at the rear & one or two at the front.
Ring Gear
The following apply to the inspection of Ring Gear.
a) Center pin and bushing condition should be verified and monitored for wear. Center pin wear
is generally due to improperly or unevenly adjusted hook rollers.
b) Proper lubrication of center pin bushing should be verified.
c) Obvious wear between ring gear teeth and swing pinion gear would indicate center pin wear
and improperly adjusted hook rollers
d) Excessive lateral wallowing, wobbling, or loud popping noise of machine base or frame
indicates center pin bushing wear.
Hook Rollers
The following apply to the inspection of Hook Rollers.
a) Hook rollers to turntable clearance should not exceed manufacturer specifications.
b) Hook rollers should be evenly adjusted to minimize uneven stress and wear on Center Pin and
Center Pin Bushing.
c) Hook roller path should be smooth, flat, and have no ridges or dents that would cause uneven
load distribution.
d) Hook rollers should be concentric with no flat spots
e) Bearings should be well lubricated and should roll smoothly with no noticeable popping or
grinding noise.
Hook Roller Brackets, Bracket Pads & Bolts
The following apply to the inspection of Hook Roller Brackets, Bracket Pads & Bolts
a) Machine should be tilted fully in both directions noting any deflection between the hook roller
bracket and the machined surface of the main frame pad where the hook roller bracket
mounts.
Consult manufacturer for tolerances
b) Hook roller bracket bolts should be checked for proper bolt torque, excess stretching, excess
rust pitting, improper size, etc.
Anti - Two Blocking Systems

This system is provided to protect hoist ropes, structural components and machinery from damage
which can occur when two sheave groups (ie) load block and boom head, come into contact as the
hoist cables are drawn in.
Note: Two - block systems are installed on cranes to assist the crane operators in the avoidance
of damage to the crane and cargo. These devices are not failsafe and should not be totally
depended on to protect the crane and cargo.

Ultimately the qualified operator is responsible for the safe operation of the crane and care
of the cargo that is to be handled.
Anti - Two - Blocking Testing Guidelines
The location of the hoist/s is important in order to determine the manner in which you test the two -
blocking systems.
If the hoist/s are mounted in or on the boom the two - blocking system only needs to stop the
upward motion of the main / auxiliary hoists or sound a warning device such as a horn or bell when
the load block or overhaul ball comes in contact with the two - blocking valve, hanging weight or
boom point.
If the hoist/s are mounted on the upper structure of the crane and the boom moves independent
the two - blocking system shall stop the upward motion of the main / auxiliary hoist the downward
motion of the boom hoist or sound a warning device when the load block or overhaul ball comes in
contact with the two - blocking valve or hanging weight.
Types of Two - Blocking Sytems & How They Should be Tested

a) Proximity Warning Device

This could be a horn or bell that would sound off when the block/s of the crane comes into
contact with a hanging weight that is attached to an air control valve or electric switch mounted
on the boom tip.

When the weight is lifted the control valve or electric switch should shift sending a signal down
the boom to the horn or bell.
When testing, the crane operator should raise the block/s up until each strike their respective
weights, the warning device should be capable of being heard over the sound of the engine at
full speed and any other noise that can affect the crane operator’s hearing.
Caution: This device is not designed to stop the hoist/s from coming into contact with the
boom point. The crane operator shall shift the control lever back to neutral.
b) Stalling of the Hoist Drum
This type of two - blocking system is used on some cranes where the hoist/s are mounted in or
on the boom.
It is easy to recognize, there is generally a wedge device hanging from the main pin in the
boom point. When the blocks are drawn into the boom point the hydraulic relief valve(s) in the
hydraulic circuit relieves the pressure from the system to stop the main/auxiliary hoist(s) from
moving in the upward direction.
When testing, the crane operator should raise the block/s slowly until each strikes the boom
point, then bring the engine to full speed and continue to pull slowly on the control lever until
the full system pressure is reached.
Caution: It is not advisable to get a running start to pull the block/s into the boom point at full
speed during the two - blocking test. If the crane is accidentally two - blocked
during normal operations at full speed the crane should be inspected before further
operations
c) Controlled Override Device
This type of two - blocking system could be an air, electric or hydraulic
system that when engaged stops the hoist from pulling before the
block/s run into the boom point.
An override device is allowed. The override can be used to bypass the
hoist up mode to raise the block a little more or lower the block to get
out of the two - block mode.
The crane operator should check to make sure the override device is not
engaged. Most override valves are spring loaded to automatically remove the
valve from the override position.
Then raise the block(s) slowly until each strikes the hanging
weight or hanging valve. The hoist being tested should stop.
Raise the engine to full speed while holding the hoist control in the full
up position. The hoist should not move or at worst case, creep up very
sowly.
Engage the override device and lower the block(s) a sufficient distance
to ensure the override device is not engaged. Engage the control lever
for the hoist to be tested in the up position.
When the block strikes the hanging weight or hanging valve the hoist
should stop completely within 12 in. to 18 in. (30.5 cm to 45.7 cm) or at
worst creep up slowly.
If the hoists are mounted on the upper structure and the boom is
independent, the two - blocking system shall be tested to make sure the
boom down function will stop if the two - blocking hanging valves or
hanging weights are engaged.
Raise the boom to approximately 45 degrees.
Lower the block(s) a few inches below the two - blocking hanging valves or
hanging weights.
Lower the boom slowly if an auxiliary hoist is on the crane the overhaul
ball should strike the hanging two - block device first, the boom should
stop going down immediately.
Engage the override and lower the overhaul ball down sufficient distance to
ensure the anti – two
- block device is not engaged. Attempt the same test on the main block,
the same results should be obtained

Caution: If the override valve is engaged the two - blocking system is

bypassed. If conducting the test at full speed, be prepared to
shift the control lever back to neutral if the speed does not
drastically change when the block(s) strike the hanging
weight or hanging valve.
d) No Override Two - Blocking System

This system was designed to eliminate the need for an over - ride device.
If the crane operator engages any part of the two - blocking or high
angle safety system, the operator only needs to reverse the control lever
to get out of the two - block safety mode.
This test can be performed as described for Proximity Warning Device,
without the need to check the override valve or to engage the override
to get out of the two - block safety mode
A qualified crane operator or qualified inspector should operate the
crane while testing safety devices.