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BRIDGE CRANES
AND GANTRY ELECTRIC

GENERAL TECHNICAL CONDITIONS

GOST 27584-88

PUBLISHING HOUSE OF STANDARDS

Moscow

STATE STANDARD OF THE USSR UNION

Valid from 01.01.90

before 01.01.95

Combinations of indicators for groups of crane operating modes should be established taking into account their actual use. Combinations of indicators are given.

2.2. Reliability requirements

2.3.6. The painting of the crane must be carried out by the consumer at the installation site in accordance with the manufacturer’s instructions set out in the operational documentation for the cranes.

(Changed edition, Amendment No. 1).

2.4.16. When the crane cabin is located at a height of more than 8.0 m from the level of the crane platform, if necessary, the crane must be equipped with an intercom that provides reliable communication with the crane workers. The installation of the intercom is provided by the consumer.

2.6.22. Deviations from the nominal dimensions and relative positions of the running wheels must not exceed the values ​​specified.

2.6.25. The radial runout of the working surface of the brake pulley after installation on the shaft should not exceed the total tolerance for the diameters of the pulley and shaft.

The radial runout of the working surface of the brake pulley (part) should not exceed the values ​​specified.

2.6.26. The radial runout of the running wheel tread should not exceed 0.2 mm for every 100 mm of diameter.

The hardness reduction gradient should be no more than 20 HB per 10 mm of wheel rim thickness.

2.7. Material requirements

2.10.3. When sending operational and shipping documentation along with the crane, it must be packed in moisture-proof packaging and placed in a box or crane operator's cabin along with components.

3. ACCEPTANCE

3.1. The manufacturer carries out acceptance and periodic tests of cranes in the manner and according to the program agreed with the consumer of the cranes. The acceptance testing program must include testing of all assembly units of metal structures and mechanisms, electrical equipment and the crane operator's cabin. At the same time, they check the correct use of materials, the quality of welded joints and coatings, and the operation of all mechanisms when idle.

3.2. One of the commercially produced cranes is subjected to periodic testing: with an annual production of cranes from 10 to 50 pcs. - at least once every 5 years and with an annual output of more than 50 pieces. - at least once every 3 years. When producing less than 10 taps per year, the frequency of testing is established in accordance with the technical specifications for the manufacture of taps.

When carrying out periodic tests, the following are checked: load capacity, speed of working movements, lifting height of cargo hooks, horizontal movements of cargo hooks, values ​​of reliability indicators, accuracy of the installation of road wheels, operation of anti-theft devices, sound level in the cabin, operation of devices for evacuating the crane operator from the cabin and the condition of external coatings of metal structures and mechanisms.

The retest program must be agreed upon with the consumer.

If the results of periodic tests are unsatisfactory for at least one item of the program, repeated tests should be carried out on another sample of the crane of the same series.

The results of repeated tests are final.

3.1, 3.2. (Changed edition, Amendment No. 1).

4. TEST METHODS

4.1. Reliability indicators (;) are checked in accordance with .

When carrying out static tests of overhead cranes, the following is checked:

the operation of each of the load lifting mechanisms when lifting the load to a height of 200 - 300 mm;

deflection of one of the bridge span beams in the center of the span during operation of the main lift mechanism(s) and the location of the cargo trolley in the center of the span. Deflection measurements should be carried out with an accuracy of at least 10% of its nominal design value.

Static tests are carried out with a load exceeding 25% of its load capacity.

When performing dynamic tests, the operation of all crane mechanisms should be checked.

The operation of the crane movement mechanisms is checked with the load trolley located in the center of the span and at both edges of the span. In this case, at least three work cycles are performed for each position of the working trolley. The load must be lifted to the maximum possible height. The length of the travel path of the crane for each cycle must be equal to at least three times the size of the crane base.

Dynamic tests are carried out with a load exceeding the crane’s lifting capacity by 10%.

4.9. The speeds of working movements are measured when working with a nominal load and idle.

The measurement accuracy must be at least 3% of the nominal values ​​of the corresponding speeds.

4.10. The lifting height and stroke length of the load hooks should be checked during idle operation. Measurement accuracy - no less than 30 mm.

4.11. The energy consumption of the crane should be checked when operating with a load equal to 50% of its lifting capacity. During measurements, at least 10 operating cycles are performed, measurement accuracy is at least ±5%.

5. TRANSPORTATION AND STORAGE

5.1. Transportation

5.1.1. Cranes should be transported by rail, road, sea and river transport.

5.1.2. Loads on open rolling stock should be placed and secured in accordance with the requirements:

when transporting by rail - GOST 22235, “Technical conditions for loading and securing cargo on open rolling stock”, “Rules for the transportation of goods”, approved by the Ministry of Railways of the USSR;

Operating mode

The GPM operating mode is set in accordance with GOST 25546–82 and standard ISO 4301/1–88. The PMG operating mode group is determined depending on the class of its use and load class. Thus, this characteristic of the crane takes into account the degree of load of the crane over the entire period of its use.

The choice of the PMG operating mode affects to economic and technical aspects of the enterprise. The operating mode of the crane and its cost are interconnected, since the higher the operating mode, the higher the costs of its production, and, consequently, the higher the final price for the client. The price difference between hydraulic and hydraulic machines with the same load capacity and span, but different operating modes, may differ. Accordingly, we conclude: you should not choose a heavy-duty crane operating mode, because... this may not be economically feasible.

When trying to save money and put into operation a PMG with a light duty cycle, it can lead to even more dire consequences. Long-term maximum loads on PMG with light operating mode, not intended for heavy work leads to increased wear of equipment mechanisms, their repair - as a result, equipment downtime leads to economic losses at the enterprise. As a result, the crane may not last the service life set by the manufacturer. The conclusion follows from this that the light operating mode of the crane is not intended for long-term loads with a weight close to the nominal one.

Determining the operating mode of a crane in production is not easy, since reliable initial data is needed, which the future owner of the crane often does not have. It is good if the faucet being purchased is purchased to replace an old one or if a similar one already exists in production. In this case, it is possible to collect initial data to calculate the optimal operating mode. If possible, it is advisable to order a visit from a gas and mechanical engineering specialist to determine the crane mode on site. And even in these cases, it is difficult to collect the necessary, and most importantly reliable, information about the nature of the goods being moved and the intensity of the crane’s work, since a rather long period of time and accurate calculation of this information are required.

SERVICE LIFE OF GPM

The service life of lifting machines is regulated by state standards, technical specifications and other regulatory documents.

On average, a faucet lasts 25–30 years.

The service life of cranes that operate outdoors can be 25% lower than that of a crane that operates indoors.

Each crane has a certain service life, specified in its technical passport, after which the mechanism must be decommissioned or examined for its further use.

The service life of the crane depends on the service life of the supporting metal structures. Practice shows that during the operation of a crane, during its service life, almost all attached parts (electric motors, pulley system, brake system) wear out and are replaced with new ones.

Cranes and lifting machines, depending on their purpose, design, nature and operating conditions, are designed for a certain service life (5-30 years), during which they must be sufficiently reliable and safe in operation.
The service life of lifting machines is regulated by state standards, technical specifications and other regulatory documents.

For example, service life before write-off jib self-propelled cranes according to GOST 22827-85 should not exceed:

• 10 years - for truck cranes,
• 11 years - for cranes with a lifting capacity of up to 16 tons,
• 12 years – for cranes with a lifting capacity from 16 to 40 tons,
• 13 years - over 40 to 100 tons, 16 years - over 100 tons.

According to GOST G3556-85 service life of tower cranes The following are installed:

• 10 years - for cranes with a lifting capacity of up to 10 tons;
• 16 years - for cranes with a lifting capacity of over 10 tons.

Service life of overhead and gantry cranes installed indoors, depend on the operating mode and design and are selected according to GOST 27584-88. For example, for cranes with a load trolley having a mode group 1K, 2K - 30 years, 4K, 5K - 25 years, 6K, 7K - 20 years. For faucets installed outdoors, service life is reduced by 25%.
Service life of tractor cranes should not exceed 10 years according to the Standards of depreciation for fixed assets of the national economy.
The service life is 25 years for railway and portal cranes according to “Standard service life of lifting and transport machines and equipment”.

CRANE INSPECTION

The service life of a lifting machine is indicated in its passport and operating instructions. At the end of its service life, the crane should not be allowed to operate and must be scrapped. However, tens of thousands of load-lifting cranes continue to work at enterprises and construction sites of the national economy after the expiration of their standard service life.

This is explained as follows:

• firstly, replacing old machines requires many new ones, the production of which is still insufficient;
• secondly, certain time and money are needed to dismantle old machines (for example, overhead cranes), install and install new ones;
• thirdly, not all machines that have served the standard period are out of order or are in disrepair.

At enterprises where supervision of the maintenance and safe operation of lifting machines is well organized, maintenance, preventive repairs and technical examinations are carried out in a timely and high-quality manner, the lifting machines are in good condition and can still operate reliably and safely for a certain time, even after the expiration of the standard service life .

To determine the technical condition, degree of reliability and suitability for use of lifting machines that have completed their standard service life (being in operation for a long time), or to make a decision on the need for their repair, reconstruction, or decommissioning, special examinations are carried out.
During a special inspection, the limiting state of the crane is determined.
Currently, there are several regulatory documents for the inspection of lifting machines, including: guidelines for conducting an inspection of assembly cranes with expired service life in order to determine the possibility of their further operation.

Tower cranes

Guidelines for conducting inspections of cranes with expired service life, RD 10-112-2-09 SKTB tower crane engineering;

Guidelines for conducting an inspection of metal structures of cranes in order to determine the possibility of their further operation, VNIIPT-mash, etc.

The inspection of cranes is carried out by a commission appointed by order of the enterprise (organization) that owns the cranes. The chief engineer of the enterprise or his deputy is appointed as the chairman of the commission. The commission includes: the chief mechanic of the enterprise or his deputy;

• the person responsible for maintaining the cranes in good condition;
• Supervision engineer for lifting machines;
• crane operator;
• welding, repair and energy specialists;
• representatives of specialized installation organizations;
• representatives of manufacturing plants and research institutes for lifting machines.

For enterprises operating a significant number of cranes (over 50), permanent commissions are created from employees of specialized services for operation and repair.

Crane inspection services are carried out by specialized organizations that have permission from the state mining and technical supervision authorities and have been certified in its engineering and consulting centers, as well as specialized divisions of VNIIPTmash.
The limiting state of a crane or assembly is understood as such a state, determined by safety requirements or reduced performance, in which their further operation is advisable or technically possible. The occurrence of a limit state corresponds to the failure of the crane or its assembly.
It must be taken into account that the conditions for the occurrence of one or another limit state depend on the nature of the loads, the accessibility of the crane elements for systematic inspection, etc.

Currently, the practice of conducting industrial safety assessments of technical devices has become widespread. The economic situation that has developed in our country is characterized by low investment activity and, as a consequence, a high rate of depreciation of fixed assets. As a consequence, the problem of ensuring the safe operation of equipment, the service life of which largely dominates the standard one, is of great economic importance. The very idea of ​​extending the time of safe operation of equipment with an expired service life through its qualified inspection was first tested on cranes back in 1976. Therefore, then the USSR State Mining and Technical Supervision Service ordered the owners lifting cranes carry out inspections of metal structures after reaching the standard service life on their own. After this, work to assess the technical condition of load-lifting cranes to identify the possibility of their further operation consisted of an examination of both load-bearing metal structures and mechanisms and was carried out by specialized organizations that had permission for this type of activity.

Currently, on the basis of this, the Industrial Safety Expertise System has been created.

Since 2002, work to extend the safe operation life of technical devices, as well as load-lifting cranes, has been carried out in accordance with the “Regulations on the procedure for extending the safe operation life of technical devices, equipment and structures at hazardous production facilities” RD 03-484-02, approved by Gosgortekhnadzor Russia (Resolution No. 343 of 07/09/02) and registered with the Ministry of Justice of the Russian Federation.

In accordance with this document, the examination of a technical device must include determining the residual life of its safe operation to minimize the risk of accidents. This gave impetus to work on the development of a number of methods for assessing the residual life by calculation. But, relatively lifting cranes, metal structures which are repairable and, as a result, their resource is restored, for which the durability indicators of individual components and elements depend on many factors influencing their formation (design features, installation quality, manufacturing technologies, operating conditions), the calculation of the residual resource can be carried out with some approaching.

Despite the fact that currently, hoisting cranes with expired service life are allowed to continue operating only if a positive conclusion is reached based on the results of the examination, accident rates on lifting structures high. This is explained as follows.

A large number of objects have been diagnosed more than once and need to be taken out of service. But for the owners of the equipment, the task remains the same - it is necessary to achieve another positive expert opinion, which will help extend the life of the technical device, and not buy a new crane. Some organizations conducting examinations, in some cases, due to their irresponsibility and incompetence, encourage the owner and issue a positive conclusion that does not reflect the actual state of the object of examination.

At the same time, the examination does not contain an analysis of diagnostic results or instrumental monitoring of parameters that outline the state of those structures and assemblies that affect the reliability and safety level of the equipment as a whole. The results of such conclusions generally lack recommendations, the use of which would help increase safety when using the crane for the period established by the results of the examination.

The owner of the equipment, determined to formally resolve the issue of extending the service life, also does not seek to receive qualified recommendations for carrying out technical measures, the task of which is to actually increase the reliability of the equipment. As a result, the effectiveness of the examination is significantly reduced.

However, the accumulated experience in carrying out examination lifting cranes asserts in most cases, when it comes, in particular, to overhead cranes, that there are alternatives by introducing changes to existing crane designs to transfer them to an operating mode in which the machine is less exposed to dynamic loads. This helps improve machine durability. In accordance with GOST 27.002 - 89, this indicator describes the property of an object to maintain an operational state until a boundary state occurs.

Therefore, in a situation where there is no chance of a one-time decommissioning with subsequent replacement of a large amount of equipment with an expired service life, it becomes necessary to search for alternative solutions to extend its safe operation life.

Significant margin of increase in application efficiency overhead cranes is the improvement of control systems for crane electric drives, which use electric motors with a wound rotor, which can change the loading mode of the drives from stepped to smooth. At the same time, the set intensity of acceleration and braking creates a significant (from 20 to 40% depending on the type of drive) reduction in dynamic loads created in the basic units of mechanisms and load-bearing metal structures of cranes as a result of cyclic alternating operation of drives. In parallel, other troubling issues related to the majority of bridge-type cranes used today, containing control systems for crane drives, created on the model of circuit solutions of the second half of the last century, can actually be resolved.

For example, one of the disadvantages of these systems is the lack of high-quality protection against overloads generated in the electric drives of working mechanisms when the standards and instructions are violated by production personnel during operation lifting machine for its intended purpose or the creation of technical breakdowns caused by untimely or unqualified maintenance of the machine during operation. Distortions caused by “overrunning” of one of the sides are one of the widespread types of failures in bridge-type crane structures. The reason for this is the non-synchronism of the functioning of the movement mechanisms crane caused by a breakdown in electrical and (or) kinematic circuits. Distortions cause increased wear on the running wheels and guides along which the crane moves, wear in kinematic pairs, cracks in metal structures and early failure of electric motors, which ultimately reduces the service life of the machine.

The human factor plays a leading role in ensuring industrial safety. Reducing the influence of this factor on the level of industrial safety by introducing technical means into the machine design that can carry out “deep” diagnostics of the most critical components at periodic intervals, allowing timely receipt of information about changes in the operation of mechanisms at an early stage, as well as disabling machine control when exceeding controlled parameters due to incorrect actions of the person who operates the machine is the most popular in solving the problem of increasing the reliability of equipment operation and reducing the risk of accidents.

Therefore, improvement of control systems crane electric drives should contain a chance to monitor (control) the technical condition of components during operation lifting machine with the implementation of multi-level adjustable current protection in three phases of the electrical network, consisting of several shutdown zones, the limits of which are delineated by the values ​​of current and time settings depending on the electrical and thermal characteristics of the protected object and operating conditions.

The chance not only to control, but also to limit the actions of maintenance personnel when such a need arises, thereby limiting the onset of negative consequences, will undoubtedly have a positive impact on the dynamics of the growth of accidents and injuries at lifting structures.

The focus of the owners of lifting structures on improving equipment based on the results of the examination will ultimately help extend the operating time of the equipment and at the same time minimize the risks of accidents.

Basic rules for operating truck cranes

Before putting into operation, the truck crane must be registered with the Gosgortekhnadzor authorities. The purpose of registration is to register the crane with the local Gosgortekhnadzor inspection for monitoring and supervision of its operation. In addition, the crane must be registered with the traffic police.

After reconstruction or repair (if a new passport was drawn up for the crane), as well as upon transfer to a new owner, the crane is again subject to registration (re-registration).

Cranes are registered with the Gosgortekhnadzor authorities on the basis of a written application from the management of the owner-company and the crane’s passport. The owner of an automobile crane is considered to be the enterprise (organization) on whose balance sheet the crane is located. When transferring a crane for temporary use to another organization, the owner’s functions can be transferred to this organization, but in this case, the fact of transfer of the owner’s functions must be reflected in the contract for the transfer of the crane.

The passport on the basis of which the crane is registered is drawn up by the manufacturer, the owner of the crane (if the manufacturer’s passport is lost) or the organization that reconstructed the crane. In all cases, the crane passport is drawn up in accordance with the requirements of the Rules.
If an organization sends its crane to work in another area, it must inform the technical supervision body in which the crane is registered, indicating the registration number of the crane, the place of its new work and the period of its stay there. In addition, upon the arrival of the crane at the work site, the work manager is obliged to inform the local technical supervision authority about the arrival of the crane and obtain a work permit.

If the faucet becomes unusable, it must be deregistered. Faucets that are transferred to the balance sheet of another owner are also subject to deregistration.

A permit to put into operation an automobile crane supplied to the owner by the factory in assembled form is issued upon its registration on the basis of the results of testing the crane at the manufacturer recorded in the passport and a technical examination (without a load test) carried out by the owner.

Permission to put a newly registered crane into operation (after reconstruction, repair or transfer of the crane to a new owner) is issued by the local technical supervision inspector based on the results of a full technical examination of the crane carried out by the enterprise. The inspector carries out a control check of the condition of the crane and writes down the work permit in its passport.

The technical examination is aimed at establishing that the crane and its installation comply with the Gosgortekhnadzor Rules and the documentation submitted during registration; the edge is in good condition, ensuring its safe operation; crane maintenance complies with the Rules.

A complete technical examination of an automotive paint includes inspection, static and dynamic tests; During partial survey, static and dynamic tests are not performed.

All mechanisms, electrical equipment, safety devices, brakes and other control equipment, lighting, alarms and dimensions regulated by the Rules are subject to inspection and testing during operation. In addition, they check the condition of metal structures and their connections, cabins, stairs, platforms and fences, the condition of ropes, the hook and its suspension parts.

Static tests of the crane are carried out with a load 25% greater than its lifting capacity. The purpose of such tests is to check the strength of individual components and the load stability of the machine. Dynamic tests are carried out with a load 10% greater than the crane's lifting capacity in order to check the operation of the crane mechanisms and their brakes.

Newly installed cranes undergo a full technical inspection before being put into operation. Cranes in operation are subject to periodic technical inspection: partial - at least once every 12 months and complete - at least once every three years.

After reconstruction of the crane, repair of its metal structures with replacement of design elements and components, installation of newly acquired types of replaceable working equipment, including hook hangers, as well as after major repairs or replacement of winches, the truck crane is subjected to an extraordinary full technical inspection.

After changing worn out ropes, as well as in all cases of repositioning them (for example, installing a grab instead of a hook, installing a boom insert, installing a jib), check the correct reeving of the rope, the reliability of fastening its ends and tighten the ropes with a working load.

A complete initial technical examination of the manufactured automotive crane is carried out by the quality control department of the manufacturer before sending the vehicle to the owner. If the crane has been repaired at a specialized repair enterprise, then a full initial technical examination after repair is carried out by the quality control department of this enterprise before sending the machine to the owner. The date of the inspection and its results are recorded in the crane passport.

Periodic technical inspection is carried out by the company that owns the crane: engineering and technical workers supervising lifting machines with the participation of those responsible for the good condition of the truck crane. The correctness of the ropes, the reliability of fastening their ends and the tightness is checked by the person responsible for the good condition of the machine.

The results of the technical examination are recorded in the vehicle crane passport indicating the date of the next examination. The record must confirm that the crane was manufactured (mounted and installed) in accordance with the Rules and Specifications and has passed strength and stability tests.

The crane passport and operating instructions are the most important technical documents in which the operator can find the answer to almost any question related to the design and operation of the crane and its operation.

The crane passport contains basic data about the crane: information about its manufacturing registration and permission to put it into operation; technical characteristics of the crane and data on the main components (motors, brakes, ropes, hooks) and materials; characteristics of safety devices. During operation, the passport contains information about the location of the crane, about the persons responsible for its good condition, about the repair of metal structures and the replacement of mechanisms, ropes, load-handling member, the results of the examination of the crane, information about its registration.

The operating instructions contain a technical description of the crane, instructions for its operation, as well as instructions for maintenance, installation, start-up, adjustment and running-in of the crane at the site of its use.

The operating instructions provide information about the purpose of the crane and its technical characteristics; description of the design and operating principle of all its main components, mechanisms and systems (drives, control transmissions, working equipment, instruments and safety devices, electrical equipment and main metal structures); instructions for operating the crane, basic rules for its operation, instructions for installing and dismantling working equipment; basic rules for crane maintenance, indicating the permissible amounts of wear and damage, as well as possible failures (or signs thereof) of the main components and the malfunctions that cause them; information about adjustments of main components, mechanisms and systems; information about the storage and transportation of cranes, as well as information about the manufacturer’s guarantees and the procedure for filing complaints.
The instructions are accompanied by: a list of spare parts, tools and accessories supplied with the crane; lists of bearings, ropes, cuffs and rings used on the crane, as well as operating instructions for the base vehicle and its engine, electric and hydraulic machines, compressors and other components.

TO Category: - Crane maintenance