BS ISO 12482-2014 Cranes Monitoring for crane design working period《起重机 起重机设计工作周期的监测》.pdf

1、BSI Standards PublicationBS ISO 12482:2014Cranes Monitoring for cranedesign working periodBS ISO 12482:2014 BRITISH STANDARDNational forewordThis British Standard is the UK implementation of ISO 12482:2014.The UK participation in its preparation was entrusted to TechnicalCommittee MHE/3/11, Crane sa

2、fety and testing.A list of organizations represented on this committee can beobtained on request to its secretary.This publication does not purport to include all the necessaryprovisions of a contract. Users are responsible for its correctapplication. The British Standards Institution 2014. Publishe

3、d by BSI StandardsLimited 2014ISBN 978 0 580 79513 8ICS 53.020.20Compliance with a British Standard cannot confer immunity fromlegal obligations.This British Standard was published under the authority of theStandards Policy and Strategy Committee on 30 September 2014.Amendments issued since publicat

4、ionDate Text affectedBS ISO 12482:2014 ISO 2014Cranes Monitoring for crane design working periodAppareils de levage charge suspendue Surveillance continue de la priode dactivit de conceptionINTERNATIONAL STANDARDISO12482First edition2014-09-01Reference numberISO 12482:2014(E)BS ISO 12482:2014ISO 124

5、82:2014(E)ii ISO 2014 All rights reservedCOPYRIGHT PROTECTED DOCUMENT ISO 2014All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting on the internet

6、 or an intranet, without prior written permission. Permission can be requested from either ISO at the address below or ISOs member body in the country of the requester.ISO copyright officeCase postale 56 CH-1211 Geneva 20Tel. + 41 22 749 01 11Fax + 41 22 749 09 47E-mail copyrightiso.orgWeb www.iso.o

7、rgPublished in SwitzerlandBS ISO 12482:2014ISO 12482:2014(E) ISO 2014 All rights reserved iiiContents PageForeword ivIntroduction v1 Scope . 12 Normative references 13 Terms and definitions . 14 Recording crane operation 24.1 General . 24.2 Methods for counting duty . 24.3 Safety factor for duty cou

8、nting 35 Assessment of design working period . 35.1 General . 35.2 Schedule 35.3 DWP calculation method 36 Special assessment . 46.1 General . 46.2 Criteria for special assessment . 46.3 Responsibilities of crane user/owner . 46.4 Manufacturers instructions 56.5 Report . 57 General overhaul (GO) 57.

9、1 General . 57.2 Categories of actions 5Annex A (normative) DWP calculation for cranes designed to ISO 43011 . 7Annex B (normative) DWP calculation for hoisting mechanisms designed to ISO 43011 .10Bibliography .13BS ISO 12482:2014ISO 12482:2014(E)ForewordISO (the International Organization for Stand

10、ardization) is a worldwide federation of national standards bodies (ISO member bodies). The work of preparing International Standards is normally carried out through ISO technical committees. Each member body interested in a subject for which a technical committee has been established has the right

11、to be represented on that committee. International organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.The procedures us

12、ed to develop this document and those intended for its further maintenance are described in the ISO/IEC Directives, Part 1. In particular the different approval criteria needed for the different types of ISO documents should be noted. This document was drafted in accordance with the editorial rules

13、of the ISO/IEC Directives, Part 2 (see www.iso.org/directives).Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of any patent rights identifie

14、d during the development of the document will be in the Introduction and/or on the ISO list of patent declarations received (see www.iso.org/patents).Any trade name used in this document is information given for the convenience of users and does not constitute an endorsement.For an explanation on th

15、e meaning of ISO specific terms and expressions related to conformity assessment, as well as information about ISOs adherence to the WTO principles in the Technical Barriers to Trade (TBT) see the following URL: Foreword - Supplementary informationThe committee responsible for this document is ISO/T

16、C 96, Cranes, SC 5, Use, operation and maintenance.ISO 12482 cancels and replaces ISO 12482-1:1995, which has been technically revised.iv ISO 2014 All rights reservedBS ISO 12482:2014ISO 12482:2014(E)IntroductionCranes are designed for a finite lifetime duty, which is specified in load cycles and lo

17、ad spectrum and is not principally related to calendar working time. Classification of crane duty provides the crane owner a means to specify the intended duty in order to achieve the intended useful operational lifetime of the crane.Typically the operational period for industrial cranes is from 10

18、to 20 years. However, a specified crane classification may be related to any calendar time depending on the application, e.g. 5 to 10 years for a special limited use or 40 years for a long-term investment.Monitoring of crane use does not in any way change requirements for periodic inspections of the

19、 cranes, independent of whatever type of instruments are used for the monitoring. Neither does it remove the requirement for regular maintenance of cranes. Inspections and monitoring of use are methods, which complete each other, giving different information of the condition.The design working perio

20、d (DWP) introduced in this standard is derived from the design classification of cranes and is not to be considered as a guaranteed operational period in any respect. Due to the probabilistic nature of metal fatigue and other influencing factors, premature failures during the DWP cannot be ruled out

21、. However, the DWP represents a reliable estimate of a safe operational period of the crane, with due consideration to specified design regulations and standardized design safety factors. ISO 2014 All rights reserved vBS ISO 12482:2014BS ISO 12482:2014Cranes Monitoring for crane design working perio

22、d1 ScopeThis International Standard specifies a method for monitoring, during long-term operation, the actual duty of the crane, and a means of comparing this to the original design duty which was specified through classification. The related design standard is ISO 4301-1. Approaching the design lif

23、e limit means an increased probability of hazards. Monitoring of crane use as described herein provides a tool for predicting the approach of the design limits and for focusing special inspections on the critical areas of a crane.This International Standard is intended to be used for adjusting/modif

24、ying the inspections defined in ISO 9927-1.It is applicable to cranes with a permanent construction throughout the life of the crane.It is not applicable to mobile or tower cranes, except permanently installed tower cranes.NOTE The method specified in this International Standard can be adapted to st

25、andards or rules other than ISO 4301-1 which specify classifications.2 Normative referencesThe following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references

26、, the latest edition of the referenced document (including any amendments) applies.ISO 4301-1:1986, Cranes and lifting appliances Classification Part 1: GeneralISO 4306-1, Cranes Vocabulary Part 1: GeneralISO 9927-1, Cranes Inspections Part 1: General3 Terms and definitionsFor the purposes of this d

27、ocument, the terms and definitions given in ISO 4301-1, ISO 4306-1 and the following apply.3.1design dutyproduction capacity of a crane or hoist during its total useful operational period, specified by the original design classification3.2design lifeestimation of the allowable period of use for a cr

28、ane based on its original design specifications and taking into consideration the load cycles and load spectra expected during its intended usage3.3design working periodDWPoperation period in a specific actual duty, within which the design duty is reachedINTERNATIONAL STANDARD ISO 12482:2014(E) ISO

29、2014 All rights reserved 1BS ISO 12482:2014ISO 12482:2014(E)3.4special assessmentSAthorough examination and evaluation of the crane or hoist, to be made when the actual crane or hoist duty approaches the design duty3.5general overhaulGOall refurbishment and maintenance actions based upon a special a

30、ssessment (SA), required to extend the safe operation life of a crane3.6work cycleoperating sequence starting from hoisting a load, transferring the load, lowering and grounding the load, detaching the load and moving the unloaded load lifting attachment back to a starting position ready to hoist an

31、other load4 Recording crane operation4.1 GeneralThe crane owner should keep records of the crane use, adequate to identify the criteria specified by the crane manufacturer and applicable to carry out the assessments described in this standard. Records should also be kept of maintenance, inspections,

32、 repairs, modifications and exceptional occurrences, e.g. overloads, extreme climatic conditions and collisions. Records should be updated at least once a year during periodic inspections, see ISO 9927-1.4.2 Methods for counting dutyEstimation of the duty history can be divided into the following ca

33、tegories, based on systematic and reliable data collection and documentation procedures.a) Crane operation data are recorded by a special, purpose-built system, which always operates automatically when the crane is in use. The crane operator does not have a possibility to switch off the recording sy

34、stem.b) The crane is provided with counters recording the crane operation data. The user collects and documents the operation data manually from the counters.c) The crane duty history is calculated based upon a regular process in which the crane is working. The crane is an integral part of the proce

35、ss. Process data are documented.d) The crane duty history is estimated based upon a general production data of the site where the crane is working.e) The crane duty history is incomplete.f) The crane duty history is unknown (e.g. in the case of a second-hand crane). The duty for DWP calculation is b

36、ased on estimate or assumed to be according to design classification and design life reduced using the factor f1from Table 1, item 5.The basic Information for counting the crane use is in all cases provided by the crane owner/user.Where recording instruments or counters are installed, the user shoul

37、d regularly inspect the instruments to ensure that they are properly functioning.2 ISO 2014 All rights reservedBS ISO 12482:2014ISO 12482:2014(E)4.3 Safety factor for duty countingWhen calculating the design working period (DWP) of a crane, the estimated duty from the history shall be increased by a

38、 safety factor, f1, according to Table 1, to cover the unreliability in the duty recording and estimation.Table 1 Safety factor f1for duty countingNo. Method of duty recording f11 Automatic recording system, 4.2 a), orCounters and manual documentation, 4.2 b)1,02 Estimation based upon a special, doc

39、umented process, 4.2 c) 1,13 Estimation based upon documented production of the crane site, 4.2 d) 1,24 Estimation based upon undocumented, estimated production of the crane site, 4.2 e) 1,35 Crane duty history is unknown, 4.2 f) 1,55 Assessment of design working period5.1 GeneralMany components of

40、a crane may fail because of metal fatigue, which is difficult to predict or estimate by physical inspections. Safeguarding against fatigue failure by physical inspections may be difficult due to the following: the safe time window for an inspection from detectable to critical crack size can be short

41、, leading to unnecessary frequent inspections; detecting a fatigue crack would require in many cases a full disassembly of a component; planning and scheduling future repairs of the crane is not possible, and non-acceptance by an inspection typically requires immediate action and possibly interrupti

42、on of crane operation.The purpose of the assessment of DWP is to estimate accumulated duty of the crane and assess its remaining life.It is assumed that all periodic inspections scheduled for the crane have been carried out, any damage suffered during the operation is recorded and appropriately repa

43、ired, and maintenance work, as well as replacement of worn parts, is carried out in accordance with the manufacturers instructions.5.2 ScheduleCollecting the data on the use of a crane and the assessment of DWP should be carried out in conjunction with periodic inspections (see ISO 9927-1) at 12 mon

44、th intervals.5.3 DWP calculation methodThe applied DWP calculation method should follow the specification and classification of the original design standard as closely as possible. Annexes A and B give DWP calculation methods for cranes classified and designed in accordance with ISO 4301-1.The DWP c

45、alculation shall cover both the crane as a whole (structures) and the mechanisms. ISO 2014 All rights reserved 3BS ISO 12482:2014ISO 12482:2014(E)The classification and design basis in the older standards might not be according to the state of the art. In order to have a solid theoretical basis for

46、the DWP calculation, the owner may ask the manufacturer or an expert engineer (see ISO 9927-1) to conduct a re-calculation in accordance with the applicable crane standards.6 Special assessment6.1 GeneralThe special assessment goes into more detail and deals with critical components of the structure

47、/hoisting mechanisms of the crane. The special assessment shall contain both a theoretical part, where the remaining DWP of each critical component of the crane is analysed based on the recorded, actual duty, and a practical part, where the crane is subjected to a major inspection in accordance with

48、 ISO 9927-1.Once it has reached the end of its design life, the crane may only be used after a general overhaul, based on a special assessment, has been carried out.It should be recognized that the different components of the crane approach the design limits at different intervals, depending on the

49、type of use and the configuration of the crane. These differences should be considered in the special assessment by selecting only the most critical components regarding the fatigue behaviour.The theoretical analysis of the components remaining DWP does not have to rely on the methods of the original design standard, but state-of-the-art methods may be applied instead. The revised analysis should take into consideration the actual, measured work cycles and their true effect on fatigue of the components. Information on