1、BSI Standards PublicationBS 7121-2-9:2013Code of practice for the safeuse of cranesPart 2-9: Inspection, maintenanceand thorough examination Cargohandling and container cranesPublishing and copyright informationThe BSI copyright notice displayed in this document indicates when the documentwas last i
2、ssued. The British Standards Institution 2013Published by BSI Standards Limited 2013ISBN 978 0 580 78198 8ICS 53.020.20The following BSI references relate to the work on this document:Committee reference MHE/3/11Draft for comment 13/30259760 DCPublication historyFirst published September 2013Amendme
3、nts issued since publicationDate Text affectedBS 7121-2-9:2013 BRITISH STANDARDContentsForeword iiIntroduction 11 Scope 12 Normative references 13 Terms and definitions 24 General 25 Personnel carrying out pre-use checks, in-service inspections, maintenanceand thorough examinations 26 Pre-use checks
4、 and in-service inspections 27 Maintenance of cargo handling and container cranes 58 Thorough examination of cargo handling and container cranes 99 Overload testing of cargo handling and container cranes 1510 Non-destructive testing of cargo handling and container cranes tosupplement thorough examin
5、ation 1711 Assessment of wire rope condition and discard criteria 18AnnexesAnnex A (informative) Container cranes Examples of checklists for pre-usechecking and in-service inspection 19Annex B (informative) Mobile harbour cranes Examples of checklists forpre-use checking and in-service inspection 21
6、Annex C (informative) Straddle carrier cranes and rubber tyred gantry cranes Examples of checklists for pre-use checking and in-service inspection 23Annex D (informative) Level luffing and slewing jib cranes Examples ofchecklists for pre-use checking and in-service inspection 26Annex E (informative)
7、 Crane container top safety frames (man riding cages) usedto access containers on ships Examples of checklists for pre-use checking andin-service inspection 27Annex F (informative) Container spreaders Examples of checklists for pre-usechecking and in-service inspection 28Bibliography 31Summary of pa
8、gesThis document comprises a front cover, an inside front cover, pages i to iv,pages 1 to 32, an inside back cover and a back cover.BRITISH STANDARD BS 7121-2-9:2013 The British Standards Institution 2013 iForewordPublishing informationThis sub-part of BS 7121-2 is published by BSI Standards Limited
9、, under licensefrom the British Standards Institution and came into effect on 30 September2013. It was prepared by Subcommittee MHE/3/11, Crane safety and testing,under the authority of Technical Committee MHE/3, Cranes and derricks. A list oforganizations represented on these committees can be obta
10、ined on request totheir secretary.Relationship with other publicationsThe BS 7121 series is being revised. The following new sub-parts of BS 7121-2have been published or are in preparation. Part 2-1: Inspection, maintenance and thorough examination General; Part 2-3: Inspection, maintenance and thor
11、ough examination Mobilecranes; Part 2-4: Inspection, maintenance and thorough examination Loadercranes; Part 2-5: Inspection, maintenance and thorough examination Towercranes; Part 2-7: Inspection, maintenance and thorough examination Overheadtravelling cranes including portal and semi-portal cranes
12、, hoists, and theirsupporting structures; Part 2-9; Inspection, maintenance and thorough examination Cargohandling and container cranes.When all sub-parts of BS 7121-2 have been published, it is intended that CP 3010will be withdrawn and BS 5744 will be revised to cover manually operated andlight cr
13、anes only.This sub-part of BS 7121-2 is intended to be used in conjunction withBS 7121-2-1.Information about this documentThe Health and Safety Executive (HSE) commends the use of this British Standardto those who have duties under the Health and Safety at Work etc. Act 1974 1.This standard was draw
14、n up with the participation of HSE representatives and itwill be referred to in the relevant HSE publications.The BS 7121-2 series has been accepted by the HSE as representing theconsensus of opinion based on practical experience for safety of cranes.Hazard warningsWARNING. This British Standard cal
15、ls for the use of procedures that can beinjurious to health if adequate precautions are not taken. It refers only totechnical suitability and does not absolve the user from legal obligationsrelating to health and safety at any stage.Use of this documentAs a code of practice, this sub-part of BS 7121
16、-2 takes the form of guidance andrecommendations. It should not be quoted as if it were a specification andparticular care should be taken to ensure that claims of compliance are notmisleading.BRITISH STANDARDBS 7121-2-9:2013ii The British Standards Institution 2013Any user claiming compliance with
17、this sub-part of BS 7121-2 is expected to beable to justify any course of action that deviates from its recommendations.It has been assumed in the preparation of this British Standard that theexecution of its provisions will be entrusted to appropriately qualified andexperienced people, for whose us
18、e it has been produced.Presentational conventionsThe provisions of this standard are presented in roman (i.e. upright) type. Itsrecommendations are expressed in sentences in which the principal auxiliaryverb is “should”.Commentary, explanation and general informative material is presented insmaller
19、italic type, and does not constitute a normative element.Contractual and legal considerationsThis publication does not purport to include all the necessary provisions of acontract. Users are responsible for its correct application.Compliance with a British Standard cannot confer immunity from legalo
20、bligations.Particular attention is drawn to the following specific regulations: Health and Safety at Work etc. Act 1974 1; Lifting Operations and Lifting Equipment Regulations (LOLER) 1998 2; Provision and Use of Work Equipment Regulations (PUWER) 1998 3; Supply of Machinery (Safety) Regulations 200
21、8 (as amended) 4.NOTE Details of the Lifting Operations and Lifting Equipment Regulations 1998 2and the Provision and Use of Work Equipment Regulations 1998 3, together withan HSE Approved Code of Practice and HSE Guidance, are given in HSE publicationsSafe use of lifting equipment 5 and Safe use of
22、 work equipment 6.BRITISH STANDARD BS 7121-2-9:2013 The British Standards Institution 2013 iiiBRITISH STANDARDBS 7121-2-9:2013This page deliberately left blankiv The British Standards Institution 2013IntroductionCargo handling and container cranes are used to load and unload vessels,internal transfe
23、r vehicles, road vehicles and trains. They can also be used to liftcontainers or materials to and from temporary storage. The cranes can beinstalled in a static location, or on rails or wheels such that the crane cantraverse a quay or storage area. They can handle containers, unit loads or bulkmater
24、ials using specialist grabs.1 ScopeThis sub-part of BS 7121-2 gives recommendations for the pre-use checks,in-service inspection, maintenance, thorough examination (in service andfollowing exceptional circumstances) and supplementary testing of cargohandling and container cranes used in ports and in
25、land facilities. This sub-part ofBS 7121-2 is applicable to the following types of cranes: ship to shore or quay cranes; slewing jib cranes, including mobile harbour cranes; level luffing slewing jib cranes; rail mounted gantry cranes; rubber tyred gantry cranes; straddle carrier cranes; scotch derr
26、icks; boat hoists.This sub-part of BS 7121-2 also covers lifting attachments for use in conjunctionwith the cranes, including container spreaders, overheight frames, rotators,grabs, magnets and crane baskets used to access containers on ships.This sub-part of BS 7121-2 is not applicable to permanent
27、ly installed cranes onmarine and other water-borne vessels.This sub-part of BS 7121-2 is not applicable to loader cranes permanentlyinstalled on quays or in other static locations (see BS 7121-2-4).2 Normative referencesThe following documents, in whole or in part, are normatively referenced in this
28、document and are indispensable for its application. For dated references, onlythe edition cited applies. For undated references, the latest edition of thereferenced document (including any amendments) applies.BS 7121-2-1:2012, Code of practice for the safe use of cranes Part 2-1:Inspection, maintena
29、nce and thorough examination GeneralBS ISO 4309:2010, Cranes Wire ropes Care and maintenance, inspection anddiscardBRITISH STANDARD BS 7121-2-9:2013 The British Standards Institution 2013 13 Terms and definitionsFor the purposes of this sub-part of BS 7121-2, the terms and definitions given inBS 712
30、1-2-1:2012 apply.4 GeneralRegular pre-use checking, in-service inspection, maintenance and thoroughexamination of cranes are essential if cranes are to function safely and reliably.The nature of these activities can be summarized as follows. Pre-use checks are visual checks which are carried out to
31、ensure that thecrane has not suffered any damage or failure, and is safe to use. In-service inspections and maintenance are carried out to ensure thatcomponents are repaired or replaced before they deteriorate to a point atwhich they would become unsafe. Thorough examinations are carried out at spec
32、ified intervals, afterinstallation on a new site, after major alteration or repair or after theoccurrence of exceptional circumstances which could jeopardize the safetyof the crane. Supplementary testing is carried out in support of thorough examinationand the extent and nature of any testing are sp
33、ecified by the competentperson carrying out the thorough examination.5 Personnel carrying out pre-use checks, in-serviceinspections, maintenance and thoroughexaminationsAttributes, competencies, competency assessment, training plans and trainingrecords of personnel should be in accordance with BS 71
34、21-2-1:2012, Clause 5.6 Pre-use checks and in-service inspections6.1 GeneralPre-use checks and in-service inspection of cranes, together with a system torectify any defects disclosed, are required by the Health and Safety at Work etc.Act 1974 1 Section 2(2)(a), and LOLER 1998 2 Regulation 9(3)(b) to
35、 ensurethat the crane is safe to use and that any deterioration is detected and rectifiedbefore the crane becomes unsafe.Checklists for pre-use checks and in-service inspection should be drawn up foreach individual crane. These should be based on information from themanufacturer, crane usage, findin
36、gs from previous in-service inspections andrecords of maintenance and thorough examination, as applicable. Examples ofchecklists for pre-use checking and in-service inspections of different types ofcranes are given in Annexes A to D. Examples of checklists for pre-use checksand in-service inspection
37、s of crane container top safety frames used to accesscontainers on ships, and container spreaders, are given in Annex E and Annex F,respectively.Pre-use checks and in-service inspections should only be carried out by personnelwho have been adequately trained and assessed as competent to carry out th
38、erequired tasks (see Clause 5). LOLER 1998 2 requires that results of all in-serviceinspections are recorded. It is recommended that the results of all pre-use checksare also recorded.BRITISH STANDARDBS 7121-2-9:20132 The British Standards Institution 2013The crane user should ensure that sufficient
39、 time is allowed for pre-use checksto be carried out before the crane starts work. The user should also ensure thata safe system of work is in place to prevent the person who is carrying out thechecks/inspections from being exposed to danger.6.2 Pre-use checksPre-use checks should be carried out at
40、the start of each period during whichthe crane is to be used. These are to test the functionality of the crane andvisually check for any obvious defects. It is essential that these are carried outfrom a position of safety.Visual checks should normally be made from floor level unless a betterpermanen
41、t vantage point is available.In the event that it does not pass the pre-use check, there should be aprocedure to isolate and lock-off the crane to prevent further use until theproblem has been resolved.6.3 In-service inspectionA regular in-service inspection should be made to identify any defects wh
42、ichmight not be detected by the pre-use checks. In-service inspections should becarried out at intervals which ensure that any deterioration is identified beforethere is a risk of failure of the crane or injury to persons. Further guidance isgiven in HSE document L113 5.It might be convenient to sch
43、edule the inspections concurrently with plannedpreventive maintenance (see 7.2.1).Steel structures suffer from fatigue, a process which can create cracks thatpropagate over time. Cracks can also develop from material or weld defectswhich were undetected during manufacture of the crane. If left unatt
44、ended,cracks can cause serious failure of the crane structure. The in-service inspectionregime should include measures to detect cracks before the safety of the craneis affected. Therefore, in-service inspections should include a structuralinspection of highly stressed areas of the crane.If there ar
45、e any indications of cracking or excessive wear in pins, bearings orstructural components, the crane should be taken out of use and a thoroughexamination should be carried out in accordance with Clause 8, with NDT ifconsidered necessary by the competent person.The period between inspections should b
46、e decided on the basis of the duty ofthe crane and the environmental conditions and might need to vary between1 week and 6 months. The period should be kept under review and adjustedaccording to the results of the inspections.In the event that it does not pass the inspection, there should be a proce
47、dure toisolate and lock-off the crane to prevent further use until the problem has beenresolved.6.4 Reporting of defectsLOLER 1998 2 requires that defects be reported immediately they areidentified. There should be provision for the personnel carrying out the pre-usechecks or in-service inspection(s
48、) to make reports of defects or observationsimmediately they are identified.BRITISH STANDARD BS 7121-2-9:2013 The British Standards Institution 2013 36.5 Records of pre-use checks and in-service inspections6.5.1 GeneralRecords of all pre-use checks and in-service inspections should be kept.6.5.2 Pre
49、-use checksThe record of a pre-use check should include at least the following information: identity of the crane; date and time of inspection; result of the check, i.e. whether or not the crane passed; name and signature of person carrying out the check.This may be kept to a minimum by, for example, completing a single line of apro-forma record.6.5.3 In-service inspectionsThe record of an in-service inspection should include at least the followinginformation: date and time of the i
