1、UDC 621.873 : 620.1 DEUTSCHE NORMEN November 1977 I Lifting Equipment Acceptance Testing of Crane Installations Principles I rn “il4 *- -30 I Hebezeuge; Abnahmeprfung von Krananlagen; Grundstze This Standard contains safety provisions within the meaning of the Law on technical working equipment. It
2、has been prepared in co-operation with the HauPtverband der gewerblichen Berufsgenossenschaften (Federation of Industrial injuries Insurance Institutions), Zentralstelle fr Unfallverhtung und Arbeitsmedizin (Central Office for Accident Prevention and Industrial Medicine), Bonn. 1 Scope This Standard
3、 applies to crane installations which are subject to the Unfallverhtungsvorschrift “Krane“ (Accident Prevention Regulations “Cranes“) (VBG 9). It therefore also applies to crane runways, crane runway inclines and power supplies insofar as safety conjunction exist with the crane installation to be ac
4、cepted, within the meaning of VBG 9. It need not be applied to cranes for which evidence for a type testing is available. The testings according to the Unfallverhtungsvorschrift “Krane“ (VBG 9) do not affect other testings required by official regulations such as the traffic permit regula- tions, co
5、nstruction and works regulations of the Federal Republic or of the Lnder (Provinces) regarding vehicles on rails, construction regulations of the Lnder (Provinces) regarding structural installations. 2 Purpose In accordance with the accident prevention regulations a crane must be tested by an expert
6、 before it is com- missioned for the first time and after substantial modi- f cations. The testing consists of preliminary and construction inspection and an acceptance testing. This Standard puts at the disposal of crane manufac- turers, crane users and experts generally valid principles for the un
7、iform carrying out of acceptance testing. The object of the testing is to determine whether: - the crane installation agrees with the details in the - the accident prevention regulations have been - the crane functions correctly and is ready for opera- Camponent parts or assemblies which have alread
8、y been subjected to an acceptance testing by other experts according to 5 28 of the Unfallverhtungsvorschrift “Krane“ (VBG 9) do not require to be tested again. test book, complied with, tion. 3 Other relevant standards and documents The standards and directions mentioned below are valid as far as t
9、hey refer to acceptance testing and this Standard does not provide differently. DIN 4132 DIN 15018 Part 1 DIN 15018Part 2 DIN 15019 Part 2 DIN 15020 Part 1 DIN 15400 DIN 15401 Part 1 DIN DIN DIN DIN DIN DIN DIN 5401 Part 2 5402 Part 1 5 402 Part 2 5404 Part 1 5404 Part 2 5405 Part 1 5 405 Part 2 DIN
10、 15407 Part 1 Crane runways; steel support structures; principles for calculation, structural design and execution (at present circulating as draft) Cranes; principles for steel struc- tures; stress analysis Cranes; steel structures; principles of construction Cranes; stability of mobile cranes with
11、out rails (at present circulating as draft) Lifting equipment, principles for rope drives; calculation and execu- tion Hooks for lifting equipment; materials and existing stresses in hooks with shanks (at present circulating as draft) Hooks for lifting equipment; single hooks, blanks Hooks for lifti
12、ng equipment; single hooks, finished parts with cylin- drical shank and screwed shank Hooksfor lifting equipment; double hooks, blanks Hooks for lifting equipment;.double hooks, finished parts with cylin- drical shanks and screwed shanks Hooksfor lifting equipment; tech- nical conditions of delivery
13、 for forged hooks Hooksfor lifting equipment; tech- nical conditions of delivery for laminated hooks Hooks for lifting equipment; moni- toring forged hooks in service Hooks for lifting equipment; moni- toring laminated hooks in service Hooks for cranes; single laminated hooks for pig iron and steel
14、pouring ladles, arrangement, main dimen- sions Continued on pages 2 and 3 Explanations on pages 3 to 5 leinverkauf der Normen durch Beuth Verlag GmbH. Berlin 30 und Kln 1 11.79 DIN 15030 engl. Preisgr. 5 Vem.-Nr. 0105 Page 2 DIN 15030 DIN 15 407 Part 2 Hooks for cranes; single laminated hooks for pi
15、g iron and steel pouring ladles, component parts Cranes; stability and safety under wind conditions on all cranes except railless cranes without tower and floating cranes VDI 2381 Testing of crane installations; leaflet for experts (at present being revised) In preparation is a standard regarding: P
16、rinciples for the testing of cranes 1) Principles for the authorisation of experts for testing cranes 1 ) Rules for calculations for light lifting equipment of the FEM (Fdration Europenne de la Manutention) 4 Time of testing The user must arrange for the execution of the testing when the whole of th
17、e equipment belonging to the crane installation has been completed and before the first taking into service. The time of the testing must be agreed between those concerned. For cranes which leave the factory ready to operate, such as mobile cranes, it has proved to be advantageous to carry out the a
18、cceptance testing on the premises of the manufacturer. 5 Test personnel The user must engage an expert to carry out the testing. Apart from the experts who come under technical supervision only those experts are recognised who are designated as such by the professional association. The expert is in
19、charge of the testing. The personnel required for the testing, e.g. crane drivers and slingers, must be qualified for the work and must be placed at the disposai of the expert by the user unless other arrangements have been made. For cranes which are accepted in the manufacturers works, such as mobi
20、le cranes, it is usual to employ the test personnel of the manufacturer. 6 Communications during the testing Satisfactory communications must be ensured between the personnel participating in the testing. If direct commu- nication between the slinging and driving points is not possible the user must
21、 provide suitable equipment to overcome this. 7 Test documents Before the testing all the documents required for the testing must be submitted to the expert in good time, in particular: a) The crane test book with the completed specification sheet and also the certificates coveringthe preliminary an
22、d construction testing. ment. b) The required certificates, e.g. for load lifting equip- c) The working instructions (see DIN 8418). d) The erection instructions for movable cranes. The certificates for preliminary and construction testing of the crane runways, anchoring and fixing attachments. Exte
23、nt of test without load Check that the crane installation corresponds with the data in the test documents according to Section 7. Check that the accident prevention regulations have been complied with. Correct functioning of drive units. O perati ng range. These testings include the checking of the
24、end positions of all working movements, buffer stops and safe distances including those from the crane runway, main power supply and the inclines. The testing also includes the checking of the Set-up arrangements. 9 Test load Unless otherwise agreed the required test load must be provided by the use
25、r. For acceptance testings in the works of the manufacturer the latter normally provides the test load. The use of a dynamometer fitted between the crane and the anchorage to replace the test ioad is not permissible. The test load Pk for cranes without stability testing is wherein (definitions accor
26、ding to DIN 15003): Pl = Load (weight of working load, load lifting assembly Pk = 1.25 - Pl + 0.25 * Po plus slings). Here the load capacity should generally be inserted, though in the case of cranes with exceptional loads the latter should be inserted instead. PO = Weight of portion(s) of lifting a
27、ppliances when the portion exceeds 5 % of the load Pl. If the stability has to be tested, DIN 15019 Part 2 *) for railless mobile cranes applies instead; for all other cranes with the exception of railless mobile cranes without tower and of floating cranes a standard is being prepared (see Section 3
28、). 10 Extent of tests for movement with test load The test load must be slung with the required care making sure that the stress on the load lifting assembly and the slings remains within the permitted limits. All move- ments with the test load must be carried out individually and with the required
29、care. A new movement must not be initiated until the oscillationsfrom the previous movement have died down. *) At present circulating as draft 1) Information on this can be obtained from the Haupt- verband der gewerblichen Berufsgenossenschaften, Zentralstelle fr Unfallverhtung und Arbeitsmedizin (F
30、ederation of Industrial Injuries Insurance Institu- tions, Central Office for Accident Prevention and Industrial Medicine), Langwartweg 103,5000 Bonn 1 DIN 15030 Page 3 For cranes which have to be tested with a large or a small test load according to DIN 15019 Part 2 *) for railless mobile cranes -f
31、or all other cranes, apart from railless mobile cranes without tower and floating cranes, a standard is being prepared (see Section 3) -here the small test load is used for testing movements. a) Brake testing of hoist During the lowering movement at an appropriate lower- ing speed the test load must
32、 be stopped and safely held with the normal return of the control switch as well as when the crane switch is operated or when the drive power fails. b) Fu nct io na I test i ng All the planned and possible movements during service must be carried out individually and in the most unfavourable positio
33、ns of the load using the necessary care, When driving the crane along the whole of the crane runway the test load must be kept as close to the ground as possible. All special equipment belonging to the crane, e.g. mecha- nical, electrical, hydraulic and/or pneumatic lifting appliances must also be s
34、ubjected to a functional testing. 11 Movement testing with nominal laod or with exceptional load a) Testing of the functions of all the drive units at maximum speed for nominal or exceptional load. Hoist brakes must stop and hold safely the load at maximum lowering speed at an emergency stop. b) Che
35、cking of effectiveness of the safety equipment. *) At present circulating as draft 12 Testing of For these cranes the same equivalent test conditions apply. In addition the safety equipment required for these cranes must be tested according to VBG 9 23 and 0 24. program-controlled crane installation
36、s 13 Ending of acceptance testing When all the tests have been carried out the complete installation must be visually inspected once again. Any defects found must be noted. The result of the accept- ance testing must be entered in the crane test book. The crane test book including all documents list
37、ed in Section 7, and where appropriate a copy of the accept- ance report, must be handed to the user. 14 Elimination of defects The defects which the expert found must be eliminated by the user within a reasonable time. 15 Re-testing If the defects are appreciable it is essential for the expert to m
38、ake a re-testing for which the user must prepare the crane. During the re-testing the expert must ensure that the defects have been eliminated. The re-testing must be entered in the crane test book. 16 Taking into service The user may only take the crane into service when the expert does not raise a
39、ny objections to this. Further standards and documents DIN 8418 DIN 15003 DIN 15026 VDI 3570 Overload protection for cranes VDI 3571 VDI 3576 VDE O100 28 Lifting equipment ZH II547 2) The ZH directions can be obtained from: Carl Heymanns Verlag KG, Gereonstrasse 18-32, 5000 Kln 1 Technical products;
40、 information in directions of use and operating instructions Lifting equipment; load lifting equipment; loads and forces; definitions Lifting equipment; identification of danger points Manufacturing tolerances for travelling bridge cranes; travel wheel, travel wheel bearings and trolley runways Rail
41、s for crane installations, rail connectors, rail fixing devices, tolerances “Directions for radiocontrol of cranes“ (June 1976 edition) 2) Explanations According to the accident prevention regulations crane installations (cranes including supporting structure and equipment) must be submitted to a te
42、sting by an expert before the initial taking into service and before taking into service again after substantial modifications. This testing is divided into a preliminary, a construction and an acceptance testing. Especially during the acceptance testing compliance with the accident prevention regul
43、a- tions must be checked. Up till now implementation regulations for acceptance testings are contained neither in the accident prevention regulations nor in DIN Standards. The present Standard contains principles for all participants concerning the procedure during acceptance testings for crane inst
44、allations thus forming an essential part for its working safety. Page 4 DIN 15030 The preliminary work for this Standard was carried out by a working group within the Unterausschuss Kran- anlagen (Sub-Committee “Crane Installations“) in the Verein Deutscher Eisenhttenleute (Association of German Iro
45、n Workers). Further work on this Standard took place in the Arbeitsausschuss “Krane“ (Advisory Committee “Cranes“) in the Fachbereich Frdertechnik (Special Group Mechanical Conveying and Handling) of the Normenausschuss Maschinenbau (NAM) (Standards Committee Machine Construction) by representatives
46、 of the Berufsgenossenschaften der Technischen Ober- wachung (Industrial Injuries Insurance Institutions for Technical Inspection), the manufacturers and users of crane installations. The accident prevention regulations represent an auto- nomous range of regulations. For certain cranes apart from th
47、e testings for cranes according to VBG 9, some additional testings are required. To these belong, e.g. mobile cranes which must be tested in accordance with the Strassenverkehrszulassungsordnung (traffic permit regulations). The testings according to the various regulations such as the accident prev
48、ention regulations (UVV) or the traffic permit regulations, are in principle independent from each other. In order to avoid dupli- cation it is good policy economically for those responsible to co-operate in the various testings. Re Section 1 Scope The scope of this Standard is described in the Unfa
49、ll- verhtungsvorschrift “Krane“ (VBG 9) (Accident Prevention Regulations “Cranes“). Accordingly accept- ance testings must be carried out for all lifting equip- ment where loads are lifted by means of a lifting appli- ance and which can be moved in one or more directions in addition. Exceptions are governed by VBG 9. The acceptance testing must be carried out before the first taking into service or after considerable modifications. Re Section 2 Purpose It is the function of this Standard to lay down principles for the acceptance testing which can be applied reason-
