Standard Inspection Method

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INSPECTION STANDARD FOR CERTIFICATED MACHINERY

FACTORIES AND MACHINERY ACT 1967


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INSPECTION STANDARD

Standard of inspection for machinery requiring a Certificate of Fitness for its operation under the Factories and Machinery Act 1967 ("the Act")

PART 1: STEAM BOILERS

1. Definition:

“Steam boilers” means any closed vessel in which for any

purpose steam is generated under pressure greater than atmospheric pressure, and includes any economiser used to heat water being fed to the vessel, and any superheater used for heating steam, and any pipes and fittings connected thereto.

2. Inspection Classification (a) Initial Inspection

Prior to initial use, all new and altered boilers shall be inspected by a Private Inspector/licensed person to ensure compliance with the Act and the relevant regulations prescribed thereunder.

(b) Regular Inspection

After an initial inspection every boiler shall be inspected at regular intervals by a licensed person/Private Inspector so long as such boiler remains in operation. The interval for any regular inspection shall ordinarily be fifteen months. The

purpose of this inspection is also for the renewal of the certificate of fitness.

(c) Supplementary Inspection In addition to initial and regular inspections, a licensed person/private inspector shall make a supplementary inspection

of every steam boiler within a period of three months subsequent to the date of any initial or regular inspection.

(d) Special Inspection

A licensed person or a Private Inspector may, at the request in writing of a prospective purchaser or owner of any boiler,

and on payment of the prescribed fee, make a special inspection of such boiler, or supervise a special hydrostatic or other tests on any boiler.

(e) Further Inspection

Pursuant to Section 55A (2)(c) of the Act, a licensed person/private inspector may at any time notwithstanding

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anything contained in the regulations, make further inspections of any boiler as he may deem necessary to ensure that any lawful order given in pursuance of the Act or any regulation made thereunder has been carried out.

3. Scope of Inspection The scope of an initial inspection is to check if the boiler has been properly installed, its fittings and pipings securely attached and whether the boiler room meets the requirements of the regulations.

3.1 Inspection Items

Inspection of foundation

To check the existence of any cracks in the brick lying, confirmation shall be done for the expansion clearance and condition of heat insulation.

Inspection of flue gas system To ensure compliance with Regulations 28 and 29, Factories & Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970.

Verification of documents and design drawings. Confirmation of approval letter from DOSH, checking manufacturer's data report for NDT report, weld mapping and mill certificate, verify against approved drawings, confirmation of drawings and physical parts of boiler, etc.

Hydrostatic Test

To comply with Regulation 72, Factories & Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970.

Inspection of fittings

To comply with Regulations 10, 11 and relevant provision of the Factories & Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970, check the necessary indication on pressure gauge, water level gauge etc., and condition of heat protection for water feeding pipe, blow-off pipe contacting with combustion gas.

Inspection of blow-down valves and cocks

To comply with Regulation 15, of the Factories & Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970. Confirmation of the stamp mark on the body against manufacturer data report

Confirmation on Person in Charge


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Check engine driver/steam engineer/visiting engineer's qualification. 3.2 Notice of regular inspection To complying with Regulation 16, Factories & Machinery (Notification, Certificate of Fitness and Inspection) Regulations, 1970, reasonable notice by prepaid registered post should be given to an occupier or owner of the intention to make a regular inspection. Such notice should be served to the occupier or owner within fourteen (14) days prior to the

inspection date. 3.3 Preparation for regular inspection An occupier or owner should be informed that upon receipt of the notice of intended regular inspection, he should ensure at the appointed date that such boilers is prepared for

inspection in accordance with Regulation 17, Factories and Machinery (Notification, Certificate of Fitness and Inspection) Regulations, 1970.

3.4 Persons to be present at inspection

An occupier or owner should be informed to instruct his engine driver or steam engineer or visiting engineer to be present

during the regular inspection.

3.5 Inspection Items

Inspection of boiler components

Drums, Drum Connections and Internal Parts

All internal surfaces and the connections to all outside attachments, including water-column connections and safety-valve nozzles should be examined for deformation, corrosion, pitting, grooving, scale deposits, and sludge accumulation. Special attention should be paid to all seams, whether welded or riveted and to the areas adjacent to them.

Welded seams and connections should be examined for cracks. The welded seams should be cleaned, prepared, and inspected by wet fluorescent magnetic-particle examination, if necessary.

The top external surface of mud drums should be cleaned of all deposits and the surface should be examined for corrosion.

Attention should be given at points where the circulation of water is poor. Such point should be examined carefully, and the minimum remaining thickness should be determined by ultrasonic technique if necessary and then recorded. Inspection of steam drum should include observations of the normal water level. Minimum remaining thickness should be determined by ultrasonic technique if necessary and then

recorded. Any bulges or uneven areas that would indicate

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excessive heat input from leaking fireside bafflers should be noted. Hammer may be used to locate defective areas in the drum plate. These areas should then be measured by ultrasonic

technique if necessary. Drum internals and connections to the drum should be inspected when the drum is inspected. Welds or rivets attaching internals or connections to the drums should be inspected in the same manner as welds and rivets in the drum proper.

Safety-valves nozzles and gauge-glass connections, especially the lower connection, should be examined for accumulation of sludge or foreign material. Any manhole davits should be tested for freedom of movement and for excessive deformation. Manhole and handhole cover plates and nozzles seats should be examined for scoring in the

manner for pipe flanges. Cover plates should be inspected for cracks. Fasteners, attachments and settings in drum internals, including internal feed header, distribution piping, dry pipes, blow down piping, deflector plates, and baffle plates, should be inspected and hammer-tested for tightness soundness, and structural stability. If these parts are welded in place,

welds should be checked for cracks. Steam separator and baffles should be carefully inspected for tightness, corrosion, and deterioration, and associated welds should be checked for cracks. In case where dry pipes are used instead of steam separator,

the holes should be inspected for freedom from deposits and scale. Tubes, downcomers, and risers should be inspected for scale or deposit buildup, erosion, and corrosion. Tubes should be checked for any cutting caused by operating a tube cleaner too long in one place.

Ultrasonic testing and hammer sounding may be used for checking tube wall loss caused by corrosion. Tube ligaments should be checked for cracks. If tubes are covered with baffle or deflector plates, a few of these plates should be removed to permit a spot check of the condition of the tubes behind them.

The methods described in API Recommended Practice 572 may be applied to all drums forming any part of a steam boiler.

Water Headers


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Each handhole and handhole plate seat should be examined for erosion, steam cutting, tool marks, and other abuses that might permit leakage. If the plate has leaked previously, it should be checked for possible deformation. Seating surfaces and faces of handholes should be examined for cracks and

unevenness.

The inside surface of the headers should be inspected for corrosion and erosion. The location and amount of scale buildup should be noted, and the tube ends should be checked for pits, scale, cutting or other damage from tube cleaner, and deposit buildup.

Downcomers and risers should also be inspected for this type of deposit. Thickness reading of headers should be obtained periodically by ultrasonic technique. The header should be calipered whenever tubes are removed. External surfaces of headers should be examined either

directly or indirectly with mirrors, and particular attention should be paid to the points where the tube enters the header for indications of leakage from the tube roll. The header surfaces adjacent to the tube rolls and handholes should be inspected for cracks. If external inspection reveals pitting, a thickness measurement should be carried out using ultrasonic techniques.

Superheater Header Inspection of superheater headers should be conducted in a manner similar to that for the inspection of waterwall headers.

All handholes should be removed for every shutdown for spot

check. If deposits or scale are present in any degree,

immediate steps should be taken to determine why they are

present. In addition, the extent of the deposit or scale

should be investigated.

Economizer

The interior of tubes and headers (if possible) should be inspected for corrosion, oxygen pitting, deposits and scale. The exterior of tubes should be inspected for corrosion, erosion and deposits, and to check particularly the soot blower locations for impediment.

The exterior of economizer casing should be inspected for leaks and tightness of access doors. To check the condition of casing installation. To check the condition of supporting steel. Tubular type air pre-heater

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Inspect the gas side for plugging and building at the inlet and for corrosion at outlet.

Examine the air leaks or air invasion from casing.

Inspect the condition of corrosion at low temperature at air inlet part. In case of fin tubes, damage condition of the fins should be checked. Make sure that there is no existing abnormality in the

condition of the expanded portion of the tubes. Make sure that there is no existence of bending of tubes. In case of air pre-heater heated by steam, the expanded portion of the tubes should be check for any steam leakage.

Regenerative type of Pre-heater

Cold end section of heater surface should be inspected for corrosion at low temperature and wear. The hot end section of heater surface should be inspected for plugging.

To examine condition of radial and circumferential seals of both hot and cold ends. To check the condition of gear drive.

External inspection of boiler fireside components

Refractory Linings

Refractory lining should be inspected for cracks, erosion, excessive fluxing (melting of the refractory), bulging, and fallout. The presence and extend of refractory erosion or fluxing should be determined.

The depth of erosion or fluxing and the remaining thickness of the refractory should be measured. Refractory that has fallen out or bulged to the point that it is in danger of falling out should be replaced. When bulging or fallen out is encountered, the cause should be ascertained so that corrective measures may be taken to prevent a

recurrence.

Tubes All tubes should be inspected for signs of overheating, corrosion, and erosion. Waterwall tubes and generating tubes nearest the furnace should be closely examined for bulging, blistering, quench cracking, sagging, and bowing.


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Boiler tubes should be inspected at the steam-drum connection for gouging and caustic corrosion due to steam blanketing. The tube's outside diameter should be measured across the blister or bulge. If the reading is equal to the tube outside

diameter plus five percent (5%) or more, then the distorted area should be replaced or properly repaired. A few selected tubes should be ultrasonically measured for minimum thickness. The locations measured and thickness found should be recorded to establish a tube corrosion rate.

When a tube rupture occurs, the tube should be visually inspected and the cause of failure should be noted. If the cause is not evident, samples of the tube should be taken and analyze chemically and microscopically. The inside of bent and straight tubes, as far as it is accessible, should be examined with strong illumination.

Tube ends should be checked for proper projection and flaring. Fins attached to the tubes should be inspected for cracks that may extend into the tubes. The tubes should be inspected for signs of leakage that may result from the cracks. The waterwall tubes should be checked for alignment. All gas

passages should be inspected for slagging or bridging from fly ash or slag buildup.

Distinct to flue and fire tube boilers

Water Side

Scale condition on flue, tubeplates, fire tubes, etc. and determine the scale thickness; Pitting condition on flue and fire tubes, and determine the maximum depth of pitting;

Grooving and overheat at booth ends of the flue;

Sludge condition on the bottom of the shell;

Hammering test to all stays except stay tubes;

Deformation and grooving on the attachment of stays;

Cracks at the penetrating part of feedwater pipe;

Leakage at the manhole, cleaning holes and inspection holes;

Clogging in small holes and connections pipes;

Slipping and clogging of drain separator;

Condition of fusible plug if provided;

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In case of a boiler which stays have been attached by welding, check for cracks in the part undercutted and grooving along the welding line.

Fire Side Cracks, looseness and leakage on the attachments of fire tubes and stay tubes;

Clogging and curving of fire tubes and stay tubes;

Deformation or swell of flue due to low water level;

Overheat or burning at the front end of flue and at the mounting of front tube plate to flue;

Overheat due to thick scale at the water side;

Damage separation plate in rear smoke box;

Corrosion at the outlet of the exhaust gas caused by rainwater;

Function of explosion door;

Gas leakage at smoke boxes and its cover.

Distinct to sectional cast iron boilers

In case where plenty of untreated raw water is supplied as make-up water, check the scale condition in water side after removing blow down valves, safety valves, feedwater pipes,

etc.;

If necessary, carry out hydrostatic test and determine the existence of leakage on the following parts by holding the pressure:-

Bottom part of back section in combustion chamber;

Bottom part and the portion around the burner of front section in combustion chamber;

Upper part or intermediate sections in combustion chamber; and

Vertical part of intermediate sections in boiler room side.

Check attachment of nipples on each section;

Check bracket braced with tie bolts;

Check the movement of boiler body on the installation bed;


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If the private inspector recognizes leakage from the nipple attachment, he shall confirm whether the section is cracked or not after dismounting the sections.

Distinct to vertical boilers

Check for looseness, crack, and leakage on the joint of firebox and attached portion of stay;

Check for cutting-off of stay bolt;

Check for deformation of firebox;

Check the following at the bottom of water leg of firebox;

Existence of deposit;

Corrosion and grooving on the bending part;

Damaged insulating refractory;

Check for leakage at the bottom crown plate to which the stack tube penetrates and overheat, corrosion at the nearby water line;

Check for overheating at the portion exposed to steam space and leakage at the attached portion tubes on the upper tube plate for tube stays or smoke tubes of vertical smoke tube boiler; Check for cracks due to overheat and presence of deposits in the narrow water portions downward a fire hole;

Check for overheating of water tubes and cross-tubes in a firebox.

Distinct to once through boilers If necessary, carry out hydrostatic test and check for leakage and other abnormalities while holding the pressure;

Check for overheating at the high temperature part of water tubes; Check for corrosion at the outside surface of the low temperature part of water tubes;

In case of having carried out acid cleaning before inspection, check for heap of scale and clogging due to scale;

For multi-tube type once-through boiler, check for the existence of the following :-

Cracks at welding joints and attachment of water tubes in upper and lower header;

Overheating of water tubes;

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Peeling off and falling off of castable refractory on upper header; and

Scale in lower header.

Distinct to electrode boiler Inspection of electrode boiler should be conducted in a manner similar to that for the inspection of flue and fire tube boiler (water side), except requirements related to flue and fire tubes is omitted.

Inspection of burning apparatus. Check for the existence of fouling, burning and leakage at the nozzle tip of gun type burner and in the rotary cup of the rotary type burner.

Check for the existence of burning at the tips of ignition electrode rods, the suitability of clearance between them and the existence of cracks in the insulator. Check for cracks and peeling of the insulator on electric wire around a burner. Check for looseness and fouling of tips of lead wire around a

burner.

Check for damage in the combustion chamber, furnace wall and burner tile.

Check for damage in baffles.

Check for the damage and deformation of exhaust gas passage.

Check for the function of exhaust gas chamber.

Check for the smooth action of link mechanism to move damper.

Check that the opening of the damper is in accordance with the

indicator outside.

Check for the existence of fuel oil leakage at the wind box.

Check for the existence of air leakage from air duct.

Check for the existence of cracks at blast tube and combustion

cup of gas burner.

Inspection of automatic control system

Temperature Controller and Temperature Limitter for Hot Water


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Check that the temperature-sensing bulb is thoroughly inserted in immersion well.

Check for the existence of fold, crush, and corrosion of the capillary bulb.

Check for the existence of scale and corrosion on the outside surface of immersion well. Pressure limitter for steam Check for the existence of abnormal conditions in the mercury

switch such as discoloration and dispersion of mercury.

Check for existence of steam leakage due to cracks to bellows. Pressure Controller for steam Check for the existence of breakage and burning of

potentiometer coils.

Check for the deformation of the wiper for potentiometer coils.

Check for the existence of steam leakage due to crack of bellows.

Water level detector

General Check for the existence of clogging connection pipes and blow pipes.

Check for the abnormal condition of mercury switch such as discoloration, dispersion of mercury, crack of glass and looseness of fixed installation.

Check for the existence of looseness of screws, adherence of dust, water and corrosion at the connection part of electric wire.

Check for the adherence of scale in the float chamber or water column. Float type Check for the existence of deformation and dent of float,

water leakage in the float and crack of bellows.

Check for the installation of link mechanism. Electrode type

Check for the existence of stain and crack of the rod and insulator.

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Check for the insulation resistance of the electrode. Copes type

Check for the adherence of dirt, paint, etc. on the expansion tube.

Check for the existence of damage heat insulation on steam side connection pipe.

Check for the existence of leakage at drain valve.

Check for smooth movement of link mechanisms.

Check for the existence of obstruction in the expansion and contraction of the expansion tube.

Check for the existence of stain on the protection glass or

shield glass.

Flue gas cut-off valve Check up for the existence of internal leaks in the cut-off valve.

Inspection of fittings

General Make sure that the overhauling and cleaning of all fittings have been satisfactorily done during inspection. For all attaching openings for fittings, ensure there is

clogging inside the holes of the boilers.

Safety and Relief valve Examine the condition of the valve disc and valve seat contact surface. Check the condition of the valve internal parts for corrosion,

galling and wear. Check for the condition of valve springs for cracks, pitting, resiliency and end coil squareness. Check for the spindle alignment and adjustment of ring threads for freedom movements.

Check for the discharge and drainage of the piping for safety condition and boiler expansion allowance. Carry out test operation of valves through steam pressure, if necessary adjust to open and close at proper pressures.

With regards to safety valve assembly, as adjustment at site is difficult such as full bore safety valve, ensure that the


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valve function properly through the results of the function test and checking through the valve manufacturer, etc.

Water relief valve/Blow down valve

Ascertain that the shut-off device such as valves, cocks, etc. have not been fitted on the water relief valve.

Pressure gauge, Manometer Confirm the offset of the pointer is at zero.

Check the outside diameter of the dial and the maximum scale of the pressure gauge. Ensure that an easy-to-see indication mark has been placed at the position indicating the maximum allowable working pressure.

Water level gauge Make sure that the mark of the normal water level of the steam boiler is indicated at the gauge glass or any position near to the gauge, and the mark is indicated so as to compare it with the actual water level.

Check if the blow off pipe is attached at the water level gauge. Confirm if illuminance is sufficient at the water level gauge. Internal feed pipe Ensure the removal of the internal feed pipe out of the shell

or drum. Ensure that there is no plugging at the spout holes and the inside of the pipe. In case where the internal feeding pipe is attached in the steam space, ensure that there is no existence of leaks from

the attached part of the boiler. Hydrostatic test Hydrostatic test shall be carried out only when it is found to be necessary. The test should be carried out in the manner stipulated in Regulation 72, Factories and Machinery (Steam

Boiler and Unfired Pressure Vessel) Regulations, 1970. Others The boiler log book should be checked. Ensure that any repairs or modifications made are recorded and persons responsible for

such works are clearly identified.

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Check for the water treatment record and make sure that the water is treated accordingly. Comparison should be made with the scale and defects obtained from the boiler waterside.

Check the inspection record book. On each subsequent inspection of such steam boiler, comparison should be made with such record and note any change since the previous inspection. Make sure that the logbook is properly maintained.

3.6 Confirmation of function of safety valves

To comply with Regulation 42, Factories & Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970. 4. Acceptance criteria

All boilers should comply with relevant regulatory requirements and defects detected must be within the acceptance criteria of the relevant codes of practice of which the boiler was design to. All defects should not affect the integrity of the boilers to operate at its allowable safe working pressure.

Action shall be taken if any item does not meet criteria. Recommendation should be made to the owner or occupier to repair or remove such defects and to comply with the acceptance criteria. If changes need to be done on the original design upon

carrying out of the defective works, approval from the Chief Inspector shall be first obtained. If necessary, recommendation should be made to the Chief Inspector to reduce the allowable safe working pressure. Recommendation to condemn the boiler should be made to the

Chief Inspector in the case of major defects or repairs to the boiler, which will cause the integrity of the boiler to be questionable.

5. Reference codes applicable to the type of inspection It is preferable, but not limited to, that the following

standards or codes are referred to: ANSI/NB-23

API 572 API 573 API 510


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Recommended practice for inspection of specific equipment or machines issued by International Organization for safety and health.

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PART II: HOISTING MACHINE – (Overhead, Gantry, Mobile, Portal, Tower Crane and Others)

1. Definition

“Hoisting machine” means any equipment for lifting, raising or lowering load and shall include a lift, escalator, hoist, crane, winch, dragline, transporter, piling machine, aerial cableway, funicular railway, access plafform, dumbwaiter, vertical conveyor lifter, mechanical loading ramp or such other equipment as may be specified by the Minister

but do not include manual hoist and materials handling equipment.

“Overhead Crane” means a crane with a moveable bridge carrying a moveable or fixed hoisting mechanism and travelling on an overhead fixed runway structure.

“Gantry Crane” means a crane similar to an overhead crane except that the bridge for carrying the trolley or trolleys is rigidly supported on two or more legs running on fixed rails or other runway.

“Portal Crane” means a crane consisting of a rotating superstructure with operating machinery and boom, all of which is mounted on a gantry structure, usually with a portal

opening between the gantry columns or legs for traffic to pass beneath the crane. The crane may be fixed or on travelling base.

“Tower Crane” means a crane that is similar to a portal crane, but with a tower intervening between the superstructure and the gantry or other base structure; ordinarily, no portal

is provided for traffic to pass beneath the crane. To prevent overturning, the assembly may be ballasted, fixed to a foundation, or a combination of both. The crane may be fixed or on a travelling base. Mobile Crane:-

“CommercialTruck Mounted Crane” means a crane consisting of a rotating superstructure (center post or turntable), boom, operating machinery, and one or more operator's station mounted on a frame attached to a commercial truck chassis, usually retaining a payload hauling capability whose power source usually powers the crane. Its function is to lift, lower, and swing loads at various radii.

“Crawler Crane” means a crane consisting of a rotating superstructure with a power plant, operating machinery, and boom, mounted on a base and equipped with crawler treads for travel. Its function is to lift, lower, and swing loads at various radii.

“Wheel Mounted Crane” means a crane consisting of a rotating

superstructure, operating machinery, and operator's station and boom; mounted on a crane carrier equipped with axis and


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rubber-tired wheels for travel, a power source(s), and having separate or single control station for driving and operating. Its function is to lift, lower, and swing loads at various radii.

2. Inspection Classification Initial Inspection

Prior to initial use, all new and altered cranes shall be

inspected by a licensed person/private inspector to ensure

compliance with the provision of this Standard.

Regular Inspection

After an initial inspection every crane shall be inspected at regular intervals by a licensed person/private inspector so long as crane remains in operation. The interval for any regular inspection shall ordinarily be fifteen months.

3. Scope of Inspection The purpose of an initial inspection is to ascertain if the crane has been properly installed and the provisions of 5.1 and 5.2 in this Guidelines have been met.

The purpose of a regular inspection is to examine the crane and to confirm they are able to continue its operation for another fifteen months. An inspection is made for all items provided under 5.1 to 5.6, except the rated load test. 4. Notice of inspection To comply with Regulation 16, Factories and Machinery

(Notification, Certificate of Fitness and Inspection) Regulations, 1970.

5. Inspection Items

5.1 Operational or Functional tests

Prior to initial use, all new or altered cranes should be tested to the extent necessary to ensure compliance with the operational or functional requirements by the manufacturer. The test should be performed first without load and then at rated load, or where appropriate, with the overload boomed-in to a rated radius.

The test should include the functioning of the following:- (a) Mobile, portal and tower crane (i) load lifting and lowering mechanism (ii) boom lifting and lowering mechanism (iii)boom extension and retraction mechanism

(iv) swinging mechanism (v) travel mechanism

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(vi) brakes and clutches (vii)limit, locking, and safety devices (b) Overhead and gantry crane

(i) hoisting and lowering

(ii) trolley travel (iii)bridge travel (iv) limit switches, locking and safety devices.

(c) Others

Cranes, which are not specifically specified, should be inspected and tested according to the manufacturer's specifications and, in addition, to comply with the appropriate and relevant items provided in these guidelines. The trip setting of hoist limit switches should be determined

by test with an empty hook travelling in increasing speeds up to the maximum speed. The actuating mechanism of the limit switch should be located so that it will trip the switch, under all conditions, in sufficient time to prevent contact of the hook or hook block with any part of the trolley. 5.2 Rated load test

Prior to initial use, all new or extensively repaired load sustaining parts which have been altered, replaced or repaired should be load tested, confirming the load rating of the crane. The load rating should not be more than 80 percent (80%) of the maximum load sustained during the test. Test load should

not be more than 125 percent of the rated load unless otherwise recommended by the manufacturer. The radii and boom angle indicator should be chosen so as to place maximum loading on the relevant crane parts. Crawler and wheel-mounted cranes should be tested in accordance with manufacturer specifications where stability

governs. Rating governed by structural strength should be established by the manufacturer and tested to 125 percent (125%) of the rating. No cranes should be re-rated in excess of the original load ratings unless such rating changes are approved by the Chief Inspector.

5.3 Vertical deflection The girder for overhead travelling and gantry crane should be tested so that the vertical deflection caused by the safe working load and the weight of the hoist or crab in the central position should not exceed 1/750 of the span unless specified otherwise in the approval letter by the Department

of Occupational Safety and Health.


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5.4 Performance test During regular inspections, arrangements should be made to enable such crane to be tested under conditions of maximum

safe working load so as to cause all safety devices to function.

5.5 Regular inspection Complete inspection of the crane should be performed depending upon its activity, severity or service, and environment of

use, or as specifically indicated below. The inspection should include any recommendation made by the manufacturer. Any deficiencies, such as those listed, should be examined and determination made as to whether they constitute a hazard:

(a) all crane function operating mechanisms for maladjustment interfering with proper operation and

excessive wear of components;

(b) motion limiting devices for proper operation with the crane unloaded. Each motion should be inched into its limiting device or run in at a slow speed with care exercised;

(c) all hydraulic and pneumatic hoses, particularly

those that flex in normal operation; (d) all other safety devices for malfunction;

(e) hooks and latches for deformation, chemical damage,

cracks and wear;

(f) braces supporting crane mast (towers) and anchor bolt base connections for looseness or loss of pre-load;

(g) rope reeving for compliance with crane

manufacturer's specifications;

(h) deformed, cracked, or corroded members in the crane structure and entire boom;

(i) loose bolts or rivets;

(j) cracked or worn sheaves and drums;

(k) worn, cracked, or distorted parts such as pins,

bearings, shafts, gears, rollers and locking devices;

(l) excessive wear on brake and clutch system parts,

linings, pawls, and ratchets; (m) load, wind, boom angle, and other indicators over

their full range, for any significant inaccuracies;

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(n) gasoline, diesel, electric, or other power plants for performance and compliance with safety requirements;

(o) electrical apparatus for signs of deterioration in

controllers, master switches, contacts, limiting devices, and controls;

(p) excessive wear of chain drive sprockets and

excessive chain stretch; (q) crane hooks inspected for cracks;

(r) travel mechanism for malfunction, excessive wear, or

damage;

(s) hydraulic and pneumatic hose, fittings, and tubing inspection:

(i) evidence of leakage at the surface of the flexible hose or its junction with the metal and couplings;

(ii) blistering or abnormal deformation of the outer covering of the hydraulic or pneumatic hose;

(iii)leakage at threaded or clamped joints that cannot be eliminated by normal tightening

or recommended procedures; (iv) evidence of excessive abrasion or

scrubbing on the outer surface of a hose, rigid tube, or fitting. Means should be taken to eliminate the interference of elements in contact or otherwise protect the components.

(t) hydraulic and pneumatic pumps, motors, valves,

hoses, fittings, and tubing for excessive wear or damage.

Visual inspection of members and their connection should be performed. Observed signs of possible damage may indicate the

need to remove paint or to use other than visual non-destructive examination techniques to permit determination as to whether a hazard exists. High strength (traction) bolts used in connections and at the slewing bearing should be checked for proper tension (torque). Loosen bolts should be checked for permanent deformation or other damage. Visible cracks, difficulty in threading or

unthreading a nut by hand, or observable necking are reason for replacement. Sheaves used in the hoisting system should be checked for cracks in the flange and spokes. When external evidence of defects exists, it may be necessary to remove the sheave from its mounting for this purpose.


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5.6 Rope inspection For any inspection, all wire ropes should be visually inspected.

Counterweight movement ropes, if provided, should be visually inspected. A visual inspection should consist of observation of all rope, which can reasonably be expected to be in use during the day's operation. The visual observation should be concerned with discovering severe damage, such as listed below, which may be

an immediate hazard. When such damage is discovered, the rope should be removed from service.

(a) Distortion of the rope such as kinking, crushing, unstranding, birdcaging, main strand displacement, or core protrusion; loss of rope diameter in a short rope length or unevenness of outer strands provide

evidence that rope replacement should be considered; (b) Reduction of rope diameter below nominal diameter

due to loss of core support, internal or external corrosion, or wear of outside wires;

(c) Severe corroded or broken wires at end connections;

(d) Severely corroded, cracked, bent, worn, or improperly applied end connections.

Care should be taken when inspecting rope sections subject to rapid deterioration, such as the following:

(a) sections in contact with saddles, equalizer sheaves,

or other sheaves where rope travel is limited;

(b) sections of the rope at or near terminal ends where corroded or broken wires may protrude;

(c) sections subject to reverse bends;

(d) sections of rope which are normally hidden during routine visual inspection, such as parts passing over sheaves.

6. Acceptance criteria All non-compliance detected should comply with relevant regulatory requirements and the acceptance criteria of the

relevant codes of practice of which the cranes were design and constructed to. All non-compliance should not affect the integrity of the cranes to operate at its rated loads.

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7. Action to be taken if item does not meet criteria Recommendation should be made to the owner to repair or remove such defects and to comply with the acceptance criteria.

If, changes need to be done on the original design upon carrying out the remedial works, approval from the Chief Inspector is required.

Recommendation to condemn the cranes should be made in case of major defects or any further repair to it will cause the integrity of the cranes to be compromised.

8. Reference codes applicable to type of inspection It is preferable, but not limited to, that the following standards or codes are referred :- ASME/ANSI B30.10

USAS B30.2.0 ASME B30.4 ASME B30.5 According to European Committee for Standardisation (CEN) rules or standards



24

PART 3: ELECTRIC PASSENGER, GOODS LIFT, HYDRAULIC LIFT, ESCALATOR AND DUMBWAITER

1.1 Definition

“Passenger lift” means a lift primarily used to carry persons other than the operator and persons necessary for loading and unloading and such lift includes a hospital bed lift.

“Goods lift” means a lift primarily used to carry goods

but in which an attendant and the persons required to load and unload the goods are permitted to ride.

“Hydrauiic lift” means a powered lift where the energy is applied by means of a liquid under pressure, in cylinder equipped with a plunger or piston.

“Escalator” means a power-driven, inclined, continuous stairway used for raising or lowering passengers and include moving side walk.

“Dumbwaiter” means a hoisting and lowering mechanism equipped with car moving guides in a substantially vertical direction and being used exclusively for carrying materials.

2.1 Inspection classification Initial Inspection

Prior to initial use, all new and altered lifts, escalators and dumbwaiter shall be inspected by a licensed person/private

inspector to ensure compliance with the provision of these Guidelines. Regular Inspection After an initial inspection every lift, escalator and dumbwaiter shall be inspected at regular intervals by a

licensed person/private inspector so long as lift, escalator or dumbwaiter remains in operation. The interval for any regular inspection shall ordinarily be fifteen months. 3.1 Scope of Inspection 3.1.1 The purpose of an initial inspection is to ascertain

whether a lift, escalator or dumbwaiter has been properly installed and the provisions of the Factories and Machinery (Electric Passenger and Goods Lift) Regulations, 1970 are met and that all the other requirements under Items 4.1 to 4.6 hereunder are complied with. 3.1.2 The purpose of a regular inspection is to examine the lift, escalator and dumbwaiter and to ascertain whether it is

able to continue its operation for another fifteen months.

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During the inspection, Items 4.1 to 4.6 shall be complied with except the loading test. 3.1.3 Prior to any inspection, a written notice shall be served on the owner within fourteen (14) days prior to the inspection date.

3.1.4 A licensed person/private inspector carrying an inspection should be accompanied by a lift competent person.

(A) Electric Passenger and Goods Lift - Inspection Items

4.1 Construction and equipment of machinery room

(a) The hoisting machine, motor and control should as a rule be located not less than 46 cm apart from pillars and walls, except where there is no obstacle to maintenance and care.

(b) The hoisting ropes, governor rope, steel tape of floor selector, etc. should not be in contact with the parts of the machinery room floor where they are passing through.

(c) No unnecessary equipment should be installed or

placed in the machinery room.

(d) Facilities should be made so that the lighting and ventilation is suitable for care and inspection, and room temperature is as a rule maintained at 40 degrees Centigrade.

(e) The locking device for the entrance door should be

in good condition.

(f) The corridors, staircases, etc. leading to the machinery room should be so arranged as to give no obstruction to maintenance and care.

(g) Other than space for the elevator shaft for emergency use, the machinery room of the emergency

lift should be partitioned off for fire protection.

4.2 Incoming panel, main switch, control board, conduit tube and wiring

(a) The incoming panel and main switch should as a rule

be located near the machinery room entrance and

should be capable of being safely and easily operated.

(b) The control board and other control equipment should

be installed firmly, and provided with measures to prevent displacement and tumbling due to vibration.

(c) The operation of contact points of every switch on

the board should be good.


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(d) The insulation resistance should satisfy the

requirements of Regulation 6 (c) (iii) of the Factories and Machinery (Electric Passenger and Goods Lift) Regulations, 1970. The insulation

resistance should be capable of being inspected on each circuit divisible by switches or over current breaker.

(e) An emergency lift should be provided with a stand-by

power source.

(f) An emergency lift for emergency use should not be affected by other lifts.

4.3 Driving machine, brake and hoisting machine

(a) The driving machine and hoisting machine should be installed firmly, and provided with measures to

prevent displacement and tumbling due to vibration. (b) The driving machine shall be in good working

condition.

(c) The brake should be fitted firmly, and capable of decelerating and stopping the car safely when the power is cut off.

(d) The sheave of hoisting machine should be free from cracks and should not permit any significant slip between the sheave and the hoisting ropes in case of automatic stopping. Where the hoisting machine is equipped with reduction gearing, the thickness of each tooth gear should not be less than 7/8 of the original.

(e) The sheaves or winding drums should be provided with measures to prevent the running out of hoisting ropes due to vibration.

4.4 Load test

4.4.1 The load test should be carried out under the following three conditions. In each case the speed and current should be measured under rated voltage and rated frequency, and shall satisfy the provision of Table 1. For a.c. Iifts, the speeds and current when loaded with 25 %, 50 % and 75 % rated loads shall be measured and noted.

(a) No load

(b) Loaded at 100 % of rated load

(c) Loaded at 110 % of rated load

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Table 1

Item When with no load, and loaded

at 110 % of rated load

Loaded at 100 %of rated

load

Speed

Not more than 125 % of the

speed given in design

documents.

Ascending speed should

be not less than 90 %

and not more than 105 %

of the speed given in

design documents.

Current

Not more than 120 % of the

rated current value driving

machine.

Not more than 110 % of

the rated current value

of driving machine

4.5 Working condition of speed governor

4.5.1 The working speed of governor should be measured with a tachometer, and should satisfy the provision of Table ll. In this procedure, if it is impossible to get an over-speed by directly running the car, the measurement may be made by driving the governor independently of the car to give the same effect as when the speed of car increase extraordinarily.

Table II

Item

Machines with rated speed of

not more than 45 m/min

Machines with rated

speed of more than 45

m/min

Overspeed

Switch

To open at not more than 63

m/min

To open at not more

than 1.3 times the

rated speed.

Catch

To work as soon as or after

the over-speed switch has

opened and before falling

speed exceeds 68 m/min

To work after the over-

speed switch has opened

and before the falling

speed exceeds 1.4 times

the rated speed.

Remarks:

In case where an emergency stop function is provided for the counterweight and actuated by a speed governor, this governor should not operate at lower speed than that

at which the governor for the car operate. 4.6. Working condition of emergency stop 4.6.1 In initial inspection, the inspection of (a) to (c) as mentioned below should be made with the car loaded with 100 % rated load and high speed. However, for a device whose safety has been proved in advance by factory test, the inspection

should be carried out similar to the regular inspection.


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In the regular inspection, as a rule, the tests under (a) and (b) below should be made with the car loaded with a load of 65 kg and at a speed which is as low as possible.

(a) Stop the car by actuating the catch of speed

governor by hand while the car is ascending. Then operate the hoisting machine to lower the car. If the car does not move irrespective of revolution of the sheave, the emergency stop is confirmed to be working. For an emergency stop which is not provided with a speed governor, its working should be confirmed from the slackening of hoisting ropes at

the car top, when the counterweight is lifted with the emergency stop in working condition.

Remarks: The emergency stop for counterweight

should be inspected in the same way, except for the "car" being interpreted as "counterweight" vice versa.

(b) Carry out inspection on the items (i) and (ii) below

with the emergency stop in working condition. (i) Mechanical device and the governor rope

shall be free from any damage. (ii) The emergency stop should work equally on

both sides. The levelness of car floor, when measured with a level, should not

exceed 1/30 anywhere.

(c) Stopping distance from initiation of emergency stop to complete stop should comply with Regulation 22, Factories and Machinery (Electric Passenger and Goods Lift) Regulations, 1970.

4.7 Inspection of inside car 4.7.1 For passenger elevator and bed elevator, check for the horizontal distance between the car floor sill and the shaft wall. 4.7.2 Signs showing the purpose, rated load and the passenger

capacity should be located where it can easily be read and their contents shall be in the proper language. 4.7.3 The door switch should work well. 4.7.4 The control device should be fitted and working well. In particular, the handle should return automatically to the stop operation position, and the stop switch in the car should work

well. 4.7.5 The communication device to the outside should work well. 4.7.6 In emergency lift, the telephone for calling the central control room should work well.

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4.7.7 As for emergency lifts, emergency equipment (emergency operation lamp, primary fire fighting switch and secondary fire fighting switch) should work well. 4.8 Inspection on car top 4.8.1 The dimension related to the car top clearance should satisfy the provision of the Regulation 25 (1) to (4), Factories and Machinery (Electric Passenger and Goods Lift) Regulations, 1970. 4.8.2 The emergency of car exit can be opened by simple

operation from outside. 4.8.3 The door switch on the car shall be fitted firmly. 4.8.4 The safety switch on the car should work well. 4.8.5 The deflecting sheaves, if provided, should be properly

installed and should be free from crack in principle parts. 4.8.6 The governor rope should be fixed firmly. 4.8.7 The linkage of emergency stop should work well. 4.8.8 The upper limit switches should be fitted firmly and be so located that its operation is ensured and that it works

properly. 4.8.9 The hoisting ropes and governor rope should be inspected on the car while the car is lifted or lowered minutely and satisfy the items of (a) to (d) below. Any part of the ropes which cannot be inspected on the car should be inspected in the machinery room or pit.

(a) the hoisting rope ends which are moulded in sockets

with Babbits metal should be so arranged that it could be observed that each strand has been bent.

(b) each hoisting rope clinch should be firmly fastened with double nuts and secured with a split pin.

(c) all hoisting ropes should share a nearly equal

tension. (d) the wearing condition of hoisting ropes should be

inspected on the most worn part, and satisfy the provision of Table III.

Table III

Wearing condition Criterion

When break of wire is

Distributed evenly.

Breaks per pitch of strand are

not more than 4.

When sectional area of broken wire is

70 % of original sectional area of

wire or less, or rusting much.

Breaks per pitch of strand are

not more than 2.


30

When breaks of wire concentrate in

one position or on a specific strand.

Total breaks of wire per pitch

of strand are not more than

12, for 6 strand steel wire

rope, or not more than 16, for

8-strand steel wire rope.

Diameter of steel wire rope is worn

part.

Not less than 90 % of diameter

of steel wire rope in intact

part.

4.8.10 Guide rails and bracket should be fitted firmly to withstand vibration and should not be rusty, deformed or worn out. 4.8.11 When a weighing device is fitted on the car top, its working condition should be good. The actuating value of a weighing device should be 105 % to 110 % of the rated load.

4.8.12 The locks and switches on landing doors should be in good working condition . 4.8.13 In the shaft, pipings, wiring, etc. not directly related to the elevator should not exist. 4.8.14 The lower part of each landing sill should be so

constructed that passengers or things might not be jammed when they are getting on and

4.8.15 In the case of emergency lifts, the electrical equipment on the car top should be provided with water protecting covers, drain holes etc.

4.8.16 In the case of emergency lifts, conduit tubes should be so constructed that no water can collect therein. 4.8.17 The guide shoes of car and counterweight should be fitted firmly, and provided with measures to prevent derailment due to vibration and the fixing condition of counterweight elements should be secured.

4.8.18 The inside shaft should be free from projections, such as unnecessary bolts and iron wires, and the bodies that is likely to interfere with the function of steel ropes or tail cords are to be provided with measures to prevent such damage.

4.8.19 The guide shoes of landing door should be fully

extended into the groove of doorsill. The fitting condition of

door hanger retainers should be secured.

4.8.20 The car frames should fasten together perfectly.

4.9 Inspection of pit

4.9.1 The inside part of the pit should be free from leakage of water and be cleaned.

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4.9.2 Lower limit switches should be fitted firmly, be in relative positions to ensure their operation and working condition. 4.9.3 The distance between the car and the buffer plus the

stroke of the buffer, when the car is horizontally staying at the lower terminal landing should be less than the top clearance of counterweight. 4.9.4 Buffers should be fitted firmly and their function should be maintained in good condition. In the case of spring buffer, they should be free from defects, such as rust and

corrosion, and in the case of hydraulic buffer, they should, in addition, be fitted with an adequate quantity of oil. 4.9.5 The distance between the counterweight and buffers when the car is staying horizontally at the upper terminal landing and the distance between the car and buffers when the car is staying horizontally at the lower terminal landing should meet

the provision of Regulation 25 (5) and (6), Factories and Machinery (Electric Passenger and Goods Lift) Regulations, 1970. 4.9.6 The lower final limit switches should work before the car reaches the buffer. 4.9.7 Travelling cables are to be protected from damage.

4.9.8 The tension device of any governor rope and other tension devices should be working properly. 4.9.9 There should be no floatage matter in an emergency lift pit.

4.9.10 In an emergency lift, the switches installed below the lower terminal landing level should be cut off during emergency operation. 4.9.11 The depth of the pit should satisfy the provision of Regulation 10 (5) (a) to (c), Factories and Machinery (Electric Passenger and Goods Lift) Regulations, 1970.

4.9.12 When counterbalance ropes or chains are equipped, their fitting conditions should be adequate. 4.9.13 In an emergency stop of drum operated system, the winding condition of the emergency stop rope should be normal. 4.9.14 When the emergency stop test is finished, the emergency

stop device should be free from damage and should returned to the normal position. 4.9.15 The car frames should fasten together perfectly. 4.9.16 When a weighing device is fitted under the car bottom, its working condition should be good. The actuating value of a

weighing device should be 105 % to 110 % of the rated load.


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4.10 Inspection of landing The condition of the switch and locking of landing door should be inspected by measuring the residual clearance between the door edge and the door frame or the opposite door

edge at the moment when the car starts running and the landing door is gradually brought into a closed position while the car and landing is closed and the control is turned into a "run" position. The measurement should satisfy either one of the following:-

(4) in the case of vertical opening doors and of

horizontal opening doors, the lift should start running when the door have been closed to a residual clearance of 5 cm or under, and the doors cannot be opened by 5 cm or over from the landing.

(4) in the case of doors other than the above, the lift should start running when the door has been closed to a residual clearance of 2 cm or less, and after

that the doors cannot be opened by 2cm or more from the landing. However, for lifts which can be operated only from inside the car, and the car door and the landing door of which are simultaneously power operated, the following shall apply:

(4) the lift should start running when the

door has been closed to a residual

clearance of 5 cm or less, and the door should not be opened by 5 cm or more from the landing.

(4) a lift whose landing doors are equipped with closing devices that do not permit the door almost closing to open by 10 cm or more against the opening effort being

applied from the landing side, should start moving when the door has closed to 10 cm or less.

(4) At landing where an emergency unlocking device is equipped, the unlocking can not be effected without use of a specific key.

(4) When a door of automatic power closing

system is equipped with a safety shoe, the shoe should work well.

(4) Indication of landing indicators should be correct.

(4) In an automatic lift, when the car-call push button at a landing is pressed, the car should arrive at the landing correctly.

(4) The emergency communication device between the

inside of a car and the established station outside should be normal.

4.10.2 In emergency lifts, car-call devices should be provided at the landing lobbies of escape floors or the floor nest upper or under, and the device should work well and properly.

4.10.3 For emergency lifts, an emergency sign and indicator lamp should be provided in each storey of the building.

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4.11 nspection of central-control room. 4.11.1 For emergency lifts, emergency devices, such as call-back switches and emergency operation lamps, should be

installed in the room and should in good working condition. (B) Hydraulic lift - Inspection Items

5.1 Construction and equipment of machinery room

5.1.1 Save for (a) and (d) below, all the inspection items are the same as those given in Item 4.1 (c) to (f) above.

(a) Hydraulic power units, oil tank, coolers and control board are as a rule to be located at a distance not less than 50 cm from the pillars and walls, except where maintenance and care work are not hindered.

(b) The machinery room is to be partitioned by a floor, walls and ceiling of fireproof or fire-resistance construction.

(c) Fire extinguishers or fire-fighting sand should be provided at a readily visible place outside the machinery room, near the entrance.

(d) In the machinery room no-smoking signs should be displayed.

5.2. Incoming panel, control board, electric conduit

and wiring 5.2.1 The inspection should be carried out in accordance with Item 4.2 (a) to (d).

5.2.2 Hydraulic power unit, pressure piping and high pressure hose

(a) Hydraulic power unit should be fitted securely and operate in good condition.

(b) A hydraulic power unit should be provided in each car.

(c) A safety valve which, automatically initiates the operation before the working pressure exceeds 125 % of the normal pressure and keeps the working pressure within 150 % of the normal pressure in cases of extreme increase in hydraulic pressure when the car is ascending, should be provided.

(d) Non-return valves in hydraulic power units should work perfectly.

(e) The speed when the hand operation descending valve is fully opened should be not more than the rated descending speed.

(f) When it is presumed that the operating oil temperature will fall to 5 degrees Centigrade or lower or rise to 60 degrees Centigrade or higher, a device to control this should be provided, and when

water is used for cooling, the water pipe should not be directly connected to the drinking water system.


34

(g) The device for preventing pump motor racing should work properly.

(h) The pressure piping should provide at least one pressure gauge.

(i) The pressure piping should be treated with effective

anti-corrosive materials, be securely fastened or supported, and the joints in it should be securely connected and be free from oil leakage.

(j) The pressure piping should provide a device to relieve the vibration and shock, and parts piercing the wall, etc. should be protected with a sleeve, etc.

(k) The joints of hydraulic rubber hoses should be securely connected and be free from oil leakage.

5.3 Load test 5.3.1 The load test should be carried out by measuring the speed and current under the rated voltage and frequency in

each of the following two cases and the measured values should satisfy the provision of Table IV.

(a) Load at 100 % of the rated load (b) Load at 110 % of the rated load

Table IV

Item

When loaded at 100 % of the rated load

When loaded at 110 % of the rated load

Speed

Ascending and descending speeds should be not less than 90 % and not more than 105 % of the

speeds given in design documents.

Ascending and descending speeds be not less than 85 % and not more than

110 % of the speeds given in design documents.

Current

Not more than 135 % of the rated current of motor

Not more than 140 % of the rated current of motor.

Working Pressure

Not more than 115 % of the design value.

Not more than 120 % of the design value.

5.4 Working condition of speed governor

5.4.1. The speed governor, if any, should be inspected in accordance with Item 4.5, however, the term "rated speed" in Table ll should be interpreted as "descending rated speed".

35

5.5 Working condition of emergency stop of indirect hydraulic-drive elevator

5.5.1 For initial inspection, the following from (a) to (c) should be carried out, at high speeds and with 100 % rated

load in the car. However, such items whose safety has been confirmed in advance by factory tests, etc. should be inspected according to the regular inspection. 5.5.2 For regular inspection, as a rule, the following from (a) to (c) should be made at the lowest speed practicable with a load of 65 kg in the car:

(a) Stop the car once by actuating the catch of speed

governor by hand while it is descending, then operate the hydraulic power unit to lower the car further. Confirm the working of emergency stop by noticing that the car does not descend irrespective of the descending of the plunger. However, for an

emergency stop of the type with no speed governor, fix the car once and then slacken the hoisting ropes or chains of the . car by lowering the plunger. Then confirm that the emergency stop is working by releasing the fixing of the car.

(b) Inspection in accordance with Item 4.6.1 (b).

(c) Inspection in accordance with Item 4.6.1 (c).

5.6 Inspection of inside car 5.6.1 The inspection should be made in accordance with Items 4.7.1 to 4.7.5

5.6.2 The leveling device should work properly within 75 mm. 5.7 Inspection of car top 5.7.1 The inspection should be made in accordance with Items 5.7.2 to 5.7.8 below, and Items 4.8.1 to 4.8.4, Items 4.8.6 to

4.8.8 and Items 4.8.10 to 4.8.13 above. 5.7.2 The sheaves or sprocket wheels should be fitted well, and their bodies should be free from any cracks.

5.7.3 Hoisting ropes or chain, of the governor rope should comply with (a) and (b) below and Item 4.8.9 (a) to (c).

(a) The wearing condition of ropes should be inspected

on the most severely worn part, and should satisfy the provision of Table III.

(b) Each of the chains should be securely tied at its ends and should bear nearly equal tension.


36

5.7.4 When operation is done on the car top, a safety top clearance should be provided, and the automatic control to arrest further rising of the car should work properly. 5.7.5 Lift the car above the upper terminal story at dead-slow

speed. The top safety clearance left when the plunger has been stopped by the stopper should be not less than 60 cm. 5.7.6 On the jack of indirect hydraulic lift, a stop switch which works before the operation of a plunger stopper should be provided, and its mounting and ~ operation should be secured.

5.7.7 The hydraulic cylinder should be installed securely. 5.7.8 The oil leakage through the cylinder packing should be properly treated. 5.8 Inspection of Pit 5.8.1 The inspection should be made in accordance with Items 5.8.2 to 5.8.5 below, Items 4.9.1, 4.9.2, 4.9.4, 4.9.7, 4.9.8, 4.9.11 4.9.16 above. 5.8.2 Except for automobile lifts, the distance between the car and buffers, when the car is staying horizontally at the lower terminal landing, should be a minimum of 70 mm for

downward rated speed up to and including 30 m/min or 150 mm over 30 m/min with a maximum of 600 mm.

5.8.3 The lower limit switch should work before the car reaches the buffer.

5.8.4 The hydraulic cylinder should be firmly fitted.

5.8.5 In indirect hydraulic lifts, which use ropes, the hoisting ropes should not run off from the grooves of sheave when they are slackened by vibration.

5.9 Inspection of landing

5.9.1 The inspection to be carried out at landings should be made in accordance with Item 4.10 above.

(c) Escalator - Inspection Items 6.1 Inspection of machinery room

6.1.1 The inspection should be made in accordance with Items 6.1.3 to 6.1.4 below, Item 4.2 (a) to (c) and Item 4.3 (a) to (c) above. 6.1.2 The insulation resistance should satisfy the provision of the code of which the escalator was design and constructed to. However, the insulation resistance may be inspected on

37

each circuit which can be separated by switches or over-current circuit breakers. 6.1.3 The loading inspection of Item 4.4 above is carried out with no load condition only.

6.1.4 The brake of driving machine should operate properly, and its breaking force should be capable of stopping the ascending steps without load within 0.1 m to 0.6 m inclusive. 6.1.5 The level of emergency stop for breakage of driving chains should work easily and safely stop the escalator

operation.

6.2 Inspection of upper and lower landings and on steps 6.2.1 The stop switch, which works in the event of step-chain breakage, should be firmly fitted and working properly.

6.2.2 The escalator should stop its upward or downward movement as soon as the fire shutters, etc. equipped near the landings begin to shut.

6.2.3 Starting switches, stop switches, emergency stop switches, signal switches, etc. fitted at upper and lower landings should work properly.

6.2.4 The handrails should move up or down at the same speed as the steps.

6.2.5 During downward operation, the handrail should not be stopped by human power of about 15 kgf pulling horizontally at the upper landing.

6.2.6 A suitable protective device should be provided at the entrance opening of handrail, and the switches attached thereto should work properly. 6.2.7 The engagement between the grooves on the steps and the comb plate teeth on the upper and lower landings should be adequate enough, and there is no risk of easy jamming of

things. 6.2.8 Where dangerous pillars, beams, etc. are located within 0.5 m horizontally from the handrails or 2.1 m above the steps, suitable guards should be provided. 6.2.9 The clearance between adjoining steps and that between

skirt guard and steps should be within the range of 2 mm to 5 mm over the whole length of the escalator. 6.2.10 The working condition of skirt-guard switches should be working properly. 6.2.11 The fitting condition of the guard plates provided in the triangular corners formed between the handrail structure


38

and the ceiling or beam structure of the building should be secured. 6.2.12 Where protective fences or nets against falling are provided, their fitting condition should be secured.

6.2.13 The safety mark on steps should be clear. (C) Electric dumbwaiter - Inspection Items 7.1 Inspection of machinery room

7.1.1 There should be no obstruction to entrance of the machinery room. 7.1.2 The inspection for installation resistance should be performed in accordance with Item 4.2 (d) above. 7.1.3 The inspection of driving machines, brakes and hoisting

machines should be made in accordance with Item 4.3 above. 7.1.4 The load test should be made in accordance with Item 4.4 above. 7.2 Inspection of loading port 7.2.1 The inspection of the loading port in the upper terminal

storey

(a) The rope setting method should be proper.

(b) The working condition of upper limit should be good. 7.2.2 The door switches and signaling equipment in each storey

should work well. 7.2.3 The fitting condition of door hanging ropes in each storey should be secured. 7.2.4 The working condition of lower limit switch should be good.

Acceptance criteria

(a) All non-compliance detected should comply with relevant regulatory requirements and the acceptance criteria of the relevant codes of practice of which the lifts, escalators or dumbwaiters were design and constructed to.

(b) All non-compliance should not affect the integrity of the lift, escalator, and dumbwaiter operating at its contract speed and loads.

Action to be taken if item does not meet criteria

(a) Recommendation should be made to the owner to repair

or remove such defects and to comply with the acceptance criteria.

39

(b) If changes need to be done on the original design

upon carrying out the defective works, approval from the Chief Inspector is required.

(c) Recommendation to condemn the lifts, escalators or dumbwaiters should be made in case of major defects or any further repair to it will cause the integrity of the lifts, escalators or dumbwaiters to be questionable.

8.0 Reference codes applicable to type of inspection It is preferable, but not limited to, that the following standards or codes are referred : ANSI A17.1 EN 115 JIS A 4302

According to European Committee for Standardization (CEN) rules or standards.



40

PART 4: UNFIRED PRESSURE VESSELS 1.1 Definition

An unfired pressure vessel is defined as any enclosed vessel under pressure greater than atmospheric pressure by any gas or mixture or combination of gases and includes any vessel under pressure of steam external to the steam boiler and any vessel which under pressure of a liquid or gas or both, and any vessel subject internally to a pressure less than atmospheric pressure but does not include gas cylinder.

2.1 Inspection Classification Initial Inspection Prior to initial use, all new and altered unfired pressure vessels shall be inspected by an Inspector or approved Private

Inspector to ensure compliance with the provisions of this Guidelines. Regular Inspection After an initial inspection, every unfired pressure vessel shall be inspected at regular intervals by a licensed person/private inspector so long as such unfired pressure

vessel remains in operation. The interval for any regular inspection shall ordinarily be fifteen months. Requirements for an Initial Inspection

3.1 Scope of an Initial Inspection

The purpose of an initial inspection of an unfired pressure

vessel is to ascertain that it has been properly installed,

its fittings and pipings have been properly attached and that

the place of installation meets the provisions concerned under

the Act.

3.2 Installation

The installation of all unfired pressure vessels shall comply with Regulation 60, Factories & Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970. 3.3 Inspection of Pipinqs

To comply with Regulation 68, Factories & Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970, a check on the method of suspension, installation of expansion joint and pipes, measures for labeling or identifying various kind of pipes, etc. has to be carried out. 3.4 Inspection of support

41

To comply with Regulation 61, Factories & Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970, a check on the existence for cracks in the floor or abnormality in the foundation, measures for absorbing the thermal expansion in the foundation, methods of fastenings etc. has to be carried

out. 3.5 Verification of documents and design drawings

The Inspector or an approved Private Inspector shall ascertain whether the owner of an unfired pressure vessel has the necessary approval from DOSH. H~ should also check on the

manufacturer's data report, NDT report, weld mapping and mill certificate and verification against approved drawings, confirmation of drawings and physical parts of unfired pressure vessel, etc. 3.6 Name Plates

To comply with Regulation 55, Factories & Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970. 3.7 Hydrostatic Test

To comply with Regulation 72, Factories & Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970.

3.8 Confirmation of function of safety valves

To comply with Regulations 48, 49 and 50 Factories & Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970. 3.9 Inspection of essential fittings

To comply with Regulation 47 and relevant provision, Factories & Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970, a check on the necessary indication on the pressure gauge, etc. has to be carried out. 3.10 Confirmation of the stamp mark on the body aginst

manufacturer data report.

Requirements for a Regular Inspection 4.1 Scope of a Regular Inspection The purpose of a Regular Inspection is to examine an unfired pressure vessel to verify that it is able to continue its

operation for another fifteen months. 4.1 Notice of regular inspection

Before a regular inspection is carried out, reasonable notice should be given to an operator or owner. 4.2 Preparation for regular inspection


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The occupier or owner should be informed that upon receipt of the notice of intended regular inspection, he shall ensure at the appointed date that all unfired pressure vessels to be inspected are prepared for inspection in accordance with Regulation 17, Factories and Machinery (Notification,

Certificate of Fitness and Inspection) Regulations, 1970. 4.3 Persons to be present at inspection

The occupier or owner should be informed to arrange for his engineer or technical representative to be present during the regular inspection.

4.4 General Conditions

The media that an unfired pressure vessel contains and the temperature and pressure at which it operates should be based on established inspection standards.

For internal inspection, the vessel must first be isolated by blinds or other positive methods from all sources of liquids, gases, or vapors. The vessel should be drained, purged, cleaned, ventilated, and gas tested before it is entered.

4.5 Pre-inspection activities

A review of the known history of the unfired pressure vessel should be performed. This should include a review of information, such as: Operating conditions

Normal contents of the vessel

Date of last inspection

Current jurisdictional inspection certificate of fitness

Department of Occupational Safety and Health registration number.

Records of wall thickness checks, especially on vessels where corrosion is a consideration.

4.6 External inspection

The purpose of an external inspection is to establish the overall condition of the unfired pressure vessel. The

following should be noted:

(i) Insulation or other covering

Unless there are reasons to suspect any unsafe condition behind them, the insulation and covering for any unfired pressure vessel need not be removed for inspection if the

external covering such as insulation and corrosion resistant linings are found to be in good condition.

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However, as a precaution, it is advisable to remove a small portion of the coverings in order to investigate their condition and the condition of the metal.

(ii) Evidence of leakage

Any leakage of gas, vapor or liquid should be investigated. A leakage coming from behind insulation coverings, supports or settings, or evidence of a past leakage should be thoroughly investigated by removing any covering necessary to establish the source.

(iii) Structural attachments

The mountings for an unfired pressure vessel should be checked for adequate allowance for expansion and contraction, such as that provided by slotted bolt holes or unobstructed saddle mountings. Attachments of legs, saddles, skirts or other supports should be examined for

distortion or cracks at welds.

(iv) Vessel connections

Manholes, reinforcing plates, nozz1es or other connections should be examined for cracks, deformation or other defects. Bolts and nuts should be checked for

corrosion or defects. Tell tale holes in reinforcing plates should remain open to provide visual evidence of leakage as well as to prevent pressure built up between the vessel and reinforcing plate. Accessible flange faces should be examined for distortion and to determine the condition of gasket seating surfaces.

(v) Miscellaneous conditions

The surfaces of the vessel should be checked for erosion.

Check for dent and ensure that the thickness of metal is not materially impaired.

If any distortion is suspected or observed, the overall dimension of the vessel should be checked to determine

the extent and seriousness of the distortion. Check for cuts or gouges. The surfaces of shells and heads should be examined for possible cracks, blisters, bulges, and other evidence of deterioration, giving particular attention to the skirt and to support attachment and knuckle regions of the head.

Welded joints and the adjacent heat affected zones should be examined for cracks or other defects. Magnetic particle or liquid penetrant examination is a useful means for doing this.

On riveted vessels, examine rivet head, butt strap, plate and caulked edge conditions. If rivet shank corrosion is suspected, hammer testing or spot radiography at an angle to the shank axis may be

useful.


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4.7 Internal Inspection A general visual inspection is the first step in making an internal inspection. All parts of the vessel should be

inspected for corrosion, erosion, hydrogen blistering, deformation, cracking and laminations. The following should also be reviewed

(i) Vessel connections

Threaded connections should be inspected to ensure that

an adequate number of threads are engaged. All openings leading to any external fittings or controls should be examined as thoroughly as possible to ensure they are free from obstruction. (ii) Vessel closures

Any special closures including those on autoclaves, normally termed quick actuating (quick opening) closures which are used frequently in the operation of pressure vessels, should be checked for adequacy and wear. A check also should be made for cracks at areas of high stress concentration.

(iii) Vessel internals

Where pressure vessels are equipped with removable internals, these internals need not be completely removed provided assurance exist that deterioration in region rendered inaccessible by the internals is not occurring to an extent that might constitute a hazard or to an extent beyond that found in more readily accessible parts

of the vessel.

If a preliminary inspection reveals unsafe conditions such as loose or corroded internals or badly corroded internal ladders or platforms, steps should be taken to remove or repair such parts so that detailed inspection may be made.

(iv) Corrosion

The type of corrosion (pitted or uniform), its location and any obvious data should be established. The liquid level lines, the bottom and the shell area adjacent to and opposite inlet nozzles are to be inspected. Welded

seams and nozzles and areas adjacent to welds need to be given attention.

4.8 Non-destructive examination (NDT)

Magnetic particle, liquid penetrant, ultrasonic, radiography, eddy current, visual, metallographic examination, and acoustic emission may be used to assess the condition of an unfired

pressure vessel.

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4.9 Pressure testing

A pressure test should be made when inspection discloses unusual, hard to evaluate forms of deterioration that may

affect the safety of the vessel. The test pressure should not exceed 1 1/2 times the maximum allowable working pressure adjusted for temperature. When the original test pressure includes consideration of corrosion allowance, the test pressure may be further adjusted based upon the remaining corrosion allowance.

4.10 Gauges

The pressure indicated by the required gauge should be compared with other gauges on the same system. The accuracy of pressure gauges should be verified by comparing the readings with standard test gauge or a dead weight tester.

4.11 Safety devices 4.11.1 Device data Nameplate marking or stamping of the device should be compared to stamping on the pressure retaining item. The set

pressure shall be no higher than the maximum allowable working pressure (MAWP) marked on the pressure retaining item.

If multiple devices are provided, the difference between set pressures shall not exceed that permitted by the original code of construction.

Verify nameplate capacity and if possible, compare to system capacity requirements.

Check identification on seals and ensure they match nameplates or other identification (repair or reset nameplate) on the valve or devices.

4.11.2 Device condition Check for evidence that the valve or devices is leaking or

not and whether the sealing has been properly carried out. Seals should be intact and show no evidence of tampering. Connecting bolting should be tight and all bolts intact. The valve should be examined for deposits or material buildup.

Evidence of rust or corrosion should be checked. Check for damage or misapplied parts.

If a drain hole is visible, ensure it is not clogged with debris or deposits.

4.11.3 Installation condition Inspect inlet piping and ensure it meets the requirements of the original code of construction. Ascertain that the inlet pipe size is not smaller than the device inlet size.


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Inspect discharge piping and ensure it meets the original code of construction. Check that the discharge pipe size is not smaller than the device outlet size.

Check that the valve drain piping is open. Check drainage of discharge piping.

Check that the discharge piping is not binding on the valve body which can lead to distortion of the valve body and leakage or malfunction.

Check the condition and adequacy of piping supports. Discharge piping should be supported independently of the device itself.

Check for possible hazards to personnel from valve discharge

or discharge pipe. Check that there are no intervening valves (such as a block valve) between the pressure source and the valve inlet or between the valve outlet and its point of discharge. (Block valves may be permitted in some pressure vessel service).

4.12 Others Unfired Pressure vessel's log book should be checked. Ensure that any repairs or modifications made are recorded and persons responsible for such works are clearly identify.

Check the inspection record book. On each subsequent inspection of such pressure vessels, a comparison should be made with such record and note any changes since the previous inspection.

4.13 Acceptance criteria

All defects detected should comply to relevant regulatory requirements and the acceptance criteria of the relevant codes of practice of which the unfired pressure vessel was design and constructed to, such as NB 23, API 510, API 572 etc.

All defects should not affect the integrity of the unfired pressure vessels to operate at its safe allowable operating pressure. Action to be taken if item does not meet criteria.

Recommendation should be made to the owner to repair or remove such defects and to comply to the acceptance criteria. If changes need to be done on the original design upon carrying out the defective works, approval from the Chief Inspector is required. If necessary, recommendation should be made to the owner to

reduce the safe allowable working pressure. Recommendation to condemn the unfired pressure vessel should be made in case of major defects or when any further repair to the boiler will cause the integrity of the boiler to be questionable or compromised.

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Reference codes applicable to type of inspection It is preferable, but not limited to, that the following standards or codes are referred to:

ANSI/NB-23 API 510 API 572 According to European Committee for Standardization (CEN) rules or standards.

Recommended practice for inspection of specific equipment or machines issued by International Organization for safety and

health.

Standard Inspection Method

Engineering

Transcript of Standard Inspection Method