After reaching its limit, the device requires an assessment of its technical condition, namely a special inspection.
Reaching the service life limit means a technical assessment is necessary
The service life defines the limiting operating parameters of a device. When determining it, the number of work cycles, load levels, intensity of use and actual operating conditions are taken into account. Therefore, the service life cannot be equated solely with the age of the machine or the number of hours worked.
When the device or one of its mechanisms reaches the established limit, the operator should carry out or commission a special inspection. This applies, among other things, to overhead cranes, cranes, hoists, winches, mobile elevating work platforms, stacker cranes and powered industrial trucks.
Using up the service life does not automatically mean that the machine must be withdrawn from service. However, the operator must check whether its structure and mechanisms allow further safe operation. The assessment may also show that repair, modernization or a major overhaul is required.
Lack of operating-history data does not exempt anyone from their obligations
The operator should keep a separate operating record for each device. They may use cycle counters, engine-hour meters, maintenance logs, service documentation and data on lifted loads. An hour meter alone is not always sufficient, because a device may operate for a short time while regularly lifting loads close to its rated capacity.
When the documentation does not specify the service life, it must be determined in accordance with current technical knowledge and engineering principles. If operating-history records are missing, the operator should reconstruct the work history. Production schedules, archived reports, maintenance records, typical loads and information from operators may be helpful.
A correctly calculated service life of lifting equipment makes it possible to plan a technical assessment before further operation of the machine becomes impermissible or dangerous.
A maintenance inspection does not replace a special inspection
The maintenance technician checks the current condition of the lifting equipment at the intervals specified in the operating instructions or regulations. They inspect drive mechanisms, brakes, load-bearing ropes and chains, safety devices, controls and the structure. Such activities help detect faults arising during normal operation.
A special inspection, on the other hand, serves as a comprehensive assessment of the device after the assumed operating period has been used. The manufacturer or a competent person determines the scope of the tests. It should include components affecting safety, including:
- the load-bearing structure and its geometry,
- bolted and welded connections,
- gearboxes, drives and brakes,
- electrical, hydraulic and pneumatic systems,
- limiters and other safety devices,
- areas exposed to corrosion, cracks and deformation.
Specialists may perform geometry measurements, non-destructive testing, material-thickness checks and strength calculations. They select the scope of work according to the type of device, its history and operating conditions.
The inspection result determines the conditions for further operation
The competent person documents the activities performed and prepares a report assessing the technical condition. They may approve the device for another period of operation, recommend more frequent inspections or indicate necessary repairs. When the condition of the structure or mechanisms requires it, the operator carries out a major overhaul before restarting the machine.
After the assessment has been completed and the recommendations have been implemented, the competent person determines the next service life. It may be shorter than the initial operating period of a brand-new device. It depends on the degree of wear, the scope of the overhaul and the expected intensity of further operation.
A timely assessment helps avoid unplanned downtime
It is best to schedule a special inspection before the service life is fully used up. This gives the facility time for testing, preparing documentation and carrying out any necessary repairs without suddenly stopping production or handling operations.
If you are looking for support with calculating the service life of lifting equipment, a special inspection or a major overhaul, take a look at Lubritech’s offer. The company combines documentation work with repairs, refurbishment and modernization of equipment, making it easier to complete the entire process.