Crane maintenance is a cornerstone of industrial operations, ensuring not only the safety of personnel but also the efficiency and reliability of equipment. As crucial assets in construction, mining, and logistics, cranes are subject to significant mechanical stress making regular crane inspections and maintenance a necessity to prevent accidents and costly downtime.
Non-Destructive Testing (NDT) plays a pivotal role in crane maintenance, offering a sophisticated means of identifying flaws and ensuring compliance with relevant Australian NDT and international ASME/ISO standards. This guide explores the importance of NDT in maintaining registerable plant equipment, with a particular focus on cranes.
Understanding Non-Destructive Testing (NDT)
Definition and Purpose of NDT
Non-Destructive Testing refers to a range of techniques used to evaluate the integrity of materials and components without causing damage. Unlike destructive testing, NDT preserves the usability of equipment while providing critical insights into its condition.
Key Benefits of NDT
- Safety: Detects flaws that could compromise structural integrity.
- Cost Efficiency: Reduces repair expenses by identifying issues early.
- Operational Reliability: Minimises unplanned downtime.
- Sustainability: Extends the lifespan of machinery through preventive maintenance.
Importance of NDT in Crane Maintenance
Enhancing Safety
NDT techniques enable the early detection of cracks, corrosion, and other defects, significantly reducing the risk of catastrophic failures.
Testing in Accordance with Australian, International Standards or OEM Procedures
Adhering to Australia’s Work Health and Safety Act 2020 and associated regulations requires regular inspections of high-risk equipment, including cranes. NDT in accordance with Australian and International standards or OEM procedures provides the means to meet these stringent requirements.
Reliability Maintenance
By uncovering potential problems before they escalate, NDT helps organisations avoid unexpected breakdowns, ensuring continuous operation and reducing repair costs. NDT examination reports are a critical component for a crane records management system which documents preventative NDT inspections or NDT inspections associated with repair work performed on the crane.
All NDT reports shall be retained for the design life of the crane.
Extending Equipment Lifespan
Routine NDT inspections contribute to the longevity of cranes by identifying and addressing wear and tear in a timely manner and add valuable data to plant asset files.
NDT Techniques Applicable to Cranes
Here is a short overview of the NDT methods we use to assess cranes, tailored to address critical inspection areas such as weld integrity, structural fatigue, corrosion detection and more.
Visual Inspection (VI)
Visual Inspection is a fundamental NDT method that involves assessing equipment for visible signs of wear or damage.
Drone inspections have become a popular enhancement to traditional VI, allowing access to hard-to-reach areas with minimal risk.
➜ Learn more about Visual Inspection
Ultrasonic Testing (UT)
Ultrasonic Testing uses high-frequency sound waves to detect internal flaws, particularly in crane components such as pins and slew-ring bolts. UT is instrumental in assessing material thickness and integrity.
➜ Learn more about Ultrasonic Testing
Magnetic Particle Testing (MPT)
This technique detects surface and near-surface discontinuities in ferromagnetic materials. It’s particularly useful for inspecting crane hooks, pins, and other critical components and identifying cracks in congested areas.
➜ Learn more about Magnetic Particle Testing
Eddy Current Testing (ECT)
Eddy Current Testing is used to detect surface and near-surface flaws in conductive materials. A major advantage of ECT is the ability to test structural welds without removing or reinstating paint coatings, saving time and cost.
➜ Learn more about Eddy Current Testing
Regulatory Compliance – Cranes
Western Australia’s Work Health and Safety Framework
The Work Health and Safety Act 2020 and the Work Health and Safety (Mines) Regulations 2022 (WHSR-2022) mandate the regular inspection and registration of cranes as per Schedule 5 requirements to ensure operational safety.
Crane Registration and Inspection Requirements
Crane registration and inspection requirements ensure compliance with safety standards and the safe operation of lifting equipment.
- Bridge and Gantry Cranes: Under WHSR-2022, registering Bridge and Gantry cranes designed to AS1418.3:2024 requires:
- A design registration form for each gantry crane (Safe Working Load > 5 tonnes), bridge crane (SWL > 10 tonnes), or any crane handling molten metal or dangerous goods.
- Independently verified design calculations and drawings for the crane and runway structure.
- Building and footing calculations to ensure compliance.
Cranes must undergo annual third-party inspections and periodic major inspections based on usage and design life. Major inspections are required after two-thirds of the crane’s design life, or after seven years of use (if unknown), or when recommissioning old cranes without prior records. Structural assessments and Design Working Period (DWP) calculations help determine the condition and usage patterns to ensure continued safe operation and compliance with applicable standards.
➜ Learn more: Bridge and Gantry Crane Registration & Inspection Requirements
- Mobile Cranes: Mobile cranes requiring plant registration include articulated cranes, truck-mounted cranes, vehicle self-loading cranes (Hiab), crawler cranes, and trailer-mounted cranes with a rated capacity of greater than 10 tonnes. WHS Regulations Schedule 5 Division 1 and 2 states that mobile cranes with a capacity greater than 10 tonnes must have their design verified and registered prior to manufacturing, and plant registered prior to commissioning the crane.
Mobile cranes must undergo annual third-party inspections. Major inspections are required in accordance with the manufacturer’s recommendations or relevant design standard, and it is determined that a major inspection is due, e.g. the design working period of 10 years has expired.
Structural inspections are required to remain aligned with Australian Standard AS2550.5, Section 7. Design Working Period (DWP) assessments of mobile cranes are required to remain aligned with Australian Standards AS2550.1 and AS1418.5.
➜ Learn more: Mobile Crane Registration & Inspection Requirements
- Vehicle Loading Cranes: Under WHSR-2022, registering vehicle loading cranes designed to AS1418.11:2014 a registration form for each crane, and independently verified design calculations and drawings in line with AS1418.1:2021 and AS1418.11:2014 standards.
Vehicle loading cranes must undergo annual third-party inspections, major inspections at the end of their design life or when unknown, and structural assessments to ensure compliance with AS1418.11:2014. Design Working Period (DWP) calculations are recommended to optimise inspection intervals based on crane usage and load conditions.
➜ Learn more: Vehicle Loading Crane Registration & Inspection Requirements
- Monorails: Monorails do not require registration with DMIRS. However, they must undergo periodic inspections at intervals not exceeding 10 years that comply with AS1418.18:2024, Section 9.
➜ Learn more: Monorail Registration & Inspection Requirements
- Tower Cranes and Vehicle Hoists: Tower cranes and vehicle hoists must comply with registration and inspection requirements to ensure safety and compliance. Registration involves submitting a registration form for each item, along with design calculations and drawings that meet relevant Australian Standards (e.g., AS1418). Independent verification of the design is typically required. Additional documents, such as an appointed person letter (for specific sites), may also be necessary.
Inspections must include periodic third-party checks, with intervals not exceeding 12 months. Major inspections are required when the equipment reaches the end of its design life or when the design life is unknown. Structural assessments and Design Working Period (DWP) calculations help determine the condition and usage patterns to ensure continued safe operation and compliance with applicable standards.
➜ Download our full guide on Registerable Plant Registration & Inspection Requirements
Role of NDT in Compliance
NDT ensures cranes meet statutory inspection obligations by detecting cracks, corrosion, and other defects without damaging the equipment. Using techniques like ultrasonic and magnetic particle testing, NDT prevents accidents, reduces downtime, and ensures compliance with international ASME/ISO standards leading to safeguarding workers and operations.
AME’s NATA Accreditation and NDT Services
ISO/IEC 17025 Accreditation
AME has achieved NATA accreditation for ISO/IEC 17020, comprising Ultrasonic Testing, Eddy Current Testing, Magnetic Particle Testing, Liquid Penetrant Testing and Visual Testing. This accreditation reinforces AME’s commitment to technical excellence in delivery of NDT Services to our clients.
➜ Learn more about AME’s ISO/IEC 17025 Accreditation
Benefits of NATA-Accredited Services
- Assurance of accurate results.
- Compliance with international standards.
- Confidence in the safety and reliability of inspections.
Case Study: Ensuring Operational Safety of a Mobile Crane in a Marine Environment
Background
A critical mobile crane used for loading and unloading supply boats on a island off the Australian coastline was recently inspected to ensure its continued safe operation. The crane plays an essential role in maintaining food and supply lines to the islands’ inhabitants, making its functionality a top priority. Operating in a challenging marine environment, the crane had previously undergone inspection with Magnetic Particle Inspection (MPI), and its boom section had been repainted. However, corrosion had developed in some areas, necessitating a thorough assessment.
Inspection and Findings
The inspection team employed a combination of advanced Non-Destructive Testing (NDT) techniques to evaluate the crane:
- Eddy Current Testing (ET): Used to inspect welds on the chassis superstructure, boom sections, and outriggers for cracks and defects.
- Ultrasonic Testing (UT): Applied to measure thickness in corroded areas, inspect the luff ram and sheave pins, and evaluate slew-ring bolts.
- Visual Testing (VT): Conducted to assess general degradation, such as surface corrosion and paint conditions.
The inspection revealed severe corrosion on two sections of the crane’s boom, with significant material loss in some areas. UT confirmed that the remaining material thickness in these sections was below acceptable limits, requiring immediate replacement. Replacement boom sections were shipped to the island to restore the crane’s operational safety and reliability.
Outcome
The comprehensive NDT approach ensured the crane was thoroughly assessed, and necessary repairs were identified to prevent potential failures. This proactive inspection not only safeguarded critical operations but also reinforced the importance of regular and detailed inspections for equipment operating in harsh environments.
Key Takeaway
The use of multiple NDT techniques, tailored to the crane’s unique environment and operational demands, highlights the critical role of inspections in maintaining safety and reliability in marine settings.
Choosing AME for Reliable NDT and Inspections of Your Cranes
Why Choose AME?
- NATA accredited for ISO/IEC 17020 and 17025.
- Extensive experience in crane inspection and maintenance.
- Use of cutting-edge technology.
- Unwavering commitment to safety and compliance.
Enquire Now for NDT Crane Inspection Services
Ensure the safety and reliability of your cranes with AME’s NATA-accredited NDT services. Contact us today to schedule an inspection and experience the assurance of accredited quality.