Lifting Tools Inspection Training Service | in Dammam - Riyadh - Jeddah - Makkah

1. Introduction to Lifting Equipment Inspection

• Importance of inspection programs including (accident prevention, equipment reliability, regulatory compliance, liability protection)

• Regulatory framework including (ASME B30 Series, LOLER, ISO 9927, OSHA 29 CFR 1910.179, EN 13155)

• Inspection categories including (initial inspection, frequent inspection, periodic inspection, special inspection)

• Inspector qualifications including (competent person definition, knowledge requirements, training, experience, certification)

• Inspection objectives including (defect detection, serviceability determination, record maintenance, trend identification)

• Common failure modes including (overloading, fatigue, corrosion, wear, abuse, improper use)

• Inspection frequency requirements per ASME B30 including (pre-use daily, monthly, quarterly, annual, documented intervals)

2. Wire Rope Inspection Techniques

• Wire rope construction review including (fiber core, independent wire rope core, strand patterns 6x19 and 6x37, lay types)

• Inspection methodology per ASME B30.9 including (systematic examination, entire length coverage, running rope through hands)

• Broken wire criteria including (number per lay length, valley breaks, crown breaks, concentration limits, random distribution)

• Wear and abrasion assessment including (diameter reduction measurement, external wear, internal wear, comparison to nominal)

• Corrosion evaluation including (surface rust, pitting, chemical damage, internal corrosion, valley corrosion)

• Deformation defects including (kinking, bird caging, core protrusion, crushing, flattening, localized wear)

• Heat damage recognition including (discoloration, annealing, arc strikes, metallurgical changes, brittleness)

• Rejection criteria per ASME B30.9 including (diameter reduction exceeding 1/32 inch for ropes up to 5/16 inch, specific broken wire limits, kinking)

3. Synthetic Sling Inspection Standards

• Synthetic sling types review including (web slings, round slings, endless configurations, eye-and-eye per ASME B30.9)

• Material identification including (nylon, polyester, polypropylene, capacity color codes, tag information)

• Visual inspection technique including (full length examination, both sides, edge inspection, inside folds)

• Cut and tear assessment including (edge damage, hole formation, punctures, severity evaluation, fiber exposure)

• Abrasion damage including (surface wear, fiber fuzzing, yarn exposure, thickness reduction, shiny appearance)

• Chemical damage indicators including (discoloration, stiffness, brittleness, unusual odor, melting, charring)

• Heat and UV damage including (hard spots, glazing, color change, strength degradation, environmental exposure)

• Rejection criteria per ASME B30.9 including (acid or caustic burns, melting or charring, snags or tears, broken stitching, illegible tag)

4. Chain Sling Inspection Requirements

• Alloy chain grades including (Grade 80, Grade 100, Grade 120, identification markings, material certificates)

• Chain components including (individual links, master links, coupling links, hooks, oblong links per ASME B30.9)

• Link-by-link inspection including (systematic examination, visual inspection, tactile inspection, measurement)

• Wear measurement including (nominal chain diameter, maximum allowable wear typically 10%, caliper measurement, multiple points)

• Elongation assessment including (pitch length measurement, link stretching, maximum elongation typically 5%, comparison to new)

• Crack detection including (visual examination, dye penetrant testing, magnetic particle inspection, critical stress points)

• Deformation evaluation including (bent links, twisted links, gouges, nicks, weld splatter, opening dimensions)

• Rejection criteria per ASME B30.9 including (wear exceeding 10%, cracks, bent or twisted links, stretch, heat damage, weld spatter)

5. Rigging Hardware Inspection

5.1 Shackle Inspection

• Shackle types including (anchor shackles, chain shackles, screw pin, bolt-type, safety bolt per ASME B30.26)

• Body inspection including (cracks, corrosion, deformation, wear in pin holes, throat opening, load marks)

• Pin examination including (thread condition, bending, wear, corrosion, proper engagement, safety devices)

• Rejection criteria including (cracks, 10% wear reduction, bent pin, damaged threads, deformation, illegible markings)

5.2 Hook Inspection

• Hook types including (eye hooks, grab hooks, sling hooks, foundry hooks, sorting hooks per ASME B30.10)

• Critical inspection points including (throat opening, saddle section, shank, bowl, tip, attachment point)

• Throat opening measurement including (caliper measurement, maximum increase typically 15%, comparison to original)

• Twist and bend assessment including (visual alignment, measurement if suspected, maximum twist typically 10 degrees)

• Crack detection locations including (load-bearing section, saddle area, thread area, stress concentration points)

• Latch functionality including (spring operation, closure verification, damage assessment, security)

• Rejection criteria per ASME B30.10 including (throat opening increase exceeding 15%, twist exceeding 10 degrees, cracks, wear exceeding 10%)

5.3 Other Hardware

• Eyebolt inspection including (shoulder condition, thread condition, forging quality, rated capacity marking, shank bending)

• Turnbuckle examination including (thread engagement, barrel condition, end fitting security, pin retention)

• Lifting beam inspection including (structural integrity, weld condition, attachment points, capacity markings, certification)

• Master link assessment including (wear, deformation, crack detection, load distribution marks, identification)

6. Hoisting Equipment Inspection

6.1 Manual Chain Hoists

• External examination per ASME B30.16 including (housing condition, load chain, hooks, labels, load limiting device)

• Functional testing including (free chain movement, brake holding, no unusual sounds, smooth operation)

• Load chain inspection including (wear, elongation, corrosion, deformation, lubrication, link condition)

• Hook inspection including (throat opening, twist, cracks, latch operation, swivel function)

• Brake examination including (holding capacity, engagement, wear, adjustment, pawl condition)

6.2 Wire Rope Hoists

• Structural components including (housing, drum, sheaves, bearings, mounting, guards per ASME B30.16)

• Wire rope examination including (fleet angle, spooling, wear, lubrication, broken wires, end connections)

• Electrical components including (controls, limit switches, emergency stop, pendant condition, wiring)

• Brake system including (holding capacity, adjustment, lining condition, response time, load testing)

• Load testing requirements including (proof load testing, test load typically 125%, documentation, frequency)

7. Inspection Documentation and Records

• Documentation requirements per ASME B30 including (inspection date, inspector identity, equipment identification, condition findings)

• Inspection forms and checklists including (standardized forms, equipment-specific checklists, defect recording, disposition)

• Equipment identification systems including (unique numbers, barcodes, RFID tags, asset tracking, location coding)

• Inspection tags and labels including (color coding, date stamps, next inspection due, service status, deficiency notes)

• Record retention including (OSHA requirements typically 3 years, permanent equipment records, disposal documentation, audit trail)

• Deficiency reporting including (immediate notification, out-of-service tagging, repair authorization, verification inspection)

• Trend analysis including (recurring failures, equipment performance, preventive maintenance scheduling, replacement planning)

• Electronic systems including (database management, mobile inspection apps, automated reminders, reporting capabilities)

8. Inspection Frequency and Scheduling

• Initial inspections including (new equipment, after repair, after modification, certification requirements per ISO 9927)

• Pre-use inspections including (daily checks, shift inspections, visual examination, functional testing)

• Frequent inspections per ASME B30.9 including (monthly for normal service, visual examination, documented findings)

• Periodic inspections including (annual for normal service, quarterly for severe service, comprehensive examination, documentation)

• Special inspections including (after incidents, following unusual occurrences, suspected damage, overload events)

• Service classification including (normal service, heavy service, severe service, inspection frequency adjustment)

• Inspection scheduling systems including (calendar-based, usage-based, condition-based, automated tracking)

• Inspection prioritization including (critical equipment, high-risk operations, regulatory priorities, resource allocation)

9. Equipment Removal and Return to Service

• Out-of-service procedures including (immediate removal, tagging "DO NOT USE", physical isolation, notification)

• Deficiency tagging including (red tags, detailed description, date, inspector name, equipment identification)

• Repair authorization including (qualified repair facilities, manufacturer specifications, engineering approval, documentation)

• Repair standards including (ASME requirements, manufacturer procedures, material specifications, weld qualifications)

• Post-repair inspection including (comprehensive examination, load testing if required, certification, documentation)

• Return-to-service criteria including (deficiency correction, inspection verification, testing completion, documentation update)

• Proof load testing per ASME B30.10 including (test load values typically 125-150%, hold time, examination after test, documentation)

• Equipment disposal including (destruction procedures, record retention, replacement acquisition, disposal documentation)