Standard Inspection Method

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INSPECTION STANDARD FOR
CERTIFICATED MACHINERY
FACTORIES AND MACHINERY ACT
1967

INSPECTION STANDARD FOR CERTIFICATED MACHINERY
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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
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
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;

21
(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.

22
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.

23
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
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
health.

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.

25
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.

26
(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

27
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.

28
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.

29
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.

31
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.

32
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.

33
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
5.7.2 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
5.8.2 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
6.1.3 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
standards or codes are referred :
ANSI A17.1
EN 115
JIS A 4302
According to European Committee for Standardization (CEN)
rules or standards.
health.

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
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
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
3.7 Hydrostatic Test
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

42
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.

43
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.

44
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.

45
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.

46
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.

47
Reference codes applicable to type of inspection
standards or codes are referred to:
ANSI/NB-23
API 510
API 572
According to European Committee for Standardization (CEN)
rules or standards.
health.

Standard Inspection Method

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