|
|
TITLE: |
||
|
|
|||
|
DOCUMENT ID: |
6140
Appendix T1 Inspection
Procedures for Rigging Equipment, Cranes, and Hoists |
||
|
|
|||
Rigging Equipment Inspection and Maintenance Guidance
·
The operator and/or person in charge (PIC) or SOTR, shall inspect all
rigging equipment prior to, during, and after each use.
·
Before operators begin a job, they will conduct an inspection of the
crane/hoist. As part of the inspection:
o
Operate mechanisms for proper function and adjustment.
Listen for unusual sounds. Check lift and lower
controls and movement. Trolley travel and bridge
travel should be in normal operating condition.
o
Upper limit device should stop the block from impacting the drum of the
hoist.
o
Hooks and hook latches should perform normally.
o
Wire rope should not have broken or cut strands, bird caging, kinks or
any other signs of wear.
o
If any questions are raised from the inspection, the MHSR shall be
notified immediately to determine if the crane/hoist can be used.
·
All safety devices and warning equipment, such as lights, alarms, and
emergency cut offs, shall be working normally.
·
Damaged equipment shall not be used for rigging loads.
Damaged or defective lifting equipment shall be immediately removed from
service and turned in to the MHSR for final determination of condition and, if
required, removed from service.
·
Avoid abusing slings by such actions as dragging on the ground, through
oil, chemicals, or water, running over them with vehicles, contact with flying welding
or burning slag, or unnecessary exposure to ultraviolet light.
·
Store rigging equipment in designated locations when not in use.
·
Chain slings shall have a permanently affixed durable identification
stating size, manufacturer’s grade, rated load and angles upon which the rating
is based, reach, and number of legs.
·
Chain slings shall be inspected in accordance with ASME B30.9, section
9-1.8-Inspection and Repair.
- Synthetic web slings should be stored by
hanging on hooks or brackets. Slings shall never be
stored in damp or dirty areas or subjected to corrosive materials, welding
light, weather, temperatures exceeding 180° F or
UV rays from sunlight (unnecessarily).
- Wire slings shall have a permanently
affixed durable identification tag stating size, manufacturer’s grade,
rated load and angles upon which the rating is based, reach, and number of
legs. If this tag is illegible, then the sling
shall be removed from service and turned in to the MHSR for disposal and
replacement.
- Synthetic slings shall be removed from service if any of the following defects are visible:
o Acid or caustic burns
o Melting or charring of any
surface part
o Snags, punctures, tears,
or cuts
o Broken or worn stitches
o Wear or elongation
exceeding the amount recommended by manufacturers
o Distortion of end fittings
·
When it is necessary to use a nylon or polyester sling in a radiation
area, the guidelines set forth in the Department of Energy DOE-HDBK-1090-95
11.3.5.1 state that the responsible manager shall ensure that the radiation
exposure does not exceed 100,000 rad during the life of the sling. If there is any possibility that this exposure has been
exceeded, the sling shall be removed from service and disposed. If a sling is left in any radiological area out of the
known safe boundaries during beam operations, it also shall be removed from
service and disposed. There is no way of measuring the
amount of exposure to the sling without it being in a controlled area. No chances shall be taken if any doubt exists.
·
Wire rope slings must be wiped clean periodically to remove abrasive
grit and then lubricated. Wearing leather gloves when
working with wire rope is strongly recommended, as it will help prevent injury
to hands from broken wires.
·
Wire rope slings shall be inspected in accordance with ASME B30.9
section 9-2.8, Sling Inspection and Replacement as outlined in Appendix 6140-T5 Wire Rope Inspection
Procedures.
·
Eyebolts shall only be used for a straight load never an angled load. If there are angled loads, swivel eyes shall be used.
·
Defective rigging shall be
removed from service
·
Supervisors shall monitor rigging operations daily and ensure their
people perform inspections regularly on all rigging equipment in use. Jefferson Lab's philosophy for determining the
serviceability of any lifting device used for rigging is: “If it looks bad,
more than likely it is bad.” Personnel shall look for:
o Shackles with cracked,
bent, twisted, or otherwise damaged components
o Wire slings that are
broken, damaged, or worn
o Wire rope connections that
are corroded, cracked, bent, or improperly connected
o Eyebolts that are bent,
cracked, or twisted
o Hooks that are bent,
cracked, or twisted
- Notify the MHSR or
the MHSR's supervisor of any unsafe situations or equipment (ext. 7406). The MHSR can replace most equipment quickly and
safely. Better to delay a lift than risk a
failure.
Sample Crane/Hoist
Inspection Procedures
Introduction
Inspection procedures for hoists and cranes are placed in two
general classifications - frequent and periodic - based on inspection intervals. The intervals are dependent on the critical components of
the crane/hoist and the degree of the equipment’s exposure to wear,
deterioration or malfunction.
Most causes of MHE failure can be detected before failure occurs
if a proper inspection procedure is followed. A good
inspection plan calls for both daily inspections and biannual inspections. These are determined by the MHER and MHSR.
Procedure for
Frequent Inspections - Daily to Monthly Intervals
1.
Operators inspect the following items for defects on a daily basis
or prior to use (unless specified monthly):
o All functional
operating mechanisms for maladjustment that would interfere with proper
operation of equipment.
o Deterioration or leakage in lines, tanks, valves, drain pumps, and other
parts of air or hydraulic systems.
o Visually inspect
hooks for deformation or cracks. Perform monthly
inspections with a certification record that includes: inspection date,
signature of the person who performed the inspection and the item serial number
(or other identifier of the hook inspected). Hooks
with cracks or having more than 15 percent in excess of normal throat opening
or more than 10 percent twist should be discarded.
o Inspect hoist chains,
including end connections for excessive wear, twist, distorted links interfering
with proper function, or stretched beyond manufacturer’s recommendations.
Monthly, inspect and document in a certification record that includes:
inspection date, signature of person who performed the inspection and an
identifier of the chain inspected.
2.
Procedure for periodic inspections of cranes/hoists - 1-12 month
intervals. Inspect for the following:
o Deformed, cracked or
corroded members
o Loose bolts or rivets
o Cracked or worn
sheaves and drums
o Worn, cracked or
distorted parts such as pins, bearings, shafts, gears, rollers, locking and
clamping devices
o Excessive wear on
brake system parts, linings, pawls and ratches
o Load, wind and other
indicators over the full range, for any significant inaccuracies
o Gasoline, diesel,
electric, or other powerplants for improper performance or noncompliance with
applicable safety requirements
o Excessive wear of
chain drive sprockets and excessive chain stretch
o
Electrical apparatus for signs of pitting or any deterioration of
controller contractors. Check limit switches and
push-button stations.
3. Inspection of cranes
not in regular use
o If crane is idle for
1 month or more, but less than 6 months, perform all inspections listed above
for frequent inspections.
o If crane is idle for
a period over 6 months, complete inspections as listed above for frequent and
periodic inspection.
o Prior to initial use,
all new and altered cranes shall have the following testing:
§ Hoisting and lowering
§ Trolley travel
§ Bridge travel
§ Limit switches,
locking and safety devices
o The trip setting of
hoist limit switches shall be determined by tests with an empty hook traveling
in increasing speeds up to the maximum speed. The
actuating mechanism of the limit switch shall be located so that it will trip
the switch in sufficient time to prevent contact of the hood or hook block with
any part of the trolley.
o Standby cranes/hoists
shall be inspected at least semi-annually and conform to the specifications
listed under frequent inspections.
o All cranes and hoists
over one-ton in rating will be tested per these guidelines. The
operators of all electric cranes/hoists shall follow these guidelines. Operators of all manual cranes/hoists shall follow the
guidelines listed for frequent inspections.
o Load tests shall not be more than 125 percent of the rated load unless otherwise recommended by the manufacturer. Test reports shall be on file with the MHSR.
|
|
ISSUING
AUTHORITY |
APPENDIX
AUTHOR |
APPROVAL
DATE |
EFFECTIVE
DATE |
EXPIRATION
DATE |
REV. |
|
|
|
|
ESH&Q Division |
08/26/05 |
08/26/05 |
08/26/08 |
0 |
|