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6140 Cranes
and Hoists |
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1.0
Introduction
Jefferson
Lab uses more than 120 cranes and hoists site
wide, ranging from 25-ton bridge cranes to
half-ton manual chain hoists. All cranes and hoists are
treated equally in regards to safety.
This chapter and its
appendices establish the responsibilities and procedures used at Jefferson Lab
to assure that cranes
and hoists
are used safely. When working with or
near cranes
and hoists,
all employees
should be aware of the safety issues concerning these different types of Material Handling
Equipment (MHE). Review this chapter
and its appendices and follow the guidelines presented here before beginning
any MHE
operation.
Crane
and hoist
usage is closely associated with other material handling activities. See Environmental, Safety, and Health
(ES&H) Manual Chapter 6145 Forklifts and
Chapter 6147 Aerial Work Platforms
when necessary for overall safe coordination of equipment across
Jefferson Lab’s divisions.
2.0
Hazard
Avoidance
Accidents involving cranes and hoists kill
and severely injure people every year.
The following example was a mishap that occurred at Jefferson Lab. The incident could have caused a death or
injury, and set back Jefferson Lab’s work for the Spallation
Neutron Source. Around 6 p.m. April 29,
2003, a three-person crew of electrical subcontractors began work on the Test
Lab high bay lights. They moved the
25-ton bridge crane
without first verifying the position of the crane hook. The hook block was
not fully raised, and it hit an electronics cabinet containing the power supply
and associated controls for a high-power radio frequency
(RF) amplifier for a 1500 MHz klystron system.
The hook
was dragged across the top of the cabinet where it ripped out two conduits and
across a portion of the top of the CMTF (Cryomodule
Test Facility) where it displaced a number of radiation shielding blocks and a
radiation monitor adjacent to the blocks before it was stopped. There were no injuries.
3.0
Responsibilities
·
Operators
shall not engage in any practice that will divert attention while actually
engaged in operating the crane.
·
Operators
shall conduct a visual and performance inspection of the crane/hoist before
operations begin.
·
Operators
shall inspect all rigging
equipment to be used. They shall ensure
that it is in acceptable condition and that they are
familiar with its use and limitations. Extra care and vigilance shall be taken if
using a special lifting fixture or a Below-the-Hook
Lifting Device. Shall know the
weight and capacity of the lifting device.
·
Operators
are responsible for the condition and safe use of a crane’s
lifting operation. If the operator is
not satisfied with the condition of the MHE, he/she
shall not operate it. Notify the
Material Handling Equipment Representative (MHER) or Material Handling Safety
Representative (MHSR) if replacement, repair, or removal of any MHE is
necessary. Ensure all job task
conditions are clear. Do not take any
chances; ask first!
·
Operators
shall NEVER lift personnel
without a Temporary
Operational Safety Procedure (TOSP), Standard
Operating Procedure (SOP) or Operational
Safety Procedure (OSP) specifically covering the work. See ES&S Manual Chapter 3310 Appendix T1 Operational Safety Procedure
(OSP) and Temporary OSP Procedure for guidance on developing these documents.
·
Operators
shall be responsible for those operations under their direct control. If there is any doubt as to the safety, the operator
shall stop operations and consult with his/her supervisor or the MHSR before
handling the loads.
·
Operators
shall clear the area of personnel
and cordon it off, if necessary, with caution tape, warning cones, or posting personnel
(preferred method).
·
When physically or
otherwise unfit, operators
shall not engage in the operation of the crane.
·
Operators
shall wear proper Personal
Protective Equipment (PPE) and ensure that all involved do likewise. At a minimum hardhats and steel toe
shoes/boots are required. However, in
certain situations a hard hat is not required, such as when the load is not
raised above the operator’s
head.
·
Operators
will respond to the stop signal when given by any member on the load
team. For all other signals, the operator
will follow only the designated signaler(s) as designated by the Person In Charge (PIC).
·
Operators
shall activate the warning device (alarm sound) if available on crane controls
before starting the bridge or trolley motions of the crane and
intermittently during travel of the crane when
approaching blind spots or personnel.
·
Operators
shall ensure the load is
secured, balanced, and positioned in the hook, slings,
or lifting device before the load is
lifted more than a few inches.
·
Operators
shall evacuate all personnel
from office spaces, work areas, and common areas in the load path
or shadow,
throughout the operation.
o
RULE to follow: One foot of clearance per one foot of height of the load. For example if the load is 25
feet high, the clearance shall be 25 feet away from the load, in all
directions. If staying further than 25
feet back is not possible, the Subcontracting
Officer’s Technical Representative (SOTR)/operator
shall make every effort to ensure the quick and safe exit of personnel
if something should occur.
·
Operators
shall never leave a load
suspended or hung for any reason. If
leaving the area, the load shall be
set down in a stable condition and detached from the hook. If the crane stops
operating during a lift, contact the MHSR immediately. If he/she is unavailable, the operator
shall summon assistance from his/her supervisor and/or the Environmental,
Safety, Health, and Quality (ESH&Q) staff.
Secure the area under the load and DO
NOT allow anyone to pass under the load or enter
the area for any reason. See ES&H Manual Chapter 6140 Appendix T4 Special Lift and Crane
Breakdown Procedures.
·
The crane
shall not be used for side pulls.
3.2
PIC
·
The PIC shall be
in overall charge of the operation/lift.
·
Assign the designated
signaler(s).
3.3
Spotter
·
Follow the instructions
given by the PIC.
·
Use hand signals, radio or
whatever method is deemed appropriate to keep the PIC appraised
of the status of the load.
·
Don't allow distractions
to take attention from assigned duties.
·
Ensure unauthorized personnel
keep clear of the load.
3.4
Supervisor
·
Responsible for Lab personnel
who report directly to him/her, generally or for a particular duration or task.
·
Arrange and monitor crane/hoist operator
training for employees
who need to use cranes/hoists.
·
Notify Occupational Health
& Safety when medical surveillance is needed for a crane/hoist operator.
·
Shall not assign tasks that
are beyond the operator's
ability without proper training and/or supervision.
·
Be aware of lifts to be
performed by your people and know how they intend to perform these lifts.
·
Ensure that appropriate PPE to
perform the job is provided and worn.
·
Ensure equipment is safe
to use and that it meets OSHA/ANSI
standards (including: cranes, hoists,
slings, hardware, etc.).
·
Address any of the operator's
questions or concerns about the assigned lift.
The lift shall not proceed until the operator's
concerns have been adequately addressed and the operator is
comfortable with how the task is to be performed and the condition of the
equipment.
·
Shall request from the customer
clear guidance of the level of planning and documentation required in the
handling of the customer’s
equipment (i.e., Lift Plan, TOSP, OSP, etc.).
·
Is responsible for the
safety of the personnel
and equipment, ensuring that proper planning is performed and the plan is
executed. If deviation from the plan is
required the supervisor is responsible for approving it. He/she shall write or oversee the writing of
a Lift Plan, TOSP
or any other documentation deemed necessary by the customer
and/or superior.
·
Ensure that all personnel
and equipment involved in accomplishing a specific task meet applicable
requirements laid down in federal regulations and are in accordance with
(IAW)-accepted industrial practices (Jefferson Lab ESH&Q Manual).
·
The following steps are
associated with (before proceeding with construction or assembly activities)
buying, building, designing or assembling a crane, hoist, lifting
fixture or any below the hook lifting
device:
o
Get permission from the
MHER or from Facilities Management. Get
information from the MHER on building structural support, location, and
construction.
o
Notify the MHSR for
guidance in load
testing and safety.
o
Follow the Crane Manufacturers
Association of American (CMAA) and NASI/AWS welding
code for design and construction of MHE.
o Submit a plan or diagram that is certified by a structural
engineer or equivalent to the MHSR and the MHER for approval.
3.5
Customer/Owner
of equipment being moved/handled
·
Notify the supervisor of
the group handling the equipment move of any special lift requirements,
precautions and the level of documentation required (i.e., Lift Plan, TOSP, OSP etc.).
·
Ensure that these
requirements are met.
3.6
Crane/Hoist
Supervisors/Owners
·
Shall be aware of who is
authorized to use a given crane/hoist.
·
Ensure that ONLY those
authorized to operate the equipment do so in a safe manner. If an operator
does not operate the equipment in a manner deemed safe by the owner then the operator's
authorization shall be revoked.
·
Ensure that operators
and contractors are trained prior to using any lifting MHE on site.
o
The MHSR can provide the
required training. Check JList
for training information.
·
Ensure that cranes/hoists are in
safe working order and inspected per ES&S Manual Chapter 6140 Appendix T1 Inspection Procedures for Rigging
Equipment, Cranes, and Hoists.
·
Ensure that the MHE’s wire
ropes are inspected quarterly per standard operating procedures set forth in ES&H Manual Chapter 6140 Appendix T5 Wire Rope Inspection
Procedure.
3.7
Jefferson Lab MHER
3.7.1
New
Cranes
·
Coordinate
the design, procurement, construction, acceptance testing, and warranty
management of new cranes/hoists.
3.7.2
All Cranes
·
Coordinate
the procurement, subcontract monitoring, and acceptance of:
o crane/hoist repairs
or maintenance services
o subcontracted crane/hoist operations
(whether with Jefferson Lab-owned or subcontractor-owned equipment)
3.7.3
Subcontracted cranes/hoist services
·
Serve
as the Jefferson Lab SOTR for
subcontracted crane/hoist
services.
·
Coordinate
subcontracted-maintenance schedules with owners and users.
·
Keep
crane
maintenance records and transfer them to owners when appropriate.
·
Contract
yearly inspections for all cranes/hoists and
coordinate work with MHSR.
3.7.4
Inspector Training
·
Coordinate
wire rope inspection training as requested for personnel
using wire rope.
3.8
Jefferson Lab MHSR
·
Develop,
implement, and conduct the Jefferson Lab Crane/Hoist/Rigging Operator
Training Courses.
·
Provide
specialized training and/or advice in material handling when requested.
·
Advise
and assist in the planning of critical, complex or unusual lifts.
·
Advise
supervisors in the selection of the proper material handling accessories such
as slings, shackles,
pulleys, eyebolts, and any associated hardware used in rigging. Ensure all equipment ordered and reviewed
meets the OSHA/ANSI
standards.
o The MHSR is the only person authorized to purchase and receive these items: He
may make direct purchases or give individuals permission to purchase specific
items. See ES&H Manual Chapter
6140 Appendix T3 Procurements Related to Jefferson Lab Cranes and Hoists
for more information.
·
Observe
and/or assist in critical
lifts, such as the movement of a cryomodule.
·
Conduct
a special rigging
and equipment inspection before all potentially high-risk lifts, special lifts,
and critical
lifts as his professional opinion dictates.
·
Provide
the crane/hoist
supervisors and the MHER with advice in accordance with OSHA/ANSI safety
requirements concerning inspection, maintenance and repairs.
·
Provide
advice on the requirements needed to meet OSHA and American Society
of Mechanical Engineers (ASME) Standards when special lifting devices or below-the-hook
lifting devices are being designed by or for Jefferson Lab to ensure
compliance with these regulations (i.e., design factors of safety, etc.).
·
Ensure
that all MHE
is suitably stored and maintained.
Remove from service any MHE that
appears unsuitable for further use.
·
Perform
random walk through inspections of the MHE and/or
operations around the site to ensure compliance with established Jefferson Lab
practices and policies. In the event
equipment, practices or situations are not in compliance, the MHSR shall take
appropriate action to remedy deficiencies.
·
The
MHSR shall recommend to the operator’s
supervisor additional training or revocation of privileges if the operator’s
performance warrants such action.
·
Perform
safety inspections on all cranes/hoists and
related equipment to ensure they comply with applicable OSHA/ANSI
regulations. This includes inspecting:
o
Hoisting
Wire Rope of Overhead Cranes every 3
months.
o
New,
repaired, or modified cranes/hoists and
equipment (No modification shall be made without approval from the MHSR).
o
Cranes/hoists and
equipment brought on site by subcontractors.
o
Maintain
records of all crane/hoist
inspections. IAW ES&H Manual Chapter 5400
Documentation and Recordkeeping.
o
Provide
assistance to supervisors for wire rope inspections on equipment other than
overhead and gantry cranes.
·
Ensure
all incident/discrepancy reports are sent to the Accelerator ESH&Q Officer,
ESH&Q Reporting Manager, MHER, owners of the
equipment, Department Head, and the responsible ESH&Q Officer.
·
Ensure
inspection results and discrepancy report findings are posted and tracked to
closure in the Jefferson Lab ESH&Q Tracking System.
·
Perform
load tests
as needed and upon request.
o
Load tests
shall be performed IAW the ASME
Standards covering the specific equipment.
Normally 125% of the rated load.
o
Verify,
tag, and keep files on equipment that is load tested.
o
Inspect
and advise on all fabricated material handling equipment unique to Jefferson
Lab.
3.9
MHSR Supervisor
·
Ensure
all inspection reports generated by the MHSR are audited and that corrective
actions are taken.
·
Ensure
an alternate MHSR is designated to carry out material handling safety
responsibilities during the MHSR’s absence.
3.10
SOTR
·
Responsible
for all actions and results of the assigned subcontractor.
·
Ensure
subcontractor personnel
are certified for crane/hoist/mobile crane
operations at Jefferson Lab. See ES&H Manual Chapter
6140 Appendix T2 Use of Mobile Cranes on Jefferson Lab Property.
·
If
no one is designated SOTR, the
MHER as designated by the Facilities Management Director, becomes the default SOTR.
·
Decide
whether or not Jefferson Lab crane/hoist operator
training is required for subcontractor operators
working under a given subcontract.
·
Coordinate
crane/hoist
training, with the MHSR, for subcontractor employees using Jefferson Lab
equipment and any additional equipment-specific training they may need to use
while performing the contracted work.
Obtain permission from the equipment owner for the subcontractor to use
that equipment.
·
Oversee
work performed by the subcontractor and ensure that it is performed safely and
in accordance with accepted industrial practices, OSHA Standards and Jefferson
Lab’s ES&H Manual.
·
Discuss
with the subcontractor’s representative the work to be performed, how it will
be accomplished and any safety considerations.
Require the subcontractor to submit a lift plan for review and approval
if necessary.
·
Shall
ensure that the subcontractor is aware of any hidden or unusual problems that
may cause a safety issue during performance of the work (i.e., buried cables,
underground vaults, unstable ground, etc.).
·
Shall
ensure that the pace of work does not compromise safety, and emphasize that
safety is Jefferson Lab’s paramount concern.
If the subcontractor fails to heed any warnings the subcontractor shall
be stopped and counseled or removed from the site. Subsequently, the SOTR informs
the Subcontracting Officer.
·
Shall
ensure that advance notice of work is given to all Jefferson Lab parties that
may be affected by the work: area safety wardens, area ESH&Q staff and when
the Accelerator is operating, the Crew Chief.
3.11
Building managers
·
Shall
identify hazards concerning MHE to ensure
that personnel
not involved with the crane/hoist
operation have a safe work environment.
4.0
Qualifications
·
Formal
qualification as a Crane/Hoist Operator is
provided by the MHSR with certification from the operator’s
supervisor. Minimum qualifications are:
o Successful completion of
Jefferson Lab Crane/Hoist Operator
Training Course (SAF 402).
o Demonstrate to your supervisor's
(or his/her designee's) satisfaction the ability to operate the piece of
equipment in a safe and professional manner to a level of proficiency necessary
for the tasks assigned.
o Medical approval by the Jefferson
Lab physician. (See Medical/physical
subsection below).
·
Use
the guidelines set forth in the Responsibilities section, under the crane/hoist operator
subsection.
4.2
Crane/Hoist Operator’s
Supervisor
·
Demonstrate
to your supervisor's (or his/her designee's) satisfaction a thorough working
knowledge of Hoisting and Rigging techniques, practices and procedures.
·
Arrange
and monitor crane/hoist operator
training for your employees
who need to use cranes/hoists.
o Observe operators
to approve them for equipment certification.
o Periodically observe operators
to witness their skill levels and determine if more training is needed. Certification is good for two years, however
training may be deemed necessary prior to the expiration of certification.
o Training and certification are
coordinated through the Jefferson Lab MHSR and the cognizant
crane/hoist
owners.
·
Where
personnel
are required to perform more complex lifts than are normally expected of
Jefferson Lab operators,
ensure additional training is provided by the MHSR, an on-site course by
special instructor(s), or an off-site school.
4.3
Medical/Physical
·
Medical
surveillance and a physical examination are prerequisites for initial training
and recertification for crane/hoist operators. Specifically, the Jefferson Lab physician
evaluates the operator
for any physical condition that could cause the employee to
be less than fully capable of conducting “lifting operations” safely,
including:
o Signs of seizures, dizziness, or
loss of physical self-control.
o Abnormal depth perception, field
of vision, reaction time, manual dexterity, and coordination.
o Inability to climb ladders.
o Use of certain prescription
drugs.
4.4
SOTR
·
Meets
the SOTR
criteria in ES&H
Manual Chapter 3410 ES&H Aspects of Procurements and must be familiar
with the crane/hoist
equipment that will be used for the job and understand the requirements to
ensure safe use of that equipment.
·
Competent
in all aspects of overseeing the subcontractor as related to cranes and hoisting
equipment and to take whatever steps are required to ensure the safe completion
of the work.
5.0
Program
Summary
5.1
Specific
crane/hoist safety
requirements for Jefferson Lab
·
The
primary responsibility of ensuring the safe operation of the Lab’s cranes and hoists rests
with the operators,
as they are actually doing the work. If
they are not comfortable with what they are asked to do, they MUST QUESTION
IT. If they are not satisfied with the
answers they are given, they shall keep going up the management chain until
they are satisfied or someone else is assigned the task. For information on addressing safety concerns
at Jefferson Lab, see ES&H
Manual Chapter 2310 ES&H Concern Resolution.
·
Crane/hoist
operation can affect other Jefferson Lab activities. For example, a number of offices in the Test
Lab must be vacated when suspended loads are to
pass overhead.
·
Heavy
equipment moving around the Accelerator site during accelerator operations can
disrupt beam operations; therefore the Crew Chief shall be notified prior to
bringing equipment inside the Accelerator site.
·
Accelerator
access hatches must not be lifted without permission from the accelerator Crew
Chief in the Machine Control Center (MCC).
·
Special
lifts require a hazard assessment and detailed written procedures.
5.2
Crane/Hoist-Related
Procurement
It is vital to ensure
that improper, suspect, or counterfeit crane/hoist
equipment is not acquired or used.
Therefore, everyone involved in crane/hoist-related
procurements must follow the procedures set forth in ES&H Manual Chapter
6140 Appendix T3 Procurements Related to Jefferson Lab Cranes & Hoists. It is also vital to ensure that subcontracted
crane/hoist
activities meet Jefferson Lab’s safety standards as set forth in ES&H Manual Chapter
6140 Appendix T2 Use of Mobile Cranes on Jefferson Lab Property.
·
Because
personnel
safety depends on the integrity of components in a crane/hoist system, crane-related
procurements must follow special procedures as set forth in ES&H Manual Chapter
6140 Appendix T3 Procurements Related to Jefferson Lab Cranes and Hoists.
·
Similarly,
to ensure that subcontracted crane/hoist
activities meet Jefferson Lab’s safety standards, specific requirements as set
forth in ES&H Manual
Chapter 6140 Appendix T3 Procurements Related to Jefferson Lab Cranes and
Hoists must be incorporated into relevant subcontracts.
6.0
References
·
OSHA
1910.179 Overhead and Gantry Cranes
·
ASME/ANSI
B30.9 Slings
·
ASME/ANSI
B30.10 Hooks
·
ASME/ANSI
B30.2.0 Overhead and Gantry Cranes
·
ASME/ANSI
B30.20 Below-the-hook Lifting Devices
The MHSR has these manuals, and
they are available for reference purposes.
Related material
·
Crane and hoist usage is
closely associated with other material handling activities. See
ES&H Manual Chapter
6145 Forklifts and Chapter
6147 Aerial Work Platforms for overall safe coordination of
equipment across Jefferson Lab’s divisions.
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ISSUING
AUTHORITY |
CHAPTER
AUTHOR |
APPROVAL
DATE |
EFFECTIVE
DATE |
EXPIRATION
DATE |
REV. |
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ESH&Q Division |
08/26/05 |
08/26/05 |
08/26/08 |
0 |
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