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6141 Appendix T3 Inspection Procedures – Overhead & Mobile Cranes, Hoists, and Rigging |
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Jefferson
Lab requires routine inspection and regular maintenance of overhead cranes,
hoists and rigging used on its behalf. ES&H
Manual Chapter 6140 Appendix T3 Inspection and Maintenance Procedure for
Material Handling Equipment provides the minimum requirements for
all material
handling equipment. It is based on
Occupational Safety and Health Administration (OSHA) and the American Society
of Mechanical Engineers national standards.
Additional requirements specific to rigging, cranes and
hoists are provided below.
This appendix defines additional inspection requirements
for:
·
Cranes, hoists, below-the-hook
lifting devices (BTHLD), and rigging equipment
owned or leased by Jefferson Lab, and
·
Subcontractor provided
cranes, hoists, and rigging.
Process steps are performed in coordination with ES&H Manual Chapter 6140 Material Handling Equipment Program and ES&H Manual Chapter 6141 Material Handling – Rigging, Cranes, and Hoists.
NOTE: Management authority may be delegated at the discretion of the responsible manager.
3.1
Qualified
Crane and Hoist Operator — Includes
anyone approved to use a crane/hoist on behalf of Jefferson Lab.
· Conduct
an inspection of the crane/hoist and rigging before beginning a job.
· Perform inspection of wire rope in accordance with Jefferson Lab requirements (See Section 4.3 Wire Rope).
3.3
Supervisor/Subcontracting Officer’s Technical
Representative
(SOTR)
· Monitor
rigging operations daily.
· Ensure
operators perform required inspections of crane/hoist and rigging equipment in
use.
3.4
Material Handling Safety
Representative (MHSR)
· Ensure
Annual Periodic Wire Rope Inspections are performed by a qualified person.
· Periodically
review operator’s performance during required inspections of cranes/hoists and
rigging equipment in use.
· Maintain
annual and periodic inspection records.
3.5
Material Handling Engineering
Representative (MHER)
· Designate
primary “wire rope” inspectors.
4.1 Daily Equipment Operability Determination: The daily pre-operational inspection results in one of the following determinations for the equipment’s status:
·
Satisfactory for Use – continue with work plan.
·
Requires a More Detailed
Inspection–
One/some/all items may be defective.
o
Lock the machine out of service (see ES&H Manual Chapter
6110 Appendix T1 Lock, Tag, Try (LTT) Procedure, and
o
Immediately contact the MHSR.
·
Remove from Service – requires repair or
replacement.
o
Lock the machine out of service (see ES&H Manual Chapter 6110
Appendix T1 Lock, Tag, Try (LTT) Procedure, and
o
Immediately contact the MHSR.
4.2
Overhead and Gantry Cranes
4.2.1
Daily/Preoperational Checks (Records are not required if
equipment is found “Satisfactory for Use”):
·
The qualified operator, or other designated person, visually
inspects the following items: (A daily inspection is required if machine is in
regular use[1].)
o
All functional operating mechanisms: for maladjustment that may
interfere with proper operation.
o
Lines, tanks, valves, drain pumps, and other parts of air or
hydraulic systems: for deterioration or leakage.
o
Hooks look for cracks, deformation, latch engagement (if
provided): for damage from chemicals and as required by DOE
Standard 1090-2007: Hoisting and Rigging Standard (Formerly Hoisting and
Rigging Manual);
Chapter
13, LOAD HOOKS.
o
Hoist rope: for significant wear, kinking, crushing, birdcaging, corrosion, or broken strands or wires.
o
Hoist chains, including end connections: for excessive wear,
twist, distorted links interfering with proper function, or stretch beyond
manufacturer’s recommendations.
o
Primary hoist upper-limit device: for proper operation.
·
Performed in accordance with DOE
Standard 1090-2007: Hoisting and Rigging Standard.
o
Chapter 7 – OVERHEAD AND GANTRY CRANES; Section
7.2.6 Frequent Inspection
o
Chapter 8 – HOISTS; Section 8.2.4 Frequent
Inspection, for requirements.
4.2.3 Cranes Not In Regular Service – idle for 1 month or longer
· Performed in accordance with DOE Standard 1090-2007: Hoisting and Rigging Standard.
o Chapter 7 – OVERHEAD AND GANTRY CRANES; Section 7.2.8 Cranes Not In Regular Service
o Chapter 8 – HOISTS; Section 8.2.6 Hoists Not In Regular Service, for requirements.
· The MHER annually designates a “qualified person” to perform a complete inspection of each crane and hoist. (These inspection services may be provided by a subcontractor who has been determined to be qualified by the MHER.)
· Upon completion an inspection a report is provided to the MHER detailing the condition of the equipment.
· Inspection reports for each crane and hoist are maintained by the MHER.
The running rope on hoists receives a monthly visual inspection, if the crane is accessible. Running rope that is inaccessible for longer than a month receives an inspection prior to first use.
This inspection is performed using the following steps:
Step 1: Lower the hook to a position immediately above the floor.
Step 2: Visually inspect the entire length of the wire rope for gross damage, including:
· Distortion of the rope such as kinking, crushing, unstranding, birdcaging, main strand displacement or core protrusion.
· General corrosion
· Broken or cut strands
Step 3: Inspect the hook and the sheaves of the hook block.
Step 4: If damage is found or suspected:
· Raise the hook to an intermediate position,
· Apply an administrative lock and tag with the electrical disconnect in the OFF position.
· Immediately contact the MHSR or the MHER to conduct a thorough rope inspection.
Alternate Step 4: If no damage is found or suspected:
· Raise the hook to the fully raised position.
Step 5: Upon completion of the inspection certify that the inspection was completed on the “Wire Rope Inspection Record” located near the crane (generally at the electrical disconnect). Report any unusual observations to the MHSR.
Table
1 Wire Rope Inventory
|
BUILDING - ROOM |
TYPE |
CAPACITY |
BRIDGE TAG |
MFR. & SERIAL No. |
Designated Primary Inspector |
|
8 CHL Compressor |
Top Running Bridge |
10,000 |
F2-6367 |
Reliable #26357 |
Tina Menifee |
|
8 CHL West Addition |
Top Running Bridge |
10,000 |
F7-1560-00 |
VA Crane #VC98-917 |
Tina Menifee |
|
38 S. Access |
Top Running Bridge |
15,000 |
F2-6361 |
VA Crane #VC89-327 |
Tina Menifee |
|
53 Injector SB |
Monorail |
6,000 |
F2-17947 |
VA Crane |
Tina Menifee |
|
58 High Bay North |
Top Running Bridge |
50,000 |
F2-2750 |
VA Crane #VC87-231 |
Tina Menifee |
|
58 High Bay South |
Top Running Bridge |
50,000 |
F2-2725 |
VA Crane #VC87-230 |
Tina Menifee |
|
58 Boiler Room |
Monorail |
10,000 |
F24321 |
Shepard Niles #119671 |
Tina Menifee |
|
67 N. Access |
Top Running Bridge |
15,000 |
F2-6363 |
VA Crane #VC89-326 |
Tina Menifee |
|
90 101-EEL |
Underhung Bridge |
10,000 |
F2-6366 |
VA Crane #VC90-361 |
Mike Powers |
|
90 127-EEL |
Underhung Bridge |
10,000 |
F2-6365 |
VA Crane #VC90-362 |
Charles Hightower |
|
101 Hall A |
Top Running Bridge |
40,000 |
|
VA Crane #VC91-474 |
Charles Hightower |
|
94 Hall B |
Top Running Bridge |
40,000 |
|
VA Crane #VC91-475 |
Charles Hightower |
|
96 Hall C |
Top Running Bridge |
40,000 |
|
VA Crane #VC91-476 |
Charles Hightower |
4.4
Slings
– Pre-Use Inspection – Prior to each use slings are inspected for
acceptable condition in accordance with DOE
Standard 1090-2007: Hoisting and Rigging Standard Chapter 11 WIRE ROPE AND
SLINGS:
· Section 11.3 – General Information
· Section 11.3.2 – Wire-Rope Slings
· Section 11.3.3 – Alloy Steel-Chain Slings
· Section 11.3.4 – Metal-Mesh Slings
· Section 11.3.5 – Synthetic-Web Slings
· Section 11.3.6 – Synthetic Roundslings
4.5
Rigging
Accessories – Pre Use Inspection – Prior to each use rigging devices
are inspected for acceptable condition in accordance with DOE
Standard 1090-2007: Hoisting and Rigging Standard Chapter 12 RIGGING
ACCESSORIES:
· Section 12.1 – General Information
· Section 12.2 – Rigging Hooks
· Section 12.3 – Shackles
· Section 12.4 – Eyebolts
· Section 12.5 – Eye Nuts
· Section 12.6 – Turnbuckles
· Section 12.7 – Links, Rings, and Swivels
· Section 12.8 – Swivel Hoist rings
· Section 12.9 – Load Indicating Devices
· Section 12.10 – Precision Load Positioners
· Section 12.11 – Compression Hardwarelink
4.6
Load
Hooks – Pre Use Inspection – Prior to each use, and at specific
intervals, load hooks are inspected for acceptable condition in accordance with
DOE
Standard 1090-2007: Hoisting and Rigging Standard Chapter 13 LOAD HOOKS:
· Section 13.1 – General Information
· Section 13.2.3 – Daily Inspection
· Section 13.2.4 – Frequent Inspection (monthly)
· Section 13.2.5 – Periodic Inspection (yearly)
o The MHER annually
designates a “qualified person” to perform a complete inspection of each load
hook. (These inspection services may be
provided by a subcontractor who has been determined to be qualified by the MHER.)
o Upon completion an
inspection report is provided to the MHER detailing the condition of the load
hook.
o Inspection reports
for each load hook are maintained by the MHER.
4.7 Below the Hook Lifting Devices (BTHLD) – Pre Use Inspection – Prior to each use, and at specific intervals, BTHLD’s are inspected for acceptable condition in accordance with DOE Standard 1090-2007: Hoisting and Rigging Standard Chapter 14 BELOW-THE-HOOK LIFTING DEVICES:
· Section 14.1 – General Information
· Section 14.2 – Structural and Mechanical Lifting Devices
· Section 14.3 – Vacuum Lifting Devices
· Section 14.4 – Magnets, Close-Proximity-Operated
· Section 14.4.4.3 – Periodic Inspection (yearly)
o The MHSR annually
designates a “qualified person” to perform a complete inspection of each. (These inspection services may be provided by
a subcontractor who has been determined to be qualified by the MHSR.)
o Upon completion an
inspection report is provided to the MHSR detailing the condition of the
BTHLD.
o Inspection reports
for each BTHLD are maintained by the MHSR.
4.8 Miscellaneous Lifting Devices[2] - Pre Use Inspection – Prior to each use miscellaneous lifting equipment is inspected for acceptable condition in accordance with DOE Standard 1090-2007: Hoisting and Rigging Standard Chapter 16 MISCELLANEOUS LIFTING DEVICES:
· Section 16.1 – General Information
4.9 Construction Site Mobile Crane and Rigging Inspection
Inspections of mobile cranes used on Jefferson Lab construction sites are primarily controlled in accordance with a Jefferson Lab approved Lift Plan. The goal of an inspection is to verify that the crane owner follows the requirements of ASME B30.5-2007 MOBILE AND LOCOMOTIVE CRANES and OSHA 29 CFR 1926 Construction Industry Regulations, 1926.550 –Cranes & Dericks. If the inspection reveals that the requirements are not met, the machine is rejected and cannot be used at Jefferson Lab pending repair or replacement, and re-inspection.
Step 1: The MHSR, or designee, inspects the mobile crane and rigging equipment upon arrival at the job site, prior to use.
Step 2: Inspector denotes on the Lift Plan that the following has been reviewed and meets the safety requirements of the referenced standard(s)[3]:
· Crane’s Annual Inspection document
· Crane’s Daily Inspection record
· Crane’s Monthly Wire Rope Inspection record
· Crane’s Quadrenial Load Test Certificate
Step 3: The MHSR inspects the rigging gear provided with the mobile crane or other subcontractors involved with the planned lift. Slings and rigging hardware are inspected using:
·
ASME B30.9-2006 SLINGS
· ASME B30.26-2004 RIGGING HARDWARE
5.0
References
·
U.S. Department of
Energy Standard DOE-STD-1090-2007:
Hoisting and Rigging Standard (Formerly Hoisting and Rigging Manual), which is
available online at:
http://www.hss.doe.gov/nuclearsafety/ns/techstds/docs/standard/std1090-07_index.html
·
ASME B30.9-2006 SLINGS
·
ASME B30.26-2004 RIGGING HARDWARE
·
ASME B30.5-2007 MOBILE
AND LOCOMOTIVE CRANES
·
OSHA 29 CFR 1926
Construction Industry Regulations, 1926.550 – Cranes & Derricks
·
OSHA 29 CFR 1926 Construction Industry
Regulations, 1926.251 – Rigging Equipment for Material Handling
·
OSHA 29 CFR 1926 Construction Industry
Regulations, 1926.753 – Hoisting and Rigging
6.0
Revision Summary
Revision 1 – 04/12/12 – Updated to reflect current laboratory
operations.
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ISSUING
AUTHORITY |
TECHNICAL POINT-OF-CONTACT |
APPROVAL
DATE |
EXPIRATION
DATE |
REV. |
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ESH&Q Division |
04/12/10 |
04/12/12 |
1 |
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