TITLE:

ES&H Manual

 

DOCUMENT ID:

6141 Appendix T3

Inspection Procedures –

Overhead & Mobile Cranes, Hoists, and Rigging

 

 

1.0          Purpose

 

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 overhead and mobile cranes, hoists, and rigging are provided below. 

 

2.0          Scope

 

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.

 

This appendix is written in coordination with ES&H Manual Chapter 6140 Material Handling Equipment Program and ES&H Manual Chapter 6141 Material Handling – Rigging, Cranes, and Hoists.  All applicable content within these chapters applies to the process steps outlined in this appendix.

 

3.0          Responsibilities

NOTE:     Management authority may be delegated at the discretion of the responsible manager.

 

3.1            Qualified Crane and Hoist OperatorIncludes 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.

 

3.2            Wire Rope Inspectors

·       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.

 

4.0          Inspection Steps

 

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.

 

4.2.2       Monthly Inspections

·       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.

 

4.2.4       Annual Inspection

·       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.

 

4.3            Wire Rope

 

4.3.1       Monthly Inspections

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 I Compressor

Top Running Bridge

10,000

F2-6367

Reliable

#26357

Bill Hunewell

8

CHL West Addition

Top Running Bridge

10,000

F7-1560-00

VA Crane

#VC98-917

Bill Hunewell

8

CHL II

Single Girder

Top Running

10,000

FMH-001425

Michigan Crane 09-5035

Bill Hunewell

36

GPB

Single Girder

Top Running

20,000

FMH-001419

VA Crane

VC10-1740

Dave Kausch

36

GPB

Single Girder

Top Running

10,000

FMH-003851

Piedmont

6100309-1

Dave Kausch

36

GPB

Single Girder

Top Running

10,000

FMH-003852

Piedmont

6100309-2

Dave Kausch

38

S. Access

Double Girder

Top Running

Hoist #1

15,000

F2-6361

VA Crane

#VC89-327

Dave Kausch

38

S. Access

Double Girder

Top Running

Hoist #2

15,000

F2-6361

VA Crane

#VC89-327

Dave Kausch

53

Injector SB

Monorail

6,000

F2-17947

VA Crane

Dave Kausch

55

TED High Bay

Double Girder

Top Running

40,000

CXTD10-Ton

Konecrane

Dave Kausch

58

High Bay North

Double Girder

Top Running

50,000

F2-2750

VA Crane

#VC87-231

Dave Kausch

58

High Bay South

Double Girder

Top Running

50,000

F2-2725

VA Crane

#VC87-230

Dave Kausch

58

Boiler Room

Monorail

10,000

F24321

Shepard Niles #119671

Dave Kausch

67

N. Access

Double Girder

Top Running

Hoist #1

15,000

F2-6363

VA Crane

#VC89-326

Dave Kausch

67

N. Access

Double Girder

Top Running

Hoist #2

15,000

F2-6363

VA Crane

#VC89-326

Dave Kausch

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

Dave Meekins

94

Hall B

Double Girder

Top Running

Polar

40,000

 

VA Crane

#VC91-475

Dave Kausch

96

Hall C

Double Girder

Top Running

Radial

40,000

 

VA Crane

#VC91-476

Dave Kausch

101

Hall A

Double Girder

Top Running Radial

40,000

 

VA Crane

#VC91-474

Dave Kausch

104 ESR-II

Double Girder

Top Running

6,000

FMH-003858

Deeborn

Bill Hunewell

203 Hall D

Double Girder

Top Running

40,000

FMH-003859

Hoist & Crane Sys.

Tom Carstens

 

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 Hardware

 

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 if available, however not required.

Step 3:          Inspector reviews the credentials of the crane operator, the lead rigger and the signal person and records the qualifications on the Lift Plan.

·       Crane Operator – Must possess a document that satisfies the requirements of OSHA 1926.1427.  An acceptable document is generally a qualification card issued by NCCCO, however, other qualification organizations may be acceptable.

·       Lead Rigger (Qualified Rigger) – must meet the “Qualified Person” definition in OSHA 1926.1401.  Many riggers do possess a training card.  The quality of the lift plan is the best indication that a knowledgeable rigger has been involved.

·       Signal Person – Must meet the “Signal Person” requirements of OSHA 1926.1428(c).  Many riggers do possess a training card.  The company the Signal Person works for is required to maintain these training records on the construction site.

 

Step 4:          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 SLINGS

·       ASME B30.26 RIGGING HARDWARE

·       OSHA 29 CFR 1926 Construction Industry Regulations, 1926.251 – Rigging Equipment for Material Handling

 

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://energy.gov/hss/downloads/doe-std-1090-2007

·       ASME B30.9-2006 SLINGS

·       ASME B30.26-2010 RIGGING HARDWARE

·       ASME B30.5-2007 MOBILE AND LOCOMOTIVE CRANES

·       OSHA 29 CFR 1926 Subpart CC – Cranes & Derricks in Construction

·       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 1.2  02/04/14  Updated Wire Rope Inspector in Table 1 from CHightower to DKausch per DKausch.

Revision 1.1  11/20/13  Periodic Review – Updated to reflect current laboratory operations and incorporate language from new OSHA1926 Subpart CC per DKausch.

Revision 1.0  04/12/12  Updated to reflect current laboratory operations.

 

ISSUING AUTHORITY

TECHNICAL POINT-OF-CONTACT

APPROVAL DATE

REVIEW REQUIRED DATE

REV.

 

 

ESH&Q Division

Dave Kausch

04/12/10

04/12/16

1.2

 

This document is controlled as an on line file.  It may be printed but the print copy is not a controlled document.  It is the user’s responsibility to ensure that the document is the same revision as the current on line file.  This copy was printed on 2/4/2014.



[1] If the crane/hoist has been idle of one month or longer see 4.1.3. Cranes Not In Regular Service

[2] Miscellaneous Lifting Devices includes: portable A-frame (aka portable gantry), Truck mounted cranes with a capacity of 1 ton or less, and self contained shop cranes (aka engine hoist)

[3] Equipment that does not meet the required standards is rejected and cannot be used at Jefferson Lab.