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 (AMSE) 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.

·         Subcontractor provided cranes, hoists, and rigging.

 

It 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 to a task qualified Jefferson Lab employee 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 as trained.

·         Annually, identify all material handling equipment needing an Annual Inspection. The equipment shall be tagged so, the inspector can easily identify the equipment needing an annual inspection.

·         Remove unnecessary equipment from service. Contact the MHM to have equipment removed from service.

·         Request equipment be placed back in service that is out service. Contact the MHM to have equipment placed back in service.

3.4              Material Handling Manager (MHM)

·         Designate primary “wire rope” inspectors. 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.

4.0             Equipment Inspections and Inspection Tags

4.1              Annual Inspection Tags (required on certain pieces of Jefferson Lab owned material handling equipment)

·         Annually, certain pieces of rigging equipment, “in service”, require inspection and documentation by a qualified person.

·         Annual Inspection tags are required on the following equipment: cranes, manual hoists, electric hoists, lever hoists, below-the-hook-lifting devices, chain slings.

·         Annual Inspections are performed by a designated and qualified person or by a qualified subcontract service as determined by the MHM.

·         Annual inspection tag colors will change from year to year.

·         Inspection tags consist of a unique color-coded tag. The tag indicates the inspector’s initials and the date the annual inspection was performed.

·         Equipment with a current annual inspection tag means; the equipment was satisfactory, only, at the time the annual inspection was performed. This tag does not release the operator from his obligation in performing his, Frequent/Pre-use/Pre-operational, inspection immediately before use of the equipment each day as trained in SAF 403.

·         Equipment may be used until the end of the month of the following year according to the date of inspection written on the annual inspection tag by the equipment inspector.

·         If the equipment is annually inspected, by the MHM or his designee, on behalf of Jefferson Lab, the tag is the record of inspection in lieu of records.

·         If the annual inspection reveals the equipment is not suitable for use, the equipment shall be removed from service by the designated inspector. The equipment will not receive an annual inspection tag if the equipment is not suitable for use.

·         Equipment missing the Annual Inspection tag shall not be used. The person needing use of the equipment shall assume the equipment is not in service.

·         Equipment with an illegible date on the annual inspection tag shall not be used.

·         Contact the MHM for any questions regarding annual inspection tags and hoisting or rigging equipment.

·         Subcontractors are excluded from this tagging requirement. Subcontractors are responsible for ensuring their hoisting equipment is in proper working order before use. The MHM or his designee visually inspects all subcontractor owned equipment before use on behalf of Jefferson Lab.

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Examples of Annual Inspection Tags (shown above).

4.2              Triennial Inspection Tags (for manual and lever hoists only) - are required on lever hoists and manually operated hoists not attached to a crane.

·         Jefferson Lab owned manual hoists and lever hoists are generally infrequently used.  

·         The MHM has determined Jefferson Lab owned manual hoists and lever hoists in service require periodic inspection, periodic maintenance and periodic load testing every three (3) years.

·         All Jefferson Lab owned hoists in service requires a Triennial Inspection Tag by the end of October 2022. Hoist owners are responsible ensuring all, “in-service”, hoists have this tag by the end of October 2022.

·         This tag signifies a hoist (manual or lever) has had periodic inspection, maintenance and testing service performed on the hoist.

·         Newly purchased hoists can receive this inspection tag immediately upon receipt by the MHM or his designee before being placed in service. All new hoists are inspected and tested by the manufacturer.

·         Hoist owners are responsible for ensuring their hoists are inspected and maintained properly.

·         Hoists that fail this inspection will not be placed back in service until it is repaired, inspected and load tested and found satisfactory by the MHM or his designee.

·         Subcontractors are responsible for ensuring their hoists are properly maintained and inspected. Subcontractors are excluded from this tagging requirement. 

Example of the Triennial Inspection Tag (shown above).

4.3              Out of Service or Do Not Use Tags

·         Equipment may be removed from service by one of the tags shown below for various reasons.

·         Crane, hoists or other related handling equipment, tagged with one of the tags shown below, shall not be used if found on the equipment.

Example of a Crane or Hoist, “Out of Service”, tag (Shown Above).

 

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Example of “Do Not Use” tag shown above. Used for all other related material handling equipment.

4.4              Daily Equipment Operability Determination (the daily pre-operational inspection results in one of the following determinations for the equipment’s status):

·         Check the Annual Inspection Tag (Only if hoisting equipment requires an annual inspection tag.) – To determine if the equipment is “In Service” or “Out of Service” in accordance with Sections 4.1, 4.2 and 4.3 of this document.

·         The operator’s pre-operational inspection is satisfactory – continue with work plan.

·         The operator’s pre-operational inspection is unsatisfactory and it requires a more detailed inspection – one/some/all items may be defective:

o   Remove from the equipment from service – Lock the machine out of service if appropriate or tag the equipment out of service. Refer to ES&H Manual Chapter 6110 Appendix T1 Lock, Tag, Try (LTT) Procedure.

o   Notify your supervisor.

o   Immediately contact the MHM.

 

4.5              Overhead and Gantry Cranes

·         Daily/Preoperational Checks (records are not required if equipment is found “Satisfactory for Use”):

o   Daily inspection is mandatory if the machine is in service.

o   The qualified operator, or other designated task qualified person, visually inspects for:

        Maladjustments that may interfere with proper operation – check all functional operating mechanisms

        Deterioration or leakage – check all lines, tanks, valves, drain pumps, and other parts of air or hydraulic systems

        Damage from chemicals and as required by DOE Standard 1090-2007: Hoisting and Rigging Standard (formerly Hoisting and Rigging Manual) Chapter 13 – check all hooks for cracks, deformation, or latch disengagement.

        Significant wear, kinking, crushing, birdcaging, corrosion, or broken strands and wires – check hoist rope

        Excessive wear, twists, distorted links interfering with  proper function, or stretch beyond manufacturer’s recommendations – check hoist chains, including end connections

        Proper operation – check primary hoist upper-limit device

·      Monthly Inspections

o   Performed in accordance with DOE Standard 1090-2007: Hoisting and Rigging Standard.

        Chapter 7 – OVERHEAD AND GANTRY CRANES; Section 7.2.6 Frequent Inspection

        Chapter 8 – HOISTS; Section 8.2.4 Frequent Inspection, for requirements.

·      Annual Inspection

o   The MHM annually designates a “task 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 MHM.

o   Upon completion an inspection a report is provided to the MHM detailing the condition of the equipment. 

o   Inspection reports for each crane and hoist are maintained by the MHM.

 

4.6              Wire Rope

·         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 MHM 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 monthly inspection, certify that it was completed on the “Wire Rope Inspection Record” located near the crane (generally at the electrical disconnect). Report any unusual observations to the MHM.

 

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

Engineering Division

Bill Hunewill

8

CHL West Addition

Top Running Bridge

10,000

F7-1560-00

VA Crane

#VC98-917

Engineering Division

Bill Hunewill

8

CHL II

Single Girder

Top Running

10,000

FMH-001425

Michigan Crane 09-5035

Engineering Division

Bill Hunewill

36

GPB

Single Girder

Top Running

20,000

FMH-001419

VA Crane

VC10-1740

Engineering Division

Mike Beck

36

GPB

Single Girder

Top Running

10,000

FMH-003851

Piedmont

6100309-1

Engineering Division

Mike Beck

36

GPB

Single Girder

Top Running

10,000

FMH-003852

Piedmont

6100309-2

Engineering Division

Mike Beck

38

S. Access

Double Girder

Top Running

Hoist #1

15,000

F2-6361

VA Crane

#VC89-327

Engineering Division

Mark Loewus

38

S. Access

Double Girder

Top Running

Hoist #2

15,000

F2-6361

VA Crane

#VC89-327

Engineering Division

Mark Loewus

53

Injector SB

Monorail

6,000

F2-17947

VA Crane

Engineering Division

Mark Loewus

55

TED High Bay

Double Girder

Top Running

40,000

CXTD10-Ton

Konecrane

Engineering Division

Jay Noble

58

High Bay North

Double Girder

Top Running

50,000

F2-2750

VA Crane

#VC87-231

Accelerator Ops, R&D

Tom DeSalvo

58

High Bay South

Double Girder

Top Running

50,000

F2-2725

VA Crane

#VC87-230

Accelerator Ops, R&D

Tom DeSalvo

67

N. Access

Double Girder

Top Running

Hoist #1

15,000

F2-6363

VA Crane

#VC89-326

Engineering Division

Mark Loewus

67

N. Access

Double Girder

Top Running

Hoist #2

15,000

F2-6363

VA Crane

#VC89-326

Engineering Division

Mark Loewus

90

101-EEL

Underhung Bridge

10,000

F2-6366

VA Crane

#VC90-361

Engineering Division

Dave Meekins

90

127-EEL

Underhung Bridge

10,000

F2-6365

VA Crane

#VC90-362

Experimental Nuclear Physics

David Wallace

94

Hall B

Double Girder

Top Running

Polar

40,000

 

VA Crane

#VC91-475

Experimental Nuclear Physics

Hall B Coordinator

96

Hall C

Double Girder

Top Running

Radial

40,000

 

VA Crane

#VC91-476

Experimental Nuclear Physics

Hall C Coordinator

101

Hall A

Double Girder

Top Running Radial

40,000

 

VA Crane

#VC91-474

Experimental Nuclear Physics

Hall A Coordinator

104 ESR-II

Double Girder

Top Running

6,000

FMH-003858

Deeborn

Engineering Division

James Davenport

203 Hall D

Double Girder

Top Running

40,000

FMH-003859

Hoist & Crane Sys.

Experimental Nuclear Physics

Hall D Coordinator

 

4.7              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 (Requires Annual Inspection Tag)

·         Section 11.3.4 – Metal-Mesh Slings (Requires Annual Inspection Tag)

·         Section 11.3.5 – Synthetic-Web Slings

·         Section 11.3.6 – Synthetic Roundslings

 

4.8              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

 

4.9              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 MHM 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 MHM.

o   Upon completion an inspection report is provided to the MHM detailing the condition of the load hook. 

o   Inspection reports for each load hook are maintained by the MHM.

 

4.10          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/Mechanical Lifting Devices (Requires Annual Inspection Tag)

·         Section 14.3 – Vacuum Lifting Devices (Requires Annual Inspection Tag)

·         Section 14.4 – Lifting Magnets (Requires Annual Inspection Tag)

·         Section 14.4.4.3 – Periodic Inspection (yearly)

o   The MHM 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 MHM.

o   Upon completion an inspection report is provided to the MHM detailing the condition of the BTHLD. 

o   Inspection reports for each BTHLD are maintained by the MHM.

4.11          Miscellaneous Lifting Devices[1] 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

 

4.12          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 Material Handling Lift Plan. The goal of an inspection is to verify that the crane owner follows the requirements of ASME B30.5 MOBILE AND LOCOMOTIVE CRANES and OSHA 29 CFR 1926 Construction Industry Regulations, 1926 Subpart CC –Cranes & Derricks in construction. 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 MHM, 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)[2]: 

·         Crane’s Annual Inspection document

·         Crane’s Daily Inspection record

·         Crane’s Monthly Wire Rope Inspection record

·         Crane’s Quadrennial 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 MHM 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

 

·         DOE-STD-1090: Hoisting and Rigging Standard (Formerly Hoisting and Rigging Manual)

·         ASME B30.9 SLINGS

·         ASME B30.26 RIGGING HARDWARE

·         ASME B30.5 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 1.6 – 04/21/20 – Updated to include a process integrating hoists not permanently attached to crane structures, including inspection requirements per CATS#INSP-2019-001-01-01

Revision 1.5 – 01/01/18 – Updated TPOC from B.Sperlazza to M.Loewus; updated Wire Rope Inspection Report Form

Revision 1.4 – 02/09/17 – Updated TPOC from D.Kausch to B.Sperlazza per B.Sperlazza; updated Wire Rope Inspectors in Table 1 and added the primary inspectors Division.

Revision 1.3 – 12/17/15 – Eliminated two positions previously identified as the MHSR and the MHER, the responsibilities of these positions are now performed by the MHM. Updated Wire Rope Inventory inspector for the Machine Shop Crane (was Mike Powers) and deleted the Test Lab Boiler Room crane.

Periodic Review – 12/04/14 – No changes

Revision 1.2 – 02/04/14 – Updated Wire Rope Inspector in Table 1 from C.Hightower to D.Kausch per D.Kausch

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

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

 

ISSUING AUTHORITY

TECHNICAL POINT-OF-CONTACT

APPROVAL DATE

REVIEW DATE

REV.

 

 

ES&H Division

Mark Loewus

04/21/20

04/21/23

1.6

 

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 4/22/2020.



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

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