TITLE	ES&H Manual
DOCUMENT ID	6141 Appendix T3: Inspection Procedures - Overhead and 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 TJNAF employee 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.

3.2 Wire Rope Inspectors

Perform inspection of wire rope in accordance with Jefferson Lab requirements (see Section 4.3 Wire Rope).

3.3 Supervisors and Technical Representatives (TR)

· 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 or identified 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 for up to one (1) 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 survey 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.

Examples of Annual Inspection Tags

4.2 Out of Service & 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.

Sample Crane or Hoist OUT OF SERVICE	Sample DO NOT USE
	used for all other related material handling equipment

4.3 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 and 4.2 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.

o Notify your supervisor.

o Immediately contact the MHM.

4.4 Overhead and Gantry Cranes

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

o Daily inspection is mandatory before the crane is used for the day.

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– check all hooks for cracks, deformation, or latch disengagement.

– Significant wear, kinking, crushing, bird-caging, 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 the applicable ASME B30 standard and OSHA regulations.

· Annual Inspection

o The MHM annually inspects and/or designates a “task qualified person” to perform a complete inspection of cranes and hoists that were identified needing an inspection by the supervisor/manager in the area of responsibility. 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 for inspections completed by a subcontractor.

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

o Detachable hoists or unsecured hoists are inspected annually by the MHM or his designee. The unique external color-coded mark is the record of inspection in lieu of records.

4.5 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

4.6 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 by the user:

· 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

4.7 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 by the user:

· 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

4.8 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 crane load hooks. 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.

4.9 Below the Hook Lifting Devices (BTHLD) Pre Use Inspection – Prior to each use, BTHLD’s are inspected for acceptable condition in accordance with DOE Standard 1090: Hoisting and Rigging Standard Section 12 BELOW-THE-HOOK LIFTING DEVICES & Section 13 MISCELLANEOUS LIFTING DEVICES :

o The MHM annually inspects or designates a “qualified person” to perform a complete inspection of each device as necessary. These inspection services may be provided by a subcontractor who has been determined to be qualified by the MHM.

o Upon completion an inspection survey, an inspection tag is placed on the BTHLD if the inspection survey was satisfactory. The BTHLD is removed from service, by tagging the equipment “out of service”, if the inspection reveals a discrepancy with the item in accordance with Section 4.2 -Out of Service or Do Not Use Tags of this document.

o The unique color-coded inspection tag is the record of inspection.

o The Person-in-Charge (PIC) is responsible for ensuring the BTHLD has a current periodic/annual inspection before use of the BTHLD each time before use. Verify the unique color-coded tag is current in accordance with SECTION 4.1 of this document.

o Contact the MHM to have any BTHLD in need of an inspection before use anytime.

4.10 Miscellaneous Lifting Devices[1] Pre-use Inspection – Prior to each use miscellaneous lifting equipment is inspected for acceptable condition by the user in accordance with DOE Standard 1090: Hoisting and Rigging Standard Section 13 MISCELLANEOUS LIFTING DEVICES.

[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.

4.11 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 1.7 – 03/30/22 – Added Note to 3.0; removed triennial inspection tag requirement (4.2 section) and some hyperlinks; made minor editorial changes to reflect current site practices; revised header and footer formats

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	REVIEW CYCLE	rev
ES&H Division	Mark Loewus	04.21.2020	03.30.2022	3 years	1.7

This document is controlled as an online 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 online file. This copy was printed on 1/27/2023.

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