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DOE-STD-1090-2007 - SLAC Group/Department Public Websites

1. Housing Cable Distortion Broken Wires Cracks End Connections Loose Hardware Excess Wear Warning Label Kinked or Distorted Corrosion Support Structure Heat Damage Worn or distorted Trolley Load Beam Chains Condition End Stops Binding Cracked Internal Inspection Twisted Brake Pad Distorted Condition Lubrication Corroded Excess Oil Excess Wear Sheaves Worn Chain Guide 8 25 Chapter 8 Hoists DOE STD 1090 2007 Page 2 of 2 EXHIBIT II continued SAMPLE FORM UNDERHUNG HOIST PERIODIC INSPECTION REPORT STATUS CODE O K A Adjusted R Repaired NR Needs Repair N A Not Applicable CODE COMMENT CODE COMMENT Hook Sheaves Loose Retaining Excess Wear Hardware Cracks Cracked or Scored Excess Wear Bearing Noise Bent Spreading Final Operations Rotating Freely Free and Easy Latch Inspection Tag Ud Comments Note any potential hazards or malfunctions CIRCLE ONE PASS FAIL INSPECTOR Print SIGNATURE Date Chapter 8 8 26 Hoists DOE STD 1090 2007 CHAPTER 9 MOBILE CRANES This chapter specifies operation inspection maintenance and testing requirements for the use of mobile cranes and implements the requirements of ASME B30 5 Mobil
2. APPROVAL Signature date Facility Manager Date Manager Oversight Organization Date Other Date Date Date means approval is mandatory 5 3 Chapter 5 Hostile Environments DOE STD 1090 2007 INTENTIONALLY BLANK Chapter 5 5 4 Hostile Environments DOE STD 1090 2007 CHAPTER 6 PERSONNEL QUALIFICATION AND TRAINING This chapter describes personnel qualification and training Only qualified personnel shall operate the equipment covered in this standard 6 1 6 2 6 3 6 4 6 5 GENERAL iii 6 1 QUALIFICATION nier ete od bae ede c qaod ete Ruben 6 2 A ege neget dite tera ede NEES 6 2 6 2 2 Operators of Cab Operated and Pulpit Operated Cranes sss 6 2 6 2 3 Operators of Mobile Cranes eene eene netten nnne 6 2 6 2 4 Operators of Truck Mounted Cranes Capacity 1 Ton or Less sssss 6 4 6 2 5 Operators of Floor Operated Cranes and Hoists sess 6 4 6 2 6 Operators of Remote Operated Cranes oooonccnnccnonononconncononononononononnncnn nono connconn conc nanccinos 6 4 6 2 7 Operators of Forklift Trucks A 6 4 6 2 8 A ee tired ta etre de icis 6 4 DH Person In Charge Plica 6 4 6 210 SA ME AAA eter er rer EEN CN 6 5 DEL Inspection EDI a epe tede aes 6 5 6 2 12 Instructors o ene EE EE erp tmd eia es 6 5 6 2 13 First Line Supervisors xn Reo A ertet qe Res 6 5 6 2 14 Maintenance Personnel Re A ete
3. essere 8 5 8 1 6 2 Air Powered Hoists eese nennen renes 8 5 8 1 6 3 Hand Chain Operated Hoists eese 8 6 8 1 6 4 Manual Lever Operated Hotsts oran crono nono rnnonnos 8 6 8 17 Wie Rope teo ias 8 6 8 1 8 Load Chain uie beer Ehre a estem REM vues 8 6 8 1 8 1 Electric Powered Air Powered and Manual Lever Operated HOIS IS oie sc 8 6 8 1 8 2 Hand Chain Operated Hoists eene 8 6 SH WD St Apis saei ertet eere een tee eerte ete er te Roe reves 8 7 8 1 10 Overtravel Protection uie tete tern rti FER earkes ae ins 8 7 8 1 10 1 Upper Limit Switches Devices ee 8 7 8 1 10 2 Lower Limit Switchesievices nono nono ene 8 7 SLIL Support et tipo rae PEE PR EPIO EP E RENE ee ripe deer 8 7 8 112 cuo 8 7 8 1 13 Load RANS eei teret rere Rr EPIO nie oni np ripe 8 7 8 2 INSPECTIONS M 8 8 821 E ee 8 8 8 2 2 Initial Inspection eere ree e RO EP Ro RE OR Pee ripe Hh 8 8 82 3 Daily Inspection ee eter rete err EE na eee ETHER Pep Sen Ee UD een dE Ea 8 8 824 Frequent Inspection anita ERES EGOE HER eeu evga std 8 8 5 2 Periodic Inspecciones RON RRIRRCIR 8 9 8 2 5 1 Holstein bees NEU 8 9 8 2 5 2 AEN 8 9 5 2 5 3 Welded Link Chal coin ida indonesia 8 10 8 24 Roller Chains 8 11 8 2 5 5 Synthetic Web Strap se DRIED t sda R
4. Persons who may perform rigging functions as an incidental part of their normal work assignment 2 Persons whose principal assignment is the performance of rigging work Only qualified and authorized riggers or rigger trainees under the direct supervision of a qualified rigger shall be permitted to perform rigging functions Initial training of riggers shall include the instructor s review of the applicant s knowledge including results of written or oral evaluation and witnessing a demonstration of the rigger s skills The following checklist contains basic factors with which a rigger should be familiar This checklist must be tailored to suit actual conditions 1 Stability equipment 2 Operating characteristics of equipment 3 Environmental hazards weather 4 Electrical hazards 5 Traveling with load load control 6 Lifting personnel 7 Inspection tests 8 Load weight estimation 9 Emergency procedures 10 Rigging equipment selection 11 Lessons learned 12 Hand signals Chapter 6 Personnel Qualification and Training 6 10 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 6 3 7 Lifting operations involving multiple cranes Maintenance storage of slings and rigging components Assembly and disassembly Load dynamics Applicable standards and regulations Critical lifts Safety features of equi
5. Check Bolt Torque e Transmission Mount e Turntable e Engine Mount e Hoist Mount e Axle Mount Engine RPM Muffler Connections Wiring harness Battery Cable Battery Water Level Master Cylinders Pump Drive Gearbox Swing Gearbox Axle Lockout Axle Differential Axle Planetary Oil Welds amp Cracks e Hoist e Boom e Sheaves e Hook e Block 9 41 Chapter 9 Mobile Cranes DOE STD 1090 2007 Page 2 of 2 EXHIBIT III continued SAMPLE FORM MOBILE CRANE FREQUENT INSPECTION REPORT FREQUENT CODE COMMENT e Motor e Valves e Cylinders Lamps e Turn Signals e Headlamps e Cab e Boom e Backup Boom Sheaves Boom Alignment Jib Alignment Machine Structure Clean Change e Differential Breather Fuel Filter Screen e Compressor Strainer e Transmission Filter Drum Wire Rope Dirt Lube Kinks Hook amp Latch Block amp Sheaves Guards in Position Emergency Stop Comments Note Any Potential Hazards or Malfunctions 9 42 Chapter 9 Mobile Cranes DOE STD 1090 2007 Page of 3 EXHIBIT IV SAMPLE FORM MOBILE CRANE PERIODIC INSPECTION REPORT MODEL SERIAL HOUR METER STATUS CODE SAT Satisfactory UNSAT Unsatisfactory R
6. Wire Rope Dirt amp Lube Hook amp Hook Block Counterweight amp Torque Handrails Lamps e Turn Signals e Flashers e Headlamps e Cab e Boom e Backup Welds amp Cracks e Hoists e Boom e Sheaves e Sheaves e Hook e Block e Motor e Valves e Cylinders REMARKS 9 38 Chapter 9 Mobile Cranes DOE STD 1090 2007 EXHIBIT II continued SAMPLE FORM Page 3 of 3 MOBILE CRANE PRE OPERATIONAL CHECKLIST INSIDE CAB Fire Extinguisher Pressure Records Are Not Required CODE COMMENT Operator Manual amp Load Chart Hand Signal Chart Glass Windshield Wiper GAUGES Oil Fuel Amp Lights amp Horn Backup Alarm Heater Boom Angle Indicator PAT Load Moment Indicator Anti Two Block Boom Stops Gearshift Control Foot amp Parking Brakes Swing Brake Control Lever Linkage Throttle Linkage Engine RPM REMARKS 9 39 Chapter 9 Mobile Cranes DOE STD 1090 2007 INTENTIONALLY BLANK 9 40 Chapter 9 Mobile Cranes DOE STD 1090 2007 Page 1 of 2 EXHIBIT III SAMPLE FORM MOBILE CRANE FREQUENT INSPECTION REPORT MODEL SERIAL HOUR METER STATUS CODE SAT Satisfactory UNSAT Unsatisfactory R Repaired N A Not Applicable FREQUENT CODE COMMENT
7. 2 Aplate specifying its empty weight and its rated load capacity or maximum intended load 3 Perimeter protection consisting of a top rail approximately 45 in 10 cm high and a midrail approximately halfway between the top rail and the toe board 4 A grab rail inside the personnel lift platform to minimize hand exposure 5 Anchorage points within the platform for attaching personnel fall protection lanyards 6 The sides of the platform enclosed from the toe board to the midrail with solid construction or expanded metal having openings no greater than Y in 1 27 cm 7 Platform access gates including sliding or folding types if installed shall have a positive acting device to restrain the gate from accidental opening Swinging type access gates shall open only to the interior of the personnel lift platform 8 Rough edges exposed to contact by employees surfaced ground smooth to prevent injury 9 High visibility color or marking for easy identification In addition to wearing hard hats personnel shall be protected by overhead protection on the personnel lift platform when there is an overhead hazard Sufficient headroom shall be provided to allow employees to stand upright in the platform 4 4 2 Platform Suspension System a Wire rope shackles rings master links and other rigging hardware must be capable of supporting without failure at least five times the maximum intended load applied or
8. 4 Lower the test load stopping by the brakes The replacement of load chain and rope is specifically excluded from this requirement however an operational test of the crane shall be made in accordance with paragraph 7 3 1 a 1 prior to putting the crane back in service If wire rope clips or wedge socket end connection are installed during wire rope installation 1 The crane should be cycled several times with a load equal to or greater than the maximum operational load normally 100 percent of the rated capacity 2 If wire rope clips are used then check and retighten nuts to the wire rope clip or wire rope manufacturer s recommended torque value 3 Ifa wedge socket is used then verify that the rope is properly seated Operational testing of altered repaired or modified cranes whose load sustaining parts or rated capacities have not been affected may be limited to the functions affected by the alteration repair or modification as determined by a qualified person The transporting of test loads as required by paragraph 7 3 2 a above shall be done DOE STD 1090 2007 insofar as interfering equipment structures However test loads should not be carried permit and in accordance with over critical systems or components recommendations from the manufacturer or a responsible engineering organization i Test loads shall be accurate to within 5 percent 0 percent of stipulated values 7 13 Chapter 7 Overh
9. b Operators shall be required by their employer to pass a practical operating skill evaluation Qualification shall be limited to the type of equipment for which the operator is being evaluated 6 2 5 OPERATORS OF FLOOR OPERATED CRANES AND HOISTS a Physical qualifications shall be based on specific job requirements b Operators shall be required by their employer to pass a practical operating skill evaluation Qualification shall be limited to the type of equipment for which the operator is being evaluated c The actual or simulated operation shall enable operators to demonstrate basic knowledge and skills at a level that ensures the safety of personnel and equipment Chapter 6 Personnel Qualification and Training 6 2 6 OPERATORS OF REMOTE OPERATED CRANES a The use of remote controlled equipment involves such a wide variety of service requirements and conditions that each installation should be carefully analyzed and operation reviewed to determine whether sections 6 2 2 a or 6 2 5 a should apply b Operators shall be required by the employer to satisfactorily pass a written examination covering operational characteristics controls and emergency control skills c Operators shall be required by their employer to pass a practical operating skill evaluation Qualification shall be limited to the type of equipment for which the operator is being evaluated d The actual or simulated operation shall enable
10. DOE STD 1090 2007 Exhibit I is intended to be a sample form only The equipment manufacturer s inspection testing criteria supercede any other criteria In cases where the equipment manufacturer does not include inspection testing criteria other forms developed to facilitate required inspection testing are acceptable 8 21 Chapter 8 Hoists DOE STD 1090 2007 INTENTIONALLY BLANK Chapter 8 8 22 Hoists DOE STD 1090 2007 Page 1 of 2 EXHIBIT I SAMPLE FORM HOIST LOAD TEST INSPECTED BY HOIST ID LOCATION DATE Notes 1 Load test prior to initial use at 125 of rated capacity all new hoists or hoists in which load sustaining parts have been modified repaired or replaced Test weights shall be accurate to within 596 0 of stipulated values Load test at 100 of rated capacity hoists with overload devices Test the function of the overload device Qualified inspector shall verify all steps as listed below 3 Craftsmen will initial all tests work and inspections completed below 1 Perform the annual periodic inspection Check unit for proper operation 2 HAND CHAIN OPERATED HOISTS ONLY Check brake mechanism for work glazed or contaminated disks worn pawls cams or ratchets Check for broken corroded or stretched pawl springs Repair as needed 3 ELECTRIC AND AIR POWERED HOISTS Check All functional operating mechanisms for maladjustment interfering with proper operation Limit swit
11. Drive carefully and slowly across the dockboard or bridge plate and never exceed its rated capacity Do not drive trucks onto any elevator unless specifically authorized to do so In cases operation are authorized 1 Do not exceed the capacity of the elevator 2 Approach elevators slowly and then enter squarely after the elevator car is properly leveled Chapter 10 Forklift Trucks 10 22 3 Once on the elevator neutralize the controls shut off the power and set brakes 4 It is advisable that all other personnel leave the elevator before truck is allowed to enter or leave Unless a towing hitch is supplied by the manufacturer do not use forklift trucks as tow trucks When a towing hitch is provided use tow bars rather than wire rope for towing At the end of the operator s shift return the forklift truck to its assigned parking place set brakes fully lower load engaging means place controls in neutral position turn ignition off and secure the key If the truck is equipped with a seat belt use it 10 5 1 3 Loading a Since the load rating for forklifts may be based on stability or hydraulic or structural competence do not exceed the rated capacity in operational application The designated person shall ensure that the weight of a load approaching the rated capacity combination of weight and location of the center of gravity has been determined within 10 percent 0 percent before
12. In addition the PIC shall a Direct operations in the case of an accident b Exercise authority to start and stop work activities 6 2 10 DESIGNATED LEADER The designated leader shall have sufficient knowledge and experience to accomplish the following responsibilities a Ensure that personnel involved understand how the lift is to be made b Ensure that the weight of the load is determined and that proper equipment and accessories are selected c Survey the lift site for hazardous or unsafe conditions d Ensure that equipment is properly set up and positioned e Ensure that a signaler is assigned if required and is identified to the operator f Direct the lifting operation to ensure that the job is done safely and efficiently g Stop the job when any potentially unsafe condition is recognized h Direct operations if an accident or injury occurs 6 2 11 INSPECTORS a Qualified inspectors shall have the necessary knowledge training and experience to properly inspect hoisting and rigging equipment b Employees who operate cranes to perform crane inspections shall be trained and qualified to operate the crane on which the inspection is being performed See general and crane specific qualification requirements in Section 6 2 Qualification c Crane operation by crane inspectors shall be limited to those crane functions necessary to perform the inspection on the crane 6 2 12 INSTRUCTOR
13. operation at heavy service coupled with abnormal operating conditions i e extreme temperatures corrosive atmospheres etc 13 2 2 INITIAL INSPECTION De Si Prior to initial use all new and repaired hooks shall be inspected by a qualified inspector to ensure their compliance with the applicable provisions of ASME B30 10 Section 10 1 2 Dated and signed inspection records shall be kept on file and shall be readily available Inspection procedure and record keeping requirements for hooks in regular service shall be governed by requirements for the kind of equipment in which they are used When such requirements are stated in standards for the specific equipment they shall take precedence over the requirements of this section 13 2 3 DAILY INSPECTION De Operators or other designated personnel shall visually inspect hooks for deficiencies such as the following each day or prior to use if the hook has not been in regular service records are not required 1 Cracks nicks and gouges 2 Deformation 3 Damage from chemicals 4 Latch engagement damage to or malfunction of latch if provided Chapter 13 Load Hooks 13 2 5 Evidence of heat damage b A designated person shall examine deficiencies and determine whether they constitute a safety hazard and whether a more detailed inspection is required 13 2 4 FREQUENT INSPECTION a Operators or other designated personnel shall visually inspect the
14. which extend below the top of the rail and project in front of the truck wheels 7 1 6 HOIST BRAKES a Each independent hoisting unit shall be equipped with at least one holding brake applied directly to the motor shaft or some part of the gear train b Each independent hoisting unit except worm geared hoists the angle of whose worm prevents the load from accelerating as it is being lowered shall be equipped with a controlled braking means in addition to the holding brake to control speed of lowering c Holding brakes on hoists shall be applied automatically when power is removed 7 1 7 POWER SHUTOFF a The power supply for the runway conductors shall be controlled by a switch or circuit breaker located on a fixed structure accessible from the floor and capable of being locked in the OPEN position b Oncab operated cranes an enclosed switch or circuit breaker with provisions for locking in the OPEN position shall be provided in the leads from the runway conductors A means of opening this device shall be located within reach of the operator when the operator is in the operating position When the operator opens this switch or circuit breaker the holding brakes should set c On floor remote or pulpit operated cranes an enclosed disconnect device shall be provided in the leads from the runway conductors This device shall be mounted on the bridge or footwalk near the runway collectors There shall be pr
15. 1 Seals and connections shall be tested for leaks by attaching a nonporous clean test plate to the vacuum pads and then stopping the vacuum source Vacuum level in the system shall not decrease by more than the rate specified by the manufacturer 2 Test indicator lights gauges horns bells pointers or other warning devices and vacuum level indicators for proper operation 14 3 5 2 Rated Load Test All new reinstalled repaired or modified vacuum lifting devices shall be tested and inspected before use Tests and inspections shall be performed by a qualified inspector or under the direction of that inspector Test Chapter 14 Below the Hook Lifting Devices 14 12 14 3 6 14 3 7 and inspection results shall be documented and kept on file The rated capacity shall not be more than 80 percent of the maximum load sustained during the test Test loads shall not be more than 125 percent of the rated capacity unless otherwise recommended by the manufacturer Test weights shall be accurate to within 5 percent 0 percent of stipulated values The rated load test shall consist of the following steps at a minimum 1 Attach pads to the designated test load 2 Raise the test load a minimum distance to ensure that it is supported by the vacuum lifting device and hold it for 2 minutes 3 Remain clear of the suspended load 4 Lower and release the load 5 Visually inspect the vacuum lifting device for defect
16. 9 2 6 5 Hydraulic and Pneumatic Cylinders Inspect for a Drifting caused by fluid leaking across the piston b Rod seal leakage c Leaks at welded joints d Scored nicked or dented cylinder rods e Dented case barrel f Loose or deformed rod eyes or connecting joints 9 2 6 6 Hydraulic Filters Evidence of rubber particles on the filter element may indicate deterioration of the hose O ring or other rubber components Metal chips or pieces on the filter may denote failure in pumps motors or cylinders Further checking will be necessary to determine the origin of the problem before corrective action can be taken 9 2 6 7 Wire Rope a A qualified inspector shall inspect wire ropes at least annually More frequent intervals shall be determined by a qualified person and shall be based on such factors as expected rope life as determined by severity of environment percentage of capacity lifts frequency rates of operation and exposure to shock loads The qualified inspector shall carefully note any deterioration such as described below that results in appreciable loss of original strength and determine whether further use of the rope constitutes an acceptable risk This inspection shall include examination of the entire rope length without detaching it from the drum 1 Reduction of rope size below nominal diameter whether due to loss of core Chapter 9 Mobile Cranes DOE STD 1090 2007 support
17. General DOE STD 1090 2007 11 3 SLINGS 11 3 1 GENERAL 11 3 1 1 Load Angle Factor Slings shall have a minimum design factor appropriate to the type of material as specified in the appropriate section Features that affect the rated capacity of the sling and that shall be considered in calculating the design factor are 1 Nominal breaking strength of material from which it is constructed 2 Splicing or end attachment 3 Number of parts in the sling 4 Type ofhitch e g straight pull choker hitch or basket hitch 5 Angle of loading and load center of gravity 6 Diameter of curvature around which the sling is bent The center of gravity of an object is a point around which the entire weight may be concentrated To make a level lift the crane hook or point of suspension must be directly above this point While slight variations are usually permissible if the crane hook is too far to one side of the center of gravity dangerous tilting will result and should be corrected at once For this reason when the center of gravity is closer to one point of the sling attachment than to the other the slings must be of unequal length Sling stresses and sling angles will also be unequal see Figure 11 6 Rigging shall be configured such that slings do not reeve or slip through the hook To attach the load locate the center of gravity position the crane hook directly above the center of gravity and then rig the
18. The proper attachment of adaptors to vacuum lifting devices for handling of special loads Users shall demonstrate the ability and competence to operate the lifting device as instructed before assuming responsibility for using it 14 3 8 OPERATION Only the following personnel shall operate vacuum lifting devices 1 2 4 Qualified operators or riggers Trainees under the direct supervision of a qualified operator Maintenance and test personnel when it is necessary in the performance of their duties Inspectors of lifting devices The following shall apply to all personnel who operate vacuum lifting devices 14 13 10 11 12 Before starting the lift verify that the vacuum on indicator has reached the required level Also verify that the vacuum lifting device has been correctly applied and a stable vacuum level exists by lifting the load a few inches and observing conditions Observe the condition of the lifting device before use and during operation If you observe a defect that affects the continued safe use of the lifting device remove it from service Place any attached load on the floor or ground and after use properly store the lifting device before leaving Before they are used on a shift test the lifting device controls If any do not operate properly adjust or repair them before operations begin Do not load the lifting device in excess of its rated capacity
19. 350 317 520 133 465 421 848 400 362 880 133 532 482 630 450 408 240 133 598 542 506 500 453 600 133 665 603 288 Above 500 453 600 133 Note 1 ton short 2 000 Ib 907 2 kg For hooks with load ratings not shown above use the next lower load rating for determining the percent f rated load to be applied Reprinted from ASME B30 10 2005 by permission of The American Society of Mechanical Engineers All rights reserved 13 5 Chapter 13 Load Hooks DOE STD 1090 2007 13 4 NONDESTRUCTIVE TESTING NDT 13 4 1 NDT REQUIREMENTS If detailed inspections are performed refer to sections 13 2 3 b 13 2 4 c and 13 2 5 b the results shall be evaluated by a qualified person to determine the need for subsequent NDT If NDT is deemed necessary it shall be performed in accordance with Section 13 4 3 13 4 2 NDT RECORDS Dated and signed NDT records traceable to the hook by a serial number or other identifier shall be kept on file as long as the hook remains in service and shall be readily available to appointed personnel 13 4 3 NDT METHODS De Use magnetic particle testing or liquid penetrant testing methods to inspect for surface intersecting discontinuities cT A qualified inspector or designated person shall perform NDTs in accordance with the following ASTM standards 1 ASTM E 709 2 ASTM E 165 e For magnetic particle testing a coil yoke or wet technique should be used to eliminate the possib
20. Chapter 1 3 Cracked or worn gears pulleys sheaves sprockets bearings chains and belts 4 Excessive wear of friction pads linkages and other mechanical parts Chapter 14 Below the Hook Lifting Devices DOE STD 1090 2007 5 Excessive wear at hoist attaching points and load support shackles or pins 6 External evidence of damage to motors or controls d A qualified inspector shall inspect fixtures not in regular use according to periodic inspection requirements before placing them in service e Dated reports of each periodic inspection shall be prepared They shall be kept on file and shall be readily available A sample load test and inspection form is included as Exhibit I at the end of this section This form is intended to be a sample only and is not intended to be mandatory 14 2 6 TESTING 14 2 6 1 Operational Test a Modified or repaired lifting devices shall be tested before initial use to ensure compliance with the requirements of this section test reports kept on file Testing shall include the following 1 Lifting devices with moving parts shall be tested to confirm that the lifting device operates in accordance with manufacturer s instructions 2 Lifting devices with manually operated or automatic latches shall be tested to verify that the latches operate in accordance with manufacturer s instructions 14 2 6 2 Rated Load Test a All new altered modified or repaired lifting
21. Consult truck nameplate 10 1 5 MODIFICATIONS a Modifications or additions that affect capacity or safe operation shall not be performed without prior written approval from the forklift truck manufacturer Capacity operation and maintenance instruction plates tags or decals shall be changed accordingly b In the event that the truck manufacturer is no longer in business and there is no successor to the business the user may arrange for a modification or alteration to a forklift truck provided however the user shall 1 Arrange for modifications or alteration to be designed tested and implemented by an engineer qualified in forklift trucks and their safety 2 Maintain a permanent record of the design test s and implementation of the modifications or alteration 3 Make appropriate changes to the capacity plate s decals tags and operation and maintenance manuals 4 Affix a permanent and readily visible label on the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration and the name of the organization that accomplished the tasks 10 1 6 WARNING DEVICES a Every truck shall be equipped with an operator controlled horn whistle gong or other sound producing device s b The using organization shall determine if operating conditions require the truck to be Chapter 10 Forklift Trucks 10 2 equipped with addition
22. GALVANIZED ROPE Rope made of galvanized wire GALVANIZED STRAND Strand made of galvanized wire GALVANIZED WIRE Wire coated with zinc GAS ELECTRIC TRUCK An electric truck in which the power source is a generator driven by an LP gas or gasoline engine GROMMET A seven strand wire rope sling made from one continuous length of strand or an endless synthetic web sling Chapter 1 Terminology and Definitions DOE STD 1090 2007 GROOVED DRUM Drum with grooved outer surface to accommodate and guide a rope GROOVES Depressions in the outer surface of a sheave or drum for positioning and supporting a rope GUY LINE Strand or rope usually galvanized for holding a structure in position HANDLING FIXTURE A cradle structure shipping fixture or container designed specifically to facilitate supporting lifting or handling a component during fabrication loading shipping storage or installation HIGH LIFT TRUCK A self loading truck equipped with an elevating mechanism designed to permit tiering Popular types are high lift platform trucks see Figure 10 3 HIGH LIFT PLATFORM TRUCK A self loading truck equipped with an elevating mechanism intended primarily for transporting and tiering loaded skid platforms see Figure 10 3 HOIST A device that applies a force for lifting or lowering HOIST LEVER OPERATED A lever operated manual device used to lift lower or pull a load and to apply or release tensio
23. Hoists DOE STD 1090 2007 If you observe wear or suspect stretching measure the chain according to the hoist manufacturer s instructions If instructions are not available proceed as follows i Suspend the hoist in normal position and apply a light load of approximately 100 lb 46 kg li Select a 12 in 305 mm section of chain that normally travels over the load sprocket iii Determine elongation by measuring with a caliper from the edge of one chain pin to the corresponding edge of another pin If elongation exceeds Y in 6 3 mm in 12 in 305 mm compared to new or unstretched chain values replace the chain iv Inspect for twists Replace if the twist in any 5 ft 1 52 m section exceeds 15 degrees v Check for straightness in a plane perpendicular to the plane of the rollers Replace if the chain has a bow exceeding LA in 6 3 mm in any 5 ft 1 52 m section Make additional inspections by removing the chain from the hoist and cleaning it thoroughly Carefully examine deficiencies such as those listed below and determine whether they constitute a safety hazard Any deficiencies are reason for questioning chain safety and considering its replacement i Pins turned from original position ii Rollers that do not run freely with light finger pressure iii Joints that cannot be flexed by easy hand pressure iv Side plates that are spread open v Corrosion pitting or discoloration
24. Metal mesh slings used for critical lift service shall have an initial proof test of 200 percent of the vertical rated capacity If proof testing cannot be verified the sling s shall be proof tested before being used to make a critical lift b The proof load for multiple leg bridle slings shall be applied to the individual legs and 11 33 shall be 200 percent of the vertical rated capacity of a single leg sling Master links to which multiple leg slings are connected shall be proof loaded to 200 percent multiplied by the force applied by the combined legs 11 3 5 SYNTHETIC WEB SLINGS Synthetic web shall posses the following qualities 1 Be of sufficient strength to meet the sling manufacturer s requirements 2 Have uniform thickness and width 3 Have selvage edges and not be split from its woven width The thread used in the manufacture of a synthetic web sling shall be of the same type of material as the web Fittings shall be 1 Of sufficient strength to sustain twice the rated capacity without permanent deformation 2 Ofa minimum breaking strength equal to that of the sling 3 Free of all sharp edges that would in any way damage the webbing The stitching in all load bearing splices shall be of sufficient strength to maintain the sling design factor Synthetic web slings may be coated with elastomers anti fungicides UV inhibitors or other treatments that will provide improved characterist
25. Platform Identification Number 1 Trial Lift Completed with anticipated lift weight lbs or kg 2 Markings Satisfactory Unsatisfactory Platform All Information Legible Suspension System 6 3 Structure Load Supporting Welds Bolts Load Supporting Members Barrier From Toe Board to Intermediate Rail Hand Rail Fall Protection Device Anchorage Points Gate Locking Mechanisms Platform Flooring Suspension Attachment Points LN NN NNN wee eye wr ww LN NN NNN wee eye wr ww 4 Attachment Mechanisms Pins Ears Bolt Up s eyes circle Wire Rope Chains Rigid Leg circle Master Links 5 Special Purpose Items 1 e Overhead Protection Floatation Platform Controls List 1 6 2 3 6 General Comments Designated Leader Signature Date Reprinted from ASME B30 23 2005 by permission of The American Society of Mechanical Engineers All rights reserved 4 15 Chapter 4 Lifting Personnel DOE STD 1090 2007 Page 1 of 1 EXHIBIT Il SAMPLE FORM ONLY PERSONNEL LIFTING PLANNING AND AUTHORIZATION 1 Location Date 2 Purpose of Lift 3 Hoisting Equipment Manufacturer Model Number Serial Number 4 Expected Radius Maximum At Work Location 5 A Rated Load at Radius B Maximum Lifted Load 5096 of 5A 6 A P
26. The braking system shall have thermal capacity for the frequency of operation required by the service The braking system shall have provisions for adjustments where necessary to compensate for wear Air powered hoist under normal operating conditions with rated load and test conditions with test loads up to 125 percent of rated load the braking system shall perform the following functions 1 Stop and hold the load hook when controls are released 2 Prevent an uncontrolled lowering of the load in the event of a loss of air pressure 3 The braking system shall have thermal capacity for the frequency of operation required by the service 4 The braking system shall have provision for adjustments where necessary to compensate for wear DOE STD 1090 2007 2 MANUALLY OPERATED LEVER HOISTS 2 1 GENERAL b Load chain shall be proof tested by the chain or hoist manufacturer with a load test of 150 a Manually operated lever hoists shall percent of the hoist rated load divided by the number of chain parts supporting the load 1 Meet or exceed the requirements of ASME ANSI B30 21 c Ifa load is supported by more than one part of load chain the tension on the parts shall 2 Have the rated load marked on the hoist be equalized or load block 2 3 LOAD BLOCKS 3 Be tested by the manufacturer with a test load of at least 125 percent of the rated load Load blocks shall have means to guard against load chain jammi
27. The number and distribution or concentration of broken outside wires 3 Worn outside wires 4 Sections of rope that are normally hidden during inspection or maintenance procedures such as parts passing over sheaves these are points most subject to deterioration 5 Corroded or broken wires at end connections 6 Corroded cracked bent worn or improperly applied end connections 7 Kinking crushing cutting or unstranding All rope on cranes that have been idle for 1 month or more due to shutdown or storage shall be inspected before the crane is returned to service A dated and signed report of the rope inspection including results shall be filed No precise rules can be given for determining the exact time to replace rope because many variables are involved Safety in this respect depends largely on the use of good judgment by an appointed DOE STD 1090 2007 person in evaluating remaining strength in a used rope after allowance for deterioration disclosed by inspection Safety of rope operation depends on this remaining strength Table 7 1 Maximum allowable rope 4 Evidence of heat damage from any cause 5 Reductions from nominal diameter greater than those listed in Table 7 1 Replacement rope and connections shall have strength at least as great as the original rope and connections furnished by the crane f manufacturer Any deviation from the original size grade or construction shall be
28. Top Running Trolley Hoist B30 11 Monorail Systems and Underhung Cranes and B30 17 Overhead and Gantry Cranes Top Running Bridge Single Girder Underhung Hoist for latest ASME standards see http catalog asme org home cfm Category CS 7 1 GENERA Di tie eI esee etr p e bee rai aa ee 7 1 7 1 1 Operator Training Qualification oo eee ee eeeeseeseeeeeeseeeeeseeeseeeaeseaeeeaeseeeeseeeneeeaees 7 1 73 2 Rated Load Mark E caiste 7 1 113 Modiica ON Em 7 1 TA eegener EE 7 1 TAS Kal mega geegent ee ENER ENEE AEN 7 1 7 1 0 Hoist Brake8 uet Hed e t o ca BERE DOE 7 1 TA deed WE 7 1 7 1 8 Hoist Limit Switch Liu a edie rare Rope 7 5 7459 Marking au reete heed teet leeds Deas seta Ee ani 7 5 TTO Load EL P 7 5 7 1 10 Maintenance History sese een een eene tenete ne tnee teneret 7 5 7 2 INSPEC LIONS perito ee tI E 7 6 EE A E E E E E E A ESI 7 6 1 222 A oiim Ob ies retire eret os 7 6 VES DEED P 7 6 7 2 4 Daily Preoperational Check 7 6 7 2 5 Monthly Rope Chain and Hook Inspecton nono cnnncnn nono ncnnccnnoo 7 6 7 2 6 Frequent Inspection ese eee ssceesecesecesecesecsseeseeesecesecssecsaesseeeeeeseseaeseaeenaeeeseeeenees 7 7 7 2 7 Periodic Inspection ecceeecccesceeescecenceceseecesceceaeecsaeeceaeecsaeeseaeeceaeeeeaeecsaeeeeaeerseeeeaeers 7 1 7 2 14 EE 7 7 1 2 1 2 A 7 8 T3 Chain Wel
29. also called a wire watcher whose sole responsibility is to maintain proper clearance The wire watcher shall be in constant communication with the crane operator 5 Tag lines to the personnel platform when used shall be of a nonconductive type such as dry rope made of polypropylene or polyethylene fiber 6 No person outside the platform or crane cab shall be permitted to touch the crane load line or platform unless the wire watcher indicates it is safe 7 Operation of the boom or the platform over power lines should be avoided Poor perception of distance and multiple potential contact points make this very hazardous Chapter 4 Lifting Personnel DOE STD 1090 2007 10 Proximity warning devices insulated 8 Consider attaching ribbons balls or links or boom cages if used shall not other visibility enhancing devices to be a substitute for any requirements of the power line to aid in visually locating this section the prohibited zone 4 7 4 CONDITION C 9 In addition to Electrical Hazard Warning Signs required on all mobile a Power lines are energized with the cranes Electrical Hazard Warning equipment inside the prohibited zone See Signs shall be posted inside the Table 4 1 Lifting personnel in the personnel lift platform condition is strictly prohibited Table 4 1 Safe working distance from power lines a When operating near high voltage power lines Normal voltage Minimum required p
30. because of the difficulties of inspection and the important nature of these ropes No precise rules can be given for determining the exact time to replace wire rope because many factors are involved Safety in this respect depends largely on the use of good judgment by an appointed person in evaluating remaining strength in a used rope after allowance for deterioration disclosed by inspection Safety of rope operation depends on this remaining strength Removal criteria for wire rope replacement shall be as follows 1 In running ropes 6 randomly distributed broken wires in one rope lay or 3 broken wires in one strand in one rope lay 2 In standing ropes more than two broken wires in one lay in sections beyond end connections or more than one broken wire at an end connection 3 In rotation resistant ropes two randomly distributed broken wires in six rope diameters or four randomly distributed broken wires in thirty rope diameters 4 One outer wire broken at the point of contact with the core of the rope that has worked its way out of the rope structure and protrudes or loops out from the rope structure additional inspection of this part of the rope is required Chapter 9 Mobile Cranes DOE STD 1090 2007 5 Wear of one third the original diameter of outside individual wires 6 Kinking crushing birdcaging or any other damage resulting in distortion of the rope structure 7 Evidence of heat damage fr
31. chain or webbing strap 4 Operating damaged or malfunctioning hoists 5 Lifting personnel or lifting loads above personnel 6 Operating a hoist with lever extensions for lever operated hoists 7 Operating hoists with other than manual power for hand chain operated hoists 8 Removing or obscuring warning labels DESIGN STANDARDS At a minimum safety features and operation shall meet the provisions of ASME B30 16 and B30 21 Mechanical electrical and structural components of hoist design shall meet accepted hoist design standards contained in ASME HST 1M 2M 3M 4M 5M and 6M Performance Standard for Electric Chain Hoists Performance Standard for Hand Chain Manually Operated Chain Hoists Performance Standard for Manually Lever Operated Chain Hoists Performance Standard for Electric Wire Rope Hoists Performance Standard for Air Chain Hoists and Performance Standard for Air Wire Rope Hoists respectively DESIGN FACTORS For electric or air powered hoists load suspending parts of powered hoists shall be designed so that the static stress calculated for the rated load will not exceed 20 percent of the average ultimate material strength This requirement is commonly reflected by quoting a minimum design factor of 5 1 b For hand chain operated and manual lever operated hoists load suspending parts shall be designed so that the static stress calculated for
32. except for test loads or handle any load for which it is not designed Apply the lifting device to the load in accordance with established procedures Before lifting ensure that lifting device ropes or chains are not kinked and multiple part lines are not interwoven Ensure that the load is correctly distributed for the lifting device being used Do not use the lifting device for side pulls or sliding the load unless specifically authorized by a qualified person or by an approved procedure Warn all personnel in the vicinity of the lifting device and place the load on the floor or ground if possible to do so if electrical power goes off while a load is being lifted Do not leave your position at the controls Do not use a lifting device that is tagged Danger Do Not Operate or otherwise designated as nonfunctional Chapter 14 Below the Hook Lifting Devices DOE STD 1090 2007 13 Do not remove Danger Do not Operate tags from lifting devices without the approval of the person who placed them or an authorized person 14 Store the lifting device in a dry inside location when not in use 15 Ensure that markings or tags are not removed or defaced Replace missing or defaced markings or tags Chapter 14 Below the Hook Lifting Devices 14 14 14 3 9 CRITICAL LIFTS See Chapter 2 Critical Lifts for critical lift requirements a Vacuum lifting devices for critical lift service shal
33. f Bridge Brake f Hooks Cracks Wear Deformation ii Throat Opening Latch Operation Hydraulics g Fluid Leaks Couplers Connection Rods h Batteries i End Trucks KR i Electric Motors j Rail Sweeps j Electric Panels k Windlocks Chock Stops k Runway Bridge Conductors Housekeeping Runway Bridge Collectors m Electrical Guards n Festoon System o Warning Tags Signs p Exposed Electrical Hazards q Trolley Stops KR Chapter 7 7 26 DOE STD 1090 2007 Page 2 of 2 EXHIBIT II continued OVERHEAD CRANE PRE OPERATIONAL CHECKLIST Records Are Not Required 3 OPERATOR CAB INSPECTION S U 4 OPERATION INSPECTION S U NA NA a Housekeeping a Power Supply Relay 2 b Warning Tags b Manual Reset c Cab Door s C Stop Button Control d Fire Extinguisher d Pendant Buttons j e Controls Identification e Upper Limit Main f Electrical Enclosures f Upper Limit Auxiliary g Pendant Strain Relief g Lower Limit Main h VisibilityWindows h Lower Limit Auxiliary i Safety Devices i Bridge Controls si j Warning Indicator Light j Bridge Brake k Alarms k Trolley Control id Main Hook m Auxiliary Hook d n Work Area o Runway Stops p Travel Limit Relays INSTRUCTIONS Inspect all applicable items each shift of operation Suspend all operations immediately when observing an unsatisfactory condition f
34. in cases where a reduced rope length is adequate by cutting off the worn end thus shifting the wear to different areas of the rope Chapter 9 Mobile Cranes 9 5 1 DOE STD 1090 2007 9 5 OPERATIONS The following shall apply to all personnel involved in mobile crane operation At the initial stage of the planning process an appointed person shall classify each lift into one of the DOE specified lift categories ordinary critical or preengineered production CONDUCT OF OPERATOR Cranes shall only be operated by personnel qualified per Chapter 6 of this Standard for the type of crane being operated Do not engage in any practice that will divert your attention while operating the crane Keep the operating area free of water snow ice oil and debris that could cause your hands or feet to slip from the controls Keep the operating cab windshields clean and free of anything that obstructs vision Replace broken windows Ensure proper functioning of tires horn lights battery controller lift system including load engaging means chains hoist rope and limit switches brakes and steering mechanisms If at any time a lifting device is found to be in need of repair is defective or is in any way unsafe report it immediately to the designated authority and take the unit out of service until it has been restored to safe operating condition or a determination has been made by the responsible manager that the
35. in questionable cases concurrence is obtained from the appropriate safety organization If a handle or latch support is required to be welded to the hook welding shall be done prior to final heat treating 13 1 3 LOAD LIMITS Hooks shall not be loaded beyond rated capacity except during load tests of the equipment of which they are a part 13 1 4 HOOK STANDARDS a Hook design shall meet generally accepted hook design standards and be compatible with the requirements of ASME B30 10 b Hook material shall have sufficient ductility to permanently deform before failure at the ambient temperatures at which the hook will be used c When a latch is provided it shall be designed to retain such items as slings under slack conditions The latch is not intended to support the load d The bearing surfaces of new hooks shall be the arc of a circle Gauge points or hook gauges for measuring spread after load testing should be provided e Field fabricated hooks shall meet the requirements of this section and shall be approved by a qualified engineer 13 1 Chapter 15 Load Hooks DOE STD 1090 2007 13 2 INSPECTIONS 13 2 1 HOOK SERVICE Hook service is defined as follows De Si e Normal service operation at less than 85 percent of rated capacity except for isolated instances Heavy service operation at 85 to 100 percent of rated capacity as a regular specified procedure Severe service
36. inspected by a qualified inspector to ensure compliance with the provisions of this chapter For new equipment an initial inspection shall verify that requirements of the purchase order or rental agreement have been met and that the equipment is suitable for its intended use This inspection shall be documented and should be retained in the forklift truck s history file A sample load test and inspection form is included as Exhibit II which appears at the end of this chapter This form is intended to be a sample only and is not intended to be mandatory 10 3 3 INSPECTION AND MAINTENANCE Inspection and maintenance of powered forklift trucks shall be performed in conformance with the following practices a The inspection and maintenance program shall follow the manufacturer s recommended procedures If equipment maintenance or inspection procedures deviate from published manufacturer s recommendations the alternate procedures shall be approved in advance by the manufacturer or another qualified person and be kept readily available b Only trained and authorized personnel shall be permitted to inspect maintain repair and adjust forklift trucks c No repairs shall be made while the truck is in a hazardous explosive classified area d Inspect brakes steering mechanisms control mechanisms warning devices lights governors lift overload devices guards and safety devices regularly and maintain them in a safe opera
37. internal or external corrosion or wear of outside wires see Table 9 2 Table 9 2 Maximum allowable rope reductions Maximum allowable reduction from nominal diameter Rope diameter Up to 5 16 in 8 mm 1 64 in 0 4 mm Over 5 16 in to 1 32 in 0 8 mm Ya in 13 mm Over Yinto in 3 64 in 1 2 mm 19 mm Over in to 1 1 8 1 16 in 1 6 mm in 29 mm Over 1 1 8 in to 3 32 in 2 4 mm 1 Yin 38 mm Reprinted from ASME B30 5 2004 by permission of The American Society of Mechanical Engineers All rights reserved 2 The number and distribution or concentration of broken outside wires 3 Worn outside wires 4 Corroded or broken wires at end connections 5 Corroded cracked bent worn or improperly applied end connections 6 Kinking crushing cutting or unstranding The qualified inspector shall take care when inspecting running rope where rapid deterioration could occur such as in the following 1 Sections in contact with saddles equalizer sheaves or other sheaves where rope travel is limited 2 Sections of the rope at or near terminal ends where corroded or broken wires may protrude The qualified inspector shall take care when inspecting certain ropes such as the following Rotation resistant ropes because of their higher susceptibility to damage The internal deterioration of rotation resistant ropes may not be readily observable 2 Boom hoist ropes
38. marked with the manufacturer s name or trademark and size or rated load d The design factor for turnbuckles shall be a minimum of 5 A 17 Appendix A Procurement Guidelines DOE STD 1090 2007 PURCHASE REQUISITION Part Delivery Receipt and Handling Complete for all Procurements EXAMPLE ONLY P O No AB81111 P O Date Requisition Date 12 18 96 Required Delivery 3 97 Deliver to Name Phone No Bldg Rm Myra T Fall 1 1111 Bldg 501 Inspection Check One O wa RI O pora O ro End Use Project No Tank Removal End User Name Phone Myra T Fall 1 1111 Packing Shipping Level Check One Storage Level Ona Da Os Oc Oo K ss On Oa Ob Ke Oo PART II Engineering QA Control Data Complete for all Procurements Type Item Documents Deliverable Onsite Visit Required O N A O Engineered Commercial O None O Comm O Eng Quality O Yes No PART III Health and Safety Date Complete for all Procurements Functional Classification O es PART IV Description Complete for all Procurements Procurement Type O assi ttem Approved Equal O app O service O assi ttem O sole Source O sole Source Il Item No Quantity Unit Description Salient Features Unit Price Total Price 1 100 FT Wire Rope Y inch Carbon Steel 6 x 19 classification EIPS Extra Improved Rlow Steel IWRC Independent Wir
39. of the upper limit device shall be located so that it will trip the device under all conditions and in sufficient time to prevent contact of the hook or load block with any part of the trolley or crane 7 3 3 RATED LOAD TEST Prior to initial use all new or reinstalled cranes and cranes in which the load sustaining parts have been altered modified repaired or replaced or whose rated capacities have been affected shall be tested by or under the direction of a qualified inspector A written report confirming the rated load testing of the crane shall be furnished by the inspector Test loads shall not be less than 100 percent or more than 125 percent of the rated capacity unless otherwise recommended by the manufacturer or a qualified person Testing shall consist of the following operations as minimum requirements 1 Hoist the test load a sufficient distance to ensure that the load is supported by Chapter 7 Overhead and Gantry Cranes the crane and held by the hoist brakes Personnel shall be kept clear of the test load while it is suspended 2 Transport the test load by means of the trolley for the full length of the bridge 3 Transport the test load by means of the bridge for the full length of the runway in one direction with the trolley as close to the extreme right hand end of the crane as practical and in the other direction with the trolley as close to the extreme left hand end of the crane as practical
40. place a side or backload on the hook 13 9 When using a device to bridge the throat opening of the hook ensure that no portion of the load is carried by the bridging device Keep hands and fingers from between the hook and the load Load duplex sister hooks equally on both sides unless the hook is specifically designed for single loading Do not load the pinhole in duplex sister hooks beyond the rated load of the hook Chapter 13 Load Hooks DOE STD 1090 2007 INTENTIONALLY BLANK Chapter 13 Load Hooks 13 10 DOE STD 1090 2007 Exhibit I is intended to be a sample form only The equipment manufacturer s inspection testing criteria supercede any other criteria In cases where the equipment manufacturer does not include inspection testing criteria other forms developed to facilitate required inspection testing are acceptable 13 11 Chapter 13 Load Hooks DOE STD 1090 2007 INTENTIONALLY BLANK Chapter 13 Load Hooks 13 12 DOE STD 1090 2007 Page 1 of 1 EXHIBIT SAMPLE FORM DEVICE DEVICE NO SERVICE CLASSIFICATION LOCATION Teodtiros A NN H Ed Zon y Ss Ss a E One third i p RENS S L 5 d E E Two directions of discontinuities are labeled on the drawing above as P and T discontinuity P parallels the contour of the hook and is considered non serious in nature and does not require removal from service Discontinuity T is transverse to contour of th
41. spelter attachment 10096 qu 79 Pressed sleeve loop back thimble attach Thimble spliced hand tucked ment 1 4 in 90 1 2in 86 5 16 in 89 5 8 in 84 1 in diameter and smaller 9596 3 8in 8896 3 4 in 82 1 1 2 in diameter and larger 92 5 7N6in 87 7 8 in 80 Flemish loop with mechanical sleeve Loop splice hand tucked attachment Efficiencies of loop splice are the same as 1 in diameter and smaller 9596 those given for thimble splice 1 1 2 in diameter and larger 92 5 Figure 11 11 Wire rope fastenings Note that the base of the clip bears against the live end of the wire rope while the U of the bolt presses against the dead end The U of the clips shall not bear against the live end of the wire rope because of the possibility of the rope Figure 11 12 Wire rope clips right being kinked or crushed Way Figure 11 13 Wire rope clips wrong way 11 23 Chapter 11 General DOE STD 1090 2007 11 3 2 4 Critical Lifts See chapter 2 Critical Lifts for critical lift requirements 1 All provisions of paragraph 11 3 2 3 a also shall apply to critical lifts 2 Wire rope slings used for critical lift service shall have an initial proof test If proof testing cannot be verified the wire rope sling s shall be proof tested before being used to make a critical lift Asa minimum the pro
42. tagged out or flagged 2 Ensure that a magnet removed for repair is tagged as defective Only qualified personnel shall work on equipment when maintenance and test are required After repairs have been made the lifting magnet shall not be returned to service until it has been inspected according to Section 14 5 4 3 Dated records of repairs and replacements shall be available Any defective condition disclosed by the inspection shall be corrected before the lifting magnet is returned to service TRAINING QUALIFICATION Operators shall be trained and qualified as specific in Chapter 6 Personnel Qualification and Training At a minimum instruction shall include the following 1 Application of the lifting device to the load and adjustments of the device if any that adapt it to various sizes or kinds of loads 2 Any special operations or precautions 3 Condition of the load itself required for operation of the lifting device such as balance degree of order of stacked Chapter 14 Below the Hook Lifting Devices DOE STD 1090 2007 loads surface cleanliness bending and properly adjust or repair them before load thickness operations begin 4 Procedure for storage of the lifting 3 Do not load the lifting device in excess device to protect it from damage of its rated capacity or handle any load for which it is not designed 5 Instructions for not exceeding the rated capacity of the lifting devic
43. transmitted to that component and guided by the following Chapter 4 Lifting Personnel DOE STD 1090 2007 1 One leg system design factor of seven 2 Two or three leg system design factor of five for each leg 3 Four leg system design factor of five with only three legs under stress 4 Where rotation resistant rope is used the slings shall be capable of supporting without failure at least ten times the maximum intended load Sling suspension systems shall utilize a master link or safety type shackle to connect the personnel lift platform to the load block to ensure that the load is evenly divided among the suspension system legs The suspension system shall be designed to minimize tipping of the platform due to movement of employees occupying the platform Chapter 4 Lifting Personnel The sling suspension system attaching the personnel lift platform to the hoist line shall not be used for any other purpose when not hoisting personnel Shackles used in any part of the suspension system shall be a safety type bolt type shackle with nut and cotter pin All eyes in wire rope slings shall be fabricated with thimbles Wire rope clips wedge sockets or knots shall not be used in suspension system sling assemblies Synthetic webbing natural or synthetic fiber rope shall not be used for the suspension systems Chain sling suspension systems shall use a minimum of grade 80 chain DOE STD 1090
44. 1 RIGGING HOOKS d ee e E ed Leste e e RUE EE eels ete rade e e o ERR eile nei eves 12 5 12 2 1 DES ota m e pr M E EE RE ERE Gai a deitas 12 5 AAA nS ies 12 5 12 23 AS OMS CUI E 12 5 1224 Ferien 12 5 IAS MB Eje eate 12 5 1226 TCS coco cR Ue iem iris pei pfe reor 12 6 DMA 12 6 12 2 8 Operation ice treten Fej Gk Tee su gece ses Panton stad sa cena coos SOC SR Seda Re denen 12 6 e E cm 12 7 JAM MECITCU c See 12 7 12 3 2 Effects of Environment erre AI 12 7 123 3 A rie E 12 7 12 34 Inspections asta airada ler 12 7 123 3 Removal Criteria ii dl 12 8 RE 12 8 12 37 Critical Lifts etti ida 12 8 E d ORIENT 12 11 12 4 T EE EE 12 11 12 4 2 Effects of Bnvronment ieaie ias 12 11 124 3 Traine tete iain died itas p e I ordo naves ates 12 11 124 4 Inspections D 12 11 12 4 35 Removal Criteria vocacion ici teg eret ies ee e pee ete v idad i ege un 12 12 12 4 6 REPIS italia 12 12 IZAT Critical Laits iere m e tte repete imt edat Sep Te cube ote eed red SR 12 12 EYE NUTS 5 irt tech te reti hte a 12 14 125 General sure ateisten en eege deed NEET E E gies 12 14 12 5 2 Effects of Environment iere tices les ettet etre te eene loe ar rhe EE 12 14 12 5 3 A rte iori terii on te TE 12 14 12 54 Inspections siete dee oe o
45. 1 Surface conditions where the forklift will be operated 2 Composition of loads to be carried and load stability 3 Load manipulation stacking and unstacking 4 Pedestrian traffic in areas where the forklift 5 Narrow aisles and other restricted places where the forklift will be operated 6 Hazardous classified locations where the forklift will be operated 7 Ramps and other sloped surfaces that could affect the forklift s stability 8 Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause a buildup of carbon monoxide or diesel exhaust 9 Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation Refresher training in relevant topics shall be provided to the operator when 1 The operator has been observed to operate the forklift truck in an unsafe manner 2 The operator has been involved in an accident or near miss incident 3 The operator has received an evaluation that reveals that the operator is not operating the forklift truck safely 4 The operator is assigned to drive a different type of forklift truck 5 Acondition in the workplace changes in a manner that could affect the safe operation of the forklift truck 15 23 QUALIFIED RIGGERS Qualified riggers shall meet the following requirements a Beat least 18 years of age b Understand spoken and written English c H
46. 14 3 8 ccu 14 13 14 3 9 Critical Li d 14 14 14 4 MAGNETS CLOSE PROXIMITY OPERATED eee 14 15 14 4 1 Design Fabrcation iiiter ere A 14 15 14 4 2 Markig 14 15 14 42 1 Rated Load Capacity ecce teprtertntreten 14 17 14 4 2 2 oin m ESS 14 17 14 4 3 Installation uenire tete reete epe tee E Sage 14 17 14 4 4 Inspections te ettet A Ie REED TENE HAE 14 17 14 4 4 1 Initial TIispection zie ettet t Hue 14 17 14 4 4 2 Frequent Inspeccion aa terae P eU 14 17 14 4 4 3 Periodic Inspection rette Dt nee RR 14 17 14 4 5 RK 14 18 14 4 5 1 Operational Test trente p Depp 14 18 14 4 5 2 Rated AA E 14 18 14 4 6 Maintenance cere HD Gn RISO DD i d 14 18 14 4 7 Troming Qualification 2 pe eI NP PER OPEP 14 19 14 4 8 Operation eoe EDI Ie d OR Uere x ata es 14 19 14 4 8 1 External Powered Electromagnets eee 14 20 14 4 8 2 Battery Operated Electromagnets oooonnnnonnnocnnonnnononanonanonnncnnncnncnno 14 20 14 4 8 3 Electrically Controlled Permanent Magnets sessse 14 20 14 4 8 4 Manually Controlled Permanent Magnets esses 14 20 14 4 9 Critical Lams ooo haeo rene ea 14 20 14 5 MAGNETS REMOTE OPERATED eere en eem eet enne rennen enne 14 21 14 5 1 D sign Fabri
47. 15 10 3 42 Fork Inspections ecce eret esee va enint Cert Peer xu erar 10 15 0 3 ACS FOr RepalE tee eco irse eens 10 16 MIS Battery Martel eu sacco AAA 10 16 103 6 History DING aout aep m kt Ed WWE ERAN 10 17 E MV CR EE 10 18 10 4 1 Forklift Truck Load Test ose epe ee dente aei etre riera 10 18 AD Fork Load Vest osea Sd e IE II ae Nate AA 10 18 10 4 3 Attachment Load Test reet eet cass ie eorr 10 18 10 5 OPERATION cite edt aaa Ded rob eae M P HU 10 19 10 5 D6o nduct oR Operator donee oreet e eoe reete Reese ee eae eei exe edes 10 19 IO SJL D General deos sects stets rote ete eire eise 10 19 10 5 1 2 Trayeling eoe e ree is 10 20 IA Dads casos xS de diea ORI DAS 10 21 10 32 Lifting or Personnel suite p mop uit S 10 22 10 5 3 Standard Hand Signals ret eet te nta eee eret tas 10 24 10 54 Ordinary LATIS oet restent ta 10 24 10 55 Critical BW Sonne eam enema eL aedi n Dre ree Pe reer re 10 24 10 5 6 Equipment et EE 10 24 Exhibit I Operations Pre Shift Inspection Form eese 10 29 Exhibit II Forklift Load Test and Inspection Form 10 31 CHAPTER 11 WIRE ROPE AND SLINGS 11 1 ILI GENERAD Lune e dete du essit at t sd dh 11 1 11 2 11 3 WIRE RRE deenen dedere vete vans poke t Ee Edad 11 4 IE2 I A Srt ve Ro A is beans 11 4 11 22 Wire Rope COSA 11 4 11 2 3 Wire Rope for General Purposes 5er eee im rre ire pea 11 4 11 2 5 1 6 x 19 Classification sonoro i GS rd ehe UR Rie 11
48. 154 0 169 0 2 7 04 166 0 182 0 2 8 10 193 0 210 0 2 8 91 208 0 226 0 2 10 00 235 0 260 0 2 11 00 253 0 280 0 2 12 10 280 0 305 0 2 13 30 301 0 328 0 Chapter 11 11 6 General DOE STD 1090 2007 FC 3 IWRC Figure 11 5 6 x 37 classification of wire rope Table 11 3 Breaking strength of wire rope 6 x 37 classification Breaking strength Breaking strength Rope Weight in tons of 2 000 Ib Rope Weight in tons of 2 000 Ib diameter Ib per diameter Ib per in ft Plow 2 oveg in ft Plow m oven steel ace steel pow steel steel Ya 0 10 2 2 2 5 Va 0 11 2 4 2 7 5 16 0 16 3 8 4 0 5 16 0 18 4 1 4 3 3 8 0 22 5 0 5 5 3 8 0 24 5 4 5 9 7 16 0 30 6 9 7 5 7 16 0 33 7 4 8 1 Ye 0 39 9 2 10 0 Ve 0 43 9 9 10 8 9 16 0 49 11 4 12 5 9 16 0 54 12 3 13 4 5 8 0 61 14 5 16 0 5 8 0 67 15 6 17 2 Ya 0 87 20 2 22 2 34 0 96 21 7 23 9 7 8 1 19 27 5 30 2 7 8 1 30 29 6 32 5 1 1 55 36 0 39 5 1 1 1 38 7 42 5 1 1 8 1 96 44 0 49 0 1 1 8 2 16 47 3 52 7 1 2 42 55 0 61 0 1 2 66 59 1 65 6 1 3 8 2 93 68 5 74 5 1 3 8 3 22 73 6 80 1 1 3 49 82 0 90 0 1 3 84 88 1 96 7 1 5 8 4 09 96 5 105 5 1 5 8 4 50 104 0 113 0 1 4 75 110 0 121 0 1 5 23 118 0 130 0 1 7 8 5 45 129 0 142 0 1 7 8 6 00 139 0 153 0 2 6 20 142 0 155 0 2 6 82 153 0 167 0 2 7 85 182 0 201 0 2 8 64 196 0 216 0 2 9 69 225 0 245 0 2 10 66 242 0 263 0 2 11 72 269 0 293 0 2 12 89 289 0 315 0 3 13 95 323 0 353 0 3 15 35 347 0 379 0 11 7 Chapter 11
49. 16 4 2 REPLACEMENT PARTS A preventive maintenance program based on the Replacement parts shall be at least equal to the manufacturer s recommendations shall be original manufacturer s specifications established Dated records shall be made available Chapter 16 16 8 Miscellaneous Lifting Devices DOE STD 1090 2007 16 5 OPERATIONS 16 5 1 CONDUCT OF OPERATOR the potential problem promptly to responsible management a Before operating the operator shall have demonstrated an understanding of the lifting 6 Ensure inspections are current and device s operating safety instructions and required markings are clearly labeled on the ability to safely operate the device the A frame and all hoisting components b The operator shall not 7 Always push the portable A frames not 1 Engage in any practice that will divert the load when movement of the A frame their attention while operating is required miscellaneous lifting devices 8 Ensure the load is not attached to the 2 Operate the lifting device beyond its floor or any other component prior to rated capacity except for rated load hoisting Remove all obstacles that tests impede lifting 3 Operate miscellaneous lifting devices 9 When moving a load keep it as close to when physically or mentally unfit the floor as possible Make sure that no part of the body is placed under the c The operator shall load at any time 1 Before moving the load lower the load 10 Not a
50. 2007 Safe Unsafe Reprinted from ASME B30 20 2006 by permission of The American Society of Mechanical Engineers All rights reserved Figure 14 5 Metal plate clamps 14 7 Chapter 14 Below the Hook Lifting Devices DOE STD 1090 2007 5 Instructions for not exceeding the rated capacity of the lifting device or the capacity of the hoisting equipment by the combined weight of the load the lifting device and the rigging Operators shall demonstrate the ability and competence to operate the lifting device as instructed before assuming responsibility for using it 14 2 9 OPERATION Only the following personnel shall operate structural and mechanical lifting devices 1 Qualified operators or riggers 2 Trainees under the direct supervision of a qualified operator 3 Maintenance and test personnel when it is necessary in the performance of their duties 4 Inspectors of lifting devices The following shall apply to all personnel who operate structural and mechanical lifting devices 1 Observe the condition of the lifting device before use and during operation If you observe a defect that affects the continued safe use of the lifting device remove it from service 2 Place any attached load on the floor or ground and after use properly store the lifting device before leaving 3 Before they are used on each shift test the lifting device controls If any controls do not operate properly adjust or re
51. 2007 4 5 INSPECTIONS All equipment used in the lifting of personnel shall be inspected tested and maintained to protect against failure during lifting operation 4 5 1 FREQUENT INSPECTION 4 5 1 4 General a The platform manufacturer shall furnish complete inspection criteria for the platform users The criteria shall address all inspection frequency classifications and shall cover 1 The platform 2 Rigging components 3 Fasteners 4 All safety features and attachments 4 5 1 2 Personnel Lift Platform a Prior to initial use and at each new job the platform shall be inspected by a qualified inspector in accordance with the instructions provided by the manufacturer b The platform suspension system attachment points and any motion controls shall be inspected at least each day before use by a designated person The inspection is to identify conditions that have been specifically indicated by the platform manufacturer or a qualified person as potentially creating a hazardous operating condition Visually inspect items such as the following 1 Platform and suspension system markings to ensure all information is legible 2 Platform structure i Load supporting members welds and bolts ii Perimeter protection top rail midrail toe board and barrier from toe board to midrail iii Fall protection device anchorage points iv Gate locking mechanisms v Platform flooring vi Suspension a
52. 2007 Table 11 9 Load capacity of wire rope slings Strand laid grommet hand tucked in pounds Design Factor 5 1 Dia in Basket or 60 45 30 Dia in inches Vertical Choker two legs degrees degrees degrees inches VA 1 840 1 320 3 600 3 200 2 600 1 840 Ya 3 8 4 000 3 000 8 000 7 000 5 800 4 000 3 8 Vp 7 000 5 200 14 000 12 200 10 000 7 000 Ve 5 8 10 800 8 000 22 000 18 800 15 200 10 800 5 8 34 15 200 11 400 30 000 26 000 22 000 15 200 3 4 7 8 20 000 15 200 40 000 34 000 28 000 20 000 7 8 Chapter 11 11 18 General DOE STD 1090 2007 Rated capacity IWRC in degrees and FC rope percent Over 120 100 90 120 60 89 74 30 59 62 0 29 N Percent of sling rated capacity in a choker hitch Point of Supporting structure Choke angle of 0 degrees Protection Angle of choke Angle of inclination Angle of inclination Reprinted from ASME B30 9 2006 by permission of The American Society of Mechanical Engineers All rights reserved Figure 11 10 Choker hitch rated capacity adjustment 11 19 Chapter 11 General DOE STD 1090 2007 11 3 2 1 Removal from Service Criteria a Wire rope slings shall be immediately removed from service if any of the following conditions are present 1 Missing or illegible sling identification 2 Broken wires i For strand laid and single part slings ten randomly distributed broken wires in on
53. 24 000 23 400 22 500 24 200 23 800 23 400 22 900 22 300 21 400 21 300 20 900 20 400 19 800 18 900 19 300 18 900 18 400 17 800 16 900 17 100 16 600 16 000 15 100 15 700 15 200 13 900 12 700 14 600 13 700 13 300 12 400 12 100 11 200 11 100 10 200 10 200 9 300 6 800 4 500 NOTES a Above ratings are maximum recommended working loads Loads between sold lines are computed at 75 of tipping load across treads with machine on firm level ground Loads outside solid lines are limited by strength of boom b For booms 80 ft and longer use cambered center section for booms 100 ft and longer use deep section inserts 9 3 Chapter 9 Mobile Cranes DOE STD 1090 2007 Over side Center of rotation front C rear outrigger outrigger Carrier on outriggers front Outrigger behind front wheels eugen Longitudinal t of carrier ay Center of rotation front outrigger outrigger Carrier on outrigger s front Outrigger behind front wheels Note These lines determine the limiting position of an load for operation within working areas indicated Reprinted from ASME B30 5 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 9 1 Sample work area chart 9 4 Chapter 9 Mobile Cranes DOE STD 1090 2007 Over side C rear wheel track Center of rotation rear axle bogie front a
54. 3 4 Operators of Truck Mounted Cranes Capacity 1 Ton or Less 6 8 6 3 5 Forklift Truck Operators iii 6 8 RNC MB RIG SERS M REL NE 6 10 E A Radon quadra dea a anre e oc Ne 6 10 6 3 8 InstEUCEOIS ninenin oe e deat des e dE ed Dod we 6 11 6 3 9 Maintenance Personnel erede c rre rero tes Se Erud eed s Ee 6 11 6 4 REQUALIFICATION dia 6 12 65 RECORDS unes obire no ie 6 13 CHAPTER 7 OVERHEAD AND GANTRY CHRANES 7 1 Tb GENERAR orte tr rapto noes botte piratis ees dud 7 1 7 1 1 Operator Fraiming Qualification te 7 1 EZ JRateu Eod Marking scree sae irn te cane te edet bia dive 7 1 Vi ONDIOUHBCHEOB e et eR e Op RS o SEE e 7 1 ME MES nM 7 1 CAES y AAA cela edo E t Ae 7 1 TEO ALOWEL SUMO rai utens ies Gide ns AS 7 1 TIT Hoist Limit Switch iae ttt d ro eee eae en 7 5 T5 Load rms soie unn E OHNE mu EE rr ene oer 7 5 TES Maintenance History deo ee cio prae pr bet e eed b Voss 7 5 7125 INSPECTIONS a td lite DE eae 7 6 REH WR A eoo oi itd pite bud i be te Le 7 6 Ju A i e od pb dO D OO 7 6 4 2 3 Initial MASP Cun rai t ap esae te viene eti i t boit DI pu rio 7 6 7 2 4 Daily Preoperational Checkout pete eene 7 6 7 2 5 Monthly Rope Chain and Hook Inspection s s s 7 6 7 2 6 Breguent Inspections E 7 7 1 2 1 Periodi A E EE 7 7 Died cl Rp ce abel La as Sie oe ER 7 7 Tir WIE ROPE hi iio A elie ordain vie abies 7 8 7 2 7 3 Chain Welded Link er erret en eda el reet 7 8 1 27 Chain Roller otis iit eek A ise 7 9
55. 4 Z Figure 1 4 Thimble TIERING The process of placing one load on or above another TINNED WIRE Wire coated with tin TROLLEY A unit consisting of frame trucks trolley drive and hoisting mechanism moving on the bridge rails in a direction at right angles to the crane runway TROLLEY GIRTS Structural members that are supported on the trolley trucks and that contain the upper sheave assemblies TROLLEY TRAVEL Horizontal travel of a trolley at right angles to runway rails TROLLEY TRUCK An assembly consisting of wheels bearings axles and structural supporting hoist mechanism and load girts TRUCK POWERED INDUSTRIAL A mobile power propelled truck used to carry push pull lift stack or tier material see Figure 10 3 TURNBUCKLE A device attached to wire rope for making limited adjustments in length It consists of a barrel and right and left hand threaded bolts TWO BLOCKING The act of continued hoisting in which the load block and head block assemblies are brought into physical contact thereby preventing further movement of the load block and creating shock loads to the rope and reeving system VERIFICATION A procedure in which a design calculation drawing procedure instruction report or document is checked and signed by one or more parties The one or more persons designated to sign verify based on personal observation certified records or direct reports that a specific action ha
56. 4 Monthly Inspection and 9 2 5 Frequent Inspection include the following 9 8 9 2 6 1 Cranes Inspect for a Deformed cracked or corroded members in the crane structure and entire boom Bolts rivets nuts and pins for being loose or absent Check for suspect counterfeit parts see Terminology and Definitions Chapter 1 Cracked or worn sheaves and drums Hooks damaged from chemicals deformation or cracks any visibly apparent bend or twist from the plane of the unbent hook or any distortion causing an increase in throat opening of 5 not to exceed L in unless otherwise recommended by the manufacturer Dye penetrant magnetic particle or other suitable crack detecting inspections should be performed at least once a year See Chapter 13 Load Hooks for additional hook requirements Worn cracked or distorted parts such as pins bearings shafts gears rollers and locking devices Excessive wear on brake and clutch system parts linings pawls and ratchets Load boom angle and other operating aids over their full ranges for any significant inaccuracies if calibration is required it shall be done by a qualified person Gasoline diesel electrical or other power plants for improper performance or noncompliance with safety requirements Radiators and oil coolers for leakage improper performance or blockage of air passages Excessive wear of chain drive sprocket
57. 4 16 CHAPTER 5 HOSTILE ENVIRONMENTS SC GENERAL dd till bagues 5 1 5 2 HOSTILE ENVIRONMENT PLAN eese nennen 5 2 5 2 1 Marking and Posting ee Eder Ee redu A ea E gs 5 2 5 2 2 Inspection and Testing ioco e teet olei teo erra PL Pe Ea RE PUR e EEHA 5 2 Exhibit I Hostile Environment Plan EE 5 3 CHAPTER 6 PERSONNEL QUALIFICATION AND TRAINING 6 1 GENERAL RD tado m tU wong wee 6 1 6 2 QUALIFICATIONS erugeet terti das 6 2 6234 Geferalt iita este La nb etum EE e 6 2 6 2 2 Operators of Cab Operated and Pulpit Operated 6 2 6 2 3 Operators of Mobile Cra eiecit t t ria En oe p ES 6 2 6 2 4 Operators of Truck Mounted Cranes Capacity 1 Ton or Less 6 4 6 2 5 Operators of Floor Operated Cranes eene 6 4 6 2 6 Operators of Forklift Trucks aeo A e tent esee eoi ree te PR EIS 6 4 6 2 7 Operators of Remote Operated Cranes sees 6 4 62 8 SPICE 6 4 6 2 9 gt PersonsInsCharge PIC aus Leone ed pe 6 4 6 2 10 Designated Leader oes S Dri i AN eta n e ERE 6 5 672 IE DE VE 6 5 5 212 TIS FU CEOIS Sena rette pure t b Paste ete utter utes 6 5 6 2 13 First Line Supervisors idee eed tae ed e eh eet ne ei eere 6 5 62 14 Maintenance Personel osuere cf 6 5 6 3 TRAINING uo 6 7 EN E cata bien dedo uuu eee rere ne ee 6 7 6 3 2 Cab Operated Pulpit Operated and Floor Operated Cranes 6 7 6 33 Mobile Crane Operators E a 6 8 6
58. 40 000 134 2 52 000 44 000 104 000 90 000 74 000 52 000 2 Wire Rope 6 x 19 and 6 x 37 IPS FC Notes 1 These values only apply when the D d ratio is 25 or greater choker and basket hitches D Diameter of curvature around which the body of the sling is bent d Diameter of rope 2 Choker hitch values apply only to choke angles greater than 120 degrees Chapter 11 General 11 14 Table 11 6 Load capacity of wire rope slings DOE STD 1090 2007 Mechanical splice IWRC in pounds Design Factor 5 1 Notes p 7 j Esset orton begs NS Basket or Dia in Vertical Choker two legs Dia in inches inches Ya 1 100 840 2 200 1 940 1 580 1 100 Ya 5 16 1 700 1 300 3 400 3 000 2 400 1 700 5 16 3 8 2 400 1 860 4 800 4 200 3 600 2 400 3 8 7 16 3 400 2 500 3 800 5 800 4 800 3 400 7 16 Vo 4 400 3 200 8 800 7 600 6 200 4 400 Ve 9 16 5 500 4 200 11 000 9 600 7 700 5 500 9 16 5 8 6 800 5 000 13 600 11 800 9 600 6 800 5 8 34 9 700 7 200 19 400 16 800 13 600 9 700 34 7 8 13 000 9 800 26 000 22 000 18 300 13 000 7 8 1 17 000 12 800 34 000 30 000 24 000 17 000 1 1 1 8 20 000 15 600 40 000 36 000 30 000 20 000 1 1 8 1 25 000 18 400 50 000 42 000 34 000 25 000 1 1 3 8 30 000 24 000 60 000 52 000 42 000 30 000 1 3 8 1 36 000 28 000 72 000 64 000 50 000 32 000 1 Ye 1 5 8 42 000 32 000 84 000 70 000 58 000 42 000 1 5 8 1 34 50 000 38
59. 5 4 QUALIFIED RIGGER A qualified rigger shall inspect the rigging prior to each shift 15 5 5 LIFTING PERSONNEL The headache ball hook or load shall not be used to transport personnel except as provided in Chapter 4 Lifting Personnel 15 5 6 SAFETY LATCHES Safety latches on hooks shall not be deactivated or made inoperable except when a qualified rigger has determined that the hoisting and placing of purlins and single joists can be performed more safely by doing so or when equivalent protection is provided in a site specific erection plan 15 5 7 WORKING UNDER LOADS a Routes for suspended loads shall be pre planned to ensure that no employee is required to work directly below a suspended load except for 1 Employees engaged in the initial connection of the steel or 2 Employees necessary for the hooking or unhooking of the load b When working under suspended loads the following criteria shall be met 1 Materials being hoisted shall be rigged to prevent unintentional displacement 2 Hooks with self closing safety latches or their equivalent shall be used to prevent components from slipping out of the hook and 3 All loads shall be rigged by a qualified rigger 15 5 8 MULTIPLE LOAD LIFTS a A multiple load lift shall only be performed if the following criteria are met 15 9 1 A multiple lift rigging assembly is used 2 A maximum of five load members are hoisted per lift 3 Only
60. 7 Synthetic web strap for abrasive wear knots cuts or tears broken stitching acid or caustic burns melting or charring or weld splatter 8 Hook latch if used for proper operation Operators or other designated personnel shall examine deficiencies and determine whether they constitute a safety hazard 8 2 4 FREQUENT INSPECTION Operators or other designated personnel shall visually inspect the hoist at the following intervals records are not required 1 Normal service monthly 2 Heavy service weekly to monthly 3 Severe service daily to weekly In addition to the requirements listed above in Daily Inspection these inspections shall include the following 1 Hoist braking system for proper operation 2 Hoist rope or chain reeving for compliance with hoist manufacturer s recommendations 3 Lever for bends cracks and the like 4 Observations during operation Examine deficiencies and determine whether a more detailed inspection is required 8 2 5 DOE STD 1090 2007 PERIODIC INSPECTION A qualified inspector shall perform a complete inspection at the following intervals 1 Normal service yearly 2 Heavy service semiannually 3 Severe service quarterly The qualified inspector shall examine deficiencies and determine whether they constitute a safety hazard and whether disassembly is required Dated and signed inspection records shall be kept on file and shall
61. 7 2 9 Cranes Notin R g lar Service xac eR et oo netta RES 7 11 43 NC HN IT 7 12 1 3 1 Operational Tests meer ette eer eere ide ee Ee er ese Rueda 7 12 7 3 2 Rated Load Test EE 7 12 74 MAINTENANCE iios terree e a Meee 7 14 To Operatino Bquiptnelil s ies et aero 7 14 15 2 Wire Rope Maintenance uos node te De ang ea Rae ee 7 14 45 OPERATION o andar ets os qu GM eite apio Were TES 7 15 7 5 1 Conduct of Operator uta ec DI RS cides 7 15 7 5 2 Hoist Limit Switch Devices onem ene desi de iR ees 7 15 7 3 3 Standard Hand Sing E 7 16 7 5 4 Identification of Sinaloa ins 7 16 LADA ZE Of EDAD s elem O ME UR THEE 7 16 7 5 6 Attaching the Load peo resp Tee ee 7 16 Dedede Moyne the Load soin erepto e od eate ced MEE MEE 7 16 E MES IDEE siria alas 7 18 7 5 9 Planned Engineered Lats as 7 18 PES TOP Dilical E eaea aeren My IMS E anene p IDEAE 7 19 Exhibit I Bridge Wall Gantry Crane Load Test esses 7 22 Exhibit II Overhead Crane Pre Operational Checklist 7 26 Exhibit III Overhead Crane Periodic Inspection Report Mechanical 7 28 Exhibit IV Overhead Crane Periodic Inspection Report Electrical 7 30 CHAPTER 8 Lei KE 8 1 8 1 GENERAT EE 8 1 8 1 1 Operator Training Qualification ooooccnnncccnoncccnoncncnnoncnonnnccnnnncnonnnanonnnoo 8 4 8 1 2 MA ITI LED eee cure pues IL I L T 8 4 5 L3 Marne aleeden 8 4 8 2 8 3 8
62. 8 2 FASTENERS WITH THE FOLLOWING HEADMARKS MARK MANUFACTURER KS Kosaka Kogyo JP GRADE A325 FASTENERS BENNETT DENVER TARGET ONLY WITH THE FOLLOWING HEADMARKS d MARK MANUFACTURER Type 1 a nass Kosaka Kogyo JP O Type 3 22 O AUGUST 1992 KEY CA CANADA JP JAPAN TW TAIWAN YU YUGOSLAVIA GF00 0202 Figure 1 5 1 12 Terminology and Definitions DOE STD 1090 2007 CHAPTER 2 CRITICAL LIFTS This chapter provides guidelines for critical lift determination and requirements for planning and performing a critical lift safely and judiciously 2 1 CRITICAL LIFT DETERMINATION eee 2 1 2 2 CRITICAL LIFT REQUIREMENTS eere 2 2 2 i Chapter 2 Critical Lifts DOE STD 1090 2007 INTENTIONALLY BLANK Chapter 2 2 ii Critical Lifts DOE STD 1090 2007 2 1 CRITICAL LIFT DETERMINATION An appointed person shall classify each lift into one of the DOE categories ordinary critical or preengineered production prior to planning the lift A lift shall be designated critical if any of the following conditions are met 1 The load item if damaged or upset would result in a release into the environment of radioactive or hazardous material exceeding the established permissible environmental limits 2 The load item is unique and if damaged would be irreplaceable or not repairable and is vital to a system facility or project operation 3 The cost to replace or repair th
63. 9 Mobile Cranes DOE STD 1090 2007 THIS AREA SHOULD BE AVOIDED j PROHIBITED ZONE SEE TABLE 9 3 Boom shall not be positioned beyond this point d d i CRANE SHALL NOT BE USED TO HANDLE MATERIALS IN THIS AREA Reprinted from ASME B30 5 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 9 3 Danger zone for cranes and lifted loads Operating near electrical transmission line 9 21 Chapter 9 Mobile Cranes DOE STD 1090 2007 9 5 2 3 Crane Operations are Within the Prohibited Zone and the Power Lines are Energized Before such operations take place a qualified person together with a qualified representative of the utility or an engineer qualified in power line transmission shall after visiting the site determine if this is the most feasible way to complete the operation and set minimum required clearances and procedures for safe operations These operations shall be under their supervision The following guidelines should be required 1 Crane load grounded to a neutral line by the utility 2 Electrical system protective devices that automatically re energize the circuit after a power line contact occurrence should be blocked or disengaged to inhibit this function 3 Insulated barriers which are not a part of nor an attachment to the crane and which will not allow contact between the energized electric power lines and the crane load li
64. B30 20 2006 by permission of The American Society of Mechanical Engineers All rights reserved Figure 14 7 Close proximity operated magnetic lifting devices Chapter 14 14 16 Below the Hook Lifting Devices DOE STD 1090 2007 14 4 2 1 Rated Load Capacity a General application magnets shall include the rated load capacity of the magnet on the lifting magnet or on a tag attached to it This capacity rating shall refer to the instruction manual for information relating to decreases in rating due to the load surface condition thickness percentage of contact with magnet temperature metallurgical composition and deflection b Specified application magnets shall include the application load capacity of the magnet on the lifting magnet or on a tag attached to it This capacity rating shall refer to the specific loads for which it applies 14 4 2 2 Controls The position of the control switch or handle of a lifting magnet shall be marked with Lift Off and Drop or equivalent terms indicating the mode of operation of the lifting magnet 14 4 3 INSTALLATION a Close proximity operated magnetic lifting devices shall be installed according to the manufacturer s recommendations b Users shall ensure that External power input is the correct voltage and amperage 2 Power conductors and controls are of adequate rating and are insulated or otherwise protected against accidental interruption or damage 1
65. DATE Page of 4 HOUR METER ODOMETER TOTAL RATED CAPACITY LOAD TEST INSPECTION REPORT The following checklist identifies the items to be inspected prior to the load test Any unusual conditions observed during the inspection should be noted in the Remarks section Equipment shall be inspected by maintenance personnel prior to load test NOTES 1 Qualified inspector shall verify the inspection is completed 2 Craftsmen shall initial and date all tests work and inspections completed below NO CRANE ITEM DEFECT OK NA NO CRANE ITEM DEFECT OK NA 1 Wire Rope 13 Hoist Clutch Lining 2 Cracked or Worn 14 Hoist Drum Brake Sheaves amp Drums Bands 3 Limit Switch Anti 15 Open Gears Two Blocking 4 Boom 16 Boom Jibs Where Applicable 5 Master Clutch NO CARRIER ITEM DEFECT OK NA 6 Steering Clutches 1 Steering Gears and Connections 7 Hydraulic Pump 2 Brakes Service and Hand 8 Hydraulic Controls 3 Tires and Wheels 9 Hydraulic Hoses 4 General Lubrication 10 Mechanical Controls OPERATING TEST 11 Drive Chains OVERALL CONDITION 12 Swing Clutches REMARKS Unusual conditions noises structural cracks misalignment etc SAFETY ITEMS Fire extinguisher signs guards etc 9 33 Chapter 9 Mobile Cranes NOTES i DOE STD 1090 2007 Page 2 of 4 EXHIBIT I continued SAMPLE FORM MOBILE CRANE LOAD TEST AND FOLLO
66. General DOE STD 1090 2007 k Other conditions including visible damage 11 3 6 2 that may cause doubt as to the continued use of the sling Proof Testing a When specified by the purchaser synthetic round slings of all types shall be certified as having been proof tested prior to initial use 1 For single or multiple leg slings and endless slings each leg shall be proof loaded to 2 times the single leg vertical hitch rated load 2 The proof load for fittings attached to single legs shall be a minimum of 2 times the single leg vertical hitch rated load 3 Master links for two leg bridle slings shall be proof loaded to a minimum of 4 times the single leg vertical hitch rated load 4 Master links for three leg bridle slings shall be proof loaded to a minimum of 6 times the single leg vertical hitch rated load 5 Master links for four leg bridle slings shall be proof loaded to a minimum of 8 times the single leg vertical hitch rated load b Test loads shall be accurate to within 5 percent 0 percent of stipulated values Either certification by the manufacturer or a pull test certified by a qualified person is acceptable 11 3 6 3 X Operation The following shall apply to all personnel who use roundslings a Determine the weight and center of gravity of the load b Selecta sling having suitable characteristics for the type of lad hitch and environment Chapter 11 General 11 42 En
67. It may be fiber a wire strand or an independent wire rope CORING LINE Wire rope used to operate the coring tool for taking core samples during the drilling of a well CORROSION Chemical decomposition by exposure to moisture acids alkalis or other destructive agents CORRUGATED A term used to describe the grooves of a sheave or drum when worn so as to show the impression of a wire rope COUNTERBALANCED TRUCK A truck equipped with load engaging means wherein during normal transporting all the load is external to the polygon formed by the wheel contacts see Figure 10 3 COVER WIRES The outer layer of wires 1 3 CRANE A machine used for lifting and lowering a load vertically and moving it horizontally and that has a hoisting mechanism as an integral part of it CRANES TYPES OF Automatic Crane A crane that when activated operates through a preset cycle or cycles Cab Operated Crane A crane controlled by an operator in a cab located on the bridge or trolley Cantilever Gantry Crane A gantry or semigantry crane in which the bridge girders or trusses extend transversely beyond the crane runway on one or both sides Floor Operated Crane A crane whose operation is controlled by use of a pendant in the hands of an operator on the floor or on an independent platform Gantry Crane A crane similar to an overhead crane except that the bridge for carrying the trolley or trolleys is rigidly supported o
68. Nameplates and Marckuugs esses een eem een enne nennen 10 1 10 1 3 1 Fork Arm Data ute ee eee pete ipee tet 10 1 10 14 Attachments insta ee hee eee oe heec HERE Reihe dabas 10 1 10 15 Modification et a E ien bee ie pce HE Reo cia 10 2 Ltr Warning Devices noto hee EE RE D HER HERE Ree reden 10 2 10 177 Overhead Guards zo Renier ec HE Rhe Nee 10 2 10 1 8 Fire H zards pco reed a 10 2 10 19 Work Atmosphere ee Rae ee re he Hec epe Ae 10 2 10 2 TYPE DESIGNATION AND AREAS OF USE eee nene eene 10 11 10 2 1 Type D signation etre ehe Ren cete he pee eem hee edid 10 11 10 2 1 1 Non Hazardous Areas eniin ae E cono cn rene eene erem rennen 10 11 10 2 1 2 Hazardous ATA enigma iti bet ee tue 10 11 10 2 2 Specific Areas of Use cei e b tbt d E eed deo the E ea 10 12 10 3 INSPECTIONS eenegen ttd e b Eeer 10 15 10 3 1 Daily Pre Operational Check 10 15 10 3 2 Initial Inspection of New and Rented Equipment eee 10 15 10 3 3 Inspection and Maintenance cconoccnnnconnnoncnnnonanonnncnnocononono nono nnnonn conan canon n rra nennen 10 15 10 34 FOrkS 1e eee ede ia in 10 16 10 3 4 1 Fork Load Ratings deed eie aiaa 10 16 10 3 4 2 Fork Inspections ned eae ied eo deed eere viov 10 16 10 3 4 3 Fork Repair ied eed died ed eite 10 17 10 3 5 Battery Mainten nce esie betta d Ete eic eie tbe eh dus 10 17 10 3 6 History Eie outils tbe e uper en 10 18 10 4 TESTINO ite et eR deno m t me tet
69. REPASA eG T AT A E CUR 12 17 eher E CC E a 12 17 LINKS RINGS AND SWIVELS s0 cccssssssecssssetscsssssctecseenetscevesee 12 19 General ovt nA TM ML ME Et 12 19 Operabine Ee e 12 19 Effects of Environment even ee e 12 19 Traning EE 12 19 ue ee 12 19 Removal Criteria eclectic secs Ee A 12 20 FRG PANES ps nies iato et Ep e HO ae e E e rater qoa a E Ee tin 12 20 Critical Lifts is aite cda am etnies 12 20 SWIVEL HOIST RINGS oreste oo data 12 21 Gnral RIT At e e 12 21 EN e EE Lu ET EE 12 21 Tran E p 12 21 INS POCOS E 12 21 Remove EE 12 22 Repairs e EN 12 22 Critical EAfts eC Re 12 22 LOAD INDICATING DEVICES eere 12 25 General ote A A IRR RE NW Bes 12 25 Critical Lafts zii nie A Soa Sa e i s 12 25 PRECISION LOAD POSITIONERS 7 eee 12 26 General egenen A aene 12 26 Critical Mea TiS tte et ODER ERO es ST 12 26 COMPRESSION HARDWARE eere nnne 12 27 Geilerdl 3 3 d acess ederet dis 12 27 Assembly Wire Rope Cipsa 12 27 Assembly Wedge SOCK CUS ade tet eso leo dive pdt Seege 12 27 Effects of Environment 12 28 ben I 12 28 et te 12 28 Removal Criteria 4s e er e eet tots etii e ren tee 12 28 hong M 12 29 Critical Difesa ceto itecto lo e Math eee aaa 12 29 CHAPTER 13 LOAD HOOKS nre eser ene eh oi ao aan 13 1 DA G
70. Removal from Service Criteria sortida 11 36 11 392 Proof Testa Sess hear ode cps Se oie de eate Goes 11 36 11 3 5 3 Opera OA Li iei toco wr eto ple Pt d edt E le oaks 11 40 11 3 5 4 Cortical LATS oo ios ofi nho P fee UP Eee mre PREDA En 11 40 11 3 6 Synthetic Roundslings vertido drid 11 41 11 3 6 1 Removal from Service Criteria Jua erre eres 11 41 T 3 52 Eeer 11 42 11 3 6 3 Operation iioi e endet tnter ree erede 11 42 11304 Critical TEINS soeben S Og eeu eer Pedo POR Te edd 11 43 CHAPTER 12 RIGGING ACCESSORIES sss 12 1 12 1 12 1 1 12 2 12 2 1 12 2 2 12 2 3 12 2 4 12 2 5 12 2 6 12 2 7 12 2 8 12 3 12 3 1 12 3 2 12 3 3 12 3 4 12 3 5 12 3 6 12 3 7 12 4 12 4 1 12 4 2 12 4 3 12 4 4 12 4 5 12 4 6 12 4 7 12 5 12 5 1 12 5 2 12 5 3 12 5 4 12 5 5 12 5 6 12 5 7 12 6 12 6 1 GENERAL sca has a ri AEAT 12 1 Good and Bad Rigging Practices dee tee e gone aches psi e ea aces 12 1 RIGGING HOONRNS esten bow rad o DTE Erg 12 5 ID a a ceda 12 5 KE S ao Re deis wale eee es eats be n tutt ee ni edd i i UA 12 5 CONSTITUCION vai AAA A e EE Pe D ea e T ERES 12 5 Eoad Limits nett teet eet re SE ha 12 5 O SS HE ria 12 5 Testing 12 6 E OT 12 6 A as apc sansa aca X H H 12 6 SHACKDBES penat Odd ba etai pe de 12 7 Generale ce nee e Rie EO e OR 12 7 Effects ot Bnyironment z i e ht eelen 12 7 bci m 12 7 IS PECHONS oom
71. Repaired N A Not Applicable PERIODIC CODE COMMENT Check Bolt Torque e Transmission Mount e Turntable e Engine Mount e Gearbox Mount e Axle Mount Engine RPM Muffler Connections Wiring harness Battery Cable Battery Water Level Master Cylinders Pump Drive Gearbox Swing Gearbox Axle Lockout Axle Differential Axle Planetary Oil Boom Sheaves Boom Alignment Jib Alignment Machine Structure Drum Wire Rope Dirt Lube Kinks 9 43 Chapter 9 Mobile Cranes DOE STD 1090 2007 EXHIBIT IV continued SAMPLE FORM Page 2 of 3 MOBILE CRANE PERIODIC INSPECTION REPORT PERIODIC CODE COMMENT Clean Change e Differential Breather e Fuel Filter Screen e Compressor Strainer e Transmission Filter Drum Wire Rope Dirt Lube Size Kink Hook amp Latch Block amp Sheave Guards in Position Emergency Stop Welds amp Cracks e Hoists e Boom e Sheaves e Hook e Block e Motor e Valves e Cylinders Lamps e Turn Signals e Headlamps e Flashers e Cab e Boom 9 44 Chapter 9 Mobile Cranes DOE STD 1090 2007 EXHIBIT IV continued SAMPLE FORM Page 3 of 3 MOBILE CRANE PERIODIC INSPECTION REPORT PERIODIC CODE COMMENT e
72. TESTING POE 16 7 16 3 1 Operational Fest c recep rr tnr Ha tr toe npe EE 16 7 16 3 2 Rated Load Dest rr ree ltr te Pire ph de ir Code rte tasca 16 7 MAINTENANCE d rrr tm DEP ER tr ele dns 16 8 OPERATION cirios a rediere 16 9 16 5 1 Conduct of Operator cnica ENFRENTE ERE NOE RD REIS 16 9 16 i DOE STD 1090 2007 INTENTIONALLY BLANK 16 ii DOE STD 1090 2007 16 1 GENERAL This chapter provides requirements for the operation inspection testing and maintenance of miscellaneous lifting devices including portable A frames sometimes referred to as portable gantries Truck mounted cranes with a capacity of ton or less not covered in ASME B30 5 Mobile and Locomotive Cranes and self contained shop cranes as addressed by ASME PALD Portable Automotive Lifting Devices 16 1 1 OPERATOR TRAINING QUALIFICATION P Operators of self contained shop cranes and portable A frames shall be familiar with understand and follow the operating instructions provided by the equipment manufacturer cT Operators of truck mounted cranes with capacities of 1 ton or less shall be trained as required in Chapter 6 Personnel Qualifications and Training 16 1 2 RATED LOAD MARKINGS SAFETY MARKINGS AND OPERATING INSTRUCTIONS P Safety markings shall be legible and conform to the ANSI Z535 cT Markings or decals etc must be provided and affixed by the use of durable materials in a location visible to the
73. Use rope having an independent wire rope wire strand core or other temperature damage resistant core if the rope will be exposed to ambient temperatures greater than 180 degrees F 82 degrees C g The rope ends should be attached to the hoist in a manner to prevent disengagement throughout rated hook travel No less than two wraps of rope shall remain on the anchorage of the hoist load sprocket drum when the hook is in its fully extended position unless a lower limit device is provided in which case one wrap shall remain on each anchorage of the drum hoist 8 1 8 LOAD CHAIN 8 1 8 1 Electric Powered Air Powered and Manual Lever Operated Hoists a Load chain may be either roller or welded link type see Figure 8 9 Chain shall be pitched calibrated so as to pass over all load sprockets without binding Welded Link Type Reprinted from ASME B30 21 2005 by permission of The American Society of Mechanical Engineers All rights reserved Roller Type Figure 8 9 Load Chain b Theload chain shall be proof tested by the chain or hoist manufacturer with a load at least equivalent to 1 5 times the hoist s rated DOE STD 1090 2007 load divided by the number of chain parts supporting the load If a load is supported by more than one part of load chain the tension on the parts shall be equalized 8 1 8 2 Hand Chain Operated Hoists a The hand chain shall be of a shape and pitch to fit the hand chain whee
74. above in Section 8 2 4 Frequent Inspection A hoist that is not in regular service idle for a period of 1 year or more shall be 8 13 inspected before being placed in service according to the requirements listed above in Section 8 2 5 Periodic Inspection The determination supporting these alternate inspection frequencies and procedures shall be made by a qualified person for each affected hoist Documentation supporting this determination shall be kept readily available Chapter 8 Hoists DOE STD 1090 2007 8 3 TESTING 8 8 4 OPERATIONAL TESTS All new hoists shall be tested by the hoist manufacturer All modified or repaired hoists or hoists that have not been used within the preceding 12 months shall be tested before being placed in service All tests shall be done by a qualified inspector or under the direction of that inspector as detailed in the following paragraphs 8 3 1 1 Electric or Air Powered Hoists a Check lifting and lowering testing through complete rated lift length is not required b Check operation of brakes c Determine the trip setting of limit devices by tests under no load conditions Conduct tests first by hand if practical and then under slowest speed obtainable Test with increasing speeds up to maximum speed 8 3 1 2 Hand Chain Operated Hoists a Check all functions of the hoist including lifting and lowering with the hoist suspended in an unloaded state b Af
75. all new repaired or modified cranes prior to initial use Load test crane at 125 of rated capacity In no case shall the load test exceed 125 of rated capacity Test weights shall be accurate to 5 0 of stipulated values Set crane up for load test and qualified inspector verify inspection is complete prior to load test The trip setting of hoist limit devices shall be determined by tests with an empty hook traveling at increasing speeds up to the maximum speed The actuating mechanism of the limit device shall be located so that it will trip the device under all conditions and in sufficient time to prevent contact of the hook or load block with any part of the trolley or crane Rig test weight to hoist hook using appropriate slings Hoist the test load a sufficient distance to ensure that the load is supported by the crane and held by the hoist brakes Transport the test load by means of the trolley for the full length of the bridge Ensure during operation that the trolley runs true on the bridge Check trolley motor brake and gear case for overheating Transport the test load by means of the bridge for the full length of the runway first in one direction with the trolley as close to the extreme right hand end of the crane as practical and next in the other direction with the trolley as close to the extreme left hand end of the crane as practical Ensure that the bridge runs true on the runway rails and that no undue girder defle
76. apply only to choke angles greater than 120 degrees 11 39 Chapter 11 General DOE STD 1090 2007 11 3 5 3 Operation The following shall apply to all personnel who use synthetic web slings a Determine the weight of the load and center of gravity Select a sling having suitable characteristics for the type of load hitch and environment Ensure that slings with end fittings that are used in a choker hitch have sufficient length to that the choking action is on the body of the sling In slings used in a basket hitch balance the load to prevent slippage Do not drag slings across the floor or over any abrasive surface Do not twist or tie slings into knots Protect slings from being cut by sharp corners sharp edges and highly abrasive surfaces Do not pull slings from under loads when a load is resting on a sling Do not use synthetic web slings to lift loads in excess of the rated capacity Properly derate for other than straight pull configuration Store synthetic web slings to prevent mechanical or chemical damage Do not use nylon slings where acid conditions exist Do not use polyester and polypropylene slings where caustic conditions exist Nylon and polyester slings shall not be used on contact with objects or at temperatures in excess of 194 degree F 90 degree C or below 40 degree F 40 degree C Polypropylene slings shall not be used in contact with objects or at temperature
77. be clear of the load c Do not wrap the hoist rope or chain around the load d Attach the load to the hook using slings or other approved devices e Do not use chain or wire rope as a ground for welding f Do not touch a welding electrode to the chain wire rope or any other part of the hoist or monorail system g Operate hand chain operated hoists with hand power only and with no more than one operator per hand chain h Do not use a lever extension cheater on manual lever operated hoists i Properly seat the slings or other approved devices in the saddle of the hook before carrying out hoisting operations 8 5 4 MOVING THE LOAD a Take care in hoisting to be certain that 1 Hoist ropes or chains are not kinked or twisted 2 The load does not contact any obstructions 3 Multiple part ropes or chains are not twisted around each other Chapter 8 Hoists DOE STD 1090 2007 b Before starting to hoist ensure that the rope or chain is properly seated on the drum sheaves or sprockets c Before starting the hoist be certain that all personnel are clear of the equipment d Do not operate hoists until the hook is positioned above the center of gravity of the load except when specifically authorized by an appointed person who has determined that the components of the hoist and its mounting will not be overstressed e Do not move or lift a load more than a few inches until it is well
78. beams and similar structural members are lifted and 4 Allemployees engaged in the multiple load lifts shall be trained in the following areas i The nature of the hazards associated with multiple lifts ii The proper procedures and equipment to perform multiple lifts as required in this section 5 No crane is permitted to be used for a multiple load lift where such use is contrary to the manufacturer s specifications and limitations Components of the multiple lift rigging assembly shall be specifically designed and assembled with a maximum capacity for total assembly and for each individual attachment point This capacity certified by the manufacturer or a qualified rigger shall be based on the manufacturer s specifications with a 5 to 1 safety factor for all components The total load shall not exceed 1 The rated capacity of the hoisting equipment specified in the hoisting equipment load charts 2 The rigging capacity specified in the rigging rating chart The multiple lift rigging assembly shall be rigged with members 1 Attached at their center of gravity and maintained reasonably level 2 Rigged from top down and 3 Rigged at least 7 feet 2 1 m apart Chapter 15 Construction Hoisting and Rigging Equipment Requirements DOE STD 1090 2007 4 The members on the multiple lift rigging assembly shall be set from the bottom up 5 Controlled load lowering shall be used whenever the load is
79. block two block warning and two block damage prevention systems for proper operation 7 Booms for damage or deformation of structural components b Operators or other designated personnel shall examine deficiencies and determine whether they constitute a safety hazard 9 2 4 MONTHLY INSPECTION a The operator or other designated person shall visually inspect the following items for damage wear or other deficiency that might reduce capacity or adversely affect the safety of the crane 1 Critical items such as brakes and crane hooks 2 Hoist ropes b Lower the hook block to its lowest position and examine for any condition that could result in an appreciable loss of strength c Hooks for cracks deformation damage from chemicals latch engagement if provided and evidence of heat damage See Chapter 13 Load Hooks for additional hook requirements d A hoist rope with any of the conditions noted in the replacement criteria in Section 9 2 6 shall be removed from service and replaced e Signed and dated inspection records shall be kept on file and shall be readily available F Before the crane is returned to service correct deficiencies that could reduce its capacity or adversely affect its safety 9 2 5 FREQUENT INSPECTION a Operators or other designated personnel shall visually inspect the crane at daily to monthly intervals records are not required b These inspections shall in addit
80. bridle sling When legs are not of equal length use smallest H L ratio NOTE Load may be carried by only 2 legs while other 2 legs balance it Therefore the required SWL is determined by the following Total Rated Capacity WLL of single vertical hitch x H L x 2 Figure 11 9 Determination of capacity 4 leg bridle sling Chapter 11 11 12 General Table 11 4 Load capacity of wire rope slings DOE STD 1090 2007 Hand tuck splice IWRC in pounds Design Factor 5 1 Q V E i i A i 4 H j A Nea Basket or Dia in Vertical Choker two legs Dia in inches inches Ya 1 100 820 2 200 1 800 1 500 1 100 Ya 5 16 1 600 1 280 3 200 2 800 2 200 1 600 5 16 3 8 2 400 1 840 4 800 4 000 3 200 2 400 3 8 7 16 3 000 2 400 6 000 5 400 4 400 3 000 7 16 Ve 4 000 3 200 8 000 6 800 5 600 4 000 Vo 9 16 5 000 4 000 10 000 8 600 7 000 5 000 9 16 5 8 6 000 5 000 12 000 10 400 8 400 6 000 5 8 34 8 400 7 200 16 800 14 600 11 800 8 400 34 7 8 11 000 9 600 22 000 19 200 15 600 11 000 7 8 1 14 000 12 600 28 000 24 000 20 000 14 000 1 1 1 8 18 000 15 800 36 000 32 000 26 000 18 000 1 1 8 1 22 000 19 400 44 000 36 000 30 000 22 000 1 1 3 8 26 000 24 000 52 000 44 000 36 000 26 000 1 3 8 1 32 000 28 000 64 000 52 000 42 000 32 000 1 1 5 8 36 000 32 000 72 000 62 000 50 000 36 000 1 5 8 1 3 4 42 000 38 000 84 000 70 000 5
81. by permission of The American Society of Mechanical Engineers All rights reserved 8 3 Chapter 8 Hoists DOE STD 1090 2007 8 1 1 OPERATOR TRAINING QUALIFICATION Hoist operators shall be trained and qualified according to requirements found in Chapter 6 Personnel Qualification and Training 8 1 2 MARKING a The rated capacity shall be permanently marked on the hoist or load block b Electric powered hoists shall be marked with 1 Name of manufacturer 2 Manufacturer s model or serial number 3 Voltage of AC or DC power supply and phase frequency of AC power supply 4 Circuit ampacity c Air powered hoists shall be marked with 1 Name of manufacturer 2 Manufacturer s model or serial number 3 Rated air pressure d Hand chain operated hoists shall be marked with 1 Name of manufacturer 2 Manufacturer s model or serial number e Manual lever operated hoists shall be marked with 1 Name of manufacturer 2 Manufacturer s model or serial number 8 1 3 WARNING LABELS Documented evidence of equivalent training of the user of the hoist demonstrating that the information on the warning labels has been conveyed and understood by the user will waive the requirement to maintain warning labels Chapter 8 Hoists 8 4 8 1 3 1 Electric or Air Powered Hoists a Labels shall be affixed to the hoist load block or controls that display the word WARNING or other legend designed to bring the
82. by the standard practice for the industry where the crane is employed and this test shall be confirmed by a recognized laboratory service 12 Operator physical examinations shall be required every three years or more frequently if supervision deems it necessary Prior to allowing mobile crane operations at DOE installations the construction manager shall implement a program or ensure that the construction contractor has an acceptable program to evaluate crane operator qualifications This program shall include written testing to evaluate operator knowledge and performance hands on testing to evaluate operator skills These tests shall include but not be limited to applicable elements of the following Pre use crane inspection 2 The crane s specifications operator s manual charts e g load charts work area charts instrumentation controls operator aids and operating characteristics 3 Operating procedures under emergency conditions 4 Set up shut down and parking of the crane 5 Crane attachments e g jibs boom extensions heavy lift equipment 6 Configurations and loading effects on the crane 7 Standards rules and regulations e g hand signals distances for working around electrical power lines DOE STD 1090 2007 8 Rigging practices 9 Personnel lifting procedures NOTE The means of determining operator qualifications shall be included in the contract documents Contra
83. by the load Rope clip nuts should be retightened periodically to compensate for any further decrease in rope diameter during usage 28 Ata minimum wire rope slings shall be marked with the following information 1 Name of trademark of manufacturer Chapter 11 General 11 22 29 30 31 32 33 ii Rated capacity for the type of hitch es 111 Diameter or size Sling identification shall be maintained by the user so as to be legible during the life of the sling Slings made of rope with 6 x 19 and 6 x 37 construction and cable laid slings shall have a minimum clear length of rope 10 times the rope diameter between splices sleeves or end fittings Braided slings shall have a minimum clear length of rope 40 times the component individual rope diameter between the loops or end fittings Grommets and endless slings shall have a minimum circumferential length of 96 times the body diameter of the grommet or endless sling Other configurations may be used provided a qualified engineer provides a documented evaluation including a destructive pull test in the configuration to be used as well as use limitations Minimum design factor of 5 1 shall be maintained DOE STD 1090 2007 Efficiencies of wire rope fittings or fastenings in percentages of strength of rope Open type Closed type Clips number of clips varies with size of rope EC gum AREA NA 75 80 Wire rope socket
84. c 3 5 34 DESIGNATED LEADER ANERER 3 6 35 TRAINING airen ER dete ee din dete ato i tad id 3 7 3 6 1 Equipment Operation s ee stoppt om pets petet oe Mame bene 3 7 302 Procedure Eed Ue Pedidos ee hss ER dee 3 7 CHAPTER 4 LIFTING PERSONNEL see 4 1 4 1 GENERA E oc tubes d a ei EE 4 1 4 1 1 Personnel Lifting Evaluation inti erred enter etre RSEN 4 1 412 Destenated Leader nn danes 4 1 A TA EA A AAA 4 2 Ad LI ODGEdUOHS uae c eere pO EE E EE 4 2 42 MOBILE CRANDEDS iier nre i EH ra 4 5 43 OVERHEAD CRANES opi ed eebe 4 6 44 PERSONNEL LIFT PLATFORM ree 4 7 4 4 1 Platform Design and Constructon 4 7 4 4 2 Platform Suspension O vec oy avs Rr ere inest PR ere PR axe 4 7 4 5 INSPECTIONS TT 4 9 4 5 Freguent Inspection suci opt PRSE EES 4 9 4 5 2 Periodic A e EE 4 9 46 TESTING eco ov ero ten atti lidia 4 10 4 6 1 Platform Manufacturer Testa ee ee dioe le neon ORE 4 10 462 Rated Load Eesti ntis Ee ee eege 4 10 4 6 3 Hoisting Equipment ices aec e recreo ud ed teret Deere oer E P oett 4 10 47 LIFTING PERSONNEL NEAR ELECTRICAL POWER LINES 4 11 qub Generals o on ea epa ey ra ed eae d 4 11 MEAE Condition CT 4 11 Z3 WE Basi dae eret ie Wen gs en 4 11 4 14 Condition s suere dida 4 12 Exhibit I Personnel Lift Platform Pre Lift Inspection ssesesseesesesssseessssesesesee 4 15 Exhibit II Personnel Lifting Planning and Authorization Form
85. cause doubt as to continue use 12 6 7 REPAIRS a Repairs alterations or modifications shall be as specified by the turnbuckle manufacturer or a qualified person Replacement parts shall meet or exceed the original equipment manufacturer s specifications 12 6 8 CRITICAL LIFTS a See Chapter 2 Critical Lifts for critical lift requirements Turnbuckles used for critical lift service shall have an initial proof test of 200 percent of the rated capacity Test loads shall be accurate to within 5 percent 0 percent of stipulated values If proof testing cannot be verified the turnbuckles shall be proof tested before being used to make a critical lift If proof tested turnbuckles shall be inspected after the test for the removal conditions stated above Chapter 12 Rigging Hardware DOE STD 1090 2007 ss Hook SS Full thread engagement Gpen body with jaw Pipe body with hook Open Body and eye fittings and eye fittings with Nuts Pipe Body Types Components Reprinted from ASME B30 26 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 12 8 Turnbuckles Chapter 12 12 18 Rigging Hardware 12 7 1 GENERAL a 12 7 2 a 12 7 5 EFFECTS OF ENVIRONMENT a DOE STD 1090 2007 12 7 LINKS RINGS AND SWIVELS Links rings and swivels are usually designed and manufactured as a part of the lifting hardware for a specific purpos
86. compliance with applicable provisions of this chapter Inspections of repaired and modified cranes may be limited to the provisions affected by the alteration repair or modification as determined by a qualified person Dated and signed inspection reports shall be kept on file and shall be readily available Chapter 7 Overhead and Gantry Cranes 7 2 4 DAILY PREOPERATIONAL CHECK a Operators or other designated personnel shall visually inspect at a minimum the following items each day or prior to first use if the hoist has not been in regular service records are not required 1 All functional operating mechanisms for maladjustment interfering with proper operation 2 Deterioration or leakage in lines tanks valves drain pumps and other parts of air or hydraulic systems 3 Hooks for cracks deformation latch engagement if provided and damage from chemicals see Chapter 13 Load Hooks for additional hook requirements 4 Hoist rope for significant wear kinking crushing birdcaging corrosion or broken strands or wires 5 Hoist chains including end connections for excessive wear twist distorted links interfering with proper function or stretch beyond manufacturer s recommendations 6 Primary hoist upper limit device for proper operation b Operators or other designated personnel shall examine deficiencies and determine whether the equipment should be removed from service or if a more d
87. construction is used on industrial equipment for flexible slings and in miscellaneous hoisting 11 5 2 6x29F A 6 x 29F is used for applications requiring a flexible rope slightly more resistant to wear than the 6 x 37 2 operation rope 3 6x41 A 6x41 rope is used widely for ropes over l in diameter in the 6 x 37 classification 11 2 4 WIRE ROPE INSPECTIONS A qualified inspector shall inspect wire ropes at least annually Inspection requirements vary depending on what type of equipment the wire ropes are used on Refer to other sections in this standard based on the equipment being used for specific inspection requirements 11 2 5 WIRE ROPE MAINTENANCE Personnel using wire rope shall ensure proper care by doing the following Store rope to prevent damage or deterioration b Unreel or uncoil rope as recommended by the rope manufacturer or a qualified person and with care to avoid kinking or inducing a twist c Before cutting a rope use some method to prevent unlaying of the strands Heat affected zones of flame cut wire rope shall not be allowed to bear load d During installation avoid dragging the rope in the dirt or around objects that will scrape nick crush or induce sharp bends e Unless prohibited by other considerations maintain rope in a well lubricated condition The object of rope lubrication is to reduce internal friction and to prevent corrosion Ensure that lubricant ap
88. deficiency will not adversely affect the safe operation of the unit When two or more cranes are used to lift one load one designated person shall be responsible for the operation That person shall analyze the operation and instruct all personnel involved in the proper positioning rigging of the load and the movements to be made That person shall also determine the necessity to reduce crane ratings position of load boom location ground support and speed of movement 9 15 Determine that no one is working on the crane or is close to it before starting the engine or beginning to operate the crane Barricade accessible areas within the swing radius of the rear of the rotating superstructure of the crane to prevent anyone from being struck or crushed by the crane Do not hoist two or more separately rigged loads in one lift even though the combined load is within the crane s rated capacity Refer to Section 15 5 8 for the exception granted for steel erection in construction When fueling the crane stop the engine s and ensure that smoking or open flames are not permitted within 25 ft of the fueling area Ensure that a 10BC or larger fire extinguisher is installed at all operator stations Fire extinguishers shall be maintained in a serviceable condition Do not store gasoline acids caustics or cleaning solvents that emit toxic fumes in operating cabs Store fuel in safety cans in safe locations Ensure t
89. determined by a qualified person based upon 1 Frequency of sling use 2 Severity of service conditions 3 Nature of lifts being made 4 Experience gained on the service life of slings used in similar circumstances b Users shall carefully note any deterioration that could result in an appreciable loss of original strength and determine whether further use of the sling would constitute a safety hazard Removal from service criteria are provided for each type of sling in their respective sections 11 3 1 7 Sling Periodic Inspection Records Individual site programs shall describe how inspections are recorded These records may include an external coded mark on the individual sling tag e g date annually changed color stripe etc indicating both periodicity and the satisfactory completion of the required inspection or a written record as acceptable documentation 11 8 2 WIRE ROPE SLINGS a Ingeneral wire rope slings are made up of 6 x 19 or 6 x 37 classification wire rope Rotation resistant wire rope shall not be used for wire rope slings Different kinds of slings have been developed for specific purposes These are divided into different groups or types as follows Endless loop slings grommet construction and single part slings with single rope legs double rope legs or multiple part rope legs DOE STD 1090 2007 2 Two leg bridle slings with single rope legs equalizing double rope legs or mu
90. device at the beginning of each shift or prior to use if it has not been in regular service b The inspection shall be for the following records are not required 1 Lifting magnet face for smoothness or presence of foreign materials if applicable 2 Magnet suspension system 3 All visible electrical conductors without disassembly 14 5 4 3 Periodic Inspection a A qualified inspector shall perform a complete inspection of the lifting device with the equipment in place at the following intervals 1 Normal service yearly 2 Heavy Service quarterly 3 Severe service quarterly 4 Special or infrequent service as authorized by a qualified person before the first use and as directed by the qualified for any subsequent occurrences Chapter 14 Below the Hook Lifting Devices DOE STD 1090 2007 Reprinted from ASME B30 20 2006 by permission of The American Society of Mechanical Engineers All rights reserved Figure 14 8 Remote operated magnetic lifting devices Chapter 14 14 22 Below the Hook Lifting Devices DOE STD 1090 2007 b Lifting device service is defined as follows 1 Normal operation with various weights within the rated load limit or uniform loads less than 65 percent of rated load 2 Heavy operation within the rated load limit that exceeds normal service 3 Severe operation under normal or heavy service with abnormal operating conditions c This inspecti
91. enin trente verde dean terreno rto et eite 11 40 11 3 6 1 Removal from Service Criteria sese 11 41 11 3 6 2 A RO GEH ERR EH TREE MEER 11 42 UR d data Pr PEE MEN 11 42 11 3 6 4 Critical E sida pi rrr Hi terr periere ERES 11 43 DOE STD 1090 2007 INTENTIONALLY BLANK 11 5i DOE STD 1090 2007 11 1 GENERAL The information in this section provides guidance for safely handling lifted loads Diagrams are used to illustrate hoisting and rigging principles and good and bad rigging practices This is not a rigging textbook the information should be applied only by qualified riggers Wire rope and slings that have been irreversibly damaged or removed from service shall be made unusable for hoisting and rigging operations before being discarded Load tables are representative only and are not exact for all materials or all manufacturers Prior to rigging a load determine the weight of the load 1 From markings on the load 2 By weighing if the load is still on a truck or railroad car 3 From drawings or other documentation 4 Bycalculation using the load dimensions and the weights of common materials in Table 11 1 Determine the center of gravity of the load as accurately as possible 1 From drawings or other documentation 2 From markings on the load 3 Bycalculation Determine the best method to attach the load and select the appropriate lifting devices e g wire rope steel c
92. hook at the following intervals records are not required 1 Normal service monthly 2 Heavy service weekly to monthly 3 Severe service b These inspections shall in addition to the requirements of Section 13 2 3 Daily Inspection include the following 1 Wear 2 Hook attachment and securing means c Adesignated person shall examine deficiencies and determine whether they constitute a safety hazard and whether a more detailed inspection is required 13 2 5 PERIODIC INSPECTION a A qualified inspector shall perform a complete inspection at the following intervals 1 Normal service yearly 2 Heavy service semiannually 3 Severe service quarterly b A qualified person shall examine deficiencies and determine whether they constitute a safety hazard DOE STD 1090 2007 The inspection shall include the requirements of Section 13 2 4 Frequent Inspection Hooks having any of the following conditions shall be removed from service until repaired or replaced 1 Deformation Any visibly apparent bend or twist from the plane of the unbent hook 2 Throat opening Any distortion causing an increase in throat opening exceeding 5 percent not to exceed 4 inch or as recommended by the manufacturer 3 Wear Any wear exceeding 10 percent or as recommended by the manufacturer of the original section dimension of the hook or its load pin 4 Cracks 5 Ifa l
93. installed and operational Employees being hoisted or working in a personnel lift platform shall 1 Remain in continuous sight of and in direct communication with the operator or signaler In situations where direct visual contact with the operator is not possible and the use of a signaler would create a hazard for that person direct communication alone such as a two way radio may be used 2 Keep all parts of their bodies inside the suspended personnel lift platform during raising lowering and positioning to avoid pinch points 3 Wear body harnesses with lanyards attached to the lower load block or overhaul ball or to a structural member within the platform that is capable of supporting a fall impact 4 Not stand on or work from the tope rail midrail or toe board of the suspended personnel platform 5 When working above water the requirements of 29 CFR 1926 106 Occupational Safety and Health Regulations for Construction shall also apply 6 When welding is being performed from the personnel lift platform the electrode holders shall be protected from contact with metal components of the personnel platform Operators of cranes hoisting personnel in a personnel lift platform shall 1 Before commencing or continuing the lift consult with the designated leader whenever there is any doubt as to the safety of the lift 2 Remainatthe controls when the personnel lift platform is occupied 3 Opera
94. load and any hazardous or toxic materials that are present 2 Identification of operating equipment to be used by type and rated capacity 3 Rigging sketches that include as applicable i Identification and rated capacity of slings lifting bars rigging accessories and below the hook lifting devices Calculate and provide the rated capacity of equipment in the configuration in which it will be used ii Load indicating devices iii Load vectors iv Lifting points v Sling angles vi Boom and swing angles vii Methods of attachment viii Crane orientations ix Other factors affecting equipment capacity e g load path sketch Chapter 2 Critical Lifts key point heights floor or soil bearing capacity 4 Operating procedures and special instructions to operators including rigging precautions and safety measures to be followed as applicable All rigging equipment used in critical lifts i e slings below the hook lifting devices and rigging hardware shall have proof load certificates See Chapters 11 12 and 14 for proof test requirements of these equipment items Experienced operators who have been trained and qualified to operate the specific equipment to be used shall be assigned to make the lift Only designated qualified signalers shall give signals to the operator However the operator shall obey a STOP signal at all times no matter who gives the signal The procedu
95. may not conform to established Government or industry accepted specifications or national consensus standards A counterfeit item is a suspect item that has been copied or substituted without legal right or authority to do so or one whose material performance or characteristics are knowingly misrepresented by the vendor supplier distributor or manufacturer see Figure 1 5 NOTE refer to DOE G 440 1 6 Implementation Guide For Use With Suspect Counterfeit Requirements of DOE O 440 1 Worker Protection Management SWAGED FITTINGS Fittings in which wire rope is inserted and attached by a cold forming method SWITCH ELECTRIC A device for making breaking or changing the connections in an electrical circuit SWITCH EMERGENCY STOP A manually or automatically operated electric switch to cut off electric power independently of the regular operating controls SWITCH LIMIT A switch that is operated by some part or motion of a power driven machine DOE STD 1090 2007 or equipment to alter the electrical circuit associated with the machine or equipment SWITCH MAIN A switch controlling the entire power supply to a crane or other equipment often called the disconnect switch TAG LINE A rope used to prevent rotation of a load TAPERING AND WELDING Reducing the diameter of the end of a wire rope and welding it to facilitate reeving THIMBLE Grooved metal fitting to protect the eye of a wire rope see Figure 1
96. net Appendix A A 6 Procurement Guidelines Wire rope shall have documentation from the manufacturer traceable to the material furnished and signed by the manufacturer s authorized representative Documentation should reference as a minimum the purchase order number the diameter number of strands core lay grade manufacturer s lot run number material number and the nominal breaking strength of a sample Shall be shipped lubricated and with a protective covering i e plastic or cardboard DOE STD 1090 2007 6 CHAIN SLINGS P Si e e Chain slings shall meet or exceed requirements of ASME ANSI B30 9 and 29 CFR 1910 184 Alloy steel chain slings shall have permanently affixed durable identification stating size manufacturer s grade rated load and angle upon which the rating is based reach number of legs and sling manufacturer Hooks rings oblong links pear shaped links welded or mechanical coupling links or other attachments shall have a rated load of at least equal to that of alloy steel chain with which they are used All welded components in the sling assembly shall be proof tested as components or as part of the sling assembly A 7 Hooks attached to chain slings shall meet the requirements of ASME ANSI B30 10 The welded components of all new slings shall be proof tested by the component or sling manufacturer to 200 percent of the rated load The proof load for multiple
97. object clears another or the clear space between them CLEVIS A U shaped fitting with pins CLIP A fitting used to clamp two parts of wire rope CLOSED SOCKET A wire rope fitting consisting of an integral becket and bail CLOSING LINE Wire rope that closes a clamshell or orange peel bucket and then operates as a hoisting rope COIL Circular bundle of wire rope not packed on a reel DOE STD 1090 2007 COLLECTOR Contacting device mounted on a bridge or trolley and used to collect current from the conductor system COME ALONG A portable hand operated device consisting of a housing a length of chain or wire rope two hooks and a ratcheting lever that is used for miscellaneous pulling CONDUCTOR Wire angles bars tees or special sections mounted to transmit current to the collectors CONICAL DRUM Grooved hoisting drum of varying diameter CONSTRUCTION WIRE ROPE Refers to the design of wire rope including number of strands number of wires per strand and arrangement of wires in each strand CONTINUOUS BEND Reeving of wire rope over sheaves and drums so that it bends in one direction as opposed to reverse bend CONTROLLER An operator s device for regulating the power delivered to a motor or other equipment CONTROLLER SPRING RETURN A controller that when released will return automatically to a neutral position CORE The center member of a wire rope around which the strands are laid
98. oerte in 10 19 TOAL Forklift Truck Load Leste atea 10 19 10 42 Fork Load Testi wie ies th ee ead A ee ie wean 10 19 10 43 Attachment Load Test Reed tae edn ted i wend 10 19 10 5 OPERATIONS tet avi A tee ete 10 20 10 5 1 Conductof Operator 5 eR e CE ese eme edi 10 20 10 5 1 1 General iuge etes ilie te CE eter Eben 10 20 10 5 1 2 BR 10 21 10 5 1 3 Loading ve te e e UR N 10 22 10 5 2 Tafung of Personnel oen ee e equ 10 23 10 5 3 Standard Hand Signals entree HR OR eur 10 25 H Ordinary Lafts utc tete HD HUP equ 10 25 10 5 5 Critical EC 10 25 10 5 6 Equipment Qualifications e e et te tee beds 10 25 10 i Exhibit I Exhibit II DOE STD 1090 2007 Operators Pre Shift Inspection Form Forklift Load Test and Inspection Form 10 ii DOE STD 1090 2007 10 1 GENERAL This chapter specifies operation inspection testing and maintenance requirements for industrial trucks powered by electric motors or internal combustion engines See Figures 10 3 for examples of powered industrial trucks Guidelines may also be taken from this chapter regarding pallet trucks and other small miscellaneous non powered lift trucks see Figure 10 4 but training operating maintenance inspection and testing requirements for non powered equipment shall be based on the manufacturer s instructions and recommendations 10 1 1 OPERATOR TRAINING QUALIFICATION Operators of forklift trucks shal
99. of its plane j Cracked end fitting k Slings in which the spirals are locked or without free articulation shall not be used l Fittings that are pitted corroded cracked bent twisted gouged or broken m Other conditions including visible damage that cause doubt as to the continued use of the sling 11 3 4 2 Proof Testing a Metal mesh slings shall be certified as having been proof tested to 200 percent of their rated capacity prior to initial use Chapter 11 General 11 3 4 3 Coated slings shall be proof tested prior to being coated Test loads shall be accurate to within 5 percent 0 percent of stipulated values Either certification by the manufacturer or a pull test certified by a qualified person is acceptable Operation The following shall apply to all personnel who use metal mesh slings Ensure that the weight of the load is within the rated capacity of the sling 2 Ensure that metal mesh slings have suitable characteristics and rated capacity for the load and environment Metal mesh slings should be long enough to provide the maximum practical angle between the sling leg and the horizontal minimum practical angle at the crane hook if vertical angles are used Do not shorten metal mesh slings with knots bolts or other unapproved methods Do not use damaged slings Securely hitch metal mesh slings to the load Ensure that sharp corners are padded Keep hands and fingers o
100. or cardboard Wire Rope shall have Documentation from the manufacturer traceable to the material furnished and signed by the manufacturer s authorized representative Documentation Shall reference as a minimum the PURCHASE ORDER number state the diameter number of strands core lay grade manufacturing lot run number or master reel number and nominal breaking strength of sample ACCEPTANCE CRITERIA Quality receipt inspection shall verify that the manufacturer is a member of the Wire Rope Technical Board for carbon steel verify the diameter lay grade core and documentation as complete and meets or exceeds the requirements of this rope FUNCTIONAL REQUIREMENTS FOR WIRE ROPE SLINGS Wire rope purchased to fabricate slings shall be made in the United States by a member of the Wire Rope Technical Board Shall meet the requirements of RR W 410D Federal Specification for Wire Rope and Strand or MIL W 83420 for aircraft cable Wire Rope Shall have Documentation from the manufacturer traceable to the material furnished and signed by the manufacturer s authorized representative Documentation Shall reference as a minimum the P O number state the diameter number of strands core lay grade manufacturing lot run number master reel number and nominal breaking strength of sample Shall be shipped lubric
101. or strand with seizing wire or strand SEIZING STRAND Small strand usually of seven wires mad of soft annealed iron wire SEIZING WIRE A soft annealed iron wire SELF LOADER A truck with tires that can fit between the top and bottom boards of a double faced pallet SERVE To cover the surface of a wire rope or strand with a wrapping of wire Figure 1 3 Shackle Chapter 1 Terminology and Definitions DOE STD 1090 2007 SHACKLE A type of clevis normally used for lifting see Figure 1 3 SHALL A word indicating that an action is mandatory SHEAVE A grooved wheel or pulley used with a rope to change direction and point of application of a pulling force SHEAVE NONRUNNING EQUALIZER A sheave used to equalize tension in opposite parts of a rope called nonrunning because of its slight movement SHEAVE RUNNING A sheave that rotates as the load block is lifted or lowered SHOULD A word indicating a recommended action the advisability of which depends on the facts in each situation SIDE LOADER A self loading truck generally high lift having load engaging means mounted in such a manner that it can be extended laterally under control to permit a load to be picked up and deposited in the extended position and transported in the retracted position see Figure 10 3 SIDE PULL That portion of a hoist pull acting horizontally when the hoist lines are not operated vertically SLINGS Wire ropes ch
102. ouch b et ee dete ee aso ee 12 7 Removal Grteriat s neta iR OWENS 12 8 DIL m EE 12 8 CAS cpa ee t NISI Re epa uet 12 8 EVE BOLUS AAA AA A RA 12 11 General O er RR ES 12 11 Effects ot BEnvironment ien erre tat e eie ee 12 11 Tratin coeno erben Nd odes ERN I I Gee DAC 12 11 IETS erster cepe Me RE 12 11 Removal Criteria Laia ld aa lili 12 12 A beac 12 12 Critical Heat tS itte eO BID A eo SR 12 12 EYE EN EE 12 14 Generalis Sete e Phe heise te t euntes ld 12 14 Effects of Environment 12 14 er Sete Eten ir ta a pres oak yo Poo Pes waa aas isto Role og oie 12 14 InspeclioBs oe pe ria E ve Eee qu nro ese n EO NIFI E REEL I EN 12 14 Removal Cnteriasz uet e E OR NR OE Tte as 12 15 Re DIS o coe nS Rr iv ede prs is aiebat esce ate etu es 12 15 rit Cal LS aeree tte e eom Peer eee re et 12 15 EILER EE 12 16 Creneral s A ER A bac eee Eee eee 12 16 12 6 2 12 6 3 12 6 4 12 6 5 12 6 6 12 6 7 12 6 8 12 7 12 7 1 12 7 2 12 7 3 12 7 4 12 7 5 12 7 6 12 7 7 12 7 8 12 8 12 8 1 12 8 2 12 8 3 12 8 4 12 8 5 12 8 6 12 8 7 12 9 12 9 1 12 9 2 12 10 12 10 1 12 10 2 12 11 12 11 1 12 11 2 12 11 3 12 11 4 12 11 5 12 11 6 12 11 7 12 11 8 12 11 9 Operating Practices aiu eo et m ete t ea eae 12 16 Effects of Environment cc ccccccccccsssssssceeecceeeesessscceececceseessssseeeeeeeeeeeeeees 12 16 dk ur 12 16 Inspection S dois 12 16 Removal Criteri 5 rl 12 17
103. passing score will depend on the subject testing technique and test difficulty Management shall determine the course of action for persons receiving negative evaluations 6 3 2 OPERATORS OF CAB OPERATED PULPIT OPERATED AND FLOOR OPERATED CRANES Only qualified and authorized operators or operator trainees under the direct supervision of a qualified operator shall be permitted to operate cab operated pulpit operated and floor operated cranes The initial training of operators shall include 1 Applicant training on equipment for which qualification is sought under the direction of a qualified operator or instructor who is designated by management to instruct in the operation of hoisting equipment 2 Instructor review of the applicant s knowledge including results of written and oral evaluation and witnessing a demonstration of the operator s skills Operators should be able to demonstrate a knowledge of equipment operating characteristics capabilities limitations effects of variables safety features and operating procedures The following checklist contains basic factors with which an operator should be familiar This checklist must be tailored to suit actual conditions 1 Operating characteristics 2 Environmental hazards weather 3 Electrical hazards 4 Traveling with load 5 Traveling without load 6 Lifting personnel 7 Inspections tests 8 Load weight estimation 9 Emergency p
104. person should be consulted The strength of eye nuts can be affected by chemically active environments such as caustic or acid substances or fumes The eye nut manufacturer or a qualified person should be consulted before eye nuts are used in chemically active environments 12 5 3 TRAINING Eye nut users shall be trained in the selection inspection cautions to personnel effects of environment and rigging practices as covered by this standard Chapter 12 Rigging Hardware 12 14 12 5 4 INSPECTIONS a Initial Inspection 1 Prior to use all new altered modified or repaired eye nuts shall be inspected by a designated person to verify compliance with the applicable provisions of this chapter Written records are not required Frequent Inspection 1 A visual inspection shall be performed the user or other designated person each shift before the eye nut is used Semi permanent and inaccessible locations where frequent inspections are not feasible shall have periodic inspections performed 2 Conditions such as those listed in Section 12 5 5 or any other condition that may result in a hazard shall cause the eye nut to be removed from service Eye nuts shall not be returned to service until approved by a qualified person 3 Written records are not required Periodic Inspection 1 A complete inspection of the eye nut shall be performed by a designated person The eye nut shall be examined for conditions
105. recommended in ANSI NFPA 505 Powered Industrial Trucks Type Designation and Areas of Use DOE STD 1090 2007 10 1 9 WORK ATMOSPHERE Contaminants Occupational Safety and Health Standards for General Industry a The operation of forklift trucks may effect the concentrations of carbon monoxide and b Where general lighting is less than 2 lumens oxygen in the work location per square foot auxiliary directional lighting Concentrations of these materials in the shall be provided on the truck work location must meet Z 1 Limits for Air 10 3 Chapter 10 Forklift Trucks DOE STD 1090 2007 Figure 10 3 Types of Trucks sheet 1 of 6 Variable Reach Truck Linkage Type Four Wheel Steer Two Wheel Steer Four Wheel Drive Two Wheel Drive Variable Reach Truck Boom Type Four Wheel Steer Two Wheel Steer Four Wheel Drive Two Wheel Drive Variable Mast Two Wheel Steer Two Wheel Drive Chapter 10 10 4 Forklift Trucks DOE STD 1090 2007 Figure 10 3 Types of Trucks sheet 2 of 6 Vertical Mast Skid Steer Vertical Mast Articulated Frame Steer Four Wheel Drive Vertical Mast Four Wheel Steer Two Wheel Steer Four Wheel Drive Two Wheel Drive 10 5 Chapter 10 Forklift Trucks DOE STD 1090 2007 Figure 10 3 Types of Trucks sheet 3 of 6 High Lift Truck Counterbalanced Truck Cantilever Truck Rider Truck
106. remain on the platform floor The use of railings planks ladders etc on the platform for the purpose of achieving additional reach or height is prohibited Ensure personnel and equipment on the platform do not exceed the available space Lower platform to floor level for personnel to enter and exit Do not climb on any part of the truck in attempting to enter or exit The operator shall remain in the control position of the forklift truck Be certain that the lifting mechanism is operating smoothly throughout its entire lift height both empty and loaded and that lift limiting devices and latches if provided are functional Means shall be provided to protect personnel from moving parts of the forklift truck that present a hazard when the personnel platform is in the normal working position Overhead protection as necessary for operating conditions shall be provided Do not transport personnel from one location to another while they are on the work platform When not in the operating position engage the parking brake and block the wheels 10 5 3 DOE STD 1090 2007 19 Be certain that required restraining means such as railings chains cable body belts with lanyards or deceleration devices etc are in place and properly used STANDARD HAND SIGNALS Standard hand signals for use at DOE locations shall be as specified in the latest edition of the ANSI standards for the particular forklift being us
107. s policy of as low as reasonably achievable ALARA radiation exposure per the provisions of 10 CFR 835 Occupational Radiation Protection Safety of personnel shall remain the first priority Chapter 5 Hostile Environments DOE STD 1090 2007 A hostile environment plan shall be prepared by a designated person and shall cover operations equipment inspection testing and maintenance See Exhibit I Hostile Environment Plan at the end of this chapter At a minimum the plan shall be reviewed and approved by responsible DOE contractor management at the facility where the crane hoist or other equipment is located and by responsible management of the appropriate DOE contractor oversight organization such as safety or quality assurance The plan shall address only those actions or features that require deviation from the requirements of this standard due to a hostile environment At a minimum it shall contain the following information 1 The specific requirements that cannot be met 2 The difference between the requirement and actual conditions 3 Justification for not meeting this standard s requirements 4 A statement of actions or features to be used to compensate for the differences 5 Specific maintenance inspections and tests to be performed whenever access is possible 6 Replacement or retirement criteria for equipment that is designed to operate with little or no maintenance Detailed
108. shall have a minimum design factor of 5 1 c Each turnbuckle body shall be permanently and legibly marked by the manufacturer to show 1 Manufacturer s name or trademark 2 Sizeor rated load 12 6 2 OPERATING PRACTICES a Turnbuckle end fitting threads shall be fully engaged in the body threads b Components including pins bolts nuts or cotter pins used with jaw ends shall be in good working condition prior to use c Contact with obstructions that could damage or bend the turnbuckle should be avoided d Shock loading should be avoided e The load applied to the turnbuckle should be in line and in tension f When turnbuckles are used at load angles other than 90 degrees the safe load rating shall be reduced per the manufacturer s recommendations g Turnbuckles should not be side loaded Turnbuckles used in applications where there is vibration shall be secured to the frame with locks pins or wires to prevent turning or loosening i Turnbuckles should be rigged or secured to prevent unscrewing during the lift j Forlong term installations turnbuckles shall be secured to prevent unscrewing k Turnbuckles should not be dragged on and an abrasive surface Chapter 12 12 16 Rigging Hardware L Turnbuckles should be adjusted with a properly sized wrench used on the flats of the turnbuckle body 12 6 3 EFFECTS OF ENVIRONMENT a When a turnbuckle is to be used at temperatures above 40
109. should be clearly defined Administrative procedures or writers guides should direct the development and review process for procedures at each site to ensure consistency at the site b Qualifications for procedure writers shall be considered including operating organization and experience c Procedures should reference applicable source documents such as facility design documents safety analysis documents vendor technical manuals and industry standards 3 4 Operating procedures should contain only one action per step Any necessary warnings cautions or notes should be easily identifiable and should not contain any action statements These items should precede the step to which they apply and should appear on the same pate as the step to which they apply The sequence of procedural steps should conform to the normal or expected Operational sequence Procedures should be developed with consideration for the human factor aspects of their intended use For example references to components should exactly match drawing and label plate identifiers and units should be the same as those marked on applicable instrumentation Important factors should be highlighted such as operating limits warnings and cautions 3 3 3 PREPARATION AND REVISION Appropriately trained personnel shall develop review and approve a step by step procedure for each lifting operation The responsible oversight organizations safety qualit
110. size or rated load and grade if needed to identify the rated load Appendix A Procurement Guidelines P Si e e DOE STD 1090 2007 15 SHACKLES Shackles shall be fabricated to meet or exceed the requirements of ASME B30 26 Shackles shall have sufficient ductility to permanently deform before losing the ability to support the load at the temperature that the manufacturer has specified for use The design factor for shackles up to and including a 150 ton rated load shall be a minimum of 5 The design factor for shackles over 150 ton rated load shall be a minimum of 4 Each shackle body shall be permanently and Appendix A Procurement Guidelines legible marked by the manufacturer Raised or stamped letters on the side of the bow shall be used to show 1 Manufacturer s name and trademark 2 Size 3 Rated capacity Pins for shackles manufactured after May 20 2006 shall be marked by the manufacturer with raised or stamped letters showing 1 Name or trademark of manufacturer 2 Grade material type or load rating DOE STD 1090 2007 16 TURNBUCKLES P Si Turnbuckles shall be fabricated to meet or exceed the requirements of ASME B30 26 Turnbuckles used for hoisting shall have sufficient ductility to permanently deform before losing the ability to support the load at temperatures at which the manufacturer has specified for use c Turnbuckles used for lifting service shall be
111. specified by a rope manufacturer the crane manufacturer or a qualified person Never use discarded rope for slings reductions 7 2 7 3 Chain Welded Link Maximum a Operate the crane under load in raising and allowable lowering directions and observe the Rope diameter reduction from operation of the chain and sprockets The Nominal diameter chain should feed smoothly into and away IPIE from the sprockets Up to 5 16 in 1 64 in 0 4 mm 8 mm b Ifthe chain binds jumps or is noisy first see that it is clean and properly lubricated Over 5 16 in to 1 32 in 0 8 mm If the trouble persists inspect the chain and Ve in 13 mm mating parts for wear distortion or other Over Y into in 3 64 in 1 2 mm damage 19 mm c Thechain should be cleaned before Over 3 4 in to 1 1 8 1 16 in 1 6 mm inspection Examine visually for gouges in 29 mm nicks weld spatter corrosion and distorted links Slacken the chain and move adjacent Over 1 1 8 in to 1 Y 3 32 in 2 4 mm links to one sire to inspect for wear at the in 38 mm contact points If wear is observed or stretching is suspected the chain should be Reprinted from ASME B30 2 2005 by permission of resumo accordinp to Ane BORSE i The American Society of Mechanical Engineers All manufacturer s instructions If instructions rights reserved are not available proceed as follows Removal criteria for rope replacement shall 1 Select an unworn unstretch
112. strikes c Excessive pitting or corrosion Chapter 12 12 22 Rigging Hardware d Bent twisted distorted stretched elongated cracked or broken load bearing components Excessive nicks or gouges A 10 reduction of the original or catalog dimension at any point Excessive thread damage or wear Evidence of unauthorized welding or modification Lack of the ability to freely rotate or pivot Other conditions including visible damage that cause doubt as to continue use 12 8 0 REPAIRS a Repairs alterations or modifications shall be as specified by the swivel hoist ring manufacturer or a qualified person Replacement parts shall meet or exceed the original equipment manufacturer s specifications 12 8 7 CRITICAL LIFTS a See Chapter 2 Critical Lifts for critical lift requirements Swivel hoist rings used for critical lift service shall have an initial proof test of 200 percent of the rated capacity or as recommended by the manufacturer Test loads shall be accurate to with 5 percent 0 percent of stipulated values If proof testing cannot be verified the swivel hoist rings shall be proof tested before being used to make a critical lift side Pull Swivel Hoist Ring Tapped Hole Types DOE STD 1090 2007 Bail Bolt Pin Swivel Bail Swivel i Hoist Ring Tapped Hole Bushing Bushing Flange Components 577 9 N gt 360 deg rot 180 rotation T d Hol
113. such as those listed in Section 12 5 5 and a determination made as to whether they constitute a hazard 2 Periodic inspection intervals shall not exceed one year The frequency of periodic inspections should be based on i Frequency of use ii Severity of service conditions iii Nature of lifts being made iv Experience gained on the service life of eye nuts used in similar circumstances 3 Guidelines for the time intervals are i Normal service yearly ii Severe service monthly to quarterly 111 Special service as recommended by a qualified person DOE STD 1090 2007 d Written records are not required 12 5 5 REMOVAL CRITERIA Eye nuts shall be removed from service if damage such as the following is visible and shall only be returned to service when approved by a qualified person a Missing or illegible manufacturer s name or trademark and or rated load identification b Indications of heat damage including welding spatter or arc strikes c Excessive pitting or corrosion d Bent twisted distorted stretched elongated cracked or broken load bearing components e Excessive nicks or gouges f A 10 reduction of the original or catalog dimension at any point around the body or pin g Excessive thread damage or wear Evidence of unauthorized welding or modification Typical Types o nut i Other conditions including visible damage that cause doubt as to
114. swivel hoist ring working load 12 21 n limit meets or exceeds the anticipated angular rigging tension see Fig 12 11 Shock loading should be avoided 12 8 3 EFFECTS OF ENVIRONMENT a When swivel hoist rings are to be used at temperatures above 400 F 204 C or below 20 F 40 C the swivel hoist ring manufacturer or a qualified person should be consulted The strength of swivel hoist rings can be affected by chemically active environments such as caustic or acid substances or fumes The swivel hoist ring manufacturer or a qualified person should be consulted before swivel hoist rings are used in chemically active environments 12 8 3 TRAINING Swivel hoist ring users shall be trained in the selection inspection cautions to personnel effects of environment and rigging practices as covered by this standard 12 8 4 INSPECTIONS a Initial Inspection 1 Prior to use all new altered modified or repaired swivel hoist rings shall be inspected by a designated person to verify compliance with the applicable provisions of this chapter Written records are not required Frequent Inspection 1 A visual inspection shall be performed the user or other designated person each shift before the swivel hoist ring is used Semi permanent and inaccessible locations where frequent inspections are not feasible shall have periodic inspections performed 2 Conditions such as those listed in Section 12 8 5 or an
115. than one and one half diameter thickness a nut shall be used under the load and shall be fully engaged and tightened securely against the load see Fig 12 6 Only shouldered eyebolts shall be used for angular loading The shoulder shall be securely tightened against the load and the eye shall be aligned with the direction of the loading The working load limit shall be reduced as recommended by the manufacturer Shock loading shall be avoided 12 4 EFFECTS OF ENVIRONMENT a When alloy steel eyebolts are to be used at temperatures above 400 F 204 C or below 40 F 40 C the eyebolt manufacturer or a qualified person should be consulted Carbon steel eyebolts shall not be used at temperatures above 275 F 135 C or below 30 F 1 C unless approved by manufacturer or a qualified person The strength of eyebolts can be affected by chemically active environments such as caustic or acid substances or fumes The eyebolt manufacturer or a qualified person should be consulted before eyebolts are used in chemically active environments 12 4 3 TRAINING Eyebolt users shall be trained in the selection inspection cautions to personnel effects of environment and rigging practices as covered by this standard 12 4 4 INSPECTIONS a b Initial Inspection 1 Prior to use all new altered modified or repaired eyebolts shall be inspected by a designated person to verify compliance with the applicable provision
116. the manufacturer See Figure 12 5 Design Factor 12 7 1 The design factor for shackles up to and including a 150 ton rated load shall be a minimum of 5 1 2 The design factor for shackles over 150 ton rated load shall be a minimum of 4 1 i Rated load shall be in accordance with the recommendation of the shackle manufacturer The terms rated capacity and working load limit are commonly used to describe rated load 12 3 3 EFFECTS OF ENVIRONMENT a When shackles are to be used at temperatures above 400 F 204 C or below 40 F 40 C the shackle manufacturer or a qualified person should be consulted b The strength of shackles can be affected by chemically active environments such as caustic or acid substances or fumes The shackle manufacturer or a qualified person should be consulted before shackles are used in chemically active environments 12 3 3 TRAINING Shackle users shall be trained in the selection inspection cautions to personnel effects of environment and rigging practices as covered by this standard 12 3 4 INSPECTIONS a Initial Inspection 1 Prior to use all new altered modified or repaired shackles shall be inspected by a designated person to verify compliance with the applicable provisions of this chapter Written records are not required b Frequent Inspection 1 A visual inspection shall be performed by the user or other designated person each day before the shack
117. the manufacturer s authorized representative Single leg hand tucked slings shall have a proof load equal to the rated load but shall not exceed 125 percent of the rated load Mechanical spliced single leg and endless wire rope slings and swaged socket or poured socket assemblies shall be load tested to 200 percent of the rated vertical load The proof load for multiple leg bridle slings shall be applied to the individual legs and shall be either 125 percent for hand tucked splice or 200 percent for mechanical splice times the vertical rated load of a single leg sling of the same size grade and construction of rope Any master link to which multiple leg slings are connected shall be proof loaded to 200 percent of the force applied by the combined legs Multiple leg bridle slings shall be tagged with a durable tag on the master link indicating the working load limit for the total combined legs for each individual sling in a vertical configuration The purchase order number or serial number and the manufacturer s ID should be supplied DOE STD 1090 2007 10 WIRE ROPE CLIPS Clamps P Si Wire rope clips shall meet or exceed requirements of ASME B30 26 Wire rope clip materials shall be of sufficient strength such that failure of the wire rope will occur before failure of the wire rope clip at the temperatures that the manufacturer has specified for use Saddles shall be forged steel c Wire rope clips shal
118. the rated load will not exceed 25 percent of the average ultimate strength This requirement is commonly reflected by quoting a minimum design factor of 4 1 8 1 6 LOAD BRAKING LOAD CONTROLLING MECHANISMS 8 1 6 1 Electric Powered Hoists a Under normal operating conditions with rated load and under test conditions with test loads up to 125 percent of rated load the braking system shall perform the following functions 1 Stop and hold the load hook when controls are released 2 Limitthe speed of the load during lowering with or without power to a maximum of 120 percent of the rated lowering speed for the load being handled 3 Stop and hold the load hook in the event of a complete power failure b The braking system shall have thermal capacity for the frequency of operation required by the service c The braking system shall have provision for adjustments where necessary to compensate for wear 8 1 6 2 Air Powered Hoists a Under normal operating conditions with rated load and under test conditions with test loads up to 125 percent of rated load the braking system shall perform the following functions 1 Stop and hold the load hook when controls are released 2 Prevent an uncontrolled lowering of the load in the event of a loss of air pressure Chapter 8 Hoists DOE STD 1090 2007 b The braking system shall have thermal capacity for the frequency of operation required by the service c Th
119. to service until approved by a qualified person 3 Written records are not required Chapter 12 12 28 Rigging Hardware c Periodic Inspection 1 A complete inspection of the compression hardware shall be performed by a designated person The compression hardware shall be examined for conditions such as those listed in Section 12 11 7 and a determination made as to whether they constitute a hazard 2 Periodic inspection intervals shall not exceed one year The frequency of periodic inspections should be based on i Frequency of use ii Severity of service conditions iii Nature of lifts being made iv Experience gained on the service life of compression hardware used in similar circumstances 3 Guidelines for the time intervals are i Normal service yearly ii Severe service monthly to quarterly 111 Special service as recommended by a qualified person 4 Written records are not required 12 11 7 REMOVAL CRITERIA Compression hardware shall be removed from service if damage such as the following is visible and shall only be returned to service when approved by a qualified person a Missing or illegible manufacturer s name or trademark and or rated load identification b Indications of heat damage including welding spatter or arc strikes c Excessive pitting or corrosion d Bent twisted distorted stretched elongated cracked or broken components e Excessiv
120. type of forklift truck the operator will be authorized to operate 2 Differences between the forklift truck and the automobile 3 Forklift truck controls and instrumentation i Where they are located ii What they do iii How they work 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 DOE STD 1090 2007 Engine or motor operation Steering and maneuvering Visibility including restrictions due to loading Fork and attachment adaptation operation and use limitations Forklift truck capacity and load weight determination Forklift truck stability and load dynamics Forklift truck inspections and maintenance that the operator will be required to perform Refueling and or charging and recharging of batteries Operating limitations Any other operating instructions warning or precautions listed in the operator s manual for the type of forklift truck that the employee is being trained to operate Traveling with and without a load Lifting personnel Emergency procedures Lessons learned Hand signals Applicable standards and regulations Critical lifts Modifications Terminology and definitions Records and documents Operating practices Fire protection d The following checklist contains basic factors with which a forklift operator should be familiar as they relate to workplace topics 1 Surface conditions wh
121. up loads MAIN HOIST The hoist mechanism provided for lifting the maximum rated load MAN TROLLEY A trolley having an operator s cab attached to it MARLINE SPIKE Tapered steel pin used in splicing wire rope MESSENGER STRAND Galvanized strand or bronze strand used to support telephone and electrical cables MODULUS OF ELASTICITY Mathematical quantity giving the ratio within the elastic limit between a definite range of unit stress on a wire rope and the corresponding elongation MOUSING A method of bridging the throat opening of a hook to prevent the release of load lines and slings under service or slack conditions by wrapping with soft wire rope heavy tape or similar materials NARROW AISLE TRUCK A self loading truck intended primarily for right angle stacking in aisles narrower than those normally required by counterbalanced trucks of the same capacity see Figure 10 3 NONDESTRUCTIVE EXAMINATION NDE The development and application of technical methods to examine materials or components in ways that do not impair future usefulness and serviceability in order to detect Chapter 1 Terminology and Definitions DOE STD 1090 2007 locate measure and evaluate discontinuities defects and other imperfections to assess integrity properties and composition and to measure geometrical characteristics NONDESTRUCTIVE TESTING NDT See NONDESTRUCTIVE EXAMINATION NONROTATING WIRE ROPE See ROTA
122. written and oral 15 3 evaluation and witnessing a demonstration of the operator s skills The following checklist contains basic factors with which a forklift truck operator should be familiar This checklist must be tailored to suit actual conditions 1 Operating instruction warnings and precautions for the type of forklift truck the operator will be authorized to operate 2 Differences between the forklift truck and the automobile 3 Forklift truck controls and instrumentation i Where they are located ii What they do iii How they work 4 Engine or motor operation 5 Steering and maneuvering 6 Visibility including restrictions due to loading 7 Fork and attachment adaptation operation and use limitations 8 Forklift truck capacity and load weight determination 9 Forklift truck stability and load dynamics 10 Forklift truck inspections and maintenance that the operator will be required to perform 11 Refueling and or charging and recharging of batteries 12 Operating limitations 13 Any other operating instructions warning or precautions listed in the operator s manual for the type of forklift truck that the employee is being trained to operate Chapter 15 Construction Hoisting and Rigging Equipment Requirements DOE STD 1090 2007 The following checklist contains basic factors with which a forklift operator should be familiar as they relate to workplace topics
123. 0 F 204 C or below 40 F 40 C the turnbuckle manufacturer or a qualified person should be consulted b The strength of turnbuckles can be affected by chemically active environments such as caustic or acid substances or fumes The turnbuckle manufacturer or a qualified person should be consulted before turnbuckles are used in chemically active environments 12 6 4 TRAINING Turnbuckle users shall be trained in the selection inspection cautions to personnel effects of environment and rigging practices as covered by this standard 12 6 5 INSPECTIONS a Initial Inspection 1 Prior to use all new altered modified or repaired turnbuckles shall be inspected by a designated person to verify compliance with the applicable provisions of this chapter Written records are not required b Frequent Inspection 1 A visual inspection shall be performed the user or other designated person each shift before the turnbuckle is used Semi permanent and inaccessible locations where frequent inspections are not feasible shall have periodic inspections performed 2 Conditions such as those listed in Section 12 6 6 or any other condition that may result in a hazard shall cause the turnbuckle to be removed from service Turnbuckles shall not be returned to service until approved by a qualified person 3 Written records are not required c Periodic Inspection 1 A complete inspection of the turnbuckle shall be performed by
124. 00 3 4 2 700 5 400 4 700 3 800 2 700 4 6 4 500 9 000 7 800 6 400 4 500 6 8 6 000 12 000 10 400 8 500 6 000 8 10 7 500 15 000 13 000 10 600 7 500 10 12 9 000 18 000 15 600 12 700 9 000 12 14 10 500 21 000 18 200 14 800 10 500 14 16 12 000 24 000 20 800 17 000 12 000 16 Light duty 14 ga 59 spirals ft of mesh width 2 900 1 800 1 600 1 300 900 2 3 1 400 2 800 2 400 2 000 1 400 3 4 2 000 4 000 3 500 2 800 2 000 4 6 3 000 6 000 5 200 4 200 3 000 6 8 4 000 8 000 6 900 5 700 4 000 8 10 5 000 10 000 8 600 7 100 5 000 10 12 6 000 12 000 10 400 8 500 6 000 12 14 7 000 14 000 12 100 9 900 7 000 14 16 8 000 16 000 13 900 11 300 8 000 16 11 31 Chapter 11 General 11 3 4 1 DOE STD 1090 2007 Removal from Service Criteria Metal mesh slings shall be removed from service if any of the following defects are present a Missing or illegible sling identification b Broken weld or a broken brazed joint along the sling edge c Broken wire in any part of the mesh d Reduction in wire diameter of 25 due to abrasion or 15 due to corrosion e Lack of flexibility due to distortion of the mesh f Distortion of the choker fitting so the depth of the slot is increased by more than 10 g Distortion of either end fitting so the width of the eye opening is decreased by more than 10 h A 15 reduction of the original cross sectional area of any point around the hook opening of the end fitting i Visible distortion of either end fitting out
125. 000 100 000 82 000 66 000 50 000 1 34 2 64 000 48 000 128 000 106 000 86 000 64 000 2 1 These values only apply when the D d ratio is 25 or greater choker and basket hitches D Diameter of curvature around which the body of the sling is bent d Diameter of rope 2 Choker hitch values apply only to choke angles greater than 120 degrees 11 15 Chapter 11 General DOE STD 1090 2007 Table 11 7 Load capacity of wire rope slings 8 part braided rope in pounds Design Factor 5 1 BN 1 d A D d S eg U LA Basket or Dia in Vertical Choker two legs Dia in inches inches 1 8 1 900 1 400 3 200 2 600 1 900 1 8 3 16 4 200 3 000 7 200 5 800 4 200 3 16 3 16 3 400 2 600 6 000 4 800 3 400 3 16 Va 6 200 4 600 10 600 8 600 6 200 Va 5 16 9 600 7 200 16 600 13 400 9 600 5116 3 8 13 600 10 200 24 000 19 400 13 600 3 8 7 16 18 000 13 800 32 000 26 000 18 600 7 16 1 2 24 000 18 000 42 000 34 000 24 000 1 2 9 16 30 000 22 000 52 000 42 000 30 000 9 16 5 8 38 000 28 000 64 000 52 000 38 000 5 8 Y 54 000 40 000 92 000 76 000 54 000 Y 7 8 72 000 54 000 124 000 102 000 72 000 7 8 1 94 000 70 000 162 000 132 000 94 000 1 Wire Rope 6 x 19 IPS and 7 x 7 Galvanized Aircraft Grade Notes 1 These values only apply when the D d ratio is 25 or greater choker and basket hitches D Diameter of curvature around which the body of the sling is bent d Diameter o
126. 000 80 000 69 300 56 600 40 000 11 53 000 42 400 106 000 91 800 74 900 53 000 12 66 000 52 800 132 000 114 300 93 300 66 000 13 90 000 72 000 180 000 155 900 127 300 90 000 Reprinted from ASME B30 9 2006 by permission of The American Society of Mechanical Engineers All rights reserved NOTES 1 Roundslings are identified by the vertical rated load shown on the tag The Size Number in this column has been adopted by the Web Sling and Tiedown Association to describe certain polyester roundslings They are included for reference only Other polyester roundslings may have different vertical rated loads 2 Color guidelines for polyester roundsling covers are widely used to indicate the vertical rated load of roundslings however this is not followed by some manufacturers Always select and use roundslings by the rated load as shown on the tag never by color Chapter 11 General 11 44 DOE STD 1090 2007 CHAPTER 12 RIGGING HARDWARE This chapter provides requirements for rigging accessories used in hoisting and rigging shackles eyebolts eye nuts links rings swivels wire rope clips turnbuckles rigging hooks and load indicating devices and implements the requirements of ANSI ASME B30 26 Rigging Hardware for latest ASME standards see http catalog asme org home cfm Category CS 12 1 12 2 12 3 12 4 12 5 12 6 GENERA Mo oasis ocd aia 12 1 12 1 1 Good and Bad Rigging Practices nennen nennen 12
127. 1 12 8 3 KE E 12 21 12 8 4 e 12 21 12 875 Removal Criteria vcs ene ee Haie npe dede re I ee cad alae 12 22 12 8 6 Repairs iii Meester deseri Ep ce Rr e eee e eae E APRES 12 22 12 87 Critical Lats iicet nee toe toner see te GU poer I HERE aee edes 12 22 12 9 LOAD INDICATING DEV IB eege gedreet net ii 12 25 12 9 Gener l secs at E eects ah ea Pees 12 25 1292 Critical Lats eie eo edes e e tette rea d eae br nell CHE E ere Ue iran 12 25 12 10 PRECISION LOAD POSITIONERS eee erennnen eren ener 12 26 ER DR 12 26 12 10 2 edel RE ierit EA eee mete sabe ees ogee i di 12 26 12 11 COMPRESSION HARDWARE ico ane eR HUP Pe ete 12 27 12 1 TI General up C petet ea eb ee bte eee eec bota 12 27 12 11 2 Assembly Wire Rope Clips eese eene nnne emeret nenne 12 27 12 11 3 Assembly Wedge Sockets esee nnne nennen nemen nenne 12 27 12 11 4 Effects of Envtronment eene enne enne nemen nnne ennt enne eene nnne 12 28 12 11 5 AAA eee PD e a e Fr n eet a teet 12 28 KH Lo Inspections iterat dee 12 28 12 TT Removal Criteria oen eH AH s aate aid ales 12 28 TD 11 8 Repaits 2 2 a eee a r a etel Pone CE ahaa 12 29 12 11 9 Critical Lafts iion C oU tere Eee te eee ti d ei Hes 12 29 Chapter 12 12 ii Rigging Hardware DOE STD 1090 2007 12 1 GENERAL The information presented in this chapter provides guidance for safely handling lifted loads Diagrams are used to illustrate hoisti
128. 1 Craftsmen shall initial and date all tests work and inspections completed below 2 Qualified inspector shall verify all steps prior to load test NO CRANE ITEM DEFECT OK NA NO CRANE ITEM DEFECT OK NA 1 Load Hook amp Blocks 18 Controllers Wire Rope and End 2 Connections 19 Relays and Coils 3 Handrails Walkways 20 Conductors and and Ladders Collectors 4 Bridge and Trucks 21 Panel Wiring 5 Bridge Wheels and 22 Resistors Bearings 6 Trolley and Rails 23 Bypass Switches z Tolley heels and 24 Limit Switches Bearings 8 Crane Alignment 25 Contactor Electrical 9 Runway Rail amp Clamps 26 Motors 10 Bumpers Endstops 27 Gauges 11 Brake System 28 Lighting System 12 Drive Shafts Gears 29 Heater and Switches Couplings amp Bearings Pawls Ratchets 13 Spuds amp Windlocks 30 Operator s Cab 14 Sheaves 31 Safety 15 Warning Devices 32 Chain and Sprockets 16 Capacity Signs 33 Structural ec Wire Rope Drum and 1 Main Disconnect 34 Machinery Foundation REMARKS unusual conditions noises structural cracks misalignment etc Chapter 7 7 22 Overhead and Gantry Cranes NOTES INITIAL DOE STD 1090 2007 Page 2 of 4 EXHIBIT continued BRIDGE CRANE AND FOLLOW UP CHECKS Craftsmen shall initial all steps completed below Qualified inspector shall verify all steps below Load test shall be performed on
129. 10 Forklift Trucks DOE STD 1090 2007 j Tools and other metallic objects shall be kept away from the top of uncovered batteries 10 3 6 HISTORY FILE A history file should be maintained for each forklift truck The history file should contain information necessary to operate maintain test and evaluate the forklift truck A typical history file would contain the following types of documentation as applicable a Manufacturer s operation and maintenance manuals b Waivers applicable to the forklift truck c Documentation for replacement forks Chapter 10 Forklift Trucks 10 18 d Documentation from the manufacturer authorizing modifications to the forklift truck e Inspection procedures and inspections records f Records of repair modification and overhaul g Fork inspection records including record of fork repair h Authorization from truck manufacturer to use specifically identified attachments NOTE For forklift trucks on rental ensure that a suitable maintenance and inspection program is established for the duration of the rental period For rental equipment onsite for 6 months or less a history file is not recommended DOE STD 1090 2007 10 4 TESTING 10 4 1 FORKLIFT TRUCK LOAD TEST Forklift truck load tests are not routinely required a Load tests shall not be conducted until verification that inspection and maintenance is up to date b Load tests shall be performed after ma
130. 10 are sent to individuals on the distribution list After two to three such supplements the manual is reissued in its entirety which incorporates the previous supplements plus the most recent unpublished changes approved by the committee An example is the complete revision issued in 1993 followed by another complete revision in 1996 1999 2001and 2004 without any intervening supplements In this case the supplements were omitted because of the numerous improvements incorporated within the very short time period The reissued June 1995 edition marked a change in classification The DOE Office of Scientific and Technical Information OSTI reclassified the manual as a handbook and it was issued as DOE Hoisting and Rigging Handbook DOE HDBK 1090 95 After further review OSTI has reclassified the handbook as a DOE Technical Standard and the September 1996 edition was issued as DOE STANDARD HOISTING AND RIGGING Formerly Hoisting and Rigging Manual DOE STD 1090 96 Rev 1 Additional revisions issued are DOE STD 1090 99 DOE STD 1090 2001 DOE STD 1090 2004 and DOE STD 1090 2007 While The Hoisting and Rigging Standard is in itself a best practice document much of its content such as the OSHA and the therein prescribed ANSI ASME and and Crane Manufacturers Association of America standards are mandatory within DOE In addition many DOE organizations have on their own initiative adopted the standard as mandatory to ensure safe and proper hoisti
131. 16 References 9 1 7 COUNTERWEIGHT a Cranes shall not be operated without the ballast or counterweight being in place as specified by the crane manufacturer Under specific conditions such as during crane assembly unusual boom configurations etc the crane manufacturer s recommendations for the amount of ballast or counterweight shall be adhered to b Ballast or counterweight as specified by the manufacturer shall not be exceeded 9 1 8 RERATING a Cranes may be modified or rerated providing such modifications are analyzed thoroughly by a qualified engineer or manufacturer of cranes Such action must be approved by the cognizant safety organization b When rerated crawler truck and wheel mounted cranes shall be tested in accordance with SAE J765 Crane Load Stability Test Code c A rerating test report shall be readily available d Nocranes shall be rerated in excess of the manufacturer s original load ratings 9 1 9 MAINTENANCE HISTORY The maintenance history of the crane shall be retained throughout it service life 9 1 10 DESIGN STANDARDS a Structural mechanical and electrical components of the crane design shall meet accepted crane design standards such as PCSA 4 Mobile Power Crane and Excavator Standards and Hydraulic Crane Standards b The safety features and operation shall conform at a minimum to the provisions of ASME B30 5 Mobile and Locomotive Crane
132. 2 Rated Load Test ct Hiit ove e epe adi s 9 12 E SOEN ERR Kg E SE E 9 13 9 4 1 Preventive Maintenance sais extendens Reeder ieee tane 9 13 9 4 2 Weaintenance Procequres agi espe a eat 9 13 9 4 3 Wire Rope E ME 9 13 9 5 OPERATION ociosa rei 9 15 9 sCONnduCE Or OA EE 9 15 95 Ll Travelin the Machine oe e amd duce cease avid s 9 16 9 5 1 2 Making Adjustments or Repas 9 16 9 5 1 3 Ensuring abla 9 17 9 5 1 4 Further Safety Considerations eese 9 18 9 5 2 Operating Near Power Lines and Transmitter Towers 9 18 9 5 2 Crane Operations De energized and Grounded Electrical Power Iu C H tat tnt 9 19 9 5 2 2 Power Lines Energized Crane Operating Less Than Erected Fully Extended Boom Length Away From Prohibited ZoNe usina ira 9 19 9 5 2 3 Crane Operations are Within the Prohibited Zone and the Power Lines are Energized ise 9 22 9 5 2 4 Crane in Transit with no Load and Boom Lowered 9 22 9 5 2 5 Crane Operations Near Transmitter Towers 9 22 9 5 3 Hoist Lamnt Switch iai it 9 22 9 5 4 Standard Hand SIgsalsag acce oU ose persto te et au o deti e ox dtes 9 25 930 dden ticatioB OE STS MALS a in Qi dps cen dd 9 25 9 5 6 Size of Load i cott todos en ek tae cute ste tei EE 9 25 9 5 7 Attaching the Ee cu nid us itd eet e vut dev des 9 25 9 35 89 Moving the Ead sait tesis O 9 25 9 2 9 Ordinary LAS tette A DR UE 9 29 9 STD Criti
133. 2 Ifthe truck must be left on an incline block the wheels DOE STD 1090 2007 3 Fully lower the load engaging means Maintain a safe distance from the edge of ramps platforms and other similar working surfaces Do not move railroad cars with a powered industrial truck Do not use a truck for operating or closing railroad car doors except as follows 1 Unless the truck utilizes a device specifically designed for opening and closing railroad car doors and the operator is trained in its use 2 The design of the door opening device shall require the truck to travel parallel to the railroad car with the force applied in a direction parallel with the door travel 3 Care should be exercised when engaging the railroad car door with the door opening device in order to prevent damage to the doors and or fork truck by heavy impact forces 4 The entire door opening operation shall be in full view of the operator 5 The fork truck shall always be positioned to safeguard the dock attendant while removing the door lock pin 6 Whenever a railroad car door requires an abnormal force to open the truck operator shall report the condition to his supervisor Wheel stops hand brakes or other recognized positive protection shall be provided to prevent railroad cars from moving during loading or unloading operations Consider both the truck and load weight when operating in railcars and semitrailers Inspect floors on
134. 31 August 2009 SLAC has adopted the 2007 revision of Department of Energy Standard 1090 Hoisting and Rigging DOE STD 1090 2007 as it applies to Chapter 41 Hoisting and Rigging and Chapter 48 Powered Industrial Vehicles The attached local version of this standard has been created because SLAC will continue to use the 2007 revision even after subsequent revisions are issued because the subsequent revisions will not have the level of detail available in the 2007 revision For guidance contact the hoisting and rigging program manager Fa y ds E k i R ARA INCH POUND DOE STD 1090 2007 Change Notice No 1 December 2007 Superseding DOE STD 1090 2004 DOE STANDARD HOISTING AND RIGGING U S Department of Energy AREA SAFT Washington D C 20585 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited Change Notice No 1 DOE STD 1090 2007 December 2007 Chapter 4 Provide ASME attribution at introduction to the Table on Contents and on Figures 4 3 4 and Exhibits 1 amp 2 Chapter 7 Provide ASME attribution at introduction to the Table on Contents and on Figures 7 1 2 3 4 5 and Table 7 1 Chapter 8 Provide ASME attribution at introduction to the Table on Contents and on Figures 8 1 2 3 4 5 6 7 8 9 and Table 8 1 Chapter 9 Provide ASME attribution at introduction to the Table on Contents and on Figures 9 1 2 3 4 5 6 and Table 9 2 Chapter 11 Provide ASME attribution at introductio
135. 4 8 1 3 1 Electric or Air Powered Hosts 8 4 8 1 3 2 Hand Chain Operated or Manual Lever Operated Hoists 8 4 SA Weston Stand ards ausis ote ett paste dde uox e 8 5 8 1 5 EN E ua ve dame re pue trn gk uremia 8 5 8 1 6 Load Braking Load Controlling Mechanisms eese 8 5 8 1 6 1 Blectric Powered Holst tidad 8 5 ge Aq Powered Holst saniert i iae Wt ba merit de hae 8 5 8 1 6 3 Hand Chain Operated Hoists eene 8 6 8 1 6 4 Manual Lever Operated Hoists eere 8 6 DT Wire E A 8 6 abst Load Cam A t one s pale de a did ae 8 6 8 1 8 1 Electric Powered Air Powered and Manual Lever Operated ER eeh 8 6 8 1 8 2 Hand Chain Operated Hoists eese 8 6 Oleh Wed EE EE 8 7 S ITO Overtrdvel Profe e o cen et rte te Api eee preti ete be 8 7 8 1 10 1 Travel Warning Devices eer ete eth enini 8 7 8 1 10 2 Lower Limit Switches Devioes iu iis esee tese eter otii 8 7 S I TT Travel Warning Devices uso oe vi t en QU ette exiens 8 7 SKI SUDDOLT cii tio irme EROR ERR OR HERO HS RN a ae E E EP NONE Perd 8 7 VH E A E 8 7 SA ARAS A AT ES 8 7 INSPECTIONS sd A A a 8 8 82 Horst SELVA 8 8 5 227 Mitial Inspection d oe E ease re ptem eed E ek ee eerie 8 8 52 5 Daly HISDOC HOT sace AA Aqua ape hat aS ae Noun 8 8 8 2 4 Frequent Inspection sisi eret Ro ane rea rete aet eros cabs eet a ea et 8 8 5 25 Periodic Inspections coy eei M ROT ees Wed ted ie E QA 8 8 5 2 5 T
136. 4 TL2 5 2 6 x Class iCat EROR be SEU I tote pi vs 11 5 11 2 4 Wire Rope InspeclloDs oves erected a 11 5 11 2 5 Wire Rope Maintenance eiii pier rint ther esa ree ed EEN eR ENEE 11 5 ABICO 11 8 11 31 General init and 11 8 11 3 1 1 Load Angle Pacto A ek 11 8 EES I2 Safe A enact latina sta e dat vea SU Meecha 11 8 USAS Desir VAC ido e pe rie ies no tari te ne 11 10 IES LA SINS Cate oco cep etr her d b et d aae Is 11 10 I1 3 1 5 Sling Storage aieo ede e e cen ede ne iet eo eere us 11 10 TE 3 1 6 INSPEC MONE oor ee ii EA TERET NS 11 10 11 3 1 7 Sling Periodic Inspection Records 11 10 11 33 Wire Rope Sings anco co e ret ORIS YE IER E eens 11 10 11 3 2 1 Removal from Service Criteria esssesss 11 20 1132 20 Proof RE 11 20 E e Operation E 11 20 11 23 22 Cri al DIE eco e easton bay iste tma be S QD dere tid 11 23 11 3 3 Alloy Steel Chain SIngs cii ds 11 24 11 3 3 1 Removal from Service Criteria sucinta citant tens 11 25 Ee e Amal InspeeHoOTS ooa di eroe aie e a a eS 11 25 11 3 3 3 Proof Testing s intei rete erae eh Reed vers ree Sonus 11 26 ERE OBGFaU ODyss en O A 11 28 eh I oos ego NI ROT PRESSE 11 29 11 34 Metal Mesh S IBS ach oni ee peii ere e tet iens aea EH Re EPIS 11 29 11 3 4 1 Removal from Service Criteria eessssss 11 32 A 11 32 LAS Operation lidad 11 32 TSAA Cs 11 33 11 3 5 Synthetic Web Sings son eret its 11 33 11 3 5 1
137. 4 44 INSPECTIONS 14 4 4 1 Initial Inspection Prior to their initial use a qualified inspector shall inspect all new modified or repaired lifting magnets to ensure compliance with Section 14 4 4 3 Periodic Inspection 14 4 4 2 Frequent Inspection a The operator or other designated person shall visually inspect each magnetic lifting 14 17 device at the beginning of each shift or prior to use if it has not been in regular service b The inspection shall be for the following records are not required 1 Lifting magnet face for freedom from foreign materials and for smoothness 2 Lifting bail or sling suspension for proper condition 3 Control handle for proper condition and operation 4 Current indicator where applicable for proper condition and operation 5 Labels markings and indicators or meters for legibility 6 Electrical conductors if applicable for loose connections continuity corrosion and damage to insulation 7 Battery for correct electrolyte level and lack of corrosion of battery posts or connectors if applicable 14 4 4 3 Periodic Inspection a A qualified inspector shall perform a complete inspection with the equipment in place at the following intervals 1 Normal service yearly 2 Heavy service yearly 3 Severe service quarterly b Lifting device service is defined as 1 Normal operation with various weights within the rated load limit or unif
138. 44202 OTOL Lice reto e Patto Banden E eo 14 17 E e SE eoe b eee Eph cbe Piece Du ttr n pues 14 17 L Ak ISDECtONS f ANE 14 17 1444 1 Initial Inspection ld eret n e oui 14 17 14 4 4 2 Frequent Inspections sse eren eee e pere repas 14 17 14 4 4 3 Periodic Inspection eere teer renti tnos 14 17 IAA D MR 14 18 14 4 5 1 Operational Test es tti ceret ne een era rens 14 18 1445 2 Rated Load Test un teet ed io Dee 14 18 I3 4 6 M ENEE 14 18 14 4 7 Training Qualification seen eene enne 14 19 MAS OPEIN ON desee inpet ts vad sings a euh a 14 19 14 4 8 1 External Powered Electromagnets esses 14 20 14 4 8 2 Battery Operated Electromagnets sues 14 20 14 4 8 3 Electrically Controlled Permanent Magnets 14 20 14 4 8 4 Manually Controlled Permanent Magnets 14 20 1440 SC poa DATES S d e cadence efr eet tun ortis e e P eb n der en 14 20 MAGNETS REMOTE OPERATED 14 21 14 5 1 Desien PabbI atl OM caen ia e ER Er t uel erm e pr dens 14 21 14 5 2 Markt O es EL peu 14 21 14 5 3 Instalan iaa BG i RAE 14 21 PALS A E E 14 21 14344 Initial Inspection sci es po nea is t eret et 14 21 14 5 4 2 Frequent Inspection cover V p re ORDERS 14 21 14 5 4 3 Periodic InspecHOon uic eod ertet etn eere eer tar 14 21 AS ESTAS AS el a ETE Cat 14 23 T4 5 5 T Operational Testo ds 14 23 AER Maintenance nessen ok a taa
139. 7 7 28 Overhead and Gantry Cranes DOE STD 1090 2007 INSPECTOR print SIGNATURE Page 2 of 2 EXHIBIT Ill continued SAMPLE FORM ITEM OK CODE ITEM OK CODE Gear Reducer Drum Grooving Gear Reducer Oil Seals Drum Shafts Axle Pinion Motor Pinion Axle Gear Motor Gear Cam Followers Guides Intermediate Pinion Energy Absorbing Bumpers Intermediate Gear End Stops Drum Pinion Hoist M Main Drum Gear A Auxiliary Hook Hoist Case Bearing Hook Bearing Mechanical Load Brake Sheaves Friction Disc Sheave Bearings Pawl Equalizer Sheave Pawl Shifter Rope Chain Ratchet or Band Rope Anchors Motor Coupling l Hoist Case Coupling Needs Immediate Action l Notes Circle One PASS FAIL Items with to be inspected prior to use as part of the Pre Operational check and lubricated as needed All other items to be inspected and lubricated annually Chapter 7 Overhead and Gantry Cranes DOE STD 1090 2007 Page of 2 EXHIBIT IV SAMPLE FORM OVERHEAD CRANE PERIODIC INSPECTION REPORT ELECTRICAL ITEMS MAKE CAPACITY LOCATION STATUS CODE SR Should be Replaced NR Needs Repair R Repaired SN See Notes N A Not Applicable ITEM OK CODE ITEM
140. 8 000 42 000 1 3 4 2 56 000 48 000 112 000 92 000 74 000 56 000 2 Wire Rope 6 x 19 and 6 x 37 IPS IWRC Notes 1 These values only apply when the D d ratio is 25 or greater choker and basket hitches D Diameter of curvature around which the body of the sling is bent d Diameter of rope 2 Choker hitch values apply only to choke angles greater than 120 degrees 11 13 Chapter 11 General Table 11 5 Load capacity of wire rope slings Hand tuck splice Fiber Core in pounds Design Factor 5 1 DOE STD 1090 2007 TEE 0 U mm Basket or Dia in Vertical Choker two legs Dia in inches inches Ya 980 760 1 960 1 700 1 400 980 Ya 5 16 1 500 1 200 3 040 2 600 2 200 1 500 5 16 3 8 2 200 1 700 4 400 3 600 3 000 2 200 3 8 7 16 2 800 2 400 5 600 5 000 4 000 2 800 7 16 Ye 3 600 3 000 7 200 6 400 5 200 3 600 Ye 9 16 4 600 3 800 9 200 8 000 6 400 4 600 9 16 5 8 5 600 4 600 11 200 9 600 8 000 5 600 5 8 Y 7 800 6 600 15 600 13 600 11 000 7 800 Y 7 8 10 400 9 000 20 080 17 800 14 600 10 400 7 8 1 13 400 11 800 26 800 22 000 18 800 13 400 1 1 1 8 16 800 14 800 33 600 28 000 24 000 16 800 11 8 1 20 000 18 000 40 000 34 000 28 000 20 000 1 1 3 8 24 000 22 000 48 000 42 000 34 000 24 000 1 3 8 1 30 000 26 000 60 000 52 000 42 000 30 000 1 1 5 8 34 000 30 000 68 000 58 000 48 000 34 000 1 5 8 134 40 000 34 000 80 000 70 000 56 000
141. Backup Paint Cracks or Leaks e Swing Gearbox Case e Transmission Case e Pump Drive Box e Engine Intake Boom Wear Pads Brake Liners Axle Planetary Hubs Cleaner Clutch Release Bearing Gear Shift Control Steering System Oil Crankcase Breather Tie Rod Ball Joints Steering Knuckles Drag Link Ends Drag Link U Joint Windshield Wiper Lever Indicator Emergency Brake Gauges Oil Fuel Amp CIRCLE ONE PASS FAIL INSPECTOR Print Signature Date 9 45 Chapter 9 Mobile Cranes DOE STD 1090 2007 INTENTIONALLY BLANK 9 46 Chapter 9 Mobile Cranes DOE STD 1090 2007 CHAPTER 10 FORKLIFT TRUCKS This chapter specifies operation inspection testing and maintenance requirements for forklift trucks powered by internal combustion engines or electric motors and implements the requirements of ANSI ITSDF B56 1 Safety Standard for powered Industrial Trucks Low Lift and High lift Trucks and ANSI ITSDF B56 6 Rough Terrain Fork Lift Trucks and ANSI UL 558 Internal Combustion Engine Powered Industrial Trucks and ANSI UL 583 Electric Battery Powered Industrial Trucks 10 1 GENERAL usa epo niae is 10 1 10 1 1 Operator Training Qualification eeeeseneeeeeeeeen eene 10 1 10 1 2 Rat d Capacity ice eom Peter RE e emere eee 10 1 10 1 3
142. Bridge Finger Tips Bridge Conductors Bridge Segments Runway Conductors Needs Immediate Action Notes Circle One PASS FAIL INSPECTOR print SIGNATURE Items with to be inspected prior to use as part of the Pre Operational check and lubricated as needed All other items to be inspected and lubricated annually 7 31 Chapter 7 Overhead and Gantry Cranes DOE STD 1090 2007 CHAPTER 8 HOISTS This chapter provides safety standards for inspecting testing and operating hoists not permanently mounted on overhead cranes and implements the requirements of ASME B30 11 Monorail Systems and Underhung Crane Hoists for lates s B30 16 Overhead Hoists Underhung and B30 21 Manually Lever Operated t ASME standards see http catalog asme org home cfm Category CS 8 1 GENERA iiic cei hess binds serpere HERREN EE HEN RE REY RUSO wea RS RU SEE ean e 8 1 8 1 1 Operator Training Qualification eee een enne 8 4 81 27 Marg ege m 8 4 8 3 Warning Labels e eee te ee ap re EE ee ER pe bea deans meatal 8 4 8 1 3 1 Electric or Air Powered Hoists eese 8 4 8 1 3 2 Hand Chain Operated or Manual Lever Operated Hoists 8 4 8 144 Design Standards euet etate ere o Eo E a 8 5 8 1 5 Design Factors sts et tette tertie tre REPE atada 8 5 8 1 6 Load Braking Load Controlling Mechanisms eee 8 5 8 1 6 1 Electric Powered Hoists
143. Chapter 11 11 2 General DOE STD 1090 2007 50 70 80 Efficiency 109 2 6 10 14 18 22 26 30 34 38 D d ratio diameter of pin or sheave D Ratio R 2 nominal diameter of rope d Figure 11 1 Efficiency of wire rope when bent and statically loaded to destruction over sheaves and pins of various diameters 11 3 Chapter 11 General DOE STD 1090 2007 11 2 WIRE ROPE 11 2 1 WIRE ROPE LAYS a Ina right lay rope the strands twist to the right around the core like a conventional screw thread in a left lay rope the strands twist to the left b A rope has a lang lay when the strands and the individual wires have the same lay direction When the strands and the wires have an opposite lay direction the rope has a regular lay c A standard wire rope unless otherwise stated is understood to be right regular lay With few exceptions all wire rope is made right lay Left lay rope is a special purpose rope d Figure 11 2 shows ropes with right and left lays combined with regular and lang lays e Lay length is the lengthwise distance measured along a wire rope in which a strand makes one complete revolution about the rope s axis 11 2 2 WIRE ROPE CORES a Wire rope consists of multistrand metal wires wrapped around a suitable core material Wire rope cores are carefully designed and must be precisely manufactured to close tolerances to
144. Chapter 8 vi Gouges nicks or weld spatter 4 Do not attempt to repair roller chain by welding or heating 5 Ensure that replacement chain is the same size grade and construction as the original chain furnished by the hoist manufacturer unless otherwise recommended by the hoist manufacturer due to working conditions 6 Never use discarded or new roller chain for slings 8 2 5 5 Synthetic Web Strap a No precise rules can be given for determining the exact time to replace web strap Safety depends largely on the use of good judgment by an appointed person in evaluating remaining strength in a used web after allowance for deterioration disclosed by inspection Conditions such as the following shall be reason for questioning continued use of the web strap or increasing the frequency of inspection 1 Severely worn end connections 2 Distortion of the web strap structure 3 Evidence of any heat damage The web strap shall be removed from service when damage such as the following is discovered 1 Melting or charring 2 Acid or caustic burns 3 Weld spatter 4 Broken stitching 5 Cuts or tears 6 Damaged eyes or fittings 7 Abrasive wear 8 Knots DOE STD 1090 2007 8 2 6 HOISTS NOT IN REGULAR SERVICE A hoist that is not in regular service idle for a period of 1 month or more but less than 1 year shall be inspected before being placed in service according to the requirements listed
145. E Headquarters HQ met to discuss the need for a DOE hoisting and rigging manual At that meeting existing applicable hoisting and rigging codes standards and regulations such as the Occupational Safety and Health Administration OSHA 29 CFR 1910 the American National Standards Institute ANST B 30 series and others were reviewed in detail Subsequently it was determined that these documents while adequate as minimum general industry standards did not contain the detail necessary to adequately accomplish the extremely complex critical and hazardous hoisting and rigging operations being performed at DOE sites in all probability at other government agency and private sectors throughout the country Because of the high potential for accidents that could result in significant property loss or serious personnel injury or death it was decided that a DOE hoisting and rigging manual was not only desirable but absolutely necessary Preliminary work on the manual was initiated in 1976 The manual that was developed at that time incorporated the minimum requirements of OSHA ANSI and similar documents and also included additional more stringent requirements deemed necessary to adequately control hoisting and rigging work processes throughout DOE Each phase of the manual was then critically reviewed by DOE and contractor personnel A final draft was completed in 1978 and implemented on a trial basis In June 1980 a decision was made to formall
146. E 14 2 1422373 Perniodie Inspec OD oot oe nter trie Paciente die 14 3 I ME DNI IUD Am ia 14 3 14 2 6 1 Operational Testa cedi e rrt edem i arr etn 14 3 14 2 6 2 Rated Load Test e ee ertet ee eere ene 14 7 14 3 14 4 14 5 14 2 7 Mantencion Pe eu ie eiat 14 7 14 2 8 Freanimo OualifiC AUOD utet gei eet ete St PA E EN daa EAE 14 7 142 9 Operation es aloes addo teo euet d nbs O 14 7 14 2 10 rt Cal LATS na 14 8 VACUUM LIFTING DEVICES consta adeft ma 14 9 1431 DestetuBAbEICOIDIE oio arescit e x pi P Yu et D eA Y vano Red us 14 9 14 32 MERI ada 14 9 14 5 3 Installation ca ta 14 11 E E e 14 11 14 3 4 1 Initial InspectlOn s ac AA ee anna eon ERE 14 11 14 3 4 2 Frequent Inspection erre terrent nene tenentes 14 11 143 45 Periodic InspecHObs s ecd ederet ele 14 11 ASI TESI pde pea ob DN att urs au Edu 14 12 143521 Operational Eesti notari mie rte uel 14 12 14 5 5 2 Rated Load esta a ct ette dues 14 12 14 3 6 Maintenance 5 dde ated eie te e e eee bg ee ta eei Ue 14 12 14 3 7 Tramimg QualifICAlofic uoce E PS RURUIN XX esas teen 14 12 1453 5 Operationens A M du ta QE 14 13 14 3 9 Critical Lifts eee eite et eor ote e I eerie pO ree ds 14 14 MAGNETS CLOSE PROXIMITY OPERATED 14 15 144 1 Desi en Bab OM EE 14 15 T4 2 2 MERITO en tortor e eur i eor ed dice en eta Gove ac a eevee 14 15 14 4 2 1 Rated Load Capacity esee 14 17 1
147. E A ai 8 12 8 2 6 Hoists Not in Regular Service 8 13 DOE STD 1090 2007 8 3 TESTING EE 8 14 8 3 T Operational Tests ue et eame ou montem e mei 8 14 8 3 1 1 Electric or Air Powered Hosts 8 14 8 3 1 2 Hand Chain Operated Hoists essere 8 14 8 3 1 3 Manual Lever Operated Hotets 8 14 8 3 2 Proof Load Testi pese eee neam heec e eere hatte 8 14 8 3 2 1 Electric or Air Powered Hoists essere 8 14 8 3 2 2 Hand Chain Operated or Manual Lever Operated Hoists 8 14 8 4 MAINTENANCE uti 8 16 8 5 OPERATION eee datas toba 8 17 5 1 Conduct of Operator moe beate eere eee eret free 8 17 8 3 2 A eere ee ive eode 8 17 8 5 3 Attaching the Load ise eed diria 8 17 8 5 4 Moving the Loads seoaren a d dee eed eee 8 17 855 HoistLimit Switch eie etd e er ee tbe Seide e SE vibe 8 18 8 5 0 Ordinary Lafts cei EE 8 18 8 5 7 Planned Engineered Luft 8 19 8 5 8 Critical Lifts oic ee dede ed t c ge tdeo Sedet EEN ee 8 20 EXHIBIT I Hoist Load Test iei t e Y idea e ida rd res 8 24 EXHIBIT II Underhung Hoist Periodic Inspection Report 8 26 8 ii DOE STD 1090 2007 8 1 GENERAL a Hoists described in this chapter include hand powered air powered and electric 4 Manual lever operated hoists wire powered hoists that are not permanently rope chain and web strap types mounted on overhead cranes c Wire rope ratchet and pawl lever operated b This chapter app
148. ENERAD 25 etd bep UR oa Uu eic E 13 1 1314F Mar P 13 1 T3 1 2 Attachments dicta cotidianeidad leds 13 1 I3 1 3 Load LUIS eee ee ee een obe baee E SAN DU bo oes Duc aE ee 13 1 13 4 Hook Standards oit air ERE Oden 13 1 13 2 INSPECTIONS iia 13 2 13 21 Hook Servi oeste eee RO ea res alld Di de esci i uita pat 13 2 13 2 2 Initial RE E 13 2 13 2 3 Daily Inspection uisi ere Rea n nep ree en eri qued gn 13 2 13 24 Frequent peca Qr pp redes 13 2 e Ge Ree Mere e 13 2 15 3 TESTING oet etie eee ne ee ee HER 13 4 13 4 NONDESTRUCTIVE TESTING NDT cr 13 6 13 4 NDT E 13 6 134 2 NDT Records oidos 13 6 1343 NDE Methods tia ita 13 6 I3 4 4 Acceptance GCritertd uo eden alee eae aie a ee 13 6 13 4 5 Discontinuity Removal aine a A ER eres 13 6 135 MAINTENANCE cri 13 8 13 6 EERSTEN 13 9 Exhibit I Exhibit Hood Periodic Inspection Report 13 11 CHAPTER 14 BELOW THE HOOK LIFTING DEVICES 14 1 14 1 GENERAL icici eee aie eei edet er RR a p E Eo ERE ups 14 1 14 2 STRUCTURAL AND MECHANICAL LIFTING DEVICES 14 2 14 2 1 Design Pabricatiori 4 drid 14 2 E EN A been pat TE 14 2 14 2 3 Modinication Reratng usi deae e e Re dade REL OA Peli te eU pedea 14 2 14 2 4 CUDEGIBE s s O est ext pne de vat EIS d i ERO Ee dT 14 2 14 75 ASP IAS ban RBS RT Ep RM E ROM a 14 2 14 2 5 1 Initial Inspection rei et neto e ea reo retra en 14 2 1425 2 Prequent tere E
149. FECTS OF ENVIRONMENT a Compression hardware are to be used at temperatures above 400 F 204 C or below 40 F 40 C the compression hardware manufacturer or a qualified person should be consulted b The strength of compression hardware can be affected by chemically active environments such as caustic or acid substances or fumes The compression hardware manufacturer or a qualified person should be consulted before compression hardware are used in chemically active environments 12 11 5 TRAINING Compression hardware users shall be trained in the selection inspection cautions to personnel effects of environment and rigging practices as covered by this standard 12 11 6 INSPECTIONS a Initial Inspection 1 Prior to use all new altered modified or repaired compression hardware shall be inspected by a designated person to verify compliance with the applicable provisions of this chapter Written records are not required b Frequent Inspection 1 A visual inspection shall be performed by the user or other designated person each shift before the compression hardware is used Semi permanent and inaccessible locations where frequent inspections are not feasible shall have periodic inspections performed 2 Conditions such as those listed in Section 12 11 7 or any other condition that may result in a hazard shall cause the compression hardware to be removed from service Compression hardware shall not be returned
150. Fork Lift Truck High Lift Truck High Lift Platform Truck Low Lift Truck Low Lift Platform Truck Chapter 10 10 6 Forklift Trucks Reach Rider Trucks DOE STD 1090 2007 Figure10 3 Types of Trucks sheet 4 of 6 10 7 Chapter 10 Forklift Trucks DOE STD 1090 2007 Figure 10 3 Types of Trucks sheet 5 of 6 Order Picker High Lift Rider Truck Narrow Aisle Rider Truck Straddle Truck Chapter 10 10 8 Forklift Trucks DOE STD 1090 2007 Figure 10 3 Types of Trucks sheet 6 of 6 DOE STD 1090 2007 Figure 10 4 Manually Operated Pallet Trucks GA89 0028 Small Miscellaneous Truck Chapter 10 10 10 Forklift Trucks DOE STD 1090 2007 10 2 TYPE DESIGNATIONS AND AREAS OF USE 10 2 1 TYPE DESIGNATION It is essential to use proper equipment in hazardous explosive areas Trucks approved for use in hazardous areas shall have the manufacturer s label or some other identifying mark indicating approval for the intended use by a recognized national testing laboratory e g Underwriters Laboratories UL or Factory Mutual FM a Durable markers indicating the designation of the type of truck for use in hazardous areas shall be applied to each side of the vehicle in a visible but protected area These markers shall be distinctive in shape as indicated in Figure 10 1 b Hazardous Area Signs The entrance to hazardous areas shall be posted with a sign to identify
151. IA Eyebolts shall be removed from service if damage such as the following is visible and shall only be returned to service when approved by a qualified person Chapter 12 12 12 Rigging Hardware Missing or illegible manufacturer s name or trademark and or rated load identification Indications of heat damage including welding spatter or arc strikes Excessive pitting or corrosion Bent twisted distorted stretched elongated cracked or broken load bearing components Excessive nicks or gouges A 10 reduction of the original or catalog dimension at any point around the body or pin Excessive thread damage or wear Evidence of unauthorized welding or modification Other conditions including visible damage that cause doubt as to continue use 12 4 6 REPAIRS a Repairs alterations or modifications shall be as specified by the eyebolt manufacturer or a qualified person Replacement parts shall meet or exceed the original equipment manufacturer s specifications 12 4 7 CRITICAL LIFTS a See Chapter 2 Critical Lifts for critical lift requirements Eyebolts used for critical lift service shall have an initial proof test of 200 percent of the rated capacity Test loads shall be accurate to within 5 percent 0 percent of stipulated values If proof testing cannot be verified the eyebolts shall be proof tested before being used to make a critical lift DOE STD 1090 2007 Non sh
152. ION AND REPAIR Modification to special lifting fixtures shall be designed approved and fabricated according to Sections 3 2 1 and 3 2 2 Design and Fabrication respectively Following modification or repair of a load bearing element of a special lifting fixture the fixture shall be inspected and tested according to the initial use requirements in Section 3 3 3 Inspection and Testing DOE STD 1090 2007 3 3 PROCEDURES A detailed approved step by step procedure shall be developed for the entire operation 3 3 1 CONTENT a Ata minimum each procedure shall contain the following information 1 Identification of the load to be lifted 2 Identification of the specific lifting fixtures to be used in the operation 3 Identification by class and capacity if applicable of the types of equipment to be used such as cranes and hoists 4 Verification that all equipment fixtures and accessories are operative up to date on required periodic inspections and maintenance and are in good condition before the operation begins 5 Specific instructions for attachment of the lifting fixtures to the load and to the lifting equipment 6 Parameters of motion required for the Operation 7 Specific instructions for removal of the lifting fixtures from both the load and the lifting equipment 3 3 2 DEVELOPMENT a The methods for developing new procedures including standard procedure formats
153. IR E OPE eas 15 9 15 5 7 Working Under Loads specs secs ien er ee aes nest Ea eda ee 15 9 T5 5 8 Multiple Load Lifts iere ee ede hies sees 15 9 CHAPTER 16 MISCELLANEOUS LIFTING DEVICES 16 1 16 1 GENERAL 4 tr Er tete ut a te ea ds tubas ea etae 16 1 16 1 1 Operator Training Qualifications eee 16 1 16 1 2 Rated Load Markings Safety Markings and Operating Instructions 16 1 16 1 3 MOGIBESUODS uerit pir nt rdiet erae eU tula eset ie ped 16 1 T6 T 4 Eoad mitin 16 2 16 15 Operatme Controls aneo AA 16 2 16 TG Load Hook ft HH 16 2 E E WRG Babe oeste E MED Me dd 16 2 16 1 7 C suba 16 2 16 2 INSPECTIONS ti lite ot equ dte ET an n Pen ae 16 5 16 2 1 General eite edet i tee N wen 16 5 16 2 2 Initial LEE 16 5 16 2 3 Daily Preoperational Inspection et ee eee 16 5 16 2 4 Periodic WIS PCH CM pric cosas pietro de te Peur 16 5 16 3 TESTING oneri rende ee da etae ere AR Ee e ERES MY tit 16 7 16 541 Operational Testi Ene EUER Depas Sr d 16 7 16 3 2 Rated Load Tests oet eai eu oae ats 16 7 164 MAINTENANCE 5 ien ont in peer te ett t aeta uut 16 8 16 5 OPERATION ioco PRSE ERRR EE REESE ee 16 9 16 5 1 Conduetol Opera ai iia 16 9 CHAPTER MT od REFERENCES APPENDIX A roni ne ran PROCUREMENT GUIDELINES History and Background In 1975 cognizant safety and health personnel at the U S Department of Energy DO
154. IT continued SAMPLE FORM MOBILE CRANE LOAD TEST LOAD AND FOLLOW UP CHECKS This information should be retained with the equipment Record the following BLOCK WEIGHT Ib TEST WEIGHT Ib RADIUS CENTER PIN TO LOAD ft PARTS LINE quantity BOOM LENGTH ft Load Test Inspection Date Qualified Inspector Operated By 9 36 Chapter 9 Mobile Cranes DOE STD 1090 2007 Page 1 of 3 EXHIBIT Il SAMPLE FORM MOBILE CRANE PRE OPERATIONAL CHECKLIST Records Are Not Required STATUS CODE SAT Satisfactory UNSAT Unsatisfactory R Repaired N A Not Applicable EXTERNAL CODE COMMENT Check Fuel Cap Crankcase Oil Level Cold Weather Starting Aid Radiator Antifreeze amp Coolant Cleaners Fan Belts Pumps amp Motors Battery Muffler Brake amp Air System Bleed Hydraulic Reservoir Hydraulic Oil Filter All Hydraulic Hoses amp Fittings Auto Transmission Oil Level Air Compressor Oil Level Outriggers amp Boxes Outriggers Float Pads Tire Condition amp Pressure Wheel Lugs Hoists Boom Attachments Lubrication Grease or Oil Leaks All Sheaves Lubed 9 37 Chapter 9 Mobile Cranes DOE STD 1090 2007 Page 2 of 3 EXHIBIT II continued SAMPLE FORM MOBILE CRANE PRE OPERATIONAL CHECKLIST Records Are Not Required EXTERNAL CODE COMMENT Wire Rope Kinks or Breaks
155. L HOISTS auian e e E er E etek sie a S ahd 8 0 5 20 12 Mare ODE aee eer ee E A EE E 8 0 9 2 5 3 Welded Iink Ch tirada 8 10 8 2 5 4 Roller Chair 8 11 8 2 5 5 Synthetic Web Strap o doceo ai p vet ede ot toic 8 12 8 2 6 Hoists Not in Regular Service eene Be pq EN 8 12 TESTING nne estia ir devenire toit iint lod ded ritatis 8 13 Bo Jal Operational Tests acacia Pet pde o Reo ndi Baden AS abs 8 13 8 3 1 1 Electric or Air Powered Hoisten 8 13 8 3 1 2 Hand Chain Operated Hoists sense 8 13 8 3 1 3 Manual Lever Operated Hoists eese 8 13 8 3 2 Proof Load Test uon Pe qe da petiit db d 8 13 8 3 2 1 Electric or Air Powered Hoists eere 8 13 8 3 2 2 Hand Chain Operated or Manual Lever Operated Hoists 8 13 MAINTENANCE nece un te Gea t t Ue Dg S 8 16 8 5 OPERATION 0 ea 8 17 5T Cond ct EEN 8 17 8 32 SIZE OF Load uie eri ete an 8 17 8 5 3 Attaching the Eo usse onerat tips t pH RIA ile tried seme 8 17 Soe Moving the baad ic oeste deett metaph en iG dates tins 8 17 8 545 Holst Ut EE 8 18 8 226 Ordinary EATUS S ue erbe ia 8 18 8 5 7 Planned Engineered Lifts iiie ierit eren dei 8 19 9 5 8 IR EN ener re ree abe qma aD Ud t e m eU 8 19 Exhibit I Hoist Load Test and Inspection ooooonnocccnnococonocanonenanonnncnonncononncononncon 8 24 Exhibit II Underhung Hoist Periodic Inspection Report 8 26 CHAPTER 9 MOBILE CRANES cita DR ER avin ed 9 1 9 1 GENERAL acini e e SER
156. OE STD 1090 2007 installed and legible Ensuring that each lifting device has its rated capacity legibly marked on the structure on each side of the primary beam Ensuring that the manufacturer s name and model number are permanently and legibly marked on each lifting device Ensuring trolley or beam clamp working load limits do not exceed the capacity rating of the A frame Hoists attached to the A frame must have a rated capacity equal to or less than all supporting components and be inspected to requirements of chapter 8 Down rating of hoist to A frame capacity is acceptable with administrative controls and markings in place Ensuring A frame components from different manufacturers are not inter mixed or with components from other A frames regardless of similarities in manufacturers or rated capacities Chapter 16 Miscellaneous Lifting Devices 16 6 7 Validating the proper dimensional relationship between trolley wheels and rail when installed on portable A frames Refer to Figures 16 4 and 16 5 8 Observing trolley side plates for any bending or distortion 9 Checking for missing or loose bolts nuts and retaining pins or retaining devices In the event any required information is missing or illegible an attempt shall be made via engineering drawings prints evaluations etc to establish the lifting device s manufacturer rated capacity and other pertinent data If this attempt is unsuccessful t
157. OK CODE Brakes Trolley Motor Rings M H Brake Shoes amp Disc M H Motor Bearings M H Brake Linings M H Motor Brushes M H Brake Linkage M H Motor Rings M H Brake Coil Misc A H Brake Shoes amp Discs A H Brake Lining A H Brake Linkage A H Brake Coil Trolley Brake Shoes amp Disc Trolley Brake Lining Controls Trolley Brake Linkage For Magnetic Control Trolley Brake Coils Master Switches Hydraulic Brake Bleeder Push button Station Motors M H Contactors Bridge Motor Bearings A H Contactors Bridge Motor Brushes Trolley Contactors Bridge Motor Rings Bridge Contactors Trolley Motor Bearings M H Overhead Relays Trolley Motor Brushes A H Overhead Relays Chapter 7 7 30 Overhead and Gantry Cranes DOE STD 1090 2007 Page 2 of 2 EXHIBIT IV continued SAMPLE FORM ITEM OK CODE ITEM OK CODE Controls continued Resistors Trolley Overhead Relays M H Resistors Bridge Overhead Relays A H Resistors M H Limit Switch Contacts Trolley Resistors A H Limit Switch Contacts Bridge Resistors For Manual Drum Control Mainline M H Finger Tips Mainline Switch M H Segments Fuses Sizes A H Finger Tips Power Wiring A H Segments Control Wiring Trolley Finger Tips Trolley Collectors Trolley Segments Runway Collectors
158. PECTOR INSPECTION DATE NOTES 1 Proof test to not more than 125 percent f rated capacity for critical lift service The test load shall be accurate to within 5 0 of stipulated values 2 Qualified inspector shall witness all steps below INSPECTION Lifting bars and spreaders shall be checked for signs of incipient failure in bending and shall be replaced if permanently bent more than 1 2 inch in 10 feet or twisted more than 5 degrees out of the original plan Hook attachment welds shall be examined for cracks and signs of failure in tension Qualified inspector shall perform test by visual examination liquid penetrant examination or magnetic particle examination Acceptance No cracks linear indication laps or seams STATIC TEST Hold weight for 10 minutes and visually inspect for deformation Type Size Rated Capacity SWL lb Actual Load Test Ib Serial Number Qualified Inspector Verify Load Test Remarks 14 27 Chapter 14 Below the Hook Lifting Devices DOE STD 1090 2007 INTENTIONALLY BLANK Chapter 14 14 28 Below the Hook Lifting Devices DOE STD 1090 2007 CHAPTER 15 CONSTRUCTION HOISTING AND RIGGING EQUIPMENT REQUIREMENTS This chapter outlines the requirements for the safe use of hoisting and rigging equipment on construction projects at DOE installations 15 1 GENERAL eet Rr a to o eio Gr nde Mac ERE as wee ae 15 1 15 2 PERSONNEL QUALIFICATIONS r
159. Qualified Inspector Verify Hook Twist SUSPENSION HOOK Qualified Inspector Verify Throat Opening Qualified Inspector Verify Hook Twist Qualified inspector shall perform nondestructive tests on hook by visual examination liquid penetrant examination or magnetic particle examination Acceptance No cracks linear indications laps or seams Hooks with more than 5 normal new hook throat opening not to exceed 1 4 in or as recommended by the manufacturer shall be replaced Hooks with any visibly apparent bend or twist from the plane of the unbent hook new hook shall be replaced Hooks having more than 10 wear in the bowl section or 5 elongation of the shank shall be replaced Lubricate hook bearing and latch pin as applicable Establish three marks A B and C with a center punch For ease in measuring set distances on an even number of inches BEFORE LOAD TEST Length AB in Length BC in AFTER LOAD TEST Length AB in Ll Length BC in Check for 1 Wear and deformation 2 Cracks 3 Signs of opening between Point A and Point B Equipment Operator Actual Load Test lb Qualified Inspector Verify Load Test Date Chapter 8 8 24 Hoists DOE STD 1090 2007 Page of 2 EXHIBIT II SAMPLE FORM UNDERHUNG HOIST PERIODIC INSPECTION REPORT HOIST MODEL LOCATION STATUS CODE O K A Adjusted R Repaired NR Needs Repair N A Not Applicable CODE COMMENT CODE COMMENT
160. RE et EAS NV E RUND E 9 1 9 1 1 Operator Training Qualification eese 9 1 9 12 Eoad re 9 1 9 1 3 Load Rating Ghart neninn e nr ED I EROR PER EE CO RYE 9 1 91 4 Eoad et e 9 6 9 1 5 Power tontrolled LDowertng ueste ne sao Te Mae RE 9 6 9 1 6 ODE ai a 9 6 A a OS 9 6 9 1 8 ocn INE 9 6 9 9 Maintenance PISTOLA eee y ele Beg a e pe BENE EE ede 9 6 9 1 10 Design Standards Dd Ae ee 9 6 92 INSPECTIONS eterne d br eI Ee a ER 9 7 OD Generals ep uer eae eth Lbs 9 7 92 20 nita IaSD CLEHOL ns se he Bes vd Pee seti e ce trees e 9 7 9 23 Preoperational Check oed o erat et HN eo EP Ehe HE RE eot RI eatis 9 7 9 2 4 Monthly Inspection uendere treni t nee eroe rir tee Ee o ende eio van 9 7 92 9 Freg ent Inspection ose rmn o ip o ne nM DOPO DUE 9 7 9 2 0 Penodie A E EE 9 8 9 2 0 V Cranes o diay baie aie esten Sd eii 9 8 9 2 6 2 Hydraulic and Pneumatic Hose Fittings and Tubing 9 9 9 2 6 3 Hydraulic and Pneumatic Pumps and Motors 9 9 9 2 6 4 Hydraulic and Pneumatic Valves eee 9 9 9 2 6 5 Hydraulic and Pneumatic Cylinders esse 9 9 9 2 6 6 Hydraulic Filters ui tate rave eret eain 9 9 ODOT EE 9 9 9 2 7 Load Hoods Load Blocks 42 2 2 te ed cag ee cid 9 11 9 2 8 Cranes Not in Regular Use itte raven darian ee eee nd 9 11 9 35 FESTING uoto tele teo c a oa ut o eS ee 9 12 9 31 Operational Tests asc ciated te rus ost reb DR eee 9 12 9 3
161. RENCES American Institute of Steel Construction AISC Specifications for the design fabrication and erection of structural steel for buildings American Iron and Steel Institute AISI Standards for Type 302 or Type 304 stainless steel American National Standards Institute and the American Society of Mechanical Engineers ANSI A10 28 Work Platforms Suspended From Cranes or Derricks ANSI A10 18 Floor and Wall Openings Railings and Toe Boards ASME B30 1 Jacks ASME B30 2 Overhead and Gantry Cranes Top Running Bridge Single or Multiple Girder Top Running Trolley Hoist ASME B30 5 Mobile and Locomotive Cranes ASME B30 6 Derricks ASME B30 7 Base Mounted Drum Hoists ASME B30 9 Slings ASME B30 10 Hooks ASME B30 11 Monorail Systems and Underhung Cranes ASME B30 12 Handling Loads Suspended from Rotorcraft ASME B30 14 Side Boom Tractors ASME B30 16 Overhead Hoists Underhung ASME B30 17 Overhead and Gantry Cranes Top Running Bridge Single Girder Underhung Hoist 17 1 ASME B30 20 Below The Hook Lifting Devices ASME B30 21 Manually Lever Operated Hoists ASME B30 22 Articulating Boom Cranes ASME B30 23 Personnel Lifting Systems ASME B30 26 Rigging Hardware ASME BTH 1 Design of Below the Hook Lifting Devices ANSI ITSDF B56 1 Safety Standard for Powered Industrial Trucks Low Lift and High Lift Trucks ANSI ITSDF B56 5 Guided Industrial Vehi
162. S Instructors responsible for developing or presenting hoisting and rigging training programs shall meet the qualification standards specified by the responsible training organization 6 2 13 FIRST LINE SUPERVISORS The first line supervisor of hoisting and rigging operations should be knowledgeable of the specific types of hoisting and rigging operations under their supervision and their operational hazards The supervisor shall be familiar with applicable rules and procedures implemented at the site to ensure that hoisting and rigging work under their control is done efficiently and safely with safety as top priority Supervisors should ensure that employees fully understand the importance of safety and that they recognize their own authority and responsibility to stop work when safety is questionable 6 2 14 MAINTENANCE PERSONNEL a Employees who operate cranes to perform crane maintenance shall be trained and qualified to operate the cranes on which maintenance is being performed b Crane operation by maintenance personnel shall be limited to those crane functions necessary to perform maintenance on the Chapter 6 Personnel Qualification and Training DOE STD 1090 2007 crane or to verify the performance of the crane after maintenance has been performed 4 Manufacturers recommendations as to points and frequency of lubrication and c Employees who perform maintenance levels and types of lubricant to be used acti
163. TD 1090 2007 7 5 OPERATION The following shall apply to all personnel involved in overhead and gantry crane operation At the initial stage of the planning process an appointed person shall classify each lift into one of the DOE specified lift categories ordinary critical or preengineered production CONDUCT OF OPERATOR Do not engage in any practice that will divert your attention while operating the crane Do not operate cranes without complying with the requirements of Chapter 6 Your immediate supervisor shall participate in this determination Operators shall be held directly responsible for the safe operation of their equipment Whenever there is any question as to the safety of the activity an operator has the authority to stop and refuse to handle loads until the matter has been resolved by supervisory personnel Sound a warning signal if furnished during travel particularly when approaching personnel If you find the crane s main or emergency switch open when starting on duty do not close it until it has been determined that no one is on or close to the crane If there is a warning sign on the switch do not remove it unless you placed it there Do not close the switch until the warning sign has been removed by the person who placed it there Before closing the main switch ensure that all controllers are in the OFF position If a power failure occurs during operation immediately switch all cont
164. TION RESISTANT WIRE ROPE OPEN SOCKET A wire rope fitting consisting of a basket and two ears with a pin ORDER PICKER TRUCK HIGH LIFT A truck controllable by an operator stationed on a platform which is movable has a load engaging means and is intended for manual stock selection The truck may be capable of self loading and or tiering see Figure 10 3 OVERHEAD GUARD A framework fitted to a truck over the head of a riding operator PALLET TRUCK A self loading non motorized or motorized low lift truck equipped with wheeled forks of dimensions sized to go between the top and bottom boards of a double faced pallet the wheels fitting into spaces between the bottom boards so as to raise the pallet off the floor for transporting see Figure 10 3 PEENING Permanent distortion of outside wire in a rope caused by pounding PERSON IN CHARGE PIC The manager or other responsible person other than the equipment operator known to be qualified and appointed to be responsible for the safe handling of critical loads POWERED INDUSTRIAL TRUCK A mobile power driven vehicle used to carry push pull lift stack or tier material PRECISION LOAD POSITIONING DEVICES A rigging accessory designed specifically to precisely raise and lower a load through a limited range of lifting lowering motion stroke Standards units typically have 12 in 30 cm stroke and can position a load within 0 001 in 0 025 mm These devic
165. Testing 3 Lubrication maintenance and repair Appendix A Procurement Guidelines DOE STD 1090 2007 3 SHOP FLOOR CRANES a cT 9 e e Shop floor cranes shall meet or exceed the requirements of ASME PALD Operating controls shall be designed in such a manner that they are readily visible and accessible to the operator and so that the operator will not be subjected to pinch points sharp edges or snagging hazards The operation of controls should be clear to the operator either by position function labeling or combination thereof The release system shall require intentional positive action by the operator for release to prevent accidental lowering Shop floor cranes shall have a positive means to prevent the load from being lowered or raised beyond the design limit of travel Shop floor cranes not equipped with internal load limit devices shall be capable of Appendix A Procurement Guidelines A 4 performing a proof test of 150 percent of the rated capacity Shop cranes equipped with internal load limiting devices shall when the load limiting device is deactivated be capable of performing a proof test of 125 percent of rated capacity Because of the potential hazards associated with the misuse of equipment of this type no alterations shall be made to the product Shop floor cranes shall be provided with a load hook and or chain at the end of the boom extension that has a capacity ca
166. The material used for stainless steel metal mesh slings shall conform at least to the American Iron and Steel Institute standards for Type 302 or Type 304 stainless steel Other materials may be used When metal mesh slings are produced from such materials however the sling manufacturer should be consulted for specific data The handle shall be designed to ensure 1 Atleast the same rated capacity as the fabric 2 No visible permanent deformation after proof testing The fabric and handles shall be so joined that Therated capacity of the sling is not reduced 2 The load is evenly distributed across the width of the fabric 3 Sharp edges do not damage the fabric Metal mesh slings may be painted plated impregnated with elastomers such as neoprene or polyvinyl chloride PVC or otherwise suitably coated The coating shall not diminish the rated capacity of a sling The design factor for metal mesh slings shall be a minimum of 5 1 based upon breaking strength Metal mesh slings shall not be used to lift loads greater than the rated capacity properly derated for other than straight pull configurations Table 11 13 Except for elastomer impregnated slings all metal mesh slings covered by this section may be used without derating in a temperature range from 20 degrees F 29 degrees C to 550 degrees F 288 degrees C Chapter 11 General DOE STD 1090 2007 j All metal mesh slings covered by th
167. USE The atmosphere or location where the powered forklift is to be used shall be classified Location classifications are described as follows a Class I locations in which flammable gases or vapors are present or may be present in the air in quantities sufficient to produce explosive or ignitable mixtures Chapter 10 Forklift Trucks 10 12 Class II locations that are hazardous because of the presence of combustible dust Class III locations where easily ignitable fibers or filings are present but are not likely to be suspended in quantities sufficient to produce ignitable mixtures Unclassified locations not possessing atmospheres defined as Class I II or III locations DOE STD 1090 2007 gt e GE Note The markers for EE EX and DY are 5 in 12 7 cm high The rest are 4 in 10 cm square The signs shall have black borders and lettering on a yellow background Figure 10 1 Markers to identify type of industrial truck Chapter 10 10 13 Forklift Trucks DOE STD 1090 2007 CAUTION ONLY TRUCKS MARKED Cu NUN ES TA V Designation NY Plate in vd PERMITTED IN THIS AREA 193 0136 Figure 10 2 Building signs for posting at entrance to hazardous areas NOTE The minimum width of the sign is 11 in 28 cm the minimum height is 16 in 40 cm The sign shall have the word caution in yellow letters on a black background The body of the sign shall have black letters on
168. W UP CHECKS Craftsman shall initial all steps completed below Qualified inspector shall verify all steps below 1 2 Set crane up for load test and inspection Perform operations test without load to verify proper function of the following e Load lifting and lowering mechanisms e Boom lifting and lowering mechanism e Boom extension and retraction mechanisms e Swinging mechanism e Travel mechanism e Safety devices Test loads shall not exceed 110 of rated capacity Refer to load chart for load test capacity at maximum and minimum working radius Check boom angle indicators for accuracy Rig test weights to hook using appropriate slings Hoist the test load a sufficient distance to ensure that the load is supported by the crane and held by the hoist brakes Hold the load for 10 min or the time required to check all primary load bearing parts while under load without slippage damage or permanent deformation At least once during the lifting portion of the hoisting cycle and once during the lowering cycle power to the hoisting equipment shall be completely turned off There shall be no slippage of the load or overheating of the brakes Lower the load to approximately 2 in off the ground to check for swing roller operation and outrigger stability Slowly swing test load between outrigger locations Move the load back to the original position and slowly lower to ground At the completion of the load test inspect the follo
169. a designated person The turnbuckle shall be examined for conditions such as those listed in Section DOE STD 1090 2007 12 6 6 and a determination made as to whether they constitute a hazard 2 Periodic inspection intervals shall not exceed one year The frequency of periodic inspections should be based on i Frequency of use ii Severity of service conditions iii Nature of lifts being made iv Experience gained on the service life of turnbuckles used in similar circumstances 3 Guidelines for the time intervals are i Normal service yearly ii Severe service monthly to quarterly 111 Special service as recommended by a qualified person 4 Written records are not required 12 6 6 REMOVAL CRITERIA Turnbuckles shall be removed from service if damage such as the following is visible and shall only be returned to service when approved by a qualified person a Missing or illegible manufacturer s name or trademark and or rated load identification b Indications of heat damage including welding spatter or arc strikes c Excessive pitting or corrosion 12 17 d Bent twisted distorted stretched elongated cracked or broken load bearing components Excessive nicks or gouges A 10 reduction of the original or catalog dimension at any point Excessive thread damage or wear Evidence of unauthorized welding or modification Other conditions including visible damage that
170. a qualified representative from the electrical utility organization shall be on site to verify that the power lines are de energized and grounded 4 In addition to Electrical Hazard Warning Signs required on all mobile cranes Electrical Hazard Warning Signs shall be posted inside the personnel lift platform 5 Proximity warning devices insulated links or boom cages if used shall not be a substitute for any requirements of this section 4 11 4 7 LIFTING PERSONNEL NEAR ELECTRICAL POWER LINES 4 7 3 CONDITION B Power lines are energized with the equipment outside the prohibited zone but working within a fully extended boom length of the prohibited zone Regardless of whether the crane boom will be fully extended the fully extended boom length shall be considered see figure 4 4 The following steps shall be taken when lifting personnel in Condition B 1 A meeting on the job site between the Personnel Lift Authorizing Manager the Designated Leader and a qualified representative of the electrical utility organization shall take place Procedures to safely complete the lift shall be established 2 The clearance specified in Table 4 1 shall be maintained between the hoisting equipment loadline and personnel basket at all times 3 Power line movements horizontal and vertical caused by wind shall be considered 4 The required clearances to the power lines shall be continuously monitored by a signal person
171. a yellow background A marker identical to the one used on the side of the truck as shown in Figure 10 1 shall be installed on the sign Chapter 10 10 14 Forklift Trucks DOE STD 1090 2007 10 3 INSPECTIONS 10 3 1 DAILY PRE OPERATIONAL CHECK a Instructions for pre operational inspections shall be readily available to the operator It is recommended that the instructions be attached to the equipment Standard instructions will be suitable for most forklift trucks however operating conditions may require additional instructions A sample Pre operational inspection checklist is included as Exhibit 1 which appears at the end of this chapter b Before operating the truck check its condition giving special attention to the following 1 Condition of the tires 2 Tire inflation if pneumatic tires 3 Warning and safety devices 4 Lights 5 Battery 6 Controls 7 Liftand tilt systems 8 Forks or other load engaging means 9 Chains and cables 10 Limit switches 11 Brakes 12 Steering mechanism 13 Fuel system s 14 Additional items as specified by the manufacturer or that are unique to the facility at which the truck is operated c Conditions adversely affecting safety shall be corrected before the forklift truck is placed into service 10 15 10 3 2 INITIAL INSPECTION OF NEW AND RENTED EQUIPMENT Prior to initial use all new or newly arrived rental equipment or modified forklifts shall be
172. ability to support the load at temperatures at which the manufacturer has specified for use c Each swivel hoist ring shall be marked to show 1 Name or trademark of manufacturer 2 Size or rated load 3 Torque value d Swivel hoist rings shall have a minimum design factor of 5 1 e When used in a threaded hole the effective thread length shall be at least one and one half times the diameter of the bolt for engagement in steel see Fig 12 10 For other thread engagements or engagement in other materials contact the swivel hoist ring manufacturer or qualified person f When used in a through hole application a nut and washer shall be used The washer and nut shall be in accordance with the swivel hoist ring manufacturer s recommendations The nut shall be fully engaged see Fig 12 10 g The bushing flange Fig 12 10 shall fully contact the load surface h Spacers or washers shall not be used between the bushing and the mounting surface of the load being lifted i The swivel hoist ring shall be tightened to the manufacturer s torque specifications j The swivel hoist ring shall be free to rotate and pivot without interference during lifting see Fig 12 11 k The load applied to the swivel hoist ring shall be centered in the bail to prevent side loading l Any attached lifting component shall be narrower than the inside width of the bail to avoid spreading see Fig 12 11 m Ensure that the
173. ached slings and other parts or surfaces of the component or equipment ii There is no interference with the functioning of hoisting rigging or handling equipment iii Maximum accessibility to the eye is maintained iv Attached slings can converge over the center of gravity of the lift v Proper stability can be maintained during lifting and positioning of the item at the installation site vi The plane of the slinging eye is coincident with the plane of the sling under loaded conditions within 5 degrees vii Sling angles are not less than 45 degrees with the horizontal In addition to marking requirements listed for ordinary lifts other items may need to be marked as determined on a case by case basis such as the reach type weight of the sling assembly and rated capacity DOE STD 1090 2007 11 3 3 ALLOY STEEL CHAIN SLINGS a This section applies to slings made from grade 80 and 100 alloy chain manufactured and tested in accordance with National Association of Chain Manufacturers welded steel chain specifications 1990 If chain other than this is used it shall be used in accordance with the recommendations of the chain manufacturer b Alloy Steel chain slings differ from wire rope slings in that components using wire are replaced by link chain Other sling components are similar Chain slings are more rugged and flexible but less shock resistant than wire rope or braided slings This size is m
174. ad shall be corrected before proceeding with the lift 7 The crane shall be inspected in accordance with Section 7 2 7 after the lift is completed and prior to being used for the lifting of any other load 8 Arecord of the planned engineered lift including calculations inspections and all distances moved shall be placed on file for availability to appointed personnel f The rated load test specified in Section 7 3 2 is not applicable to planned engineered lift provisions 7 5 10 CRITICAL LIFTS See Chapter 2 Critical Lifts for critical lift requirements 7 19 Chapter 7 Overhead and Gantry Cranes DOE STD 1090 2007 Exhibit I is intended to be a sample form only The equipment manufacturer s inspection testing criteria supercede any other criteria In cases where the equipment manufacturer does not include inspection testing criteria other forms developed to facilitate required inspection testing are acceptable Chapter 7 7 20 Overhead and Gantry Cranes DOE STD 1090 2007 INTENTIONALLY BLANK 7 21 Chapter 7 Overhead and Gantry Cranes DOE STD 1090 2007 Page of 4 EXHIBIT SAMPLE FORM BRIDGE WALL GANTRY CRANE LOAD TEST FORM EQUIPMENT NO MAKE RATED CAPACITY DATE LOAD TEST INSPECTION REPORT The following checklist identifies the items to be inspected prior to the load test Any unusual conditions observed during the inspection should be noted in the Remarks section NOTES
175. ail 4 An access opening in the guard rail may be hinged or removable or chains may be used if proper positioning is easily accomplished and secured condition is discernible 5 Guard rails and access openings shall be capable of withstanding a concentrated force of 200 Ib 91 kg in any direction 6 Means to securely attach the platform to the lifting carriage or forks in such a manner that it cannot slide or bounce off the forks 7 Means to correctly locate the platform centered laterally on the truck 8 Floor dimensions that neither exceed two times the load center distance listed on the truck nameplate measured parallel to the longitudinal center plane of the truck nor have a width greater than the overall width of the truck measured across the load bearing tires plus 10 in 25 cm on either side 9 The following information should be prominently indicated on the platform Chapter 10 Forklift Trucks DOE STD 1090 2007 i Maximum load including personnel and equipment ii Weight of empty platform iii Minimum capacity of the truck on which the platform can be used b The combined weight of the platform load and personnel shall not exceed one half of the capacity as indicated on the nameplate of the truck on which the platform is used c Whenever a truck except for high lift order picker trucks is equipped with vertical hoisting controls elevateable with the lifting carriage or forks take
176. ain furnished by the crane manufacturer unless otherwise recommended by the manufacturer due to working conditions Roller chain discarded or new shall not be used for slings 7 2 8 CRANES NOT IN REGULAR SERVICE Cranes that have been idle for 1 month or more but less than 1 year shall be inspected before being placed in the service according to the requirements listed above in Section 7 2 6 Frequent Inspection 7 11 Cranes that have been idle for 6 months or longer shall be inspected before being placed in service according to the requirements listed above in Section 7 2 7 Periodic Inspection The determination supporting these alternate inspection frequencies and procedures shall be made by a qualified person for each affected crane Documentation supporting this determination shall be kept readily available Chapter 7 Overhead and Gantry Cranes DOE STD 1090 2007 7 3 TESTING 7 3 4 OPERATIONAL TESTS Prior to initial use all new reinstalled repaired or modified cranes shall be tested by a designated person to ensure compliance with this chapter including the following functions 1 Lifting and lowering 2 Trolley travel 3 Bridge travel 4 Locking limiting and indicating devices if provided 5 Limit switches devices The trip setting of hoist limit devices shall be determined by tests with an empty hook traveling at increasing speeds up to the maximum speed The actuating mechanism
177. ains synthetic web and metal mesh made into forms and with or without fittings for handling loads SLINGS BRAIDED Very flexible slings composed of several individual wire ropes braided together SMOOTH FACED DRUM Drum with a plain not grooved face SPAN The horizontal center to center distance of runway rails SPIRAL GROOVE Groove that follows the path of a helix around a drum similar to the thread of a screw SPLICING Interweaving of two ends of rope to make a continuous or endless length without appreciable increasing the diameter Also refers Chapter 1 Terminology and Definitions 1 10 to making a loop or eye in the end of a rope by tucking the ends of the strands Splice Hand Tucked A loop or eye formed in the end of a rope by tucking the end of the strands back into the main body of the rope in a prescribed manner Splice Mechanical A loop or eye formed in the end of a wire rope by pressing or swaging one or more metal sleeve over the wire rope junction STAINLESS STEEL ROPE Wire rope made of chrome nickel steel wires having great resistance to corrosion STEEL CLAD ROPE Rope with individual strands spirally wrapped with flat steel wire STRAND An arrangement of wires helically laid about an axis or another wire or fiber center to produce a symmetrical section SUSPECT COUNTERFEIT ITEMS S Cl A suspect item is one in which visual inspection testing or other means indicate that it
178. al has been given 11 Replace all guards and shields before resuming operation Place blocking or other adequate supports under the boom before beginning boom disassembly operations Never stand under or on the boom during this work Before disconnecting oil lines if machine has hydraulic controls be sure to place boom on the ground or in the boom rest then move the pedals and control levers to equalize pressures within the cylinders Always release any air supercharge on the hydraulic reservoir and shut off the engine or declutch pumps before disconnecting oil lines Do not reach into hydraulic boom holes unless the sections are securely anchored together 9 5 1 3 Ensuring Stability a Know the rated capacity of the crane and the weight of the load A safe lift depends on many factors including boom length boom angle and load radius Follow these requirements to avoid buckling the boom or tipping 1 Know the radius of the load the radius is measured from center of rotation not from the boom foot pin 9 17 2 Always operate within the rated capacity of the machine 3 The gross capacity includes weight of hook block and any material handling devices i e slings concrete bucket magnet lifter etc subtract the weight of all these to find the true weight net capacity the crane can handle safely 4 Ratings are based on operating the machine on firm level ground outriggers should be proper
179. al sound producing or visual devices such as lights or blinkers and shall be responsible for providing and maintaining such devices Backup or motion alarms that sound continuously may be warranted in special cases but generally are less effective than operator controlled devices 10 1 7 OVERHEAD GUARDS An overhead guard is intended to offer protection to the operator from falling objects but it cannot protect against every possible impact Therefore it should not be considered a substitute for good judgment and care in load handling a High lift rider trucks including order picker trucks shall be equipped with an overhead guard manufactured in accordance with ANSI ITSDF B56 1 unless the following conditions are met 1 Vertical movement of the lifting mechanism is restricted to 72 in 1800 mm or less from the ground 2 The truck will be operated only in an area where i The bottom of the top tiered load is not higher than 72 in 1800 mm and the top is not more than 120 in 3000 mm from the ground where tiered ii Only stable preferably interlocked unitized or containerized loads are handled iil There is protection against falling objects from adjacent high stack areas b Rough terrain forklift trucks shall be fitted with an overhead guard manufactured in accordance with ANSI ITSDF B56 6 10 1 8 FIRE HAZARD AREAS Powered forklift trucks for operation in fire hazard areas shall be of the type
180. all be trained and qualified to operate the equipment on which maintenance is being performed b Hoisting equipment operation by maintenance personnel shall be limited to those equipment functions necessary to perform maintenance on the hoisting equipment or to verify the performance of the hoisting equipment after maintenance has been performed Chapter 15 Construction Hoisting and Rigging Equipment Requirements DOE STD 1090 2007 15 3 INSPECTION AND TESTING P Si Only equipment that has been built to nationally recognized manufacturers standards shall be used at DOE installations Existing equipment shall be brought to an acceptable level of compliance as determined by the construction management contractor In some instances the inspection and testing requirements of referenced applicable chapters of this standard exceed those of OSHA ASME and in such instances the requirements of this standard shall prevail Prior to being used at a DOE installation mobile cranes boom trucks forklift trucks shall be inspected and approved for operation by appropriate construction management contractor personnel or those having overall responsibility for ordinary hoisting operations Chapter 15 Construction Hoisting and Rigging Equipment Requirements 15 6 Equipment with deficiencies that may affect the safety of the operation shall not be allowed to operate at DOE installations No repairs modifications or addit
181. all have sufficient ductility to permanently deform before failure at the temperature at which the hook will be used Rated capacities for hooks shall equal or exceed the rated capacity of the chain wire rope or other suspension members to which they are attached 12 2 4 LOAD LIMITS A hook shall not be loaded beyond its rated capacity except as is necessary to conform to the requirements for load testing of the sling or hardware to which it is attached 12 2 5 INSPECTIONS 12 2 5 1 a Initial Inspection A designated inspector shall inspect all new and repaired hooks prior to initial use Dimensional data on the hooks shall be recorded to facilitate subsequent inspections for wear and throat openings Dated and signed inspection records shall be kept on file and shall be readily available Inspection procedure and record keeping requirements for hooks in regular service shall be determined by the kind of equipment in which they are used When such requirements for hooks are stated in standards for the specific equipment they shall take precedence over the requirements of this section 12 5 12 2 5 2 Daily Inspection a The operator or other designated person shall visually inspect hooks daily or prior to first use if the hook is not in regular service for the following records are not required Cracks nicks gouges Deformation Damage from chemicals ep O Damage engagement or malfuncti
182. ams shall describe how periodic inspections for below the hook lifting devices are recorded These records may include an external coded mark or tag on the device e g date annually changed color stripe etc indicating both periodicity and the satisfactory completion of the required periodic inspection or a written record as acceptable documentation Refer to Sections 14 2 5 3 d 14 3 4 3 d 14 4 4 3 e and 14 5 4 3 d Chapter 14 Below the Hook Lifting Devices DOE STD 1090 2007 14 2 STRUCTURAL AND MECHANICAL LIFTING DEVICES a Structural and mechanical lifting devices are often one of a kind designs Typical devices include 1 Load supporting lifting devices Figure 14 1 2 Friction type pressure gripping lifting devices Figure 14 2 3 Indentation type gripping lifting devices Figure 14 3 4 Cask lift fixtures Figure 14 4 14 2 1 DESIGN FABRICATION Structural and mechanical lifting devices shall be designed fabricated labeled and assigned a design category according to the provisions of ASME B30 20 and ASME BTH 1 14 2 2 MARKING P Si The rated capacity of each lifting device shall be marked on the main structure where it is visible and legible If the lifting device comprises several items each detachable from the assembly each lifting device shall be marked with its rated capacity Ata minimum a nameplate name tag or other permanent marker shall be affixed displaying the follow
183. an overhead fixed runway structure Power Operated Crane A crane whose mechanism is driven by electricity air hydraulics or internal combustion Pulpit Operated Crane A crane operated from a fixed operator station that is not attached to the crane Remote Operated Crane A crane controlled by an operator not in a pulpit or cab attached to the crane by any method other than pendant or rope control e g radio controlled crane Semigantry Crane A gantry crane with one end of the bridge rigidly supported on one or more legs that run on a fixed rail or runway the other end of the bridge being supported by a truck running on an elevated rail or runway Shop Crane A Portable Automotive Lifting Device PALD self contained hydraulic and pneumatic hydraulic crane characterized by a pair of laterally spaced legs an upright mast a pivoting boom with a boom extension and hook and a hydraulic unit The hydraulic unit moves the boom up and down at a pivot point for the purpose of raising removing transporting in the lowered position and replacing automotive engines transmissions and other components Shop cranes have a capacity of 4 tons 8000 pounds or less Wall Mounted Crane A crane having a jib with or without a trolley supported from a side wall or line of columns of a building It is a traveling type crane and operates on a runway attached to the side wall or line of columns Chapter 1 Terminology and Definitio
184. and readings compared to establish the breakaway force required to manufacturer s standards vertically remove the lifting magnet from a low carbon rolled steel plate of the A qualified inspector shall inspect a lifting minimum thickness stated by the magnet magnet that has been idle for 1 month or manufacturer The portion of this plate in more according to periodic inspection contact with the magnet shall have a 125 requirements before placing it in service pin 3 2 x 10 mm finish and be flat within 0 002 in ft 0 05 mm m but not exceeding Dated inspection reports shall be prepared 0 005 in 0 127 mm total The full for each inspection Inspection records shall operating face of the lifting magnet shall be be kept on file and shall be readily available in contact with the steel plate which shall be between 60 degrees F 15 degrees C 1445 TESTING Battery operated electromagnets and external powered lifting electromagnets 14 4 5 1 Operational Test shall be operated at the manufacturer s recommended current All new modified or repaired lifting magnets shall be tested prior to their initial e The application breakaway force test shall use Tests shall be performed by a qualified establish the application breakaway forces inspector or under the direction of that of the lifting magnet under the variety of inspector Dated reports shall be kept on loading conditions for which the magnet is file specified The details of thi
185. ane ide 11 8 11 351 Load Angle Factoria nds 11 8 IL3 12 Salte Lordi ii REESE ta 11 8 IL3 5 Desi Factor mitin iii 11 10 RE EE 11 10 IRIS SUMS EE 11 10 11 3 1 6 Inspections uere Eed ee 11 10 11 3 1 7 Sling Periodic Inspection Records see 11 10 113 2 Wire Rope Sl Suerte URS P I pe PERI CAMP eet 11 10 11 3 2 1 Removal from Service Criteria ooooonnoninnnonnnocnnoncnoncnnncnn ccoo conc non ccnnncnnccnnooo 11 20 113 2 2 JProOf LesUng xueseeERD Ou OE ER Er RI e Sense etnies eee 11 20 ea MEC MR 11 20 11 3 2 4 Critical Lifts usen as cti ci 11 24 IL3 3 Alloy Steel Chat Slimgs e ise irent eter tet t ca rna nennen eere Gu RUE ci 11 25 11 3 3 1 Removal from Service Criteria sese 11 25 11 3 3 2 Proof Testing i i onset tr rite ai 11 26 RE E e EE 11 28 11 3 3 4 Critical Lifts iater te ek ai 11 29 11 3 4 Metal Mesh Slihgs iens tete teet e aet ec a 11 29 11 3 4 1 Removal from Service Criteria sese 11 32 11 3 42 Proof Testing inei eth ie Eee ai 11 32 RBE ER e EE 11 32 11 3 44 Critical Lifts iei rete ee e gk aia 11 33 14 3 5 Synthetic Web S ings soe eegent oye grt erred pene agas 11 33 11 3 5 1 Removal from Service Criteria oooonnoninnnonnnocnnoncnoncnnncnnnonn conc cnn ncnnncanccnnooo 11 36 11 3 52 Proof TSUN G uae ertet t dla 11 36 IN S MEG cc O Rn 11 40 11 3 5 4 Critical E due erit RH ERREUR 11 40 11 3 0 Synthetic Roundslings ener tett
186. angle upon which it is based See Chapter 2 Critical Lifts for critical lift requirements 4 Core material a Synthetic roundslings used for critical lift 5 Cover material if different than core service shall have an initial proof test of 200 material percent of the vertical rated capacity If proof testing cannot be verified the sling s shall be Synthetic roundslings e g Kevlar K Spec proof tested before being used to make a nylon polyester may be used in radiation critical lift areas only when a qualified person ensures that the absorbed dose does not exceed b Proof testing shall be performed in 100 000 rad during the life of the sling accordance with Section 11 3 6 2 Proof Testing 11 43 Chapter 11 General DOE STD 1090 2007 Table 11 16 Load capacity of Single Leg Polyester Roundslings in pounds Endless and Eye and Eye Type Design Factor 5 1 Na 60 S Size Basket or degrees Note 1 Vertical Choker two leg 45 30 degrees degrees 1 2 600 2 100 5 200 4 500 3 700 2 600 3 82 5 300 4 200 10 600 9 300 7 500 5 300 123 6 400 6 700 16 800 14 500 11 900 6 400 5 84 10 600 8 500 21 200 18 400 15 000 10 600 345 13 200 10 600 26 400 22 900 18 700 13 200 7 86 16 800 13 400 33 600 29 100 23 800 16 800 7 21 200 17 000 42 400 36 700 30 000 21 200 8 25 000 20 000 50 000 43 300 35 400 25 000 9 31 000 24 800 62 000 53 700 43 800 31 000 10 40 000 32
187. anual if the size or shape of the unit prohibits the inclusion of the above markings Chapter 14 Below the Hook Lifting Devices DOE STD 1090 2007 Four pad powered vacuum lifting device Four pad powered vacuum lifting device manipulator Reprinted from ASME B30 20 2006 by permission of The American Society of Mechanical Engineers All rights reserved Figure 14 5 Powered vacuum lifting devices Reprinted from ASME B30 20 2006 by permission of The American Society of Mechanical Engineers All rights reserved Figure 14 6 Mechanical vacuum lifting devices Chapter 14 14 10 Below the Hook Lifting Devices DOE STD 1090 2007 14 3 VACUUM LIFTING DEVICES 14 3 8 INSTALLATION source Vacuum levels in the system shall not decrease by more than the a Vacuum lifting devices shall be assembled manufacturer s specified rate and installed in accordance with the manufacturer s instructions 14 3 4 3 Periodic Inspection b The power supply to the vacuum lifting a A qualified inspector shall perform a device shall be the same as that shown on complete inspection at the following the nameplate and shall be connected to the intervals line side of the crane disconnect or to an independent circuit 1 Normal service yearly Inspect equipment at site of use c The user shall check for correct rotation of all pumps 2 Heavy service semiannually Inspect equipment at site of use unless external 14 3 4 INSPECTIONS c
188. apr Ges Through Hole 100 capacity in any direction that the bail will swivel or rotate Installation Loading Reprinted from ASME B30 26 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 12 10 Swivel Hoist Rings 12 23 Chapter 12 Rigging Hardware DOE STD 1090 2007 Attach lifting device ensuring free fit to swivel hoist ring bail and ensuring no interference between load work piece and bail Always ensure free movement of the bail Never use hoist rings if bail is bent or elongated Do not reeve slings Qa WRONG After slings hava DP Buckling may occur if trom one bail to HENN been propert the Kad is not stiff another This will A attached to t AX enough to resist the alter the load and hoist ring 2 y X compressive focos angle of loading force slowly Watch which result from on the hoist ring the load and PA S the angular be prepared Pd ch K R loading tostop et Do ci i applying 7 Ee a e P force if bc M i the load E ae te ewe starts buckling e Figure 12 11 Guidelines for Attaching and Using Swivel Hoist Rings Chapter 12 12 24 Rigging Hardware DOE STD 1090 2007 12 9 LOAD INDICATING DEVICES 12 9 4 GENERAL Load indicating devices are not required in routine operations where loads of known and essentially consistent weight are to be handled Rather load indicating devices are required for use with loads of unce
189. asible the hoisting equipment to be used for lifting personnel should be the equipment used to perform the load test at the job site g Dated test reports shall be kept on file and shall be readily available to appointed personnel 4 6 3 HOISTING EQUIPMENT a Hoisting equipment shall be tested in accordance with requirements of Chapter 7 Overhead amp Gantry Cranes or Chapter 9 Mobile Cranes 4 10 DOE STD 1090 2007 4 7 1 GENERAL 4 7 2 a When lifting personnel near electrical power lines it is advisable to perform the lift so there is not possibility of the crane load line or personnel platform becoming a conductive path Cranes shall not lift personnel under electrical power line if any combination of boom personnel platform load line or machine components will enter the prohibited zone See figure 4 3 Lifting personnel near electrical power lines is not allowed unless there is no less hazardous way to perform the job The following conditions must be considered when lifting personnel near electrical power lines CONDITION A Power Lines are de energized and grounded The safest and preferred condition The following steps shall be taken when lifting personnel in Condition A 1 The electrical utility organization shall de energize the power lines 2 Asaminimum the power lines shall be visible grounded to avoid the possibility of electrical feedback 3 Before lifting personnel
190. atch is provided and it becomes inoperative because of wear or deformation or fails to fully bridge the throat opening the hook shall be removed from service until the device has been repaired or replaced and the throat opening has been assessed as described above 6 Any self locking hook that does not lock If hooks are painted a visual inspection should take the coating into consideration Surface variations can disclose evidence of heavy or severe service The surface condition may call for stripping the paint in such instances Hooks in severe service as defined in 13 2 1 c may show the need for a nondestructive testing Dated and signed inspection records shall be kept on file and shall be readily available Chapter 15 Load Hooks DOE STD 1090 2007 13 3 TESTING a Each new or replacement hook of 150 ton capacity or greater and a prototype of each d Hooks that have been proof tested may be hook design of less than 150 ton capacity subsequently inspected by the magnetic shall be proof tested by the manufacturer in particle method in accordance with ASTM accordance with Table 13 1 E 709 Standard Practice for Magnetic Particle Examination and shall show no b When proof tests are used the hooks shall cracks inclusions or other relevant withstand the proof load application without discrepancies casting shall be evaluated in permanent deformation when the load is accordance with ASTM E 165 Standard app
191. ated and with a protective covering i e Plastic or cardboard Shall be mechanical flemish eye spliced Single leg slings Shall be either 6 x 19 or 6 x 37 classification Exhibit 1 Purchase Requisition Example continued A 19 GA99 0026 Appendix A Procurement Guidelines DOE STD 1090 2007 CONCLUDING MATERIAL Review Activity Preparing Activity DOE Field Offices DOE HS 11 GC ID HS ORP Project Number NE SAFT 0112 NA NNSA CTA Site Offices ICP Livermore Pantex WIPP Appendix A A 20 Procurement Guidelines
192. ated load for not more than 15 percent of the time for manual lever operated hoists or for not more than 25 percent of the time for electric or air powered hoists Heavy service operation within the rated capacity that exceeds normal service Severe service operating at normal or heavy service under abnormal operating conditions i e extreme temperatures corrosive atmospheres 8 2 2 INITIAL INSPECTION Prior to their initial use all new repaired or modified hoists shall be inspected by a qualified inspector to ensure compliance with the applicable provisions of ASME B30 11 B30 16 and B30 21 Dated and signed inspection records shall be kept on file and shall be readily available 8 2 3 DAILY INSPECTION Operators or other designated personnel shall visually inspect items such as the following at the beginning of each shift or prior to first use if the hoist has not been in regular service records are not required 1 Controls and operating mechanisms for proper operation 2 Hoist upper limit switch as applicable for proper operation 3 Lines valves and other parts of air systems for leakage 4 Hooks for cracks deformation and damage from chemicals see Chapter 13 Load Hooks for additional hook requirements Chapter 8 Hoists 8 8 5 Hoist rope for kinking crushing birdcaging and corrosion 6 Hoist chain for nicks gouges distortion wear cracks and corrosion
193. ation features c Type ES Forklifts electrically powered units that are provided with all the requirements for the type E units and that have additional safeguards to the electrical system to prevent emission of hazardous sparks and to limit surface temperatures d Type EE Forklifts electrically powered units that are provided with all the requirements for the type E and ES units and that also have electric motors and all other electrical equipment completely enclosed e Type EX Forklifts electrically powered units that differ from type E ES or EE units in that the electrical fittings and equipment are designed constructed and assembled so that the units may be used in atmospheres containing specifically named flammable vapors dusts and under certain conditions fibers type EX units are specifically tested and classified for use in Class I Group D or for Class II Group G locations as defined in NFPA 70 National Electrical Code f Type GS Forklifts gasoline powered units that in addition to all the requirements for the type G units are provided with additional safeguards to the exhaust fuel and electrical systems g Type LPS Forklifts liquefied petroleum gas powered units that in addition to the requirements for the type LP units are Chapter 10 Forklift Trucks DOE STD 1090 2007 provided with additional safeguards to the exhaust fuel and electrical systems 10 2 20 SPECIFIC AREAS OF
194. ator inspector training and qualification requirements S Definition of critical lifts and the additional requirements for making them 4 The need and responsibilities of a person in charge for critical lifts 5 The need and responsibilities of a designated leader for ordinary lifts 6 The definition and special requirements for preengineered production lifts 7 Special requirements for the testing inspection and maintenance of hoisting equipment in hostile environments 8 Nondestructive testing nondestructive examination requirements for such items as hooks welds and spreader bars 9 Special requirements for inspection and load testing of hoisting and rigging equipment accessories 10 Hook latch requirements for cranes slings and rigging accessories 11 Design standards for such equipment as cranes forklifts and hooks DOE STD 1090 2007 12 Operating practices for hoisting and rigging operations 13 Rigging information and load tables 14 Good and bad rigging practices Because the possibility of serious accidents resulting in personnel injury or death or significant property damage exists whenever hoisting and rigging take place the requirements for these operations must be clearly defined and precautions ensured including proper preplanning extreme care attention to detail teamwork on the part of trained operators riggers and the use of equipment that is reliable properly designed inspected and maintained Although no
195. ators of mobile cranes shall be trained and qualified as required in Chapter 6 Personnel Qualification and Training 9 1 2 LOAD LIMITS a Since the load rating for mobile cranes may be based on stability and hydraulic or structural competence load ratings established by the manufacturers shall not be exceeded in operational application b No crane shall be loaded beyond its rated capacity except for load test purposes as described in Section 9 3 Testing c When loads are to be handled that are limited by hydraulic or structural competence rather than by stability the appointed person shall ensure that the weight of a load approaching rated capacity has been determined within 10 percent 0 percent before it is lifted 9 1 3 LOAD RATING CHART a Durable rating chart s with legible letters and figures shall be provided with each crane and attached in a location accessible to the operator while at the controls See Table 9 1 for a sample load rating chart The data and information to be provided on these charts shall include but not be limited to the following 1 A full and complete range of manufacturer s crane load ratings at all stated operating radii boom angles work areas and all stated boom lengths and configurations jib lengths and angles or offset as well as alternate ratings for use and nonuse of optional equipment on the crane such as outriggers and extra counterweights that affec
196. ave basic knowledge and understanding of equipment operating characteristics capabilities and limitations Understand rigging principles as applied to the job for which they are to be qualified d Demonstrate to appropriate management personnel skill in using rigging principles e Be free of any detectable or known disease or physical restriction that would render them incapable of safe operating or rigging duties Where any loss or loss of function of an upper or lower extremity exists the acceptability of the candidate shall be the decision of the supervisor after consulting with the designated physician f Have normal depth perception field of vision reaction time manual dexterity and coordination 15 2 4 PERSON IN CHARGE PIC The PIC shall have the necessary knowledge and experience of the specific type of equipment and the hazards of critical lifts to direct the safe completion of the operation The PIC shall understand the rules and procedures implemented at the site to ensure that the following are completed a Necessary administrative requirements b Personnel assignments and responsibilities c Selection of proper equipment tools d Recognition and control of hazardous or unsafe conditions e Job efficiency and safety Chapter 15 Construction Hoisting and Rigging Equipment Requirements 15 4 DOE STD 1090 2007 f Critical lift documentation In addition the PIC shall a Direct operations
197. aximum wind speeds for operation operations undertaken at wind speeds in excess of 25 mph should be evaluated by a qualified person to determine if the size shape and weight of the load can be safely lifted w When acrane is to be operated at a fixed radius the boom hoist pawl or other positive locking device shall be engaged x On truck mounted cranes no loads shall be lifted over the front area except as approved by the crane manufacturer y Crane cabs necessary clothing and personal belongings shall not interfere with access or operations z Tools oil cans waste extra fuses and other necessary articles shall be stored in the tool box and shall not be permitted to lie loose in or about the cab 9 5 1 1 Traveling the Machine When traveling the machine a Secure the boom and book block b Check bridges before crossing make sure they will support the weight of the machine 9 16 Check river depths before fording Check clearances under overpasses overhead lines or any overhead obstruction when side clearances are tight install a barrier or post a lookout and make certain there is sufficient clearance for tail swing When traveling with a load snub the load to prevent swaying if possible never travel with near capacity loads Never travel a rubber tired unit with a load over the side On soft surfaces always move with the load behind it helps to raise the leading end of the crawlers and ma
198. balanced in a sling or lifting device f Donotlift lower or travel the hoist while anyone is on the load or hook g Avoid carrying loads above personnel h Testthe brakes each time a load approaching the rated capacity is handled by raising the load just enough to clear the floor or supports and checking for brake action Continue the lift only after you are sure that the braking system is operating properly i Do not lower a loaded wire rope hoist drum beyond the point where less than two full wraps of wire rope remain on the drum j Inchthe hoist into engagement with a load and avoid unnecessary stops and starts k Do not perform side pulls with hoists except as specifically authorized by a qualified person l If power goes off during operation of cab operated equipment immediately place all controllers in the OFF position Before reuse check operating motions for proper direction m Do not leave a suspended load unattended unless specific precautions have been instituted and are in place n Tag lines should be used as required to guide snub or otherwise control the load o Take signals from only one person using the standard hand signals shown in Chapter 7 Chapter 8 Hoists Overhead and Gantry Cranes Obey a STOP signal regardless of who gives it Lift the hoist load block above head level for storage when the equipment is not in use 8 5 5 HOIST LIMIT SWITCH At the beginning of a sh
199. be due to the security classification of the load to be lifted or other reasons approved by the responsible 14 9 manager In these cases the lifting device shall be marked with an identification number and its documentation shall contain both its rated capacity and weight A label or labels shall be affixed t each vacuum lifting device in a readable position that displays the word WARNING or other legend designed to bring the label to the attention of the operator The label shall also contain information cautioning against 1 Exceeding the rated capacity or lifting loads not specified in the manufacturer s instruction manual 2 Operating a damaged or malfunctioning unit or a unit with missing parts 3 Operating when vacuum indicators show insufficient vacuum 4 Operating the unit when vacuum pads are not spaced for equal loading 5 Incorrect positioning of the lifting device on the load 6 Lifting people 7 Moving loads above people 8 Removing obscuring warning labels 9 Operating the lifting device when the rated capacity lifting device weight or safety markings are missing except in cases where the device cannot for security or other reasons be marked 10 Making alterations or modifications to the lifting device 11 Lifting loads higher than necessary and leaving suspended loads unattended A label shall be affixed to each unit that directs the user to consult the manufacturer s m
200. be equipped with properly sized wire rope sheaves in lieu of flat spools 16 1 8 ASSEMBLY a Portable A frames shall only be assembled by qualified personnel Manufacturer s instructions shall be adhered to regarding Chapter 16 16 2 Miscellaneous Lifting Devices setup and assembly Portable A frame components from different manufacturers shall not be intermixed with components from other A frames regardless of similarities in manufacturers or rated capacities Only manufacture approved methods attaching a hoist to the A frame structure such as approved beam clamp or trolley shall be used Trolleys or beam clamp working load limits shall not exceed the capacity rating of the A frame and must be designed for the type frame flange see figures 16 4 and 16 5 Hoists attached to the A frame must have a rated capacity equal to or less than all supporting components Down rating of hoist to A frame capacity is acceptable with administrative controls and markings in place Load carrying trolleys must suit the shape and weight of the specific load Trolley wheel design must be matched properly to the rail shape and size to ensure that trolleys do not slip off the track and drop the load If a new or replacement trolley is installed on a monorail the qualified person installing the trolley shall ensure by actual operational verification or measurement that the installed trolley stops on the system are compatible with the new trol
201. be followed as a result of radiation or radioactive contamination toxic hazardous chemicals or gases or temperature extremes Hostile environments are environments that have been rendered inaccessible to workers during hoisting or rigging operations due to these health hazards Hoisting and rigging activities can usually be accomplished where the environment will allow normal operations with access for hands on equipment contact In those situations operations maintenance inspections and tests shall be done in accordance with the balance of this standard or other applicable regulatory requirements Applicable regulations include but are not limited to 29 CFR 1910 179 and 29 CFR 1910 184 Hoisting and rigging equipment or operations shall be reviewed by a designated 5 1 person to determine compliance with the requirements of this standard or other applicable regulatory requirements If it is determined to be impossible or unreasonable for the requirements of the balance of this standard or other regulatory requirements to be met as a result of hostile environmental conditions a hostile environment plan shall be prepared to document alternative compliance methods and procedures Alternate compliance methods and procedures shall be consistent with a facility s safety basis documents i e Documented Safety Analysis and Technical Safety Requirements All hoisting and rigging operations shall be consistent with DOE
202. be readily available A sample load test and inspection form is included as Exhibit I which appears at the end of this chapter This form is intended to be a sample only and is not intended to be mandatory 8 2 5 1 Hoists In addition to the requirements listed in Section 8 2 4 Frequent Inspection periodic inspections of hoists shall include the following 1 Bolts rivets nuts and pins for being loose or absent 2 Check for suspect counterfeit parts see Terminology and Definitions Chapter 1 3 Cracked or worn drums or sheaves 4 Worn corroded cracked or distorted parts such as pins bearings shafts gears rollers locking and clamping devices 5 Excessive wear on motor or load brakes 6 Excessive wear of chains ropes synthetic web strap load sprockets drums sheaves and chain stretch 7 Deterioration or damage of end connections and terminations of wire rope load chains and synthetic web 8 Hooks damaged from chemicals cracks any visibly apparent bend or twist from the plane of the unbent hook or any distortion causing an increase in throat opening of 5 not to exceed 1 4 inch unless otherwise recommended by the manufacturer See Chapter 13 for additional hook requirements 9 Hook retaining nuts or collars and pins welds or riveting used to secure the retaining members 10 Suitable crack detecting inspections for hooks such as dye penetrant or magnetic particle inspecti
203. be verified the lifting device shall be proof tested before being used to make a critical lift 14 8 DOE STD 1090 2007 14 3 VACUUM LIFTING DEVICES Typical power operated and mechanically operated vacuum lifting and manipulating devices are shown in Figures 14 5 and 14 6 This section does not cover devices used to handle porous materials which requires special design and construction 14 3 1 DESIGN FABRICATION Power and mechanically operated vacuum lifting devices shall be designed and fabricated according to the provisions of ASME B30 20 20 2 2 2 14 3 2 MARKING P Si e Zb The rated capacity maximum width and length and minimum thickness of load shall be marked on the main structure where it is visible and legible Individual pads or groups of pads controlled by shutoff valves shall be marked with the rated capacity of each pad or group of pads At a minimum a nameplate name tag or other permanent marker shall be affixed to each lifter displaying the following data 1 Manufacturer s name 2 Model number or unit identification 3 Weight of lifting device 4 Electric power when applicable 5 Pressure and volume of compressed air when applicable 6 Rated capacity Manual shutoff valves on individual pads or groups of pads shall be marked to show operating position Cases may exist where a lifting device cannot be marked with its rated capacity and weight This may
204. by measuring with a caliper from the edge of one chain pin to the corresponding edge of another pin If elongation exceeds L in 6 3 mm in 12 in 305 mm compared to new or unstretched chain values the chain shall be replaced 4 Inspect for twist Replace if the twist in any 5 ft 1 52 m section exceeds 15 degrees 5 Check for straightness in a plane perpendicular to the plane of the rollers Replace if the chain has a bow exceeding 4 in 6 3 mm in any 5 ft 1 52 M section 6 Additional inspection shall be made by removing the chain from the crane and cleaning it thoroughly Deficiencies such as those listed below shall be carefully examined and a determination shall be made as to whether they constitute a safety hazard i Pins turned from original position ii Rollers that do not run freely with light finger pressure iii Joints that cannot be flexed by easy hand pressure iv Side plates that are spread open v Corrosion pitting or discoloration vi Gouges nicks or weld spatter Roller chain shall be replaced if any of the conditions exist as stated in paragraphs 7 2 7 4 b 1 through 5 above Deficiencies as stated in paragraph 7 2 7 4 b 6 above are reason for questioning chain safety and considering its replacement Repairing of roller chain by welding or heating shall not be attempted DOE STD 1090 2007 Replacement chain shall be the same size grade and construction as the original ch
205. cal E O rena tute ad 9 30 Exhibit I Mobile Crane Load Testi 9 33 Exhibit I Mobile Crane Daily Pre Operational Check 9 37 Exhibit III Mobile Crane Frequent Inspection Report 9 41 Exhibit IV Mobile Crane Periodic Inspection Report 9 43 CHAPTER 10 FORKLIFT TRUCKS sissies eee REIN eens 10 1 10 1 e E E td tdi mercati pei 10 1 10 1 1 Operator Training Qualification eene 10 1 10 1 2 Rated Capacity EE 10 1 10 1 3 Nameplate s and Markings essere 10 1 10 1 3 1 Fork Arm Data 10 1 10 1 4 Attachiments cid id 10 1 101 5 Modificati ns esee Ita O 10 2 PONG ER 10 2 10 1 7 Overhead Guards unidad ade 10 2 T0 1 5 Pire Hazard TOS eee esito tit eo etae eds sr coepi tee e ceo senda 10 2 10 1 9 Work Atmosphere ui ee etii aE eR OS ale ai adea 10 2 10 3 TYPE DESIGNATIONS AND AREAS OF USE 10 10 10 2 1 Type D signation 2er cas 10 10 10 2 1 1 Nonhazardous Areas o eere Ro cirea e repas 10 10 10 2 52 Hazardous Areas tees o po rite tea sco De eU ma s 10 10 10 2 2 Specific Areas of USE reete ette le ie eret taba erui eoe cds 10 11 TOS INSPECTIONS essct ER ead nte ben co e eem 10 14 10 3 1 Daily Preoperational Check iouis dee tri hes ee nota enne Pues 10 14 10 3 2 Initial Inspection of New and Rented Equipment 10 14 10 3 3 Inspection and Maintenance nere 10 14 10 34 FOKS oc 10 15 IO SLT Fork Load Ra o e el nete ed 10
206. cation and Training At a minimum instruction should include the following 1 Application of the lifting device to the load and adjustments to the device if any that adapt it to various sizes or kinds of loads 2 Any special operations or precautions 3 Condition of the load itself required for operation of the lifting device such as balance degree of order of stacked loads surface cleanliness bending and load thickness 4 Procedure for storage of lifting device to protect it from damage DOE STD 1090 2007 ES D e Balanced pallet Lifting beam spreader beam Telescoping coil grab Coil lifting hook beam Reprinted from ASME B30 20 2006 by permission of The American Society of Mechanical Engineers All rights reserved Figure 14 1 Load supporting lifting devices Jh Roll grab core grip Bar Tong Motor driven roll grab end grip Vertical Axis Coil Grab Reprinted from ASME B30 20 2006 by permission of The American Society of Mechanical Engineers All rights reserved Figure 14 2 Friction type pressure gripping lifting devices 14 5 Chapter 14 Below the Hook Lifting Devices DOE STD 1090 2007 Reprinted from ASME B30 20 2006 by permission of The American Society of Mechanical Engineers All rights reserved Figure 14 3 Indentation type gripping lifting device A gt Ts Figure 14 4 Typical cask lift fixture Chapter 14 14 6 Below the Hook Lifting Devices DOE STD 1090
207. cation nn ar RR e ee de 14 21 14 5 2 Marking see EU Bee E E 14 21 14 5 3 Installation ice ene ERE e ERE ate 14 21 14 5 4 Inspections Ue te E e E RR 14 21 14 5 4 1 Initial Inspection coves soc teen ebrei E 14 21 14 5 4 2 Frequent Inspection eet teer et rente dsg 14 21 14 5 4 3 Periodic Inspection nissene n enne teret reste ge 14 21 14 5 5 D C E 14 23 14 5 5 1 Operational Test eie etre tenu Heres 14 23 14 5 6 Maintenatice si ee Re OO pe er Der RC EU EM EE 14 23 14 5 7 Traiming Qualification eiecit tete rete Hen e e b t de o Ee dt 14 23 14 5 8 Operation eee ee UI HER RT DE Re er ee 14 24 14 5 9 Critical Lifts os node pete e n Oe De OH e nte fed 14 24 Exhibit I Lifting Bars and Spreaders Load Test and Inspection sess 14 27 14 i P Si DOE STD 1090 2007 14 1 GENERAL Below the hook lifting devices are arranged in the following groups because of the diversity of types 1 Structural and mechanical lifting devices 2 Vacuum lifting devices 3 Close proximity operated magnets 4 Remote operated magnets Slings and rigging accessories that may be components in a below the hook lifting device are covered in Chapters 11 and 12 Wire Rope and Slings and Rigging Accessories respectively of this standard The working load limit WLL of below the hook lifting devices shall not be exceeded in their as configured application Individual site progr
208. ches or devices for proper operation c External evidence of damage or excessive wear of load sprockets idler sprockets and drums or sheaves d External evidence of wear on motor or load brake e Electrical apparatus for signs of pitting or any deterioration of visible controller contacts f All anchorage or hoist suspensions 4 Sethoist up for load test and inspection Where applicable ensure that the load chart is legible 5 Perform load test using the required test weights See Note 1 and appropriate slings Measure a length of the load chain under tension measure a length of 15 links If wire rope is used measure the diameter IF HOIST IS EQUIPPED WITH A TROLLEY 1 Mount hoist on a monorail 2 Rig test weight to load hook see step 4 above 3 Perform load test moving weight along monorail Observe hoist and trolley Observe performance of all load bearing components 4 Lower test weight to floor Note performance of hoist during lowering operation Remove rigging 8 23 Chapter 8 Hoists DOE STD 1090 2007 Page 2 of 2 EXHIBIT I continued HOIST LOAD TEST At the completion of the load test inspect the following items 1 Visually inspect and remeasure the load chain and or hoist rope after the load test Check for deformed or broken links stretch etc 2 Inspect load hook and suspension hook for bending or twisting LOAD HOOK PREVIOUS PRESENT Qualified Inspector Verify Throat Opening
209. cles ANSI ITSDF B56 6 Rough Terrain Fork Lift Trucks ASME B56 7 Industrial Crane Trucks Special Notice 6 88 ASME B56 11 4 Forks and Fork Carriers for Powered Industrial Fork Lift Trucks Hook Type ASME PALD Portable Automotive Lifting Devices ANSI ASTM Specification A391 Specification for Alloy Steel Chain ANSI ASTM Specification E 165 Standard Practice for Liquid Penetrant Inspection Method ANSI ASTM Specification E 709 Standard Practice for Magnetic Particle Examination ANSI AWS D14 1 Specification for Welding of Industrial and Mill Cranes and Other Material Handling Equipment ASME HST 1M Performance Standard for Electric Chain Hoists Chapter 17 References DOE STD 1090 2007 ASME HST 2M Performance Standard for Hand Chain Manually Operated Chain Hoists ANSI ASME HST 3M Performance Standard for Manually Lever Operated Chain Hoists ANSI ASME HST 4M Performance Standard for Electric Wire Rope Hoists ANSI ASME HST 5M Performance Standard for Air Chain Hoists ANSI ASME HST 6M Performance Standard for Air Wire Rope Hoists ANSI MH 27 1 Specifications for Underhung Cranes and Monorail Systems ANSI N14 6 Standard for Special Lifting Devices for shipping Containers Weighing 10 000 Pounds 4500 kg or More for Nuclear Materials ASME NQA 1 Quality Assurance Program Requirements for Nuclear Facilities ASME Cranes for Nuclear Facilities ASME NUM 1 Rul
210. continue use 12 5 6 REPAIRS a Repairs alterations or modifications shall be as specified by the eye nut manufacturer or a qualified person Replacement parts shall meet or exceed the original equipment manufacturer s specifications 12 5 7 CRITICAL LIFTS a Through hole bottom nut Installation Eye Nuts See Chapter 2 Critical Lifts for critical lift requirements Eye nuts used for critical lift service shall have an initial proof test of 200 percent of the rated capacity Test loads shall be accurate to within 5 percent 0 percent of stipulated values If proof testing cannot be verified the eye nut shall be proof tested before being used to make a critical lift In line loading only Loading Reprinted from ASME B30 26 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 12 7 Eye Nuts 12 15 Chapter 12 Rigging Hardware DOE STD 1090 2007 12 6 TURNBUCKLES 12 6 1 GENERAL a Turnbuckles include open and pipe bodies and have hook eye jaw or stub end fittings See Figure 12 8 Before each use turnbuckles shall be inspected for damage Damaged threads jamb nuts or bent frame members make the unit unsuitable for use b Turnbuckles shall be fabricated from material of sufficient ductility to permanently deform before losing the ability to support the load within the temperature range that the manufacture specified and
211. cotter pins snap rings or other fasteners or retaining devices Other conditions including visible damage that cause doubt as to continue use 12 7 7 REPAIRS a Repairs alterations or modifications shall be as specified by the link ring or swivel manufacturer or a qualified person Replacement parts shall meet or exceed the original equipment manufacturer s specifications 12 7 8 CRITICAL LIFTS a See Chapter 2 Critical Lifts for critical lift requirements Links rings and swivels used for critical lift service shall have an initial proof load test of 200 percent of the rated capacity Test loads shall be accurate to within 5 percent 0 percent of stipulated values If proof testing cannot be verified the links and or rings shall be proof tested before being used to make a critical lift If proof tested the link rink or swivel shall be inspected after the test for the removal conditions stated above Ring and Thimble Link and Thimble Link and Closed Socket Link Short Link Swivel and Thimble Figure 12 9 Ring Links and Swivels Chapter 12 12 20 Rigging Hardware DOE STD 1090 2007 12 8 SWIVEL HOIST RINGS 12 8 1 GENERAL a This section specifies requirements for swivel hoist rings that are used as rigging hardware during hoisting and rigging activities b Swivel hoist rings excluding bushings and bearings shall have sufficient ductility to permanently deform before losing the
212. ct documents shall also include requirements for maintenance of testing records Consideration should be given to local state or federal crane operator licensing requirements within the work jurisdiction as well as certification programs administered by recognized private organizations 15 2 2 QUALIFIED OPERATORS OF FORKLIFT TRUCKS a Physical qualifications shall be based on specific job requirements b Operators shall be required by the employer to pass a practical operating skill evaluation Qualification shall be limited to the type of forklift for which the operator is being evaluated c The actual or simulated operation shall enable operators to demonstrate basic knowledge and skills at a level that ensures the safety of personnel and equipment d Only qualified and authorized operators shall be permitted to operate powered forklift trucks Operator trainees may operate powered forklift trucks under the direct supervision of a qualified operator or trainer and only where such operation does not endanger the trainee or other employees e The initial training of operators shall include 1 A combination of formal instruction e g lecture discussion interactive computer learning video tape written material 2 Practical training demonstrations performed by the trainer and practical exercises performed by the trainee 3 Evaluation of the operator s performance in the workplace including results of
213. ction occurs Check for bridge motor brake and gear case overheating Move the test load back into the original position and lower the test load stopping by the brakes Hold the load for 10 minutes or the time required to check all primary load bearing parts while under load for slippage damage or permanent deformation Slowly lower the test load to the floor At the completion of the load test visually inspect the following load bearing parts for signs of wear deformation and deterioration 7 23 Chapter 7 Overhead and Gantry Cranes DOE STD 1090 2007 Page 3 of 4 EXHIBIT I continued DEFECTIVE OK NA a f g Bridge track Bridge wheels Trolley track Trolley wheels Gears Magnetic brakes Blocks Visually inspect rope in accordance with Chapter 11 Wire Rope and Slings a b C d e Rope diameter Previous Wear Kinks Broken wires Other signs of deterioration Visually inspect the rope drum for a b C Hook Inspection Wear Deformation Deterioration Present A qualified inspector shall perform nondestructive tests on hook by visual examination liquid penetrant examination or magnetic particle examination Acceptance No cracks linear indications laps or seams Hooks with more than 596 normal new hook throat opening not to exceed 1 4 in or as recommended by the manufacturer shall be replaced Hooks with any visibly apparent bend or twist from
214. d Pneumatic Cylinders eene 9 9 9 2 6 6 Hydraulic Filters cota Eher 9 9 9 2 6 7 Wire Rope tene cem or i tei Pp tesoro decet 9 9 9 2 7 Load Hooks Load Blocks esee eene eene 9 11 9 2 8 Cranes Not in Regular Use one eie tete tee Eo dete tee bre Lond 9 11 9 3 TESTING EE 9 12 9 31 Operational Tests ia iii ist 9 12 9 32 Rated Load Peste A ep O tyre bre Cod 9 12 9 4 MAINTENANCE ei iei erro ibid 9 13 9 4 1 Preventive Maintenance oooncccncnnonnnonenononenonononononononnnnn nono eene nennen ren eene enne 9 13 9 4 2 Maintenance Procedures serotoninei iinei nennen rem nem nennen 9 13 9 4 3 Wire Rope Maintenance oconccconnconononenononenonenonnnonononnnnnnonn nono nn nennen erem ren nennen neret 9 13 9 5 OPERA TION WE 9 15 95 1 Conduct of Operator iii et ete erp a RR Tk a ase ee GE RR pee Rec 9 15 9 5 1 1 Traveling the Machine ooooconoconoconoccnononononnnonncnn ccoo ccoo cnn cnn eene rennen 9 16 9 5 1 2 Making Adjustments or Repas 9 16 9 5 1 3 EIA AAA teatri oci eres ka 9 17 9 5 1 4 Further Safety Considerations essere 9 18 9 5 2 Operating Near Power Lines and Transmitter Towerg 9 18 DOE STD 1090 2007 CHAPTER 9 MOBILE CRANES 9 5 3 9 5 4 9 5 5 9 5 6 9 5 7 9 5 8 9 5 9 9 5 10 9 5 11 9 5 12 EXHIBIT I EXHIBIT II EXHIBIT III EXHIBIT IV 9 5 2 1 Crane Operations De Energized and Grounded Electrical Power Eines aca a te E AU ERE Re 9 19 9 5 2 2 Power L
215. d by performing an NDT after grinding to verify removal of relevant discontinuities DOE STD 1090 2007 Two thirds CFB GK One third 45 Y Two thirds SS One third m Ya Figure 13 2 Eye hook dd Chapter 13 Load Hooks DOE STD 1090 2007 13 5 MAINTENANCE a A hook latch that is inoperative or missing shall be repaired or replaced b Ahook with a latch that does not bridge the throat opening shall be removed from service until the latch is replaced or repaired and the hook is examined for deformation with special attention to the throat opening c Adesignated person shall repair cracks nicks and gouges by grinding Chapter 15 Load Hooks 13 8 longitudinally following the contour of the hook provided no dimension is reduced more than 10 percent or as recommended by the manufacturer of its original value All other repairs shall be performed by the manufacturer or a qualified person Replacement parts such as load pins for clevis hooks shall be at least equal to the original manufacturer s specifications DOE STD 1090 2007 13 6 OPERATION Hook users shall do the following P Si Q e Determine that the weight of the load to be lifted does not exceed the load rating f the hook Avoid shock loading Center the load in the base bowl or saddle of the hook to prevent point loading of the hook Do not use hooks in such a manner as to
216. d test personnel when it is necessary in the performance of their duties 4 Inspectors of lifting devices The following shall apply to personnel who use close proximity operated magnets 1 Place any attached load on the floor or ground and after use properly store the lifting device before leaving it 2 Before they are used during a shift test all controls If any do not operate properly adjust or repair them before operations begin 3 Do not load the lifting device in excess of its rated capacity or handle any load for which it is not designed 4 Apply the lifting device to the load in accordance with established procedures 5 Before lifting ensure that lifting device ropes or chains are not kinked and that multiple part lines are not interwoven Chapter 14 Below the Hook Lifting Devices DOE STD 1090 2007 6 Ensure that the load is correctly distributed for the lifting device being used 7 Ensure that the temperature of the load does not exceed the maximum allowable limits of the lifting device 8 Do not use the lifting device for side pulls or sliding the load unless specifically authorized by a qualified person 9 Keep the lifting magnet face and the magnet contact area clean 10 Ensure that the load to be lifted is within the magnet s rated capacity or application capacity and lifting equipment rated capacity 11 Observe all meters and indicators on the lifting magnet to confirm pro
217. d to powered hoists having a load rating of 5 tons and above b When planned engineered lifts are made the load shall not exceed 125 of the hoist load rating except as provided in para 8 5 7 d c Planned engineered lifts shall be limited to two occurrences on any hoist within any 8 19 continuous 12 month period except as provided in para 8 5 7 d If greater lift frequency is desired consideration shall be given to rerating or replacing the hoist The hoist manufacturer shall be consulted if the planned engineered lift exceeds 125 of rated load or if the frequency of planned engineered lifts exceeds two during a continuous 12 month period Each planned engineered lift shall comply with the following requirements 1 A written review of the hoist service history shall be prepared including reference to previous planned engineered lifts structural repairs and modifications of original design 2 The design of the structural mechanical electrical pneumatic and hydraulic components of the hoist shall be reviewed by means of applicable calculations for the load to be lifted and approved by the hoist manufacturer or a qualified person in accordance with accepted hoist design standards if the load to be lifted exceeds 125 of rated load or if the frequency of planned engineered lifts exceeds two during a continuous 12 month period 3 The design of the hoist supporting structure shall be reviewed and appro
218. de energization of the power lines has occurred 9 19 The power company or owner of the power lines shall de energize the lines The lines shall be visibly grounded to avoid electrical feedback and appropriately marked at the job site location A qualified representative of the owner of the lines or a designated representative of the electrical utility shall be on site to verify that steps a and b have been completed and that the lines are not energized 9 5 2 2 Power Lines Energized Crane Operating Less than Erected Fully Extended Boom Length away from the Prohibited Zone see Figure 9 3 An on site meeting between project management and a qualified representative of the owner of the lines or a designated representative of the electrical utility shall take place to establish the procedures to safely complete the operations The specified clearance between the power lines and the crane load line and load shall be maintained at all times as specified in Table 9 3 Load control when required shall utilize tag lines of a non conductive type A designated signaler whose sole responsibility is to verify that the required clearance is maintained shall be in constant contact with the crane operator No one shall be permitted to touch the crane or the load unless the designated signaler indicates it is safe to do so Operation of boom and load over electric power lines is extremely dangerous due to perception
219. de of the crane except dead ends 2 Place derails not less than 50 ft from the crane on each side except dead ends 3 Allow only authorized personnel to remove warning signs flags and derails 9 4 8 WIRE ROPE MAINTENANCE Personnel using wire rope shall ensure proper care by doing the following a Store rope to prevent damage or deterioration b Unreel or uncoil rope as recommended by the rope manufacturer and with care to avoid kinking or inducing a twist c Before cutting a rope use some method to prevent unlaying the strands Heat affected zones of flame cut wire rope shall not be allowed to bear load d During installation avoid dragging the rope in the dirt or around objects which will scrape nick crush or induce sharp bends in it Chapter 9 Mobile Cranes DOE STD 1090 2007 9 4 MAINTENANCE Maintain rope in a well lubricated condition to reduce internal friction and to prevent corrosion Ensure that lubricant applied as part of a maintenance program is compatible with the original lubricant Consult the rope manufacturer when in doubt Lubricant applied shall be of the type that does not hinder visual inspection Those sections or rope that operate over sheaves or are 9 14 otherwise hidden during inspection and maintenance procedures require special attention when the rope is lubricated When an operating rope shows greater wear at its ends than on the remainder its life can be extended
220. ded Link ecrit eret bn ddr 7 9 TAA Chain ROUET A ertt Fre rer aee i derent 7 10 7 2 8 Cranes Not in Regular Service 7 11 7 3 AA X 7 12 PS Operational E CT 7 12 43 2 Rated Load Test uin eec te ee edin ee ERE pcastendyseee scandent 7 12 7 4 MAINTENANCE ertet rrr rate etre ee e e ide ep subs sided ee eat epe indic 7 14 FAA Opera ng Equipment uie tt erbe eee terre tH GR e PO RE PEE ae kenn 7 14 AD Wire Rope Maintenance iis ios e eph eda a iE 7 14 7 5 OPERATION 000 Eet ee 7 15 TS Conduct of Eet Ee ie isla DE 7 15 7 5 2 Hoist Limit Switch Device essere nennen eene emen nnnm renenene 7 15 4 5 3 Standard Hand Signals aoo eege E Eesen e 7 16 7 5 4 Identification of Sugnalers sssini esie in ea E E R A 7 16 T33 SIZE EE ii 7 16 1 3 0 Attaching the Load iaa E MU SED 7 16 47 5 7 Moving the Load iia a 7 16 4 5 8 Ordinary Lafts ostias 4 5 9 Planned Engineered Lafts senges Root Ire er RETO RR GP ee 7 18 7 5 10 EXHIBIT I EXHIBIT II EXHIBIT III EXHIBIT IV DOE STD 1090 2007 Critical Lifts neu iot epe nq eee end gs 7 19 Bridge Wall Gantry Crane Load Test 7 22 Overhead Crane Pre Operational Checker 7 26 Overhead Crane Periodic Inspection Report Mechanical esses 7 28 Overhead Crane Periodic Inspection Report Electrical esses 7 30 7 ii DOE STD 1090 2007 7 1 GENERAL Overhead and gantry cranes inc
221. devices shall be tested and inspected before use The results of the test and inspection shall be documented in the equipment history file b The rated capacity shall not be more than 80 percent of the maximum load sustained during the test Test loads shall not be more than 125 percent of the rated capacity unless otherwise recommended by the manufacturer Test weights shall be accurate to within 5 percent 0 percent of stipulated values Chapter 14 Below the Hook Lifting Devices 14 4 The rated load test shall consist of the following 1 Hoist the test load a sufficient distance to ensure that it is supported by the lifting device or apply the required load if the test is made using a testing machine Personnel shall remain clear of suspended loads 2 Visually inspect the lifting device for deformation cracks or other defects after the load test is completed 14 2 7 MAINTENANCE A preventive maintenance program shall be established based upon manufacturer s recommendations If equipment maintenance procedures deviate from published manufacturer s recommendations the alternate procedures shall be approved in advance by the manufacturer or another qualified person and be kept readily available Replacement parts shall be equivalent to the original specifications 14 2 8 TRAINING QUALIFICATION Below the hook lifting device operators shall be trained and qualified as required in Chapter 6 Personnel Qualifi
222. ds or riveting used to secure the retaining members for soundness m Nondestructive examination of hooks welds bearings or other suspect load bearing parts when required by the inspector n Testing of motion limit devices which interrupt power or cause a warning to be activated for proper performance each motion shall be inched or operated at low speed into the limit device with not load on the crane o All function instruction caution and warning labels or plates for legibility 7 2 7 2 Wire Rope Chapter 7 7 8 Overhead and Gantry Cranes A qualified inspector shall inspect all ropes atleast annually This inspection shall include examination of the entire length of the rope without detaching it from the hoist drum More frequent intervals shall be determined by a qualified person and shall be based on such factors as expected rope life as determined by experience on the particular installation or similar installations severity of environment percentage of capacity lifts frequency rates of operation and exposure to shock loads The qualified inspector shall carefully note any deterioration such as described below resulting in appreciable loss of original strength and determine whether further use of the rope constitutes an acceptable risk Reduction of rope size below nominal diameter whether due to loss of core support internal or external corrosion or wear of outside wires see Table 7 1 2
223. e Rope Core RRL Right Regular Lay 1 00 100 00 2 10 EA Wire Rope Slings v2 x 6 ft made with carbon steel wire Rope minimum working load limit 4 000 Ibs 10 00 100 00 3 10 EA Synthetic Slings 6 ft length Flat Eye and Eye with a Minimum rated vertical capacity of 6 000 Ibs 20 00 200 00 4 10 EA Shackles screw pin anchor 25 Ton capacity 40 00 400 00 SEE CONTINUATION SHEET FOR FUNCTIONAL REQUIREMENTS TOTAL Suggested Supplier Name Phone No Total Est Cost Price 800 00 Marvin s Rigging Supply Ee Anytown USA 800 999 0000 Budget Ceiling y 1 000 00 APPROVALS APPROVER PRINTED NAME SIGNATURE Social Security No Phone No Date Requestor Freddie Hartzop 222 22 2222 1 1112 12 18 96 O Safety Manager Joe Boss 220 02 0000 1 1114 12 19 96 O Engineering O Other GA99 0027 Exhibit 1 Purchase Requisition Example Appendix A A 18 Procurement Guidelines DOE STD 1090 2007 CONTINUATION PURCHASE REQUISITION EXAMPLE ONLY ITEM NO QUANTITY UNIT DESCRIPTION Salient Features UNIT PRICE TOTAL PRICE FUNCTIONAL REQUIREMENTS FOR WIRE ROPE Carbon steel wire rope shall be made in the United States by a member of the Wire Rope Technical Board Shall meet the requirements of RR W 410D Federal Specification for Wire Rope and Strand or MIL W 83420 for aircraft cable Shall be shipped lubricated and with a protective covering i e plastic
224. e such as the peak link on multiple leg slings positioning However the rings and links may also be found on the load attachment end of slings Figure 12 9 shows typical rings links and swivels Links rings and swivels shall be fabricated from material of sufficient ductility to permanently deform before losing the ability to support the load within the temperature range specified by the manufacturer and shall have a minimum design factor of 5 1 Each link ring or swivel body shall be permanently and legibly marked by the manufacturer to show 1 Manufacturer s name or trademark 2 Sizeorrated load 3 Grade if required to identify rated load OPERATING PRACTICES Contact with obstructions that could damage the link ring or swivel should be avoided Shock loading should be avoided The load applied to the link ring or swivel should be in line and in tension Links rings and swivels should not be side loaded Links rings and swivels should not be dragged on any abrasive surface The link ring or swivel shall be of proper shape and size to ensure that it seats properly in the hook or lifting device When link rings or swivels are to be used at temperatures above 400 F 204 C or below 40 F 40 C the link ring or swivel manufacturer or a qualified person should be consulted The strength of link rings or swivels can be affected by chemically active environments such as caustic or acid substance
225. e and Locomotive Cranes for latest ASME standards see http catalog asme org home cfm Category CS 9 1 GENERAL urraca EE ERR prlde ii 9 1 9 1 1 Operator Training Qualification oooonncnnnnnonnnonnnonnnonconnnononono nono nnncnnncnn cnn cnn conca nnncnn cnn nnos 9 1 012 Load Limits EE 9 1 9 1 3 Load Ratio Chart ceret e eH EEN eege 9 1 9 1 4 Load Hoist Brakes iere tiet te ee eei EH EUR be EROR deeds 9 6 9 1 5 Power Controlled Lowering eese nennen retener nnne 9 6 QUO EE 9 6 HK SI Dau engines inae ea ei AE E E E ar E IREN E RERE EE iesit 9 6 KEE e CUu Rt 9 6 9 19 Maintenance story uit rettet er eei i re e e eei diese 9 6 9 1 10 Design Standards iere tette et EORR eng ect dyes 9 6 9 2 kd ei KE 9 7 HOT A ENEE EE EE aaueny ses EA E ESE 9 7 9 2 2 Initial Inspection ceo mme e etre ete HU er erii 9 7 9 2 3 Daily Preoperational Check 9 7 92 4 Monthly Inspection ss uenerit tne Ere er rre ree EE Eee ib beg ENEE 9 7 925 Frequent Inspection see eee rente eem et Pob rae e R EEEE E ipei gets 9 7 Hip Penodie Inspection esis eere time pe a rore rae PU Eee b agri rio Re HER 9 8 9 2 6 1 o 9 8 9 2 6 2 Hydraulic and Pneumatic Hose Fittings and Tubing 9 9 9 2 6 3 Hydraulic and Pneumatic Pumps and Motors 9 9 9 2 6 4 Hydraulic and Pneumatic Valves oooonccnincnoncnonanononononancnnncnnc cono canc nono nanonnos 9 9 9 2 6 5 Hydraulic an
226. e braking system shall have provision for adjustments where necessary to compensate for wear 8 1 6 3 Hand Chain Operated Hoists The Hoist shall be designed so that when the actuating force is removed it will automatically stop and hold any test load up to 125 percent of the rated load 8 1 6 4 Manual Lever Operated Hoists a The hoist shall be equipped with a load controlling mechanism b Theload controlling mechanism shall perform the following functions under normal operating conditions with test loads up to 125 percent of rated capacity 1 Stop and hold the load when the lever force is removed and the lever stroke is completed 2 Provide for incremental movement of the load when lifting or lowering c The friction brake mechanism shall have provision for adjustment where necessary to compensate for wear 8 4 7 WIRE ROPE a Wire rope shall be of a construction specified by the hoist manufacturer or by a qualified person b Ifa load is supported by more than one part of wire rope the tension on the parts shall be equalized c Socketing shall be done in the manner specified by the manufacturer of the assembly or the rope d Eye splices shall be made in a manner recommended by a qualified person Rope thimbles should be used in the eye Chapter 8 Hoists 8 6 e Swaged or compressed fittings shall be applied as recommended by the rope hoist or fitting manufacturer or a qualified person f
227. e done only by designated persons 14 4 7 TRAINING QUALIFICATION a Magnetic lifting device operators shall be trained and qualified as specified in Chapter 6 Personnel Qualification and Training At a minimum instruction shall include the following 1 Application of the lifting device to the load and adjustments of the device if any that adapt it to various sizes or kinds of loads Any special operations or precautions Condition of the load itself required for operation of the lifting device such as balance degree of order of stacked loads surface cleanliness bending and load thickness Procedure for storage of lifting device to protect it from damage Instructions for not exceeding the rated capacity of the lifting device or the capacity of the hoisting equipment by the combined weight of the load the lifting device and the rigging 6 Charging of the lifting magnet battery if required 7 The purpose of indicators meters or alarms on the lifting magnet 8 The proper attachment of adaptors to lifting magnets for handling of special loads Operators shall demonstrate the ability and competence to operate the lifting device as instructed before assuming responsibility for using it 14 48 OPERATION Only the following qualified personnel shall operate lifting devices 1 Designated persons 2 Trainees under the direct supervision of a designated person 3 Maintenance an
228. e hook and is more serious in nature Discontinuity T when occurring in Zones B C or D may reduce longevity of the hook If the inspection identifies discontinuities NDT should be considered Original Measurements Date Throat Opening Tram AA Tram BB Twist Angle Crack Wear Hook Latch NDT Performed Pass Fail Inspector COMMENTS NOTES ON RESULTS 13 13 Chapter 15 Load Hooks DOE STD 1090 2007 INTENTIONALLY BLANK Chapter 13 Load Hooks 13 14 DOE STD 1090 2007 CHAPTER 14 BELOW THE HOOK LIFTING DEVICES This chapter provides the requirements for below the hook lifting devices used in hoisting and rigging such as spreader bars lifting yokes and lift fixtures This section implements the requirements of ASME B30 20 Below the Hook Lifting Devices for latest ASME standards see http catalog asme org home cfm Category CS NOTE Special lifting devices for shipping containers weighing 10 000 Ib or more that are used for radioactive materials are governed by ANSI N14 6 Standard for Special Lifting Devices for Shipping Containers Weighing 10 000 Pounds 4 500 kg or More for Nuclear Materials 14 1 GENERAL rai 14 1 14 2 STRUCTURAL AND MECHANICAL LIFTING DEVICES eee 14 2 14 2 1 Design Fabrication au tdi 14 2 14 2 2 E MR 14 2 14 2 3 elek ee ee EE 14 3 14 2 4 G ardin S ies onda a
229. e load item or the delay in operations of 2 1 having the load item damaged would have a negative impact on facility organizational or DOE budgets to the extent that it would affect program commitments 4 Alift not meeting the above criteria shall also be designated critical if mishandling or dropping of the load would cause any of the above noted consequences to nearby installations or facilities Further site specific criteria may be developed to supplement those cited above and may include loads which require exceptional care in handling because of size weight close tolerance installation or high susceptibility to damage as well as lifts using multiple pieces of lifting equipment Chapter 2 Critical Lifts DOE STD 1090 2007 2 2 CRITICAL LIFT REQUIREMENTS Ensure that the requirements are met for ordinary lifts specified in each section of this standard for each particular equipment category The operating organization shall appoint a Person In Charge PIC for the entire operation This person shall meet the definitions of appointed designated and qualified as described in Chapter 1 Terminology and Definitions and shall be present at the lift site during the entire lifting operation The PIC shall ensure that a pre job plan or procedure is prepared that defines the operation and includes the following 1 Identification of the items to be moved the weight dimensions and center of gravity of the
230. e nicks or gouges f A 10 reduction of the original or catalog dimension at any point g Evidence of unauthorized welding or modification h Unauthorized replacement components i Insufficient number of wire rope clips j Improperly tightened wire rope clips k Indications of wire rope slippage DOE STD 1090 2007 1 Improper assembly or other conditions including original equipment manufacturer s visible damage that cause doubt as to continue specifications use 12 11 9 CRITICAL LIFTS 12 11 8 REPAIRS a See Chapter 2 Critical Lifts for critical lift a Repairs alterations or modifications shall be as requirements specified by the compression hardware b Compression hardware used for critical lift manufacturer or a qualified person service shall be proof tested as part of the completed assembly b Replacement parts shall meet or exceed the E n End Saddle M Live Dead End u U Bolt ct m co Saddle SSE USES ES foot d Double Saddle A Clip Base Ea Width 3 e os AOS E Types Components Turnback 1 SSS GENERAL NOTE Correct number of clips for wire rope size shall be used NOTES 1 correct turnback length should be used 2 correct orientation of saddle on live end shall be observed 3 correct spacing of clips should be used 4 correct torque on nuts shall be applied Reprin
231. e of a crane suspended work platform and attest to the need for the operation through a written justification attesting to that need A statement describing the operation and its time frame shall be included The statement after being approved by the authorizer shall be retained at the job site d The manager specifically responsible for the overall work function shall not allow or require any operator to lift personnel under the following circumstances 1 The operator does not feel physically or mentally fit to perform the operation 2 The operator has been working for more than 10 hours prior to the start of the lift or the lift will not be completed before the operator has been working for 12 hours 3 The operator did not have at least eight hours off immediately prior to the work shift containing the person 4 1 2 DESIGNATED LEADER The Authorizing Manager shall appoint a Designated Leader for the entire personnel lifting operation The Designated Leader shall ensure that a pre job plan is prepared that defines the operation The Designated Leader shall ensure 1 At each new job site prior to hoisting personnel the personnel lift platform rigging and hook block shall be proof tested by a qualified inspector to 125 percent of the personnel platform s rated capacity by holding it suspended for 5 minutes with the test load suitably distributed on the personnel platform 2 After proof testing any deficie
232. e or the 4 Apply the lifting device to the load in capacity of the hoisting equipment by accordance with established procedures the combined weight of the load the lifting device and the rigging 5 Before lifting ensure that lifting device ropes or chains are not kinked and that 6 Charging of the lifting magnet battery multiple part lines are not interwoven if required 6 Ensure that the load is correctly 7 The purpose of indicators meters or distributed for the lifting device being alarms on the lifting magnet used 8 The proper attachment of adaptors to 7 Ensure that the temperature of the load lifting magnets for handling of special does not exceed the maximum loads allowable limits of the lifting device b Operators shall demonstrate the ability and 8 Do not use the lifting device for side competence to operate the lifting device as pulls or sliding the load unless instructed before assuming responsibility for specifically authorized by a qualified using it person 14 5 8 OPERATION 9 Do notuse a lifting magnet that is tagged Danger Do Not Operate or a Only the following qualified personnel shall otherwise designated as nonfunctional operate lifting devices 10 Do not remove Danger Do Not 1 Designated persons Operate tags without the approval of the person who placed them or an 2 Trainees under the direct supervision of authorized person a designated person 11 Store the lifting device in a des
233. e original diameter of outside individual wires 3 Kinking crushing birdcaging or any other damage resulting in distortion of the rope structure 4 Evidence of heat damage from any cause 5 Reductions from nominal diameter greater than those shown in Table 8 1 d The qualified inspector shall give special attention to end fastenings and shall examine ropes frequently at socketed fittings on the development of two broken wires adjacent to this point resocket or replace the rope Resocketing shall not be attempted if the resulting rope length will be insufficient for proper operation Those portions of the rope subjected to reverse bends and operation over small diameter drums or sheaves shall be closely examined e Replacement rope and connections shall have a strength rating at least as great as the original rope and connections furnished by the hoist manufacturer Any deviation from the original size grade or construction shall be specified by a rope manufacturer the hoist manufacturer or a qualified person f Never use discarded rope for slings DOE STD 1090 2007 8 2 5 3 Welded Link Chain a A qualified inspector shall do the following during periodic inspections 1 Operate the hoist under load in raising and lowering directions and observe the operation of the chain and sprockets The chain should feed smoothly into and away from the sprockets Make sure that if the chain binds jumps or
234. e protectors 11 37 Chapter 11 General DOE STD 1090 2007 Table 11 14 Typical load capacity of Class 5 synthetic web slings in pounds Design Factor 5 1 Regular eye and eye twisted eye triangle fittings choker fittings Web width se Basket or Web width in Vertical Choker two legs in Single Ply Web Slings 6 800 Ib in material 1 1 100 880 2 200 1 900 1 600 1 100 1 2 2 200 1 760 4 400 3 800 3 100 2 200 2 3 3 300 2 640 6 600 5 700 4 700 3 300 3 4 4 400 3 520 8 800 7 600 6 200 4 400 4 5 5 500 4 400 11 000 9 500 7 800 5 500 5 6 6 600 5 280 13 200 11 400 9 300 6 600 6 Double Ply Web slings 6 800 bim material 1 2 200 1 760 4 400 3 800 3 100 2 200 1 2 4 400 3 520 8 800 7 620 6 200 4 400 2 3 6 600 5 280 13 200 11 400 9 300 6 600 3 4 8 200 6 560 16 400 14 200 11 600 8 200 4 5 10 200 8 160 20 400 17 700 14 400 10 200 5 6 12 300 9 840 24 600 21 300 17 400 12 300 6 Reprinted from ASME B30 9 2006 by permission of The American Society of Mechanical Engineers All rights reserved 1 For an endless sling with vertical hitch carrying a load of such size as to throw the legs more than 5 degrees off vertical use rated load data for regular eye and eye sling basket hitch and corresponding leg angles 2 Follow manufacturer s capacities they vary from manufacturer to manufacturer and from this chart 3 Choker hitch values apply only to choke ang
235. e rope lay or five broken wires in one strand in one rope lay ii For cable laid slings 20 broken wires per lay iii For six part braided slings 20 broken wires per braid iv For eight part braided slings 40 broken wires per braid 3 Severe localized abrasion or scraping 4 Kinking crushing birdcaging or any other damage resulting in damage to the rope structure 5 Evidence of heat damage 6 End attachments that are cracked deformed or worn to the extent that the strength of the sling is substantially affected 7 Severe corrosion of the rope end attachments or fittings 8 For hooks removal criteria as stated in Section 12 2 9 Other conditions including visible damage that cause doubt as to the continued use of the sling 11 3 2 2 Proof Testing a Allswaged socket and poured socket sling assemblies shall be proof tested to the wire Chapter 11 11 20 General rope or fitting manufacturer s recommendations but in no case greater than 50 percent of the component wire rope s or structural strand s nominal strength All other sling assemblies shall be proof tested when specified by the purchaser As a minimum the proof load shall be equal to the rated capacity but shall not exceed 1 125 percent of the vertical rated capacity for single let hand tucked slings 2 200 percent of the vertical rated capacity for mechanical splice single leg slings and endless slings The proof load for
236. ead and Gantry Cranes DOE STD 1090 2007 7 4 MAINTENANCE 7 4 1 OPERATING EQUIPMENT A preventive maintenance program shall be established and based on the recommendation of the crane manufacturer If equipment maintenance procedures deviate from published manufacturer s recommendations the alternate procedures shall be approved in advance by the manufacturer or another qualified person and be kept readily available Dated maintenance records should be kept where readily available to appointed personnel Replacement parts shall be at least equal to the original manufacturer s specifications All moving parts of the crane for which lubrication is specified shall be regularly lubricated Check lubricating systems for delivery of lubricant Follow manufacturer s recommendations as to points and frequency of lubrication maintenance of lubricant levels and types of lubricant to be used Maintenance personnel shall take the following precautions before performing maintenance on a crane 1 Move the crane to a location where it will cause the least interference with other cranes and operations 2 Place any attached loads on the ground or floor 3 Place all controllers in the OFF position 4 Perform a lockout tagout procedure 5 Use warning signs and barriers on the floor beneath the crane where overhead maintenance work creates a hazard Chapter 7 Overhead and Gantry Cranes 7 14 6 Ifthe runway remains e
237. easured by the link stock c Two basic types with many variations are used basket type and hook type An example of each is shown in Figure 11 14 Double basket type Figure 11 14 Types of chain slings d Alloy steel chain slings shall not be heated above 1 000 degrees F 537 degrees C after being received from the manufacturer e When exposed to service temperatures in excess of 600 degrees F 315 degrees C reduce working load limits in accordance with the chain manufacturer s recommendations f Extremely low temperatures less than 0 degrees F may cause brittle fractures Under these conditions sudden loading should be avoided and the load should be lifted a very short distance while the chains are carefully inspected The design factor for steel chain slings shall be a minimum of 4 1 based upon breaking strength Chains should be stored in racks or in designated locations when not in use Chains should never be stored in damp or dirty places nor in places exposed to the weather For long term storage they should receive a coating of oil The ends of all empty chains should be hooked onto the hoist hook or bull ring Chains should not be lubricated when in use because this might make them dangerous to handle Chains should be cleaned periodically to remove abrasive grit and to facilitate inspection The total load that can be lifted safely with steel chain slings depends on the manner by which the s
238. ected prior to such repairs temperature the vehicle shall be removed from service and not returned to service until the cause for such overheating has been eliminated Industrial trucks originally approved for the use of gasoline for fuel may be converted to liquefied petroleum gas fuel provided the complete conversion results in a truck which embodies the features specified for LP or LPS designated trucks Conversion equipment and the recommended method of installation shall be approved by the manufacturer All parts that require replacement shall be replaced only with parts that are equivalent in regards to safety to those used in the original design Attachments shall be included in a scheduled maintenance inspection program Inspection steps shall be tailored for the attachment Load bearing components shall be examined for deformation and load bearing welds shall be visually examined for cracks Mechanical or hydraulic components shall be inspected and maintained in accordance with the manufacturer s instructions Attachments shall be inspected not less than annually and the inspection should be documented Hooks that are included as part of attachments shall be inspected as specified for hooks on cranes hoists see Chapter 13 0 Load Hooks Water mufflers shall be filled daily or as 10 3 4 FORKS frequently as is necessary to prevent depletion of the supply of water below 75 10 3 4 1 Fork Load Rating percen
239. ed Extremely low temperatures less than 0 degrees F may cause brittle fractures Under these conditions sudden loading should be avoided and the rope should be carefully observed while the load is being applied Do not use knotted slings Do not use single let wire rope slings unless proper precautions are taken to prevent suspended loads from rotating Rigging shall be configured such that slings do not reeve or slip through the hook Do not make a complete turn of wire rope around the crane hook Use protector pads or blocking at sharp corners Keep hands and fingers out of the area between the sling and the load Ensure that the weight of the load is within the rated capacity of the sling Do not use damaged slings Ensure that all personnel stand clear of the suspended load 16 17 18 19 20 21 22 23 24 Avoid shock loading In a basket hitch ensure that the load is balanced to prevent slippage Avoid handling hot material with wire rope slings Use shackles or adjustable choker hooks when making choker hitches Store slings on racks away from moisture and acids when not in use Ensure that damaged wire rope slings are rendered unusable removed from service discarded and replaced with new slings Before use and before storage check wire rope slings for i Broken or cut wires or strands ii Rust or corrosion ii Kinks iv Bro
240. ed see Figure 10 5 The operator shall recognize signals only from the designated signaler However Obey a STOP signal no matter who gives it For operations not covered by standard hand signals special signals shall be agreed on in advance by both the operator and the signal person and should not conflict with the standard signals 3 Surveying the lift site for hazardous unsafe conditions 4 Ensuring that equipment is properly set up and positioned 5 Ensuring that a signaler is assigned if required and is identified to the operator 6 Directing the lifting operation to ensure that the job is performed safely and efficiently 7 Stopping the job when any potentially unsafe condition is recognized 8 Directing operations if an accident or injury occurs 10 5 5 CRITICAL LIFTS See Chapter 2 Critical Lifts for critical lift requirements 10 5 4 ORDINARY LIFTS 10 5 6 EQUIPMENT QUALIFICATION a The requirements of all preceding paragraphs in Section 10 5 Operation shall also apply to ordinary lifts To qualify for operation a forklift truck should have the following Ordinary lifts involving hoisting and rigging operations require a designated leader who a Arecord of successful inspections and shall be present at the lift site during the maintenance entire lifting operation If the lift is being made by only one person that person b Afrequent preuse inspection instruction as
241. ed capacity in an area readily visible and not subject to wear For example the designation 1500 24 means 1 500 Ib 680 kg capacity at 24 in 600 mm load center 10 1 4 ATTACHMENTS Attachments almost always affect rated capacity of the truck When a forklift truck is equipped with an attachment the rated capacity of the truck attachment combination shall be established by the truck manufacturer In the event the truck manufacturer is nonresponsive the attachment may be used if written approval is obtained from a qualified Professional Engineer If the response from the original truck manufacturer is negative the engineer must perform a safety analysis and address all safety and or structural issues contained in the manufacturer s disapproval Capacity operation and maintenance instruction plates tags or decals shall be changed accordingly a The rated capacity of an attachment truck combination shall not be exceeded b Onevery removable attachment excluding fork extensions a corrosion resistant nameplate with the following information is required 1 Model number 2 Serial number on hydraulically actuated attachments 3 Maximum hydraulic pressure on hydraulically actuated attachments 4 Weight Chapter 10 Forklift Trucks DOE STD 1090 2007 5 Capacity 6 The following instructions or equivalent Capacity of truck and attachment combination may be less than capacity shown on attachment
242. ed length of be as follows the chain e g at the slack end 1 Inrunning ropes 12 randomly 2 Suspend the chain vertically under distributed broken wires in one rope lay tension and using a caliper type gauge or 4 broken wires in one strand in one measure the outside length of any rope lay convenient number of links approximately 12 in 305 mm to 14 in 2 Wear of one third of the original 356 mm overall diameter of outside individual wires 3 Measure the same number of links in 3 Kinking crushing birdcaging or any the used sections and calculate the other damage resulting in distortion of percentage of increase in length the rope structure d Conditions such as the following shall be sufficient reason for questioning safety and for considering replacement 1 Ifthe used chain exceeds a crane manufacturer s recommended length or in the absence of such a recommendation the used chain is 1 5 percent longer than the unused chain for powered hoists or is 2 5 percent longer Chapter 7 Overhead and Gantry Cranes DOE STD 1090 2007 than the unused chain for hand operated chain replace the chain 2 The existence of gouges nicks corrosion weld spatter or distorted links Repairing the load chain by welding or any other means shall not be attempted by anyone other than the chain manufacturer Replacement chain shall be the same size grade and construction as the original chain furnished by the crane
243. ed person shall repair cracks nicks and gouges by grinding longitudinally following the contour of the hook provided that no dimension is reduced more than 10 percent of its original value or as recommended by the manufacturer b Allother repairs shall be performed by the manufacturer 12 2 8 OPERATION The following shall apply to rigging hook users a Determine that the load does not exceed the lesser of the rated capacity of the hook or the load rating of the equipment of which it is a part b Avoid shock loading c Keep hands fingers and body from getting between the hook and the load d Load shall be centered in the base of the hook to prevent point loading of the hook e Hooks shall not be used in such a manner as to place a side load or back load on the hook f When using a device to close the throat opening of the hook care shall be taken that the load is not carried by the closing device g The use of a hook with a latch does not preclude the inadvertent detachment of a slack sling or a load from the hook Visual verification of proper hook engagement is required in all cases h Self locking hooks shall be locked during use i Whenalock is equipped with a latch the latch shall not be constrained from closing during use DOE STD 1090 2007 12 3 SHACKLES 12 3 1 GENERAL a Shackles are made of drop forged steel bent into shape The shackle shall have sufficient ductility to permane
244. end of its permitted travel or when two moving cranes or trolleys come into contact CAB The operator s compartment CABLE A term loosely applied to wire ropes wire strands manila ropes and electrical conductors CABLE LAID WIRE ROPE A type of wire rope consisting of several independent wire ropes laid into a single wire rope CABLE CROWD ROPE A wire rope used to force the bucket of a power shovel into the material being handled CANTILEVER TRUCK A self loading counterbalanced or noncounterbalanced truck equipped with a cantilever load engaging means such as forks see Figure 10 3 Chapter 1 Terminology and Definitions 1 2 CARRIAGE A support structure for forks or attachments generally roller mounted traveling vertically within the mast of a cantilever truck CENTER A single wire or fiber in the center of a strand around which the wires are laid CENTER CONTROL The position near the center of a truck cab from which the operator controls movement of the truck CHOKER ROPE A short wire rope sling used to form a slip noose around the object to be moved or lifted see Figure 1 1 Sliding choker hook Figure 1 1 Choker Rope CIRCUMFERENCE Measured perimeter of a circle circumscribing the wires of a strand or the strands of a wire rope CLAMP STRAND A fitting used to forma loop at the end of a length of strand consists of two grooved plates and bolts CLEARANCE The distance by which one
245. ensure a perfect fit in the rope The most common types of cores include the following see Figure 11 3 1 Fiber Core FC or Sisal Core Sisalanna is the most common fiber that is used in the manufacture of wire rope cores In smaller ropes cotton and jute are sometimes used for the core 2 Independent Wire Rope Core IWRC The primary function of the core is to provide adequate support for the strands As the name implies an IWRC is a separate small diameter wire rope that is used as the core for a larger wire rope When severe crushing or flattening of the rope is encountered an IWRC is usually specified Chapter 11 General 3 Strand Core This type of core has a single strand used as the core This type is generally confined to the smaller ropes as a substitute for IWRC The strand core may or may not have the same cross section as the surrounding strands Left Lang Lay Figure 11 2 Wire Rope lays Strand Core Figure 11 3 Wire rope cores 11 23 WIRE ROPE FOR GENERAL PURPOSES 11 2 3 1 6 x 19 Classification Most applications can use a rope from this classification it is the most versatile of all ropes made Figure 11 4 shows four varieties of 6 x 19 wire ropes with FCs and IWRCs Table 11 2 provides breaking strengths for 6 x 19 wire ropes with FC and IWRC cores 11 2 3 2 DOE STD 1090 2007 b The principle types of ropes in this classification include 1 6x I9F The
246. ent of the rated capacity Performance testing of hooks shall not be required except where necessary to conform to requirements for the equipment of which they are a part of Appendix A Procurement Guidelines DOE STD 1090 2007 13 SWIVEL HOIST RINGS Swivel hoist rings shall be fabricated to meet or exceed the required of ASME B30 26 P Si Excluding bushings and bearings swivel hoist rings shall have sufficient ductility to permanently deform before losing the ability to support the load at temperatures at which the manufacturer has specified for use Appendix A Procurement Guidelines c Swivel hoist rings used for lifting service shall be marked with the manufacturer s name or trademark rated load and torque value d The safe working load shall have a safety factor of 5 DOE STD 1090 2007 14 LINKS AND RINGS P Si 9 Links and rings shall be fabricated to meet or exceed the requirements of ASME B30 26 Links and rings shall have sufficient ductility to permanently deform before losing the ability to support the load at the temperature that the manufacturer has specified for use The design factor for links and rings shall be a minimum of 5 Prior to initial use welded rings or links shall proof tested by the manufacturer Proof testing is not required for forged rings or links Rings or links should be marked by the manufacturer with the manufacturer s name or trademark
247. equipment required b The equipment operation training shall include 1 A demonstration by the individual of operational competence with the equipment 2 A demonstration of appropriate safe operating practices 3 Documented evidence of the individual s knowledge of safety related information Chapter 3 Preengineered Production Lifts 3 7 Equipment operation training shall be repeated for personnel whenever a new or different type of equipment is introduced into the procedure 3 5 2 PROCEDURE Personnel shall be trained and qualified in the proper execution of each specific procedure The training shall include 1 A demonstration by the individual of operational competence in performance of the procedure 2 Documented evidence of the individual s knowledge of the steps and requirements of the procedure Training on a procedure shall be repeated periodically or when a modification to the procedure results in a significant change in the operation DOE STD 1090 2007 CHAPTER 4 LIFTING PERSONNEL This chapter specifies the design and inspection requirements for personnel lift platforms as well as the operational requirements for such platforms and appurtenant hoisting equipment It implements the requirements of ASME B30 23 Personnel Lifting Systems for latest ASME standards see http catalog asme org home cfm Category CS 4 1 GENERAL eae wee ep A ee da 4 1 4 1 1 Personnel Lifting Evaluation ee
248. er 2 Sizeorrated load 3 Grade for alloy eyebolts d Eyebolts shall have a minimum design factor of 5 1 e Only shouldered eyebolts shall be used for rigging hardware except when prohibited by the configuration of the item to be lifted Where non shouldered eyebolts are required they shall only be used in vertical pulls or in rigging systems that are designed and approved by a qualified person f Nuts washers and drilled plates shall not be used or assembled to make shouldered eyebolts g Wire type or welded eyebolts shall not be used Shoulders shall seat uniformly snugly and flush against the surface on which they bear See Fig 12 6 i When eyebolts cannot be properly seated and aligned a steel washer or spacer with the smallest inside diameter that will fit the eyebolt shank may be used to put the plane of the eye in the direction of the load when the shoulder is seated The washer or spacer shall not exceed one thread pitch in thickness or as recommended by the manufacturer j XEyebolts shall be tightened or otherwise secured against rotation during the lift k When used in a tapped blind hole the effective thread length shall be at least one and one half times the diameter of the bolt for engagement in steel see Fig 12 6 For other thread engagements or engagement in other materials contact the eyebolt manufacturer or qualified person 12 11 n When used in a tapped through hole of less
249. er capacity and usually higher speed than the main hoist BACK STAY Guy used to support a boom or mast or that section of a main cable as ona suspension bridge or cableway and the like leading from the tower to the anchorage BAIL A U shaped member of a bucket socket or other fitting BASKET OR SOCKET The conical portion of a socket into which a splayed rope end is inserted and secured with zinc BATTERY ELECTRIC TRUCK An electric truck in which the power source is a storage battery BECKET LOOP A loop of small rope or a strand of rope fastened to the end of a large wire rope to facilitate installation BENDING STRESS Stress on wires of a wire rope imposed by bending This stress need not be added to direct load stresses When sheaves and drums are of suitable size bending stress does not affect the normal life of the wire rope BIRDCAGE A colloquialism describing the appearance of a wire rope that is forced into compression The outer strands form a cage and at times displace the core BIRDCAGING The twisting of fiber or wire rope in an isolated area in the opposite direction of the rope lay causing it to take on the appearance of a birdcage BOOM Crane A member hinged to the rotating superstructure and used for supporting the hoisting tackle BOOM LINE A wire rope for supporting or operating the boom on derricks cranes draglines shovels and the like BRAKE A device used for slowing or s
250. er conditions including visible damage that cause doubt as to the continued use of the sling Chapter 11 General 11 26 11 3 3 2 Proof Testing Single leg and endless alloy steel chain slings shall be certified as having been proof tested to 200 percent of the rated capacity prior to initial use The proof load for multiple let bridle slings shall be applied to the individual legs and shall be 200 percent of the vertical rated capacity of a single leg sling Master links to which multiple leg slings are connected shall be proof loaded to 200 percent multiplied by the force applied by the combined legs Test loads shall be accurate to within 5 percent 0 percent of stipulated values Either certification by the manufacturer or a pull test certified by a qualified person is acceptable DOE STD 1090 2007 Table 11 10 Rated load for Grade 80 Alloy Steel Chain Slings SAN OS Size in 60 45 30 inches Single Leg Two Legs Two Legs Two Legs 9 32 3 500 6 100 4 900 3 500 3 8 7 100 12 300 10 000 7 100 Ve 12 000 20 800 17 000 12 000 5 8 18 100 31 300 25 600 18 100 3 4 28 300 49 000 40 000 28 300 7 8 34 200 59 200 48 400 34 200 1 47 700 82 600 67 400 47 700 1 72 300 125 200 102 200 72 500 Reprinted from ASME B30 9 2006 by permission of The American Society of Mechanical Engineers All rights reserved Notes 1 Other grades of proof tested steel chain inc
251. er s name and address 2 Serial number 3 Lifter weight if over 100 Ib 45 kg 4 Cold current amps when applicable 5 Rated voltage when applicable 6 Rated load as described in section 14 2 2 a 7 ASME BTH 1 Design Category 8 ASME BTH 1 Service Class Tf the lifting device is made up of several lifters each detachable from the group these lifters shall also be marked with their individual rated loads Appendix A Procurement Guidelines DOE STD 1090 2007 5 WIRE ROPE P Wire rope shall meet or exceed the requirements of Federal Specification RR W 410E for wire rope Mil Specification MIL DTL 83420 for air craft cable and MIL W 83140 for non rotating stainless steel wire rope cT Wire rope shall be made in the United States by a member of the Wire Rope Technical Board except stainless steel and unless recommended otherwise by a crane or hoist manufacturer Stainless steel wire rope shall be made in the United States and shall be 302 or 304 grade stainless steel unless otherwise recommended by a crane or hoist manufacturer American Wire Rope Inc St Joseph MO Bridon American Corp Exeter PA Continental Cable Co Hinsdale NH Loos and Co Inc Pomfret CO Wire Rope Corp of America St Joseph MO Wire Rope Works Inc Williamsport PA Note This list is up to date as of the date of publication Further information is available from the WRTB at 703 299 8550 or at wrtb usa
252. er supply 2 The cold current or watts at 68 degrees F 20 degrees C and rated voltage Cases may exist where a lifting device cannot be marked with its rated capacity and weight This may be due to the security classification of the load to be lifted or other reasons approved by the responsible manager In these cases the lifting device shall be marked with an identification number and its documentation shall contain both its rated capacity and weight A label or labels shall be affixed to each lifting magnet in a readable position that displays the word CAUTION or other legend designed to bring the label to the attention of the operator The label shall also contain information cautioning against 1 Operating when the battery capacity is inadequate 2 Exceeding magnet duty cycle and disconnecting the magnet with the power on for externally powered electromagnets 3 Operating if the internal control function indicator where applicable does not indicate a complete cycle on electrically controlled permanent magnets 4 Operating with the control handle not fully in the Lift position on manually controlled permanent magnets Chapter 14 Below the Hook Lifting Devices DOE STD 1090 2007 Close proximity operated lifting electromagnet Close proximity operated electrically controlled permanent magnet Close proximity operated manually controlled permanent magnet Reprinted from ASME
253. ere the forklift will be operated 2 Composition of loads to be carried and load stability 3 Load manipulation stacking and unstacking 4 Pedestrian traffic in areas where the forklift will be operated 5 Narrow aisles and other restricted places where the forklift will be operated 6 Hazardous classified locations where the forklift will be operated 7 Ramps and other sloped surfaces that could affect the forklift s stability 8 Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause a buildup of engine exhaust gasoline or diesel 9 Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation Refresher training in relevant topics shall be provided to the operator when 1 The operator has been observed to operate the forklift truck in an unsafe manner 2 The operator has been involved in an accident or near miss incident 3 The operator has received an evaluation that reveals that the operator is not operating the forklift truck safely 4 The operator is assigned to drive a different type of forklift truck Chapter 6 Personnel Qualification and Training 6 3 6 DOE STD 1090 2007 5 Acondition in the workplace changes in a manner that could affect the safe operation of the forklift truck RIGGERS Training programs for riggers should address two levels of required performance
254. ermination made as to whether they constitute a hazard 2 Periodic inspection intervals shall not exceed one year The frequency of periodic inspections should be based on i Frequency of use ii Severity of service conditions a 111 Nature of lifts being made 1v Experience gained on the service life of links rings or swivels used in similar circumstances Chapter 12 Rigging Hardware DOE STD 1090 2007 3 Guidelines for the time intervals are i Normal service yearly ii Severe service monthly to quarterly 111 Special service as recommended by a qualified person 4 Written records are not required 12 7 6 REMOVAL CRITERIA Links rings or swivels shall be removed from service if damage such as the following is visible and shall only be returned to service when approved by a qualified person a Missing or illegible manufacturer s name or trademark and or rated load identification b Indications of heat damage including welding spatter or arc strikes c Excessive pitting or corrosion d Bent twisted distorted stretched elongated cracked or broken load bearing components e Excessive nicks or gouges f A 10 reduction of the original or catalog dimension at any point g Excessive thread damage or wear Evidence of unauthorized welding or modification For swivels lack of ability to freely rotate when not loaded For swivels loose or missing nuts bolts
255. erson shall carefully examine any deficiencies and determine whether they constitute a hazard Deficiencies noted during the inspection shall be corrected before the lifting device is used 14 2 5 3 Periodic Inspection 14 3 A qualified inspector shall perform a complete inspection at the following intervals 1 Normal service yearly Inspect equipment at site of use 2 Heavy service semiannually Inspect equipment at site of use unless external conditions indicate that disassembly should be done to permit detailed inspection 3 Severe service quarterly Inspect equipment at site of use unless external conditions indicate that disassembly should be done to permit detailed inspection 4 Special or infrequent service as recommended by a qualified person before the first such use and as directed by the qualified person for any subsequent uses Lifting device service is defined as follows 1 Normal operation with various weights within the rated load limit or uniform loads less than 65 percent of rated load 2 Heavy operation within the rated load limit that exceeds normal service 3 Severe operation at normal or heavy service under abnormal operating conditions This inspection shall include the items listed in Section 14 2 5 2 Frequent Inspection in addition to the following 1 Loose bolts or fasteners 2 Check for suspect counterfeit parts see Terminology and Definitions
256. es a For electric or air powered hoists the hoist shall not be installed where during normal operating conditions the hook can be lowered beyond rated hook travel unless the hoist is equipped with a lower limit device Lower limit devices should be provided for hoists where the load block enters pits or hatchways in the floor b For hand chain operated and manual lever operated hoists before the load chain can be completely run out of the hoist it shall be restrained in its fully extended position The restraint shall be such that the unloaded hoist can withstand a lowering hand chain or operating lever force equivalent to twice the pull required to lift the rated load or with the rated load on the hoist a hand chain or operating lever force equivalent to the pull required to lift the rated load 8 1 11 SUPPORT Support structures including trolleys and monorails shall have a rated capacity at least equal to that of the hoist 8 1 12 LOCATION The hoist shall be installed only in locations that will permit the operator to remain clear of the load at all times 8 1 13 LOAD RATING The rated capacity shall not be exceeded except for properly authorized tests Chapter 8 Hoists DOE STD 1090 2007 8 2 INSPECTIONS 8 2 1 HOIST SERVICE Hoist service is defined as follows a Normal service operation with randomly distributed loads within the rated load limit or uniform loads less than 65 percent of r
257. es commonly include a built in load scale and in such cases may also serve as a load indicating device Chapter 1 1 8 Terminology and Definitions PREFORMED WIRE ROPE Wire rope in which the strands are permanently shaped before being fabricated into the rope to the helical form they assume in the wire rope PREFORMED STRAND Strand in which the wires are permanently shaped before being fabricated into the strands to the helical form they assume in the strand PRESTRESSING Stressing a wire rope or strand before use under such a tension and for such a time that stretch that would otherwise occur once the load is picked up is largely nonexistent PROOF LOAD A specific load applied in the performance of a proof load test PROOF TEST A nondestructive tension test performed to verify construction and workmanship of slings or rigging accessories PUBLIC CARRIER A for hire company engaged in the public transportation of goods QUALIFIED A person who by possession of a recognized degree certificate or professional standing or who by extensive knowledge training and experience has successfully demonstrated an ability and competence to solve or resolve problems relating to the subject matter and work QUALIFIED ENGINEER QUALIFIED ENGINEERING ORGANIZATION An engineer or engineering organization whose competence in evaluation or design of the type of equipment in question has been demonstrated to the satisfaction
258. es for Construction of Cranes Monorails and Hoists With Bridge or Trolley or Hoist of the Underhung Type ASME NOG 1 Rule for Construction of Overhead and Gantry Cranes Toprunning Bridge Multiple Girder American Society for Nondestructive Testing Recommended Practice No ASNT TC 1A American Welding Society ANSI AWS D1 1 Structural Welding Code Steel Crane Manufacturers Association of America CMAA No 70 Specification for Electric Overhead Traveling Cranes CMAA No 74 Specification for Top Running and Under Running Single Girder Electric Overhead Traveling Cranes Chapter 17 References 17 2 Department of Energy DOE 440 1A Worker Protection Management for Federal and Contractor Employees DOE 440 1 6 Suspect Counterfeit Items Guide Department of Labor 29 CFR 1910 Occupational Safety and Health Standards for General Industry 29 CFR 1926 Occupational Safety and Health Regulations for Construction Department of Transportation 49 CFR 391 41 physical Qualification for Drivers National Fire Protection Association ANSI NFPA 505 Powered Industrial Trucks Type Designation and Areas of Use NFPA 70 National Electrical Code Power Crane and Shovel Association PCSA 4 Mobile Power Crane and Excavator Standards and Hydraulic Crane Standards Society of Automotive Engineers SAE J376 85 Load Indicating Devices in Lifting Crane Service Code SAE J765 Crane Load Stabili
259. esceeeseeeeneeeeeeeseneeeeaeeeeaeceneeeeeueeeeaeeseaeeenaeeseaeeeaaes 4 1 AMD Designated Leaders isse ias 4 1 O Tial E EE 4 2 4 1 4 Lifting Operations ere ee ett eine ei te ii 4 2 4J 4 L Pres Lift Mesias is 4 2 4 4 2 Pre Lift Inspection eter A 4 2 4 1 4 3 Lifting Personnel cunoticias rero 4 2 4 2 MOBILE CRANES cuca ida 4 5 4 3 OVERHEAD CRANES 1 eese nette nnennennennet netten teen enne teste nnne nennen enne 4 6 4 4 PERSONNEL LIFT PLATFORM AAA 4 7 4 4 1 Platform Design and Constructon nennen een rennen 4 7 4 4 2 Platform Suspension System 4 7 4 5 INSPECTIONS att lio soe teat 4 9 45 Frequent Inspection e eter tetro rte errem Petre rie eie eee red 4 9 Al General int sontes eterno e Erit ORE IEEE 4 9 4 5 1 2 Personnel Lift Platform eese nne 4 9 45 2 E een EE 4 9 4 5 2 1 Personnel Lift Platform eese nennen eene rennen 4 9 4 5 22 Hoisting Equipment centre ett eben Rn ttt rain ite 4 9 4 6 TESTING eere eebe otitis 4 10 4 6 1 Platform Manufacturer Test 4 10 4 6 2 Rated Load Leste to Dee ee RH ton repair pe tege hv EN eere tpe deeds 4 10 4 6 3 Hoisting Equipnient eene rere Hp topi e eee tv Pretorio 4 10 4 7 LIFTING PERSONNEL NEAR ELECTRICAL POWER LINES 4 11 4T C Cc 4 11 A A en aech eebe 4 11 4 753 CO eire t pectus sp ice merced er aede age tees 4 11 4 4 O Ci ee O 4 12 Exhibit I Pers
260. espect depends largely on the use of good judgment by an appointed person in evaluating the degree of damage 4 Noone except the chain manufacturer shall repair the load chain by welding or any other means 5 Ensure that replacement chain is the same size grade and construction as the original chain furnished by the hoist manufacturer unless otherwise recommended by the hoist manufacturer due to working conditions 6 Load chain links that pass over the hoist load sprocket on edge alternate to those that lie flat in the pockets should be installed with the welds away from the center of the sprocket This precaution is not required on idler sprockets which change the direction but not the tension in the chain 7 Ensure that replacement chain is installed without any twist between the hoist and an anchored end on either the loaded side or the slack side 8 Whenachain is replaced disassemble and inspect the mating parts sprockets guides stripper for wear and replace if necessary 9 Never use discarded load chain for slings 8 2 5 4 Roller Chain A qualified inspector shall do the following during periodic inspections Testthe hoist under load in raising and lowering directions observing the operation of the chain and sprockets If the chain binds jumps or is noisy clean and properly lubricate it If the trouble persists inspect the chain and mating parts for wear distortion or damage Chapter 8
261. etailed inspection is required 7 2 5 MONTHLY ROPE CHAIN AND HOOK INSPECTION a Ona monthly basis a designated person shall thoroughly inspect the following items for damage wear or other deficiencies that might reduce capacity or adversely affect the safety of the crane 7 2 6 DOE STD 1090 2007 1 This shall be accomplished by lowering the hook block to its lowest position and examining for any condition that could result in an appreciable loss of strength 2 Hoist rope including end connections for significant wear kinking crushing birdcaging corrosion broken strands or wires 3 Hoist chains including end connections for excessive wear twist distorted links interfering with proper function or stretch beyond manufacturer s recommendations 4 Hooks for cracks deformation damage from chemicals and evidence of heat damage The hook attachment and securing means should also be checked See Chapter 13 Load Hooks for additional hook requirements 5 Signed and dated inspections records shall be kept on file and shall be readily available Before the crane is returned to service deficiencies that could reduce its capacity or adversely affect its safety shall be corrected FREQUENT INSPECTION Operators or other designated personnel shall visually inspect the crane at the following intervals records are not required 1 Normal service monthly 2 Heavy service weekly to
262. etermine whether they constitute a safety hazard The inspection shall include the requirements of Section 12 2 5 3 Frequent Inspection Hooks having any of the following conditions shall be removed from service until repaired or replaced 1 Any visibly apparent bend or twist from the plane of the unbent hook 2 Any distortion causing an increase in throat opening exceeding 5 percent not to exceed inch or as recommended by the manufacturer 3 Any wear exceeding 10 percent or as recommended by the manufacturer of the original section dimension of the hook 4 Cracks If a latch is provided and it becomes inoperative or fails to fully bridge the throat opening the hook shall be removed from service until the device has been repaired or replaced 12 2 6 TESTING a Chapter 12 Performance testing of hooks shall not be required except where necessary to conform to the requirements for the equipment of which they are part When tests are specified documentation shall be uniquely identified to the hook by serial number or other identifier If detailed inspections are performed refer to Sections 12 2 5 2 b 12 2 5 3 d and 12 2 5 4 c the results shall be evaluated by a designated 12 6 Rigging Hardware person to determine the need for subsequent nondestructive testing NDT If NDT is deemed necessary it shall be performed in accordance with Section 13 4 3 12 2 7 MAINTENANCE a Adesignat
263. etic Sling Shackles Reprinted from ASME B30 26 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 12 2 Shackle Types Bow Ear Slds 77 Pin Reprinted from ASME B30 26 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 12 3 Typical Shackle Inspection Points 12 9 Chapter 12 Rigging Hardware DOE STD 1090 2007 30 deg min horizontal angle of loading 120 deg max y included angle Load Multiplier o 1 000 60 1 155 45 1 414 30 2 000 Reprinted from ASME B30 26 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 12 4 Effect of Loading Angle O deg gt deg Mi ol Reprinted from ASME B30 26 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 12 5 Side Loading Chapter 12 12 10 Rigging Hardware DOE STD 1090 2007 12 4 EYEBOLTS 12 4 1 GENERAL a This section specifies requirements for eyebolts that are used as rigging hardware during normal hoisting and rigging activities b Eyebolts used for hoisting shall be fabricated from forged carbon or alloy steel and shall have sufficient ductility to permanently deform before losing the ability to support the load at temperatures at which the manufacturer has specified for use c Each eyebolt shall be marked to show 1 Name or trademark of manufactur
264. ew by another member of a qualified engineering organization and the responsible oversight organizations safety quality assurance etc e Deviations in design that may result in design factors less than consensus standard requirements shall require documented justification and approval of the designer s manager and the manager of the responsible oversight organizations safety quality assurance etc f Applications not specifically addressed in the ASME standards or in this standard may be approved by the responsible manager and oversight organizations safety quality assurance etc when justification and documentation are provided and all other provisions of this section are met 3 2 0 FABRICATION Special lifting fixtures shall be fabricated according to the specifications of the approved design package 3 2 3 2 3 INSPECTION AND TESTING Before initial use of each special lifting fixture a qualified inspector shall perform a documented acceptance inspection and test on it This process shall include 1 Verification of configuration of the fixture against the design drawing specifications 2 Proof testing as specified in the approved design package 3 Nondestructive examination as specified in the approved design package Personnel performing the lift shall visually inspect special lifting fixtures before use for visible signs of wear deformation deterioration or damage Records are not requi
265. f Section 7 2 6 Frequent Inspections periodic inspections shall include the following a Components for deformation cracks or corrosion Bolts rivets nuts and pins for being loose or absent Check for suspect counterfeit parts see Terminology and Definitions Chapter 1 Chapter 7 Overhead and Gantry Cranes DOE STD 1090 2007 d Sheaves and drums for cracks or wear e Parts such as pins bearings shafts gears rollers locking and clamping devices bumpers and stops for wear cracks or distortion f Brake system parts linings pawls and latches for excessive wear g Load wind and other indicators over their full range for any significant inaccuracies h Gasoline diesel electric or other power plants for improper performance or noncompliance with other applicable standards i Chain drive sprockets for excessive wear and chains for excessive stretch j Electrical apparatus for signs of pitting or any deterioration of controllers master switches contacts limit switches and push button stations not limited to these items k Hooks for damage from chemicals deformation cracks any visible apparent bend or twist from the plane of the unbent hook or any distortion causing an increase in throat opening of 5 not to exceed 1 4 in unless otherwise recommended by the manufacturer See Chapter 13 for additional hook requirements l Hook retaining nuts or collars and pins wel
266. f The American Society of Mechanical Engineers All rights reserved Figure 7 5 Standard hand signals for controlling overhead crane operation 7 17 Chapter 7 Overhead and Gantry Cranes DOE STD 1090 2007 d Cranes shall not be used for side pulls except when specifically authorized by an appointed person who has determined that the stability of the crane is not endangered and that load bearing parts of the crane will not be overstressed e Avoid carrying loads above people f Each time a load approaching the rated capacity is handled test the hoist brakes by raising the load a few inches and applying the brakes Any slippage or downward motion is unacceptable g Do not lower the hook below the point where less than two full wraps of rope remain on the hoisting drum h When the load or hook approaches personnel sound the warning signal i Tag lines should be used as required to guide snub or otherwise control the load j Do not leave a suspended load unattended unless specific precautions have been instituted and are in place k Work on suspended loads is prohibited under normal conditions If the responsible manager decides that it is necessary to work on a suspended load guidelines for safe operation shall be established through consultation with the appropriate safety organization Suspended loads that must be worked on shall be secured against unwanted movement 7 5 8 ORDINARY LIFTS a The req
267. f each boom telescopic section of those exists 9 Whether sections are telescoped with power or manually 9 2 Chapter 9 Mobile Cranes DOE STD 1090 2007 Table 9 1 Sample Load Rating Chart This table is an example of the type of load rating chart that should be included in each crane Manitowoc Model 3900 Liftcrane Extra Heavy Boom Working 50 60 70 80 90 100 120 Radius lbs 120 000 120 000 111 200 110 800 109 000 104 200 103 600 102 700 100 000 95 000 97 800 97 400 97 000 96 600 92 500 90 000 93 200 92 400 91 600 90 600 89 600 86 000 83 000 87 800 86 800 85 800 84 800 83 800 82 800 80 000 83 400 81 200 80 300 79 400 78 700 77 800 75 200 75 900 75 500 74 700 73 900 73 200 72 600 70 500 68 100 67 700 67 300 66 900 66 400 65 800 64 000 61 700 61 300 60 900 60 500 60 000 59 400 58 500 56 500 56 100 55 700 55 300 54 800 54 200 53 300 52 000 51 600 51 200 50 800 50 300 49 700 48 800 48 100 47 700 47 300 46 900 46 400 45 800 44 900 44 700 44 300 43 900 43 500 43 000 42 400 41 500 41 700 41 300 40 900 40 500 40 000 39 400 38 500 39 100 38 700 38 300 37 900 37 400 36 800 35 900 36 800 36 400 36 000 35 600 35 100 34 500 33 600 34 700 34 300 33 900 33 500 33 000 32 400 31 500 32 900 32 500 32 100 31 700 31 200 30 600 29 700 31 200 30 800 30 400 30 000 29 500 28 900 28 000 29 300 28 900 28 500 28 000 27 400 26 500 27 900 27 500 27 100 26 600 26 000 25 100 26 500 26 100 25 700 25 200 24 600 23 700 25 300 24 900 24 500
268. f more than one crane or derrick refer to 29 CFR 1926 751 15 5 2 DEFINITIONS CONTROLLED LOAD LOWERING Lowering a load by means of a mechanical hoist drum device that allows a hoisted load to be lowered with maximum control using the gear train or hydraulic components of the hoist mechanism Controlled load lowering requires the use of the load hoist drive motor rather than the load hoist brake to lower the load MULTIPLE LIFT RIGGING Rigging assembly manufactured by wire rope rigging suppliers that facilitates the attachment of up to five independent loads to the hoist rigging of a crane STEEL ERECTION The construction alteration or repair of steel buildings bridges and other structures including the installation of metal decking and all planking used during the process of erection 15 5 3 PRESHIFT INSPECTION OF CRANES a Cranes being used in steel erection activities shall be visually inspected by a competent person prior to each shift The inspection shall include observation for deficiencies during operation At a minimum this inspection shall include the following 1 All control mechanisms for maladjustments 2 Control and drive mechanism for excessive wear of components and contamination by lubricants water or other foreign matter Chapter 15 Construction Hoisting and Rigging Equipment Requirements 3 Safety devices including but not limited to boom angle indicators boom stops boom kick out de
269. f prohibited zone 9 23 Chapter 9 Mobile Cranes DOE STD 1090 2007 PROHIBITED ZONE SEE TABLE 9 3 Reprinted from ASME B30 5 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 9 5 Danger zone for cranes and lifted loads operating near electrical transmission line 9 24 Chapter 9 Mobile Cranes DOE STD 1090 2007 9 5 4 STANDARD HAND SIGNALS The standard hand signals for DOE use shall be as specified in the latest edition of the ASME B30 standards for the particular type of crane or hoist being used see Figure 9 6 9 5 5 IDENTIFICATION OF SIGNALERS a All personnel acting as signalers during crane operations shall be clearly identified to the crane operator Options for improving signaler visibility include using an orange hardhat orange gloves or an orange vest b Inthose cases where the crane operator cannot see the signaler a second person relay signaler shall be stationed where he or she can see both the signaler and the crane operator and can relay the signals to the operator The relay signaler shall also be clearly identified to the crane operator c The operator shall obey signals only from the designated signaler Obey a STOP signal no matter who gives it 9 5 6 STANDARD VOICE SIGNALS a Prior to beginning lift operations using voice signals the signals shall be discussed and agreed upon between the person in charge the crane operator the ap
270. f proof test amount of load applied sling capacity and lot run number The LTC shall be signed by the manufacturers authorized representative NOTE Sling lengths shall be within a specified tolerance Synthetic sling manufacturers normal length is 1 percent of the sling length If closer tolerance is required the purchaser should specifically request required tolerance on the purchase order DOE STD 1090 2007 8 SYNTHETIC ROUNDSLINGS P Si e e e ES ge Slings should meet or exceed requirements of the Web Sling and Tiedown Association Inc Synthetic roundslings including those incorporating welded fittings shall be proof tested to 200 percent of the vertical rated capacity A load test certificate LTC shall be provided for each lot of slings supplied The LTC shall reference at a minimum date of proof test amount of load applied sling capacity and lot run number The LTC shall be signed by the manufacturer s authorized representative The core s shall be formed from one or more ends of yarn wound together on a plurality of turns The core s should be uniformly wound to ensure even distribution of the load The cover s should be of the same fiber type as the load bearing core s When the cover is a different fiber type than the load bearing core follow the manufacturer s recommendations for use The cover should be made from one length of material When the core and cove
271. f rope 2 Choker hitch values apply only to choke angles greater than 120 degrees Chapter 11 11 16 General DOE STD 1090 2007 Table 11 8 Load capacity of wire rope slings Cable laid grommet hand tucked in pounds Design Factor 5 1 N NS AR 60 ye Dia in Basket or degrees Dia in inches Vertical Choker two legs 45 30 inches degrees degrees 3 8 2 600 1 900 5 000 4 400 3 600 2 600 3 8 9 16 5 600 4 200 11 200 9 800 8 000 5 600 9 16 5 8 7 800 6 000 15 800 13 600 11 200 6 800 5 8 Y 10 200 7 600 20 000 17 600 14 400 10 200 34 15 16 15 800 11 800 32 000 28 000 22 000 15 800 15 16 1 1 8 22 000 16 800 44 000 38 000 32 000 22 000 1 1 8 15 16 30 000 22 000 60 000 52 000 42 000 30 000 15 16 1 38 000 28 000 78 000 66 000 54 000 38 000 1 111 16 48 000 36 000 98 000 84 000 68 000 48 000 111 16 1 7 8 60 000 44 000 120 000 104 000 84 000 60 000 1 7 8 2 84 000 62 000 168 000 146 000 118 000 84 000 2 2 5 8 112 000 84 000 224 000 194 000 158 000 112 000 2 5 8 3 144 000 108 000 286 000 248 000 202 000 144 000 3 Wire Rope 7 x 6 x 7 and 7 x 6 x 19 IPS IWRC Notes 1 These values only apply when the D d ratio is 10 or greater choker and basket hitches D Diameter of curvature around which the body of the sling is bent d Diameter of rope 2 Choker hitch values apply only to choke angles greater than 120 degrees 11 17 Chapter 11 General DOE STD 1090
272. f vacuum lines connections conditions 5 Leaks or damage to the vacuum c This inspection shall include those reservoir conditions or items specified in Section 14 3 4 2 Frequent Inspection in addition 6 Failure of the entire vacuum system to to the following function properly by attaching a non porous clean test plate to the vacuum External evidence of looseness wear pads and then stopping the vacuum deformation cracking or corrosion 14 11 Chapter 14 Below the Hook Lifting Devices 14 3 5 DOE STD 1090 2007 2 External evidence of damage to supporting structure motors controls and other auxiliary components 3 Check for suspect counterfeit parts see Terminology and Definitions Chapter 1 4 Presence of warning label required by Section 14 3 2 Marking A qualified inspector shall inspect fixtures not in regular use according to periodic inspection requirements before placing them in service Dated inspection reports shall be prepared for each inspection Inspection records shall be kept on file and shall be readily available TESTING 14 3 5 1 Operational Test a All new reinstalled modified or repaired vacuum lifting fixtures shall be tested prior to use Tests shall be performed by a qualified inspector or under the direction of that inspector to ensure compliance with the requirements of this section Dated reports shall be dept on file Testing shall include the following
273. fore being used to make a critical lift DOE STD 1090 2007 12 11 COMPRESSION HARDWARE 12 11 1 GENERAL a This section specifies requirements for U bolt and double saddle wire rope clips see Fig 12 12 and wedge sockets see Fig 12 13 Other compression hardware shall be used only in accordance with recommendations of the manufacturer or a qualified person Wire rope clip materials shall be of sufficient strength such that failure of the wire rope will occur before failure of the wire rope clip at the temperatures that the manufacturer has specified for use Saddles shall be forged steel Wedge socket materials shall be of sufficient strength such that failure of the wire rope will occur before failure of the wedge socket at the temperatures specified for use by the manufacturer The rated load for wire rope assemblies using compression hardware is based on the wire rope minimum breaking force 80 minimum connection efficiency and the design factor of the wire rope application The rated load shall not be exceeded Compression hardware is not required to be proof tested unless specified by the purchaser If a proof test is specified the load shall be applied to the wedge socket or the connection made by the wire rope clips after the assembly is complete The proof load shall be at least 40 but not exceed 50 of the minimum breaking force unless approved by the compression hardware manufacturer or a qualified pers
274. fter assembly the connection shall be loaded to at least the expected working load After unloading wire rope clips shall then be re tightened to the torque recommended by the manufacturer or a qualified person 12 11 3 ASSEMBLY WEDGE SOCKETS a The wedge socket shall be assembled as recommended by the manufacturer or a qualified person b Before installing a wedge socket on plastic coated or plastic impregnated wire rope consult the wedge socket manufacturer wire rope manufacturer or a qualified person c Thelive end of the wire rope in the wedge socket cavity shall be in alignment with the socket s pin see Fig 12 13 d The assembler shall match the proper wedge with the socket for the wire rope to be installed NOTE Wedges shall not be interchanged between different manufacturers sockets or models e The length of the dead end tail of the wire rope shall be as required by the manufacturer or a qualified person f The dead end tail of the wire rope extending beyond the wedge socket shall be secured in a manner recommended by the wedge socket Chapter 12 Rigging Hardware DOE STD 1090 2007 manufacturer or a qualified person see Fig 12 13 g The dead end of the wire rope shall not be secured to the live end of the wire rope such that it restricts the movement of the live end see Fig 12 13 h After assembly the connection shall be loaded to fully seat the wedge before use 12 11 4 EF
275. g operations at DOE sites The standard quotes verbatim or paraphrases with minor editorial changes for consistency the requirements of the U S Occupational Safety and Health Administration OSHA and the therein refenced standards of the American National Standards Institute ANSI It also encompasses under one cover applicable hoisting and rigging codes standards and regulations eliminating the need to maintain extensive and often incomplete libraries of hoisting and rigging standards throughout DOE When formally invoked by contract the use of the imperative voice as in Never use discarded load chain for slings or the word shall within this standard connotes a mandatory action whereas use of the word should denotes a recommended action From chapter to chapter the reader may notice what appears to be excessive repetition Such repetition however is by design enabling the use of each chapter if needed or convenient as a stand alone document The standard occasionally goes beyond the minimum general industry standards established by OSHA and ANSI and also delineates the more stringent provisions necessary to accomplish the extremely complex diversified critical and oftentimes hazardous hoisting and rigging work found within the DOE complex In doing so it addresses the following items that are not covered in detail in the general industry standards 1 Management responsibility and accountability 2 Oper
276. g operations for ordinary lifts require a designated leader who shall be present at the lift site during the entire lifting operation If the lift is being made by only one person that person assumes all responsibilities of the designated leader d Leadership designation may be by written instructions specific verbal instructions for the particular job or clearly defined responsibilities within the crew s organizational structure e The designated leader s responsibility shall include the following 1 Ensure that personnel involved understand how the lift is to be made 2 Ensure that the weight of the load is determined that proper equipment and accessories are selected and that rated capacity is not exceeded 3 Survey the lift site for hazardous unsafe conditions 4 Ensure that equipment is properly set up and positioned Chapter 9 Mobile Cranes DOE STD 1090 2007 5 Ensure that a signaler is assigned if required and is identified to the operator 6 Direct the lifting operation to ensure that the lift is completed safely and efficiently 7 Stop the job when any potentially unsafe condition is recognized 8 Direct operations if an accident or injury occurs The designated leader shall inspect all cranes to ensure that they are still within the inspection interval The designated leader shall inspect all lifting devices to ensure that the rated capacity of these items of equipment wil
277. g or bending of the chain links as well as possible scarring of the load 5 When making choker hitches with chain slings always face the hook opening out and away from the pull of the sling so that the hooks will not slip out when slack is taken out of the sling Chapter 11 General 11 28 10 11 12 13 14 15 Do not weld or perform local repairs on chain slings All defective chain slings should be returned through a formal procedure to the manufacturer for examination repair and recertification Avoid sudden loading of chain slings Maintain latches on hooks in good condition If a chain sling does not look safe do not use it Do not assume that a chain sling 1s safe because it looks new look for stretched links If in doubt check with the supervisor Do not carry loads on the point or tip of a hook Avoid unbalanced loads Do no use homemade links makeshift fasteners formed from bolts rods and the like or other nonstandard attachments Do not use makeshift or field fabricated hooks on steel chain slings Hook the ends of all empty chain onto the hoist hook or bull ring Each steel chain sling shall be marked at a minimum with i Nominal Chain Size ii Grade ii Rated load for the type s of hitch es used and the angle on which the rating is based iv Length Reach v Number of legs vi Name or trademark of manufacturer DOE STD 1090 2007 16 Where
278. ghout The contribution of DOE s Hoisting and Rigging Committee which has met annually since 1980 is also recognized Representing many DOE sites this group has provided their advice as to the tone and content of this standard Without their time and talent which has been provided gratuitously there would be no standard The standard is a safety not a design document intended for use by safety professionals and managers In keeping with this philosophy only those portions of standards and regulations dealing with safety particularly those deemed most relevant to DOE operations have been included In that the target audience for this document is safety professionals and managers and not hoisting and rigging equipment designers the design references cited within Chapter 17 of this Standard References should be consulted for specific design fabrication and other performance criteria While it is convenient to have focused in depth hoisting and rigging safety information concentrated into one document the significance of the above source material is acknowledged and readers are strongly encouraged to review each of them so as to have a full description of the subject area covered DOE STD 1090 2007 Introduction The U S Department of Energy DOE Hoisting and Rigging Standard is intended to be used by supervisors line managers safety personnel equipment operators and any other personnel responsible for safety of hoisting and riggin
279. h wire rope or strand is wound for storage or shipment REEVING A system in which a rope travels around drums or sheaves REGULAR LAY ROPE Wire rope in which the wires in the strands and the strands in the rope are laid in opposite directions REVERSE BEND Reeving of a wire rope over sheaves and drums so that it bends in opposite directions RIDER TRUCK A truck that is designed to be controlled by a riding operator RIGGING The hardware or equipment used to safely attach a load to a lifting device The art or process of safely attaching a load to a hook by means of adequately rated and properly applied slings and related hardware 1 9 ROLLERS Relatively small diameter cylinders or wide faced sheaves used for supporting or guiding ropes ROTATION RESISTANT WIRE ROPE Wire rope consisting of a left lay lang lay inner rope covered by right lay regular lay outer strands RUNNING SHEAVE A sheave that rotates as the load block is raised or lowered RUNWAY Assembly of rails girders brackets and framework on which a crane operates SAFE WORKING LOAD Load that a rope may carry economically and safely SEALE A strand construction having one size of cover wires with the same number of one size of wires in the inner layer and each layer having the same length and direction of lay Most common construction is one center wire nine inner wires and nine cover wires SEIZE To securely bind the end of a wire rope
280. hain metal mesh or synthetic web slings Bending a wire rope over a fixed object such as a pin or a shackle has an effect on the capacity of the rope the outside wires and strands of a bend have to stretch farther and therefore take a greater percentage of the load There is a convenient method for estimating the efficiency of the rope as it passes over the bend This method uses the ratio R of the diameter D of the object sheave pin corner about which the wire rope is being bent to the diameter d of the rope The efficiency of the bend can then be estimated using the formula shown in Figure 11 1 Note that the efficiency decreases quickly as the ratio of the diameters decreases Aside from efficiency there are other reasons to avoid sharp bends in wire rope including physical damage to the rope reduction of service life and damage to the object about which the rope is bent When the ratio of the diameter of the bend to the nominal rope diameter D d ratio is small the strength efficiency factor is lower than when the D d ratio is relatively large Load tables do not take into account such factors as abnormal temperatures excessive corrosion and vibration Determine the appropriate ratings of the device to be used allowing for 1 The number of sling legs Note that a sling leg completely doubled back on itself constitutes two sling legs 2 The angle between the horizontal surface of the load and t
281. hase to phase clearance Up to 50 kV 10 ft 3 1 m Over 50 to 200 kV 15 ft 4 6 m Over 200 to 350 kV 20 ft 6 1 m Over 350 to 500 kV 25 ft 7 6 m Over 500 to 750 kV 35 ft 10 7 m Over 750 to 1000 kV 45 ft 13 7 m b While in transit with no load and boom or mast lowered Normal voltage Minimum required phase to phase clearance Up to 0 75 kV 4 ft 1 8 m Over 0 75 to 50 kV 6 ft 1 3 m Over 50 to 345 kV 10 ft 3 5 m Over 345 to 700 kV 16 ft 4 9 m Over 750 to 1000 kV 20 ft 6 1 m Chapter 4 4 12 Lifting Personnel DOE STD 1090 2007 This Area Should Be Avoided Prohibited Zone See Table 4 1 Reprinted from ASME B30 23 2005 by permission of The American Society of Mechanical Engineers All rights reserved Figure 4 3 Danger Zone for Cranes and Lifting Personnel Near Electrical Transmission Line 4 13 Chapter 4 Lifting Personnel DOE STD 1090 2007 This Area Should Be Avoided Prohibited Zone See Table 4 1 Boom Shall Not Be Positioned Beyord ThisLine E Personnel Shall Not Be i Handledin this Area Reprinted from ASME B30 23 2005 by permission of The American Society of Mechanical Engineers All rights reserved Figure 4 4 Danger Zone for Cranes Lifting Personnel Near Electrical Transmission Lines Chapter 4 4 14 Lifting Personnel DOE STD 1090 2007 Page 1 of 1 EXHIBIT SAMPLE FORM ONLY PERSONNEL LIFT PLATFORM PRE LIFT INSPECTION Inspector Date
282. hat alternate egress routes are not locked on mobile units with operating enclosures Position the crane on a solid and level footing It may be necessary in certain situations to use heavy timber mats to build a good working foundation When swinging the crane watch out for centrifugal force Swing the crane slowly to avoid an outward swing of the load Attach a tag line to the load if necessary to control the swing Watch for boom kickback Never operate with the boom at a higher angle than shown on the capacity charts Use extreme caution when operating the crane near workers in elevated areas Chapter 9 Mobile Cranes DOE STD 1090 2007 r Use power lowering when lowering loads When lowering heavy loads keep the hoist brake as reserve Use a safety pawl on the boom hoist drum when not lowering s Avoid two blocking caused when the hook block makes contact with boom point sheaves A continuing pull on the hoist lines can break the rope or pull the boom back over the cab on some types of booms On hydraulically telescoping booms be sure to play out the hoist line when extending and spool in the hoist line when retracting t Lock carrier air brakes ON when operating and check the pressure of the air brakes frequently u Watch out for the carrier cab on truck mounted units when swinging the boom Keep boom high enough to swing clear of cab v Inthe absence of crane manufacturer s instructions regarding m
283. he lifting device shall be removed from service until engineering personnel have thoroughly evaluated the design and adequacy of the structure Engineering calculations must support all conclusions The lifting device shall be identified load tested and marked accordingly DOE STD 1090 2007 16 3 TESTING 16 3 4 OPERATIONAL TEST The load lifting and lowering mechanisms shall be tested during an initial test and after load testing 16 3 2 RATED LOAD TEST P Prior to initial use all new portable A frames and small cranes 1 ton or less and those upon which load sustaining parts have been modified replaced or repaired shall be load tested by a qualified inspector or under the direction of that inspector T A written report shall be furnished by the inspector showing test procedures and confirming the adequacy of repairs or alterations Test reports shall be kept on file and shall be readily available to appointed personnel Test loads shall not be less than 100 percent or more than 125 percent of the rated capacity unless otherwise recommended by the manufacturer or a qualified person Shop cranes built to design specifications are proof tested by the manufacturer in accordance with ASME PALD Portable Automotive Lifting Devices Part 12 After repair or modification a qualified engineer shall determine if testing is required DOE STD 1090 2007 16 4 MAINTENANCE 16 4 4 MAINTENANCE PROGRAM
284. he sling leg The smaller the angle the smaller the lifting capacity of the equipment 3 Wear The reduction in strength of the equipment due to normal wear The working load limit WLL of wire ropes and slings shall not be exceeded in their as configured application Chapter 11 General DOE STD 1090 2007 Table 11 1 Weights of Common Materials Name of Metal Weight Name of Metal Weight Ib ft pr Aluminum 166 Bluestone 160 Antimony 418 Brick pressed 150 Bismuth 613 Brick common 125 Brass cast 504 Cement Portland packed 100 120 Brass rolled 523 Cement Portland loose 70 90 Copper cast 550 Cement slag packed 80 100 Copper rolled 555 Cement slag loose 55 75 Gold 24 carat 1 204 Chalk 156 lron Cast 450 Charcoal 15 34 lron wrought 480 Cinder concrete 110 Lead commercial 712 Clay ordinary 120 150 Mercury 60 degrees F 846 Coal hard solid 93 5 Silver 655 Coal hard broken 54 Steel 490 Coal soft solid 84 Tin cast 458 Coal soft broken 54 Uranium 1 163 Coke loose 23 32 Zinc 437 Concrete or stone 140 155 Earth rammed 90 100 Name of wood Granite 165 170 Gravel 117 125 Ash 35 Lime quick ground loose 53 Beech 37 Limestone 170 Birch 40 Marble 164 Cedar 22 Plaster of paris cast 80 Cherry 30 Sand 90 106 Chestnut 26 Sandstone 151 Cork 15 Shale 162 Cypress 27 Slate 160 180 Ebony 71 Terra cotta 110 Elm 30 Traprock 170 Fir Balsam 22 Water 65 Hemlock 31 Maple Oak 62 Pine Poplar 30
285. hich slow the lowering speeds is prohibited Crane load lines shall be capable of supporting without failure at least seven times the maximum intended load except where rotation resistant rope is used the lines shall be capable of supporting without failure at least ten times the maximum intended load Hydraulic cranes shall have check valves or other devices that will prevent uncontrolled movement in the event of system failure engine failure or hose rupture Cranes shall have a means to prevent retraction of hydraulically or pneumatically activated outriggers or stabilizers in the event a hydraulic or pneumatic line fails Pendant supported jib type boom extensions without positive stops are prohibited for personnel lifting Twotypes of pasitve hooks Figure 4 1 Positive Hooks Hooks on overhaul ball assemblies lower load blocks or other attachment assemblies shall be of the type that can be closed and locked eliminating the hook throat opening See Figure 4 1 Alternatively an alloy anchor type shackle with a bolt nut and retaining pin may be used Chapter 4 Lifting Personnel DOE STD 1090 2007 4 3 OVERHEAD CRANES Overhead cranes are designed and intended for handling materials not personnel In addition to the general requirements in Section 4 1 General the following requirements shall be met when lifting personnel with an overhead crane Chapter 4 Lifting Personnel Personnel are perm
286. his standard please provide suggested text changes as well as supporting technical documentation to Mr Patrick F Finn PE U S Department of Energy HS 11 270 Corporate Square Building 1000 Independence Avenue SW Washington DC 20585 0270 il DOE STD 1090 2007 CHAPTER 1 TERMINOLOGY AND DEFINITIONS The following are specialized terms commonly used when discussing hoisting and rigging operations Many may not be used in this standard but are included for general information The terms are arranged in alphabetical order Illustrations are included for clarity ABRASION Surface wear ACCELERATION STRESS Additional stress imposed due to increasing load velocity ALTERNATE LAY Lay of wire rope in which the strands are alternately regular and lang lay ANSI American National Standards Institute APPOINTED Assigned specific responsibilities by the employer or the employer s representative AREA METALLIC Sum of the cross sectional areas of individual wires in a wire rope or strand ATTACHMENT A device other than conventional forks or load backrest extension mounted permanently or removable on the elevating mechanism of a truck for handling the load Popular types are fork extension clamps rotating devices side shifters load stabilizers rams and booms AUTHORIZED Assigned by a duly constituted administrative or regulatory authority AUXILLARY HOIST Supplemental hoisting unit of light
287. hoker hardware Combination hardware consists of a triangle for one end of the sling and a triangle rectangle choker attachment for the other end With this arrangement both choker and basket hitches as well as straight hitches may be rigged They help reduce wear in the sling eyes and thus lengthen sling life Synthetic web slings can be cut by repeated use around sharp cornered objects They eventually show signs of abrasion when they are repeatedly used to hoist rough surfaced products There are however protective Chapter 11 General 11 34 devices offered by most sling manufacturers that minimize these effects see Figure 11 20 Other protective devices include 1 Buffer strips of leather nylon or other materials that are sewn on the body of a sling protect against wear While offering some resistance to wear and cutting leather is subject to weathering and gradual deterioration Leather is not recommended in lengths over 6 ft due to the different stretching characteristics of the leather and webbing On the other hand nylon web wear pads are more resistant to weathering oils grease and most alkalis and they stretch in the same ratio as the sling body 2 Edge guards consist of strips of webbing or leather sewn around each edge of the sling This is necessary for certain applications where the sling edges are subject to damage 3 Sleeve or sliding tube type wear pads are available for slings used
288. ial over loose splice on 12 ft long running line Hoisting Structural Steel Right Load over 12 ft long CN MN Sime Tay Bad Sharp corners Steel can padded cut rope Wrong Load over 12 ft long Figure 12 1 Good and bad rigging practices 12 3 Chapter 12 Rigging Hardware DOE STD 1090 2007 GOOD AND BAD RIGGING PRACTICES Eyebolts Hoisting Structural Steel qum a a EN memmomib 1 PICA Bad Use space Can bend blocks and flanges and pad corners cut rope Good practice vertical lift on eyebolt Eye Splices o eg Sie AT GA tH VEZ ES VLA NE 8227227727 o 1 Good practice Note use of thimble in eye splice Os Good practice Use of thimble in eye splice Bad practice Wire rope knot eh clip Efficiency 50 or ess Bad practice lifting on eye e bolts from an andis reduces ped pactos milio de O SHTO IDAOS BETUS ad of eye and reduce wear on rope Figure 12 1 continued Chapter 12 12 4 Rigging Hardware DOE STD 1090 2007 12 2 RIGGING HOOKS 12 2 1 DESIGN Hook design shall meet generally accepted hook design standards and shall comply with the requirements of ASME B30 10 See Chapter 13 Load Hooks for equipment load hook requirements 12 2 2 MARKING The manufacturer s identification shall be forged cast or die stamped on a low stress and nonwearing area of the hook 12 2 3 CONSTRUCTION a The hook material sh
289. ically responsible for the Chapter 4 4 4 Lifting Personnel DOE STD 1090 2007 4 2 MOBILE CRANES Mobile cranes are designed and intended for handling materials not personnel In addition to the general requirements in Section 4 1 General the following requirements shall be met when lifting personnel with a mobile crane a Personnel are permitted to ride only in one of the following 1 A personnel lift platform that is supported from the crane s hook which meets the requirements of Section 4 4 Personnel Platform 2 A personnel basket attached directly to the boom which is approved by the crane manufacturer Cranes and derricks with variable angle booms shall be equipped with a boom angle indicator that is readily visible to the operator Cranes with telescoping booms shall be equipped with a device to indicate clearly to the operator at all times the boom s extended length or an accurate determination of the load radius to be used during the lift shall be made prior to hoisting personnel A positive acting device shall be used that prevents contact between the load block or overhaul ball and the boom tip anti two blocking device or a system shall be used that deactivates the hoisting action before damage occurs in the event of a two blocking situation two block damage prevention feature Cranes having booms in which lowering is controlled by a brake without aid from other devices w
290. ich a malfunction could occur FATIGUE The tendency of a material to break under repeated stress FIBER CENTERS Cords or rope made of vegetable fiber used in the center of a strand FIBER CORES Cords or rope made of vegetable fiber used in the core of a wire rope 1 5 FIRST POINT The first setting on the operator s controller that starts crane motion slowly in each direction FITTING Any accessory used as an attachment for wire rope FLAG Mark or marker on a rope to designate position of load FLAT ROPE Wire rope made of parallel alternating right lay and left lay ropes sewn together by relatively soft wires FLATTENED STRAND ROPE A wire rope with either oval or triangular strands that present a flattened rope surface FLEET ANGLE Angle between the position of a rope at the extreme end wrap on a drum and a line drawn perpendicular to the axis of the drum through the center of the nearest fixed sheave FORKS Horizontal tine like projections normally suspended from the carriage used to engage and support loads FORK HEIGHT The vertical distance from the floor to the load carrying surface adjacent to the heel of the forks with the mast vertical and in the case of reach trucks with the forks extended FORKLIFT TRUCK A high lift self loading truck equipped with load carriage and forks for transporting and tiering loads see Figure 10 3 GALVANIZE To coat with zinc to protect against corrosion
291. ics such as abrasion resistance sealing of pores increased coefficient of friction and UV resistance The design factor for synthetic web slings shall be a minimum of 5 1 based upon breaking strength Chapter 11 General DOE STD 1090 2007 Rated capacities are affected by the type of hitch used and by the angle from the vertical when used as multi legged slings or in basket hitches The sling manufacturer shall supply data on these effects Synthetic web slings are available in a number of configurations as follows see Figure 11 17 1 Endless or Grommet Sling Both ends of one piece of webbing are lapped and sewn to form a continuous piece They can be used as vertical hitches bridle hitches in choker arrangements or as basket slings 2 Standard Eye and Eye Webbing is assembled and sewn to form a flat eye sling with an eye at each end and the eye openings in the same plane as the sling body The eyes may either be full web width or may be tapered by being folded and sewn to a width narrower than the webbing width 3 Twisted Eye An eye and eye type that has twisted terminations at both ends The eye openings are at 90 degrees to the plane of the sling body This configuration is also available with either full width or tapered eyes 4 Metal End Fittings In place of the sewn eyes synthetic web slings are also available with metal end fittings see Figure 11 19 The most common are triangle and c
292. identify requirements to which the manufacturer shall adhere More specific information or requirements may be obtained by consulting the applicable section of this standard or an equipment manufacturer The manufacturer shall provide requested documentation as appropriate e g rated load certification proof load test certification material certification Proof load test certification is essential for items to be used for critical lifts The documentation shall be signed by the manufacturer s authorized representative l MANUAL ELECTRIC AND AIR OPERATED HOISTS eee A 1 2 MANUALLY OPERATED LEVER HOISTS eene retentis A 3 3 SHOP FEOOR CRANES i eite tiet de tee RR E ted stad ade Ere eben A 4 4 BELOW THE HOOK STRUCTURAL AND MECHANICAL LIFTING DEVICES A 5 4 Ll CAGA A tette EES e ec neret es A 5 5 WIRE ROBDE rd dede eee ed ed ede et tt d d ret eA us ends A 6 6 CHAIN SEINGS ERRORES A 7 7 SYNTHETIC WEB ECH LE A 8 8 SYXNTHETIC ROUNDSEIUNGS 45 1 ertet bre Ue er qme A 9 9 WIRE ROPE SLINGS eren ere ee e m gts A 10 10 WIRE ROFE CLIPS Clapips 2 ertet ete e Bg ta A 11 11 EYE BOL TS A eee tede sts A 12 12 HOOK Sevi em E eem e pne eek A 13 A i Appendix A Procurement Guidelines DOE STD 1090 2007 13 SWIVEL HOISTIRINGS EE A 14 14 RINGS AND LINKS citando lille A 15 15 SHACKLES EE A 16 16 TURNBUCKIES 3 2 uec heo eq dne pies A 17 EXHIBIT 1 Purchase Requi
293. ied the load indicating device shall be proof tested before being used to make a critical lift Chapter 12 Rigging Hardware DOE STD 1090 2007 12 10 1 GENERAL a Chapter 12 A precision load positioning device in the load path shall have a design factor of no less than 5 1 based on ultimate strength of the device s load bearing components A precision load positioner shall be operated maintained calibrated and tested in accordance with the manufacturer s instructions Prior to initial use all new repaired and altered precision load positioning devices shall be load tested and a written report shall be furnished confirming the load rating If the load test is not performed by the manufacturer it shall be done under the direction of a designated or authorized person in strict compliance with the Rigging Hardware 12 26 12 10 PRECISION LOAD POSITIONERS manufacturer s instructions Special attention should be paid to the manufacturer s instructions concerning testing of devices equipped with load gages as they may be damaged during the load test 12 10 2 CRITICAL LIFTS a See Chapter 2 Critical Lifts for critical lift requirements Precision load positioners used for critical lift service shall have an initial proof load test per the manufacturer s specifications confirming the load rating If proof testing cannot be verified the precision load positioners shall be proof tested be
294. if electrical charge is induced on the crane The following precautions shall be taken when necessary to dissipate induced voltages 1 The equipment shall be provided with an electrical ground directly to the upper rotating structure supporting the boom 2 Ground jumper cables shall be attached to materials being handled by boom equipment when electrical charge is induced while working near energized transmitters crews shall be provided with nonconductive poles having large alligator clips or other similar protection to attach the ground cable to the load 3 Combustible and Flammable materials shall be removed from the immediate area prior to operations 9 5 3 HOIST LIMIT SWITCH Check all limit switches if supplied without a load on the hook at the beginning of each work shift or the first time the crane is used that shift Inch each motion into its limit switch to ensure that two blocking does not occur during the test If a lift is in progress during a shift change this testing requirement is considered to have been Chapter 9 Mobile Cranes DOE STD 1090 2007 satisfied for the completion of that lift However test the limit switch again before the next lift Reprinted from ASME B30 5 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 9 4 Danger zone for cranes and lifted loads Operating near electrical transmission line See Table 9 3 for minimum radial distance o
295. ift test the upper limit switch of each hoist under no load conditions If the hoist has a lower limit switch test it with no load before lowering any load that could bring the lower limit switch into operation Exercise extreme care inch the block into the limit switch or run in at slow speed If the limit switch does not operate properly notify the designated person immediately If a lift is in progress during a shift change this testing requirement is considered to have been satisfied for the completion of that lift However test the limit switch again before the next lift Never use the hoist limit switch that controls the upper limit of travel of the load block as an operating control 8 5 6 ORDINARY LIFTS 8 18 Hoisting and rigging operations for ordinary lifts require a designated leader The designated leader shall be present at the lift site during the entire lifting operation If the lift is being made by only one person that person assumes all responsibilities of the designated leader Leadership designation may be by written instructions specific verbal instructions for the particular job or clearly defined responsibilities within the crew s organizational structure The designated leader s responsibility shall include the following 1 Ensure that personnel involved understand how the lift is to be made 2 Ensure that the weight of the load is determined that proper equipment and accessories a
296. ignated 3 Maintenance and test personnel when it location when not in use is necessary in the performance of their duties 14 5 9 CRITICAL LIFTS 4 Inspectors of lifting devices See Chapter 2 Critical Lifts for critical lift requirements b The following shall apply to all personnel who operate remote operated magnets a Remote operated magnets for critical lift service shall have been tested for proper 1 Place any attached load on the floor or operation of all electrical equipment and a ground and after use properly store the visual inspection of the lifting device for lifting device before leaving it defects If testing and inspection cannot be verified the lifting device shall be tested and 2 Before they are used during a shift test inspected before being used to make a all controls If any do not operate critical lift Chapter 14 14 24 Below the Hook Lifting Devices DOE STD 1090 2007 Exhibit I is intended to be a sample form only The equipment manufacturer s inspection testing criteria supercede any other criteria In cases where the equipment manufacturer does not include inspection testing criteria other forms developed to facilitate required inspection testing are acceptable 14 25 Chapter 14 Below the Hook Lifting Devices DOE STD 1090 2007 INTENTIONALLY BLANK Chapter 14 14 26 Below the Hook Lifting Devices DOE STD 1090 2007 EXHIBIT SAMPLE FORM LIFTING BARS AND SPREADERS LOAD TEST INS
297. ility of prod burns or arc strikes e Perform an NDT with the hook in place unless conditions indicate that disassembly for thread or shank inspection is necessary Chapter 13 Load Hooks 13 44 ACCEPTANCE CRITERIA A designated person shall document and resolve the following relevant indications a Arc strikes welding or electrical b Surface intersecting discontinuities 0 25 in long or longer 13 45 DISCONTINUITY REMOVAL a Two directions of discontinuity P and T are shown on Figures 13 1 and 13 2 Discontinuity P parallels the contour of the hook is considered nonserious and does not require removal Discontinuity T on the other hand is transverse to the contour of the hook and is more serious when occurring in zones B C or D discontinuity T may reduce the longevity of the hook b Discontinuities may be removed by grinding longitudinally following the contour of the hook to produce a smooth gently undulating surface In zones B and D such grinding shall not reduce the original hook dimension by more than 10 percent Such a reduction will not affect the working load limit rating or the ultimate load rating of the hook In zone C grinding shall not reduce the original dimension by more than 5 percent c Under normal and proper application zone A is an unstressed zone Therefore it is not required that discontinuities in that zone be ground out d The hook shall be reexamine
298. in the case of an accident b Exercise authority to start and stop work activities 15 2 5 DESIGNATED LEADER The designated leader shall have sufficient knowledge and experience to accomplish the following responsibilities a Ensure that the personnel involved have received proper and current training and qualification for the procedure b Ensure that the equipment and accessories specified in the procedure are available c Survey the lift site for hazardous or unsafe conditions d Ensure that equipment is properly set up and positioned e Ensure that a signaler is assigned if required and is identified to the operator f Direct the lifting operation to ensure that the job is done safely and efficiently g Stop the job when any potentially unsafe condition is recognized 15 5 h Direct operations if an accident or injury occurs 15 2 6 INSPECTOR a Qualified inspectors shall have the necessary knowledge and experience to properly inspect hoisting and rigging equipment b Employees who operate hoisting equipment to perform inspections shall be trained and qualified to operate the equipment on which the inspection is being performed c Hoisting equipment operation by inspectors shall be limited to those equipment functions necessary to perform the inspection on the equipment 15 2 7 MAINTENANCE PERSONNEL a Employees who operate hoisting equipment to perform hoisting equipment maintenance sh
299. ines Energized Crane Operating Less Than Erected Fully Extended Boom Length Away From Prohibited Lo ita 9 19 9 5 2 3 Crane Operations are Within the Prohibited Zone and the Power Lanes are Energized eee Hee e qe 9 22 9 5 2 4 Crane in Transit with no Load and Boom Lowered 9 22 9 5 2 5 Crane Operations Near Transmitter Towers oooonocnnnnnocncoconononancnnncnnccnnonnos 9 22 Hoist Limit Swatch erase mau neue 9 22 Standard Hand SIMA Sita 9 25 Identification of S1gnalers 2 tee eee rastrera 9 25 Standard Voice Signals et epe linda 9 25 Special Signals aste eene eundi 9 25 Size OL Loads ege Reseau 9 25 Attaching the ege eege alaridos 9 25 Moving the Load siste pneu 9 25 Ordinary KUER 9 29 Critical En GT 9 30 Mobil Crane Load Test reete eene t e er te ies 9 33 Mobile Crane Daily Pre Operational Check 9 37 Mobile Crane Frequent Inspection Report 9 41 Mobile Crane Periodic Inspection Report 9 43 9 ii DOE STD 1090 2007 9 1 GENERAL This chapter applies to commercial truck mounted cranes crawler cranes locomotive cranes wheel mounted cranes multiple control stations wheel mounted cranes single control station and any variation that retains the same fundamental characteristics These cranes have a superstructure capable of rotating 360 degrees mounted on a carrier and have boom raising and lowering capabilities 9 1 1 OPERATOR TRAINING QUALIFICATION Oper
300. ing data 1 Manufacturer s name contractor s name if fabricated onsite 2 Lifting device weight if over 100 Ib 3 Serial number if applicable 4 Rated capacity All new structural and mechanical lifting devices shall be marked with but not limited to the following information 1 Manufacturer s name and address 2 Serial number Chapter 14 Below the Hook Lifting Devices 3 Lifter weight if over 100 Ib 45 kg 4 Cold current amps when applicable 5 Rated voltage when applicable 6 Rated load as described in section 14 2 2 a 7 ASME BTH 1 Design Category 8 ASME BTH 1 Service Class All repaired or modified structural and mechanical lifters shall be provided with identification displaying but not limited to the following information 1 name and address of the repairer or modifier 2 repairer s or modifier s unit identification 3 lifter weight if altered 4 cold current amps if altered 5 rated voltage if altered 6 rated load if altered as described in section 14 2 2 a 7 ASME BTH 1 Design Category if altered 8 ASME BTH 1 Service Class if altered A rerated lifting device shall be relabeled with the new rated capacity Cases may exist where a lifting device cannot be marked with its rated capacity and weight This may be due to the security classification of the load to be lifted or other reasons approved by the responsible manager In these cases the lift
301. ing device shall be marked with an identification number and its documentation shall describe both its rated capacity and weight DOE STD 1090 2007 14 2 3 MODIFICATION RERATING a Structural and mechanical lifting devices may be modified or rerated if the changes are analyzed by a qualified engineer or the manufacturer of the lifting device b Rerated or modified lift fixtures shall be load tested as described in Section 14 2 6 2 Rated Load Test below 14 2 4 GUARDING Exposed moving parts or pinch points such as gearing chain drives and rotating shafts that may be a hazard to personnel during lifting operations shall be guarded 14 2 5 INSPECTIONS 14 2 5 1 Initial Inspection Prior to their initial use a qualified inspector shall inspect all new modified or repaired lifting devices to ensure compliance with Section 14 2 5 3 Periodic Inspection 14 2 5 2 Frequent Inspection a The operator or other designated person shall visually inspect each lifting device at the beginning of each shift or prior to use if it has not been in regular service for the following items or conditions records are not required 1 Structural deformation cracks or excessive wear on any part 2 Loose or missing guards fasteners covers stops or nameplates 3 All operating mechanisms and automatic hold and release mechanisms for maladjustments interfering with operation b The operator or designated p
302. ings and endless slings each leg shall be proof loaded to 2 times the single leg vertical hitch rated load b The proof load for fittings attached to single legs shall be a minimum of 2 times the single leg vertical hitch rated load c Master links for two leg bridle slings shall be proof loaded to a minimum of 4 times the single leg vertical hitch rated load d Master links for three leg bridle slings shall be proof loaded to a minimum of 6 times the single leg vertical hitch rated load e Master links for four leg bridle slings shall be proof loaded to a minimum of 8 times the single leg vertical hitch rated load DOE STD 1090 2007 Triangle end fittings Figure 11 19 Examples of Metal End Fittings REGULAR This is the type of edge protection that is sewn on to give EDGEGUARD A strip of webbing or fixed protection at expected wear leather is sewn around each edge of the points They can be sewn anywhere sling This is necessary for certain appli cations where the sling edges are sub on the sling at any length on one side or on both sides ject to damage SLEEVE Sometimes called sleeve or sliding tube type wear pads these pads are ideal for handling material with sharp edges because the sleeve does not move when the sling stretches and adjusts to the load Sleeves cover both sides of the sling and can be shifted to points of expected maximum wear Figure 11 20 Examples of Web and edg
303. internal control function indicator where applicable to confirm proper operation of the lifting magnet 14 4 8 4 Manually Controlled Permanent Magnets Before raising the load confirm that the control handle is in the LIFT or ON position and the control handle latch is operating 14 4 49 CRITICAL LIFTS Se Chapter 2 Critical Lifts for critical lift requirements a General application magnets are required to satisfy the rated breakaway force test The breakaway force measured in this test must exceed 200 percent of the rated load If the rated breakaway force test cannot be verified the lifting device shall be required to satisfy the rated breakaway force test before being used to make a critical lift b Specified application magnets are required to satisfy the rated breakaway force test The breakaway force measured in this test must exceed 200 percent of the rated load If the rated breakaway force test cannot be verified the lifting device shall be required to satisfy the rated breakaway force test before being used to make a critical lift DOE STD 1090 2007 14 5 MAGNETS REMOTE OPERATED Typical remote operated magnetic lifting devices are shown in Figure 14 8 14 5 1 DESIGN FABRICATION Remote operated magnetic lifting devices shall be designed and fabricated in accordance with the provisions of ASME B30 20 20 4 2 2 14 5 2 MARKING P At a minimum all new lifting magnets shall be
304. ion to the requirements of Section 9 2 3 Preoperational Check include the following Chapter 9 Mobile Cranes 9 2 6 DOE STD 1090 2007 1 All control mechanisms for maladjustment excessive wear and contamination by lubricants or other foreign matter that could interfere with proper operation 2 All safety devices for malfunction 3 Rope reeving for noncompliance with crane manufacturer s recommendations 4 Electrical apparatus for malfunctioning signs of excessive deterioration and accumulation of dirt or moisture 5 Tires for recommended inflation pressure 6 Boom sections for damaged deformed or missing structural members or parts Operators or other designated personnel shall examine deficiencies and determine whether a more detailed inspection is required PERIODIC INSPECTION Complete inspections of the crane shall be performed by a qualified inspector at 1 to 12 month intervals depending on the crane s activity severity of service and environment The qualified inspector shall examine deficiencies and determine whether they constitute a hazard Dated and signed inspection records shall be kept on file and shall be readily available A sample load test form is included as Exhibit I which appears at the end of this chapter This form is intended to be a sample only and is not intended to be mandatory These inspections shall in addition to the requirements of Sections 9 2
305. ions that affect the capacity or safe operation of the equipment shall be made by the contractor without the manufacturer s written approval Where manufacturer s specifications are not available the limitations assigned to the equipment shall be based on the determinations of a qualified engineer Dated and signed records shall be kept on file Mobile cranes boom trucks and forklifts that have left the control of the construction management contractor and are then returned shall be reinspected prior to making a critical lift DOE STD 1090 2007 15 4 OPERATION 15 4 1 GENERAL The operational requirements of all chapters referenced in Section 15 1 General of this standard shall apply to construction hoisting and rigging operations 15 4 8 WIRE ROPE SLINGS For construction applications eyes in wire rope slings bridles or bull wires shall not be formed by wire rope clips or knots refer to 29 CFR 1926 25 1 c 4 ii 15 7 Chapter 15 Construction Hoisting and Rigging Equipment Requirements DOE STD 1090 2007 15 5 STEEL ERECTION 15 5 1 GENERAL a The following hoisting and rigging requirements apply only to steel erection activities as described in 29 CFR 1926 750 a cT In addition to the conditions listed under Section 2 1 a lift shall be designated as a critical lift if 1 the lift exceeds 75 percent of the rated capacity of the crane or derrick or 2 the lift requires the use o
306. ire rope shall meet the requirements of Federal Specification RR W 410D or Military Specification MIL W 83420 Wire rope shall have documentation from the manufacturer traceable to the material furnished and signed by the manufacturer s k authorized representative Documentation shall reference as a minimum the diameter number of strands core lay grade manufacturing lot run number master reel l number and nominal breaking strength of sample Shall be shipped lubricated and with a protective covering i e plastic or cardboard m Slings should be either 6 x 19 or 6 x 37 classification Slings should be made of wire rope produced from EXIPS Extra Improved Plow Steel with an IWRC Independent Wire Rope Center Consideration may be given to other grades or types of wire rope dependent upon the type of expected service due to the type of load hitch or n environment Shall have a minimum of 5 to 1 safety factor Shall be individually tagged with a durable tag including the following information Procurement Guidelines 1 Manufacturer s name or trademark WLL Working Load Limit 2 Rated load for the type of hitch used and the angle upon which it is based 3 Diameter or size Shall have a load test certificate LTC for each lot of slings supplied The LTC shall reference as a minimum date of proof test amount of load applied sling capacity lot run number The LTC shall be signed by
307. is iio 14 3 14 2 5 Inspections initi trae EUER RESI teers hes eroe Dese eer Gores 14 3 14 2 5 1 Initial Inspection 1 RR rre eet 14 3 14 2 5 2 Frequent Inspection ette tete eterne tette terni 14 3 14 2 5 3 Periodic Inspection sse 14 3 14 2 6 KD D 14 4 14 2 6 1 Operational Test ucc rc NN 14 4 14 2 6 2 Rated Load Testis cissesscchswesssisasass nenne etie etta te tus eee euin 14 4 14 2 7 Maintenance e 14 4 14 2 8 Traming Qualification ceci ect iret itecto ean deae aunke lene aetas 14 4 14 2 9 In 14 8 14 2 10 Critical Lifts iuc ere ct terae ERE bn et deseada 14 8 14 3 VACUUM LIFTING DEVJICBS erecto ctetu tatnen etn a e a a onu ee eR ee Lunae 14 9 14 3 1 Design FabticatiOn Lee ier erit etie echt ea ea Ln vb eue eee ye ERES 14 9 14 3 2 Esp 14 9 14 3 3 Ine 14 11 14 3 4 A T E ET ETETE EEE T 14 11 14 3 4 1 Imttal Inspection etre rr eerte 14 11 14 3 4 2 Frequent Inspecton nennen rennen 14 11 14 3 4 3 Periodic Inspection 5 ettet eet ee 14 11 14 3 5 Hn p 14 12 14 3 5 1 Operational Test dete etre EE 14 12 14 3 5 2 Rated Load Test iue ere ie iere REPOS RES 14 12 14 3 6 ENEE 14 12 14 3 7 Training Qualification eese nenne nnne nne 14 12
308. is noisy first clean and properly lubricate it If the trouble persists inspect the chain and mating parts for wear distortion or other damage The chain should be cleaned before inspection Examine visually for cracks gouges nicks weld spatter corrosion and distorted links Slacken the chain and move adjacent links to one side to inspect for wear at the contact points If you observe wear or suspect stretching measure the chain according to the hoist manufacturer s instructions If instructions are not available proceed as follows i Select an unworn unstretched length of the chain e g at the slack end ii Suspend the chain vertically under tension and using a caliper type gauge measure the outside length of any convenient number of links approximately 12 in 305 mm to 14 in 356 mm overall iii Measure the same number of links in the used sections and calculate the percentage of increase in length iv Ifthe used chain exceeds a hoist manufacturer s recommended length or in the absence of such a recommendation if the used chain is 1 5 percent longer than the unused chain for powered hoists or is 2 5 percent longer than the unused chain for hand operated hoists replace the chain 8 11 v Examine the chain for gouges nicks corrosion weld spatter or distorted links Any of these conditions shall be sufficient reason for questioning safety and considering replacement Safety in this r
309. is section and impregnated with PVC or neoprene shall k For operation at temperatures outside these be used only in a temperature range from 0 ranges or for other impregnations consult the degrees F 18 degrees C to 200 degrees F manufacturer for specific data 93 degrees C Fabric thickness Crossrods Metal mesh Spirals welded or brazed to crossrods Figure 11 15 Typical metal mesh sling Reprinted from ASME B30 9 2006 by permission of The American Society of Mechanical Engineers All rights reserved Chapter 11 11 30 General DOE STD 1090 2007 Table 11 13 Load capacity of carbon and stainless steel metal mesh slings in pounds Design Factor 5 1 a 60 45 30 Sling width Vertical or Basket or Basket or Basket or Basket or Sling width in choker two legs two legs two legs two legs in Heavy duty 10 ga 35 spirals ft of mesh width 2 1 500 3 000 2 600 2 100 1 500 2 3 2 700 5 400 4 700 3 800 2 700 3 4 4 000 8 000 6 900 5 600 4 000 4 6 6 000 12 000 10 400 8 400 6 000 6 8 8 000 16 000 13 800 11 300 8 000 8 10 10 000 20 000 17 000 14 100 10 000 10 12 12 000 24 000 20 700 16 900 12 000 12 14 14 000 28 000 24 200 19 700 14 000 14 16 16 000 32 000 27 700 22 600 16 000 16 Medium duty 12 ga 43 spirals ft of mesh width 2 1 350 2 700 2 300 1 900 1 400 2 3 2 000 4 000 3 500 2 800 2 0
310. it is lifted Only stable safely arranged loads shall be handled Block and secure them if necessary Caution shall be exercised when handling off center loads which cannot be centered Always spread the forks to suit the load width Extra caution s required when handling loads exceeding the dimensions used to establish truck capacity Stability and maneuverability may be adversely affected The forks shall be placed under the load as far as possible the mast shall be carefully tilted backward to stabilize the load DOE STD 1090 2007 Do not transport loads or miscellaneous items within the operator s compartment or other areas of the truck unless a secure area has been provided and designated by the user A load backrest extension shall be used whenever necessary to minimize the possibility of the load or part of it from falling rearward Do not attach or operate any attachment on a forklift truck that has not been approved for use by forklift truck manufacturer or a qualified engineer in the absence of manufacturer approval When attachments are used extra care shall be taken in securing manipulating positioning and transporting the load Operate trucks equipped with attachments as partially loaded trucks when not handling a load Fork length should be at least two thirds of the load length Use extreme care when tilting load forward r backward particularly when high tiering Do not tilt forward wi
311. iter tinere certe Hearne ene IRE das cree Ene RR Rage 15 2 15 2 1 Qualified Operators of Mobile Cranes rennen 15 2 15 22 Qualified Operators of Forklift Trucks eese 15 3 1523 Qualified Riggets itte tp reor e D e ae 15 4 152 4 Personin Charge PIG erit er ani EE 15 4 15 2 5 Designated Leader niinic eei rete EEEE R ER 15 5 15 2 6 A E ee ER EE EE EET IEEE 15 5 15 277 Maintenance sc ete teo aee nee ne tia 15 5 15 3 INSPECTION AND TESTING 3 etd eee eret eee tede 15 6 15 4 OPERATIONS siz tetas eet ed rti oe de erede e deeds 15 7 I5 HL Generali eee ee eee hA ete ei e eee edi 15 7 15 52 Wire Rope Sings tutti ere eem et aes eee ede 15 7 15 5 STEEL ERECTION a dest etie eerte mt teet met e ete decer 15 8 SSL Generale lesa e tne e etre aet ede 15 8 15 5 2 D finitions tt ente e eme 15 8 15 5 3 Pre Shift Inspection of Cranes eese nennen nennen enne ia 15 8 15 5 4 Qualified Rigger e tre aper deiode 15 9 15 5 5 Lifun Personnel oo Ie ete pong eB ib 15 9 15 5 6 Safety Eatches 56e e tob Ine aee deinde teitesa 15 9 Dt Working Under Eoads rn e bere mehr eine 15 9 15 5 8 Multiple Load Lil cion rtr trente 15 9 DOE STD 1090 2004 INTENTIONALLY BLANK 15 ii DOE STD 1090 2007 15 1 GENERAL cT g The versatility of hoisting and rigging equipment makes it extremely useful on construction projects Improper and unsafe use however can result in serious accidents This chapter out
312. ith statutory or approved variances from these regulations b Any overhead wire shall be considered to be an energized line unless and until the person owning the line or the electrical utility authorities indicate that it is not an energized line c Durable signs shall be installed at the operator s station and on the outside of the crane warning that electrocution or serious bodily injury may occur unless a minimum clearance of 10 ft 3 1m is maintained between the crane or the load being handled and energized power lines Greater clearances are required because of higher voltage as stated in Table 9 3 These signs shall be revised but not removed when a local jurisdiction requires greater clearances d Exercise caution when working near overhead lines having long spans as they tend to move laterally or vertically due to the wind which could cause them to breach the safety zone e Cranes shall not be used to handle materials stored under electric power lines unless any combination of the boom load load line or machine component cannot enter the prohibited zone f Crane operators shall not rely on the coverings of wires for their protection 9 5 2 1 Crane Operation Near De energized and Grounded Electric Power Lines This is the preferred condition under which the operation can be performed safely The hazard of injury or death due to electrocution has been removed The following steps shall be taken to assure
313. itted to ride only in a personnel lift platform that is supported from the crane s hook which meets the requirements of Section 4 4 A hoist limit switch device shall be provided in the hoisting direction to stop the hoisting motion to prevent two blocking DOE STD 1090 2007 4 4 PERSONNEL LIFT PLATFORM 4 4 1 PLATFORM DESIGN AND CONSTRUCTION There is no attempt to comprehensively address platform design and construction in this chapter Nevertheless because many platform design and construction features can be observed and should be known by the platform user see Figure 4 2 the following key design and construction requirements are presented a The personnel lift platform and suspension system shall be designed by a qualified person competent in structural design and familiar with national consensus standards governing personnel platform design 1 Positive locking A R hook with locking i m bolt nut assembly iL Safety Shackle Overhead protection required Safety Lanyard harness anchorage Identification plate Grab rail Figure 4 2 Personnel Lift Platform b All welding of the platform shall be performed in accordance with ANSI AWS D1 1 Where special steels or other materials are used the manufacturer shall provide welding procedures Inspections shall be to the appropriate ANSI AWS protocols c The personnel lift platform shall have 1 A minimum design factor of five
314. jor repair or modification to components that affect the load carrying ability of the truck c The manufacturer should be consulted if questions arise as to whether a load test is appropriate d Forklift trucks shall be load tested by or under the direction of a qualified person and in accordance with the manufacturer s recommendations e Test weights shall be accurate within 5 0 of stipulated values f After a load test is performed a written report shall be furnished by the qualified 10 19 person that shows test procedures and confirms the adequacy of repairs or alterations Test reports shall be retained in the truck s history file 10 4 2 FORK LOAD TEST A fork that has undergone repair other than repair or replacement of positioning locks or marking shall be subject to a load test as described in ANSI ITSDF B56 1 Section 7 27 Forks Item 3 which lists loading and method of test for forks except for the test load which shall correspond to 250 percent of the rated capacity marked on the fork 10 4 3 ATTACHMENT LOAD TEST a Load capacity of an attachment shall be verified by the manufacturer or by a load test at 100 percent capacity that is performed onsite Load tests are not routinely required since a catalog cut user s manual decals on attachment or other manufacturer s data serves as capacity verification Chapter 10 Forklift Trucks DOE STD 1090 2007 10 5 OPERATIONS The followi
315. ken seizing wire v Damage to swaged fittings vi Other signs of damage or abuse The capacity of wire rope slings is derated by the manufacturer by applying the efficiency factors such as those given in Figure 11 11 Do not use wire rope clips to fabricate wire rope slings except where the application of slings prevents the use of prefabricated slings and where the specific application is designed by a qualified person Fabrication of wire rope slings for construction applications is also prohibited See Section 15 4 2 Slings made with wire rope clips should not be used as a choker hitch see Figures 11 12 and 11 13 Chapter 11 General DOE STD 1090 2007 25 If wire rope clips are used to fabricate slings the capacity of the sling shall be derated in accordance with the clip manufacturer s recommendations Manufacturer s recommendations shall also be followed with regard to clip spacing number of clips and torque values 26 Wire rope clips used to fabricate wire rope slings shall be of drop forged steel Malleable cast iron clips shall not be used 27 Wire rope clips attached with U bolts shall have the U bolt over the dead end of the rope and the live rope resting in the clip saddle Clips shall be tightened evenly to the recommended torque After the initial load is applied to the rope the clip nuts shall be retightened to the recommended torque to compensate for any decrease in rope diameter caused
316. kes traveling safer Always set swing brakes when the unit is idle or holding loads for a period of time especially on slopes if swinging during travel is necessary engage swing jaw clutch before releasing brakes Never back up until it is determined that everyone is clear of the machine Position the boom in the direction of travel for long moves Block treads when moving uphill be sure they are blocked to prevent downhill movement before shifting steering clutches Lock the turntable before traveling on a highway Use a house lock or swing brake and lower boom into the rack to prevent swing When loading machine on the trailer always use a ramp if a ramp is not available use blocking to build one 9 5 1 2 Making Adjustments or Repairs a When making adjustments or repairs 1 Stop the machine 2 Lower the boom or secure it against dropping 3 Neutralize all controls Chapter 9 Mobile Cranes DOE STD 1090 2007 4 Lock starter and remove ignition key to make the machine inoperative 5 Display proper warning signs on controls of machine 6 Keep hands feet and clothing away from gears ropes drums and sheaves 7 Never put hands on wire rope when climbing to the top of the cab 8 Use a bar or stick to guide wire rope onto drums 9 Keep hands well away from the fan drive while engine is running 10 Safeguard the crane oiler do not resume operation until a positive ALL CLEAR sign
317. l Hoist slowly shown as example RAISE THE BOOM AND LOWER THE LOAD With arm extended thumb pointing up flex fingers in and out as lone as load movement is desired LOWER THE BOOM AND RAISE THE LOAD With arm extended thumb pointing down flex fingers in and out as long as load movement is desired SWING Extend arm point with finger in direction of swing of boom STOP Extend arm palm down move arm back and forth horizontally EMERGENCY STOP Both arms extended palms down move arms back and forth horizontally TRAVEL Extend arm forward hand open and slightly raised make pushing motion in direction of travel DOG EVERYTHING Clasp hands in front of body TRAVEL Both Tracks Use both fists in front of body making a circular motion about each other indicating direction of travel forward or backward for land cranes only Figure 9 6 continued 9 27 Reprinted from ASME B30 5 2004 by permission of The American Society of Mechanical Engineers All rights reserved Chapter 9 Mobile Cranes DOE STD 1090 2007 TRAVEL One Side Track Lock the track on side indicated by raised fist Travel opposite track indicated by circular motion of other fist rotated vertically in front of body for land cranes only EXTEND BOOM Telescoping Booms Hold both fists in front of body thumbs pointing outward RETRACT BOOM Telescoping Boom
318. l the cover and core should be of the same type of material However in chemically active environments the cover and core shall be of the same type of material 3 When the core and cover are the same yarn type the thread should be of the same yarn type When the cover and the core are of different yarn type the thread should be of the same material as the core 4 Finishes and coatings shall be compatible with material of the core cover and thread and not impair the performance of the roundsling Fittings shall be 1 Of sufficient strength to sustain twice the rated capacity without permanent deformation 2 Ofa minimum breaking strength equal to that of the roundsling 3 Free of all sharp edges that would in any way damage the roundsling 4 Compatible with the mechanical and environmental requirements imposed on the roundsling The roundsling manufacturer should be consulted before roundslings are used in chemically active environments Polyester slings shall not be used on contact with objects or at temperatures in excess of 194 degree F 90 degree C or below 40 degree F 40 degree C Polypropylene slings shall not be used in contact with objects or at temperatures in excess of 150 degree F 66 degree C or below 40 degree F 40 degree C The sling manufacturer should be consulted for the temperature range of slings made from other synthetic yarns 11 41 e The design factor for synthetic r
319. l be trained and qualified as described in Chapter 6 Personnel Qualification and Training 10 1 2 RATED CAPACITY Rated capacity is the maximum weight the truck can transport and stack at a specified load center and for a specified load elevation Trucks shall not be used or tested above their rated capacities 10 1 3 NAMEPLATE S AND MARKINGS Every truck shall have appended to it a durable corrosion resistant nameplate s legibly inscribed with the following information a Truck model and truck serial number b Weight of truck c Rated capacity d Designation of compliance with the mandatory requirements of ANSI ITSDF B56 1 Safety Standard for Low and High lift Trucks applicable to the manufacturer e Type designation to show conformance with the requirements such as those prescribed by Underwriters Laboratories Inc and Factory Mutual Research Corporation f Batteries for use in electric trucks shall have the battery weight legible stamped on the 10 1 battery tray near the lifting means as follows Service Weight Ib kg In addition to the above requirements additional information is required and allowed on nameplates on high lift trucks electric trucks and trucks intended for hazardous locations see ANSI ITSDF B56 1 Section 7 5 Nameplates and markings 10 1 3 1 Fork Arm Data For forklift trucks purchased after December 1984 each fork arm shall be clearly stamped with its rat
320. l have an initial proof load test of not more than 125 percent of its rated capacity If proof testing cannot be verified the lifting device shall be proof tested before being used to make a critical lift DOE STD 1090 2007 14 4 MAGNETS CLOSE PROXIMITY OPERATED Close proximity operated magnetic lifting devices are used for single or multiple steel piece handling operations in which the operator of the magnet is required to manually guide the load during its movement They are also used in situations where remotely operated magnets are operated close to people Typical close proximity operated magnetic lifting devices are shown in Figure 14 7 14 4 4 DESIGN FABRICATION Close proximity operated magnetic lifting devices shall be designed and fabricated in accordance with the provisions of ASME B30 20 20 3 2 2 and 20 3 2 3 14 4 2 MARKING P Si At a minimum a nameplate name tag or other permanent marker shall be affixed to each lifting magnet and shall display the following data 1 Manufacturer s name or if the magnet has been repaired or modified the name and address of the repairer modifier 2 Model or unit identification 3 Weight 4 Duty cycle if applicable 5 Cold current 6 Rated capacity Also battery powered and external powered lifting electromagnets and electrically controlled permanent magnet lifting magnets shall be marked with 1 The voltage of the battery or primary pow
321. l have the manufacturer s name or trademark and the saddle size either forged or die stamped into the saddle d Wire rope clips should be shipped with application instructions and product warnings for each type or size clip A 11 Appendix A Procurement Guidelines DOE STD 1090 2007 11 EYE BOLTS P Si Eyebolts shall be fabricated to meet or exceed the requirements of ASME B30 26 Eyebolts used for hoisting shall be fabricated from forged carbon or alloy steel and shall have sufficient ductility to permanently deform before losing the ability to support the load at temperatures at which the manufacturer has specified for use Appendix A Procurement Guidelines Eye bolts used for lifting service shall be marked with the manufacturer s name or trademark size or rated load and grade for alloy eyebolts The safe working load shall have a safety factor of 5 DOE STD 1090 2007 12 HOOKS P Si e Hooks used for lifting service shall meet or exceed the requirements of ANSI ASME B30 10 Manufacturer s identification shall be forged cast or die stamped on a low stress non wearing area of the hook When proof tests are used to verify manufacturing process material or configuration hooks shall be able to withstand proof load application without permanent deformation when a load is applied for a minimum of 15 seconds Proof loads for hooks up to 50 ton capacity shall be 200 perc
322. l manual electric or air operated hoists shall have affixed to the hoist or load block a label or labels displaying precautionary information concerning operating procedures Load sprockets shall have teeth or pockets to allow engagement of the load chain shall be guarded and provisions shall be made to guard against jamming of the load chain within the hoist mechanism under normal operating conditions Manufacturer shall supply instruction manual for each hoist the manual shall include the following information and instructions 1 Installation 2 Operation 3 Inspection and Testing 4 Lubrication maintenance and repair 5 Wiring diagram electric powered only maybe supplied separately A load test certificate shall be provided by the manufacturer referencing the specific hoist date of test and amount of load applied 1 2 LOAD CHAIN Load chain may be either roller or welded link chain Load chain shall be pitched so as to pass over all load sprockets without binding Load chain shall be proof tested by the chain or hoist manufacturer with a load test of 150 percent of the rated load divided by the number of chain parts supporting the load A load test certificate shall be provided by the manufacturer or supplier referencing the specific hoist identification number date of test and amount of load applied Appendix A Procurement Guidelines DOE STD 1090 2007 1 3 HOIST HOOKS If hooks are of the swi
323. l not be exceeded The operator shall inspect for damage and defects in accordance with Section 9 2 3 including observations during operation A 9 30 qualified person shall examine deficiencies and determine whether they constitute a hazard i Check hoist limit switches if provided according to Section 9 5 3 Hoist Limit Switch j Ensure that basic operating instructions of power operated equipment together with charts tables or diagrams showing the rated capacity boom angle swing and stability data are posted in convenient view of the operator k Check load lines after strain is put on them but before the load is lifted clear of the ground if load lines are not plumb reposition the slings or equipment so that the lines are plumb before continuing 9 5 12 CRITICAL LIFTS See Chapter 2 Critical Lifts for critical lift requirements Chapter 9 Mobile Cranes DOE STD 1090 2007 Exhibit I is intended to be a sample form only The equipment manufacturer s inspection testing criteria supercede any other criteria In cases where the equipment manufacturer does not include inspection testing criteria other forms developed to facilitate required inspection testing are acceptable 9 31 Chapter 9 Mobile Cranes DOE STD 1090 2007 INTENTIONALLY BLANK 9 32 Chapter 9 Mobile Cranes DOE STD 1090 2007 SAMPLE FORM EXHIBIT MOBILE CRANE LOAD TEST LICENSE OR EQUIPMENT NO MAKE
324. l to 14 23 14 5 7 Tramme Qualification 2 etr rte cas 14 23 12 3 5 OST ALTON A ivo exte NR SU iu e aiit ed o es 14 24 145 9 Critical Lifts oe ooa De A pero Re Dele ea 14 24 Exhibit I Lifting Bars and Spreaders Load Test and Inspection 14 27 CHAPTER 15 CONSTRUCTION HOISTING AND RIGGING EQUIPMENT REQUIREMENTS 15 1 15 1 GENERADA MEER tnu ES 15 1 15 2 PERSONNEL QUALIFICATIONS cere 15 2 15 2 1 Qualified Operators of Mobile Cranes sese 15 2 15 2 2 Qualified Operators of Forklift Trucks 15 3 15 23 Qualified EE Soe TEUER YER E ae 15 4 15 2 4 Persori m Charge PIC ad 15 4 13 2 5 Designated Leader ici aee eee p We HOUSE oust ERE 15 5 15 2 6 TS A sd roe ee E preste set apnea b E QR AN 15 5 15 2 5 Malena sido oe enr A AT 15 5 15 3 INSPECTION AND TESTING e ceeeeeeeeee eee enne nnne tnnt 15 6 I5 P OPERATION at a 15 7 15 41 General deeper basi ru ee eee teer ute pedi 15 7 15 4 2 Wire Rope Slings oscila EA nce ido neg eb vote rie is 15 7 I5 5 STEEL ERECTION cie eg cab RES er E N 15 8 15 5 1 EE 15 8 15 52 Definitions ee ectetuer ti etii ru etes 15 8 15 5 3 Pre Shift Inspection of Crates eec Eee re tol 15 8 13 34 Q lified Rag eer mec wee ek esto pets Cty dae ut e Ente areas 15 9 15 5 5 Lifting Personne lcs esencia Ra ep ur eden erp AME 15 9 15 356 Safety Latches esie eros eri we EO VS
325. l without binding or jamming under normal operating conditions The hand chain shall be guarded to prevent disengagement from the hand chain wheel The hand chain shall withstand without permanent distortion a force of three times the pull required to life the rated load 8 1 9 WEB STRAP The following applies for manual lever operated hoists Web strap should be nylon polyester or similar synthetic material If a load is supported by more than one part of web strap the tension on the parts shall be equalized End terminations shall be done in the manner specified by the manufacturer of the assembly or the web strap Eyes shall be made in a manner recommended by the hoist manufacturer or a qualified person Nylon and polyester web straps shall not be exposed to an ambient temperature greater than 200 degrees F 93 degrees C The web strap shall be attached to the hoist in a manner to prevent disengagement throughout rated hook travel no less than two wraps of web strap shall remain on the hoist load sprocket drum when the hook is extended to its full rated lift 8 1 10 OVERTRAVEL PROTECTION 8 1 10 1 Upper Limit Switches Devices For electric or air powered hoists the hoist shall be designed and constructed so that the load hook either loaded or empty shall not exceed the upper limit of travel In lieu of a limit switch a mechanism such as a slip clutch may be used 8 1 10 2 Lower Limit Switches Devic
326. label to the attention of an operator b The label shall contain cautionary language against any of the following 1 Lifting more than the rated load 2 Operating a hoist when the load is not centered under the hoist 3 Operating a hoist with twisted kinked or damaged chain or wire rope 4 Operating a damaged or malfunctioning hoist 5 Lifting personnel or lifting loads above personnel 6 Operating a wire rope hoist with a wire rope that is not properly seated in its grooves 7 Removing or obscuring warning labels c A label shall be affixed on all electrical control enclosures The label shall be in compliance with ASNI Z535 4 and shall include but not be limited to information such as 1 Disconnect power and lockout tagout disconnecting means before removing cover or servicing this equipment 2 Do not operate without cover in place 8 1 3 2 Hand Chain Operated or Manual Lever Operated Hoists a Labels shall be affixed to the hoist or load block and shall display the word WARNING or other legend designed to bring the label to the attention of an operator b The label shall contain cautionary language against any of the following 8 1 4 8 1 5 DOE STD 1090 2007 1 Lifting more than the rated load 2 Operating a hoist when it is restricted from forming a straight line with the direction of loading 3 Operating the hoist with twisted kinked or damaged wire rope
327. latform Identification B Platform Rating 7 Platform Weight 8 A Number of Platform Occupants B Approximate Weight with equipment 9 Total Lift Weight C 8B No more than 5B above 10 Personnel Lift Supervisor 11 What are the alternatives to this personnel lift 12 Why are they not being used 13 Pre Lint Briefing Held Time AM PM Attendees 14 Anticipated Hazards wind weather visibility power lines 15 Lift Accomplished Date Time AM PM 16 Remarks Designated Leader Signature Date Reprinted from ASME B30 23 2005 by permission of The American Society of Mechanical Engineers All rights reserved Chapter 4 4 16 Lifting Personnel DOE STD 1090 2007 CHAPTER 5 HOSTILE ENVIRONMENTS This chapter describes provisions for hoisting and rigging operations in hostile work environments 5 1 GENERAL 2 n ln eae ings IU SEN 5 1 52 HOSTILE ENVIRONMENT DL AN AAA 5 2 5 2 1 Marking and PoSUnp cuite eth EE e e mre net at 5 2 9 2 2 Inspection and Testing aee e aee ee 5 2 EXHIBIT I Hostile Environment Plan eet ttem t e ett e 5 3 5 i Chapter 5 Hostile Environments DOE STD 1090 2007 INTENTIONALLY BLANK Chapter5 5 ii Hostile Environments DOE STD 1090 2007 5 1 GENERAL This chapter contains special provisions for hoisting and rigging operations and equipment in hostile environments where standard operating maintenance inspection or test procedures cannot
328. le is used Semi permanent and inaccessible locations where frequent inspections are not feasible shall have periodic inspections performed 2 Conditions such as those listed in Section 12 3 5 or any other condition that may result in a hazard shall cause the shackle to be removed from service Shackles shall not be returned to service until approved by a qualified person Chapter 12 Rigging Hardware C DOE STD 1090 2007 3 Written records are not required Periodic Inspection 1 A complete inspection of the shackle shall be performed by a designated person The shackle shall be examined for conditions such as those listed in Section 12 3 5 and a determination made as to whether they constitute a hazard 2 Periodic inspection intervals shall not exceed one year The frequency of periodic inspections should be based on i Frequency of use ii Severity of service conditions iii Nature of lifts being made iv Experience gained on the service life of shackles used in similar circumstances 3 Guidelines for the time intervals are i Normal service yearly ii Severe service monthly to quarterly 111 Special service as recommended by a qualified person 4 Written records are not required 12 3 5 REMOVAL CRITERIA a Chapter 12 Rigging Hardware Shackles shall be removed from service if damage such as the following is visible and shall only be returned to service when approved by a q
329. leg slings shall be applied to the individual legs and shall be 200 percent of the rated load of a single leg sling A certificate of proof test shall be provided by the manufacturer or supplier referencing the specific sling identification number date of test and amount of load applied Employer shall retain a certificate of the proof test and shall make it available for examination Appendix A Procurement Guidelines DOE STD 1090 2007 7 SYNTHETIC WEB SLINGS P Si e e e re gs Appendix A Synthetic slings shall meet or exceed the requirements of 29 CFR 1910 184 and ASME ANSI B30 9 Synthetic web slings shall be manufactured from webbing specifically constructed for overhead lifting Synthetic sling webbing shall have the following characteristics 1 Sufficient certified tensile strength to meet the sling manufacturer s J requirements 2 Uniform thickness and width 3 Full woven width including selvage k edges 4 Webbing ends shall be sealed by heat or other suitable means to prevent l raveling Thread used in the manufacture of synthetic web slings shall be of the same type yarn as m the sling webbing Stitches shall be lock stitched and preferably continuous When not continuous it shall n be back stitched at the ends to prevent raveling The load carrying splice shall be sewn with a pattern of sufficient strength to justify the O manufacturer s
330. les greater than 120 degrees Chapter 11 General 11 38 DOE STD 1090 2007 Table 11 15 Typical load capacity of Class 7 synthetic web slings in pounds Design Factor 5 1 Regular eye twisted eye triangle fittings choker fittings Web width va in Basket or Web width Vertical Choker two legs in Single Ply Web Slings 9 800 Ib in material 1 1 600 1 280 3 200 2 800 2 900 1 600 1 2 3 100 2 480 6 200 5 400 4 400 3 100 2 3 4 700 3 760 9 400 8 100 6 600 4 700 3 4 6 200 4 960 12 400 10 700 8 800 6 200 4 5 7 800 6 240 15 600 13 500 11 000 7 800 5 6 9 300 7 440 18 600 16 100 13 200 9 300 6 Double Ply Web slings 9 800 bim material 1 3 100 2 480 6 200 5 400 4 400 3 100 1 2 6 200 4 960 12 400 10 700 8 800 6 200 2 3 8 800 7 040 17 600 15 200 12 400 8 800 3 4 11 000 8 800 22 000 19 100 15 600 11 000 4 5 13 700 10 960 27 400 23 700 19 400 13 700 5 6 16 500 13 200 33 000 28 600 23 000 16 500 6 Reprinted from ASME B30 9 2006 by permission of The American Society of Mechanical Engineers All rights reserved 1 For an endless sling with vertical hitch carrying a load of such size as to throw the legs more than 5 degrees off vertical use rated load data for regular eye and eye sling basket hitch and corresponding leg angles Follow manufacturer s capacities they vary from manufacturer to manufacturer and from this chart Choker hitch values
331. less otherwise recommended by the manufacturer or a qualified person The replacement of load chain is specifically 8 15 excluded from this hoist load test however a functional test of the hoist should be made in accordance with Section 8 3 1 2 or 8 3 1 3 Hand Chain Operated Hoists and Manually Lever Operated Hoists respectively prior to putting the hoist back in service Chapter 8 Hoists DOE STD 1090 2007 8 4 MAINTENANCE A preventive maintenance program shall be established and be based on the hoist manufacturer s recommendations If equipment maintenance procedures deviate from published manufacturer s recommendations the alternate procedures shall be approved in advance by the Chapter 8 Hoists 8 16 manufacturer or another qualified person and be kept readily available Dated maintenance records should be kept where readily available to appointed personnel Replacement parts shall be at least equal to the original manufacturer s specifications DOE STD 1090 2007 8 5 OPERATION The following shall apply to all personnel involved in hoist operations At the initial stage of the planning process an appointed person shall classify each lift into one of the DOE specified categories ordinary critical or preengineered production 8 5 1 CONDUCT OF OPERATOR Do not engage in any practice that will divert your attention while engaged in operating the hoist Do not operate equipmen
332. ley thereby preventing trolley travel past a point where it could fall from the rail On those systems where a series of monorails may be connected by a bridge or turntable verification of functional trolley stops on all accessible rails must be established or administrative controls placed limiting access to a specific work area during the period the trolley is in service DOE STD 1090 2007 Boom Extensicn nad Hook Hydraulic Power Unit EE em Operat ng Controls Upright Mast Base Reprinted from ASME PALD by permission of The American Society of Mechanical Engineers All rights reserved Figure 16 1 Self Contained Shop Crane Extension _ Load Hook _ Boom Elevation _ Remote Pendant Control Mounting Base Figure 16 2 Truck Mounted Crane Capacity 1 Ton or Less DOE STD 1090 2007 et e M SN AS mans MIR H W P L lt 4j Ree a Ka AL T cM Za O i ay Figure 16 3 Portable A Frame Chapter 16 16 4 Miscellaneous Lifting Devices DOE STD 1090 2007 16 2 INSPECTIONS 16 21 GENERAL Equipment shall operate with a smooth regular motion without any hesitation abnormal vibration binding or irregularity There shall be no apparent damage excessive wear or deformation of any load bearing part of the equipment All safety devices controls and other operating parts of the equipment shall be checked during each in
333. lied for a minimum of 15 seconds This Practice for Liquid Penetrant Inspection condition is considered satisfied if the Method permanent increase in the throat opening does not exceed 0 5 percent or 0 01 in 0 25 e Performance testing of hooks shall not be mm whichever is greater required except where necessary to conform to the requirements for the equipment of c Fora duplex sister hook having a pin eye which they are part When testing is the proof load for the eye shall be in specified documentation shall be uniquely accordance with Table 13 1 The proof load identified to the hook by serial number or shall be shared equally between the two other identifier prongs of a sister hook unless the hook is designed for unbalanced loading Chapter 15 Load Hooks 13 4 DOE STD 1090 2007 Table 13 1 Proof test load Proof load Rated load minimum tons kg rated load tons 2 000 Ib 2 000 Ib kg 0 50 453 6 200 1 907 2 1 907 2 200 2 1 814 4 5 4 536 200 10 9 072 10 9 072 200 20 18 144 15 13 608 200 30 27 216 20 18 144 200 40 36 288 25 22 680 200 50 45 360 30 27 216 200 60 54 432 35 31 752 200 70 63 504 40 36 288 200 80 72 576 45 40 824 200 90 81 648 50 45 360 200 100 90 720 60 54 432 193 116 105 235 75 68 040 183 137 124 286 100 90 720 166 166 150 595 125 113 400 150 188 170 554 150 136 080 133 200 181 440 175 158 760 133 233 211 378 200 181 440 133 266 241 315 250 226 800 133 333 302 098 300 272 160 133 399 361 973
334. lies to the following types hoists should not be used for lifting service of equipment see Figures 8 1 through 8 6 see Figure 8 8 1 Overhead hoists underhung d Systems used for transporting personnel and specially insulated hoists used for handling 2 Jib cranes hoists floor and wall electrically energized power lines require mounted special considerations and are not included in this chapter 3 Monorail systems Figure 8 1 Hand chain operated hoists Figure 8 2 Electric air powered chain and wire rope hoists Reprinted from ASME B30 16 2007 by permission of The American Society of Mechanical Engineers All rights reserved 8 1 Chapter 8 Hoists DOE STD 1090 2007 Figure 8 3 Electric air powered wire rope hoists Reprinted from ASME B30 16 2007 by permission of The American Society of Mechanical Engineers All rights reserved Figure 8 5 Manual lever operated hoist wire rope type Reprinted from ASME B30 21 2005 by permission of The American Society of Mechanical Engineers All rights reserved Chapter 8 8 2 Hoists DOE STD 1090 2007 LJ prammen Drive pinion Load brake hub Figure 8 7 Recommended hoists with friction brake type load controlling mechanisms Ratchet pawl Ratchet load sprocket Load holding pawl Guide N l T Wire rope Figure 8 8 Not recommended hoists with ratchet and pawl load controlling mechanisms Reprinted from ASME B30 21 2005
335. lines the requirements for lifting service on construction and demolition activities and provides references to other chapters of this Standard applicable to the use of hoisting and rigging equipment at construction projects on DOE installations The following chapters of this Standard are applicable to construction hoisting and rigging operations 1 Chapter 1 Terminology and Definitions 2 Chapter 2 Critical Lifts 3 Chapter 4 Lifting Personnel 15 1 Chapter 7 Overhead and Gantry Cranes Chapter 8 Hoists Chapter 9 Mobile Cranes Chapter 10 Forklift Trucks Chapter 11 Wire Rope and Slings Chapter 12 Rigging Accessories Chapter 13 Hooks Chapter 14 Below the Hook Lifting Devices Chapter 16 Miscellaneous Lifting Devices Chapter 15 Construction Hoisting and Rigging Equipment Requirements DOE STD 1090 2007 15 2 PERSONNEL QUALIFICATIONS 15 2 1 QUALIFIED OPERATORS OF P MOBILE CRANES Only qualified personnel or trainees under the direct supervision of qualified personnel who meet the following physical qualifications and requirements shall be allowed to operate mobile cranes 1 Beat least 18 years of age 2 Understand spoken and written English 3 Have vision of at least 20 30 Snellen in one eye and 20 50 in the other with or without corrective lenses 4 Be able to distinguish colors regardless of p
336. lings are attached to the load If all legs of a steel chain sling are hooked back into the master link the safe load capacity of the whole sling may be increased by 100 percent if the capacity of the master link is not exceeded The safe load level of any chain sling is a function of three basic factors size and number of legs condition of chain and other components and sling angle between legs and horizontal Table 11 10 shows safe loads in pounds per leg which can be carried by various chain sling arrangements Note the effect of very low hook height and wide leg spreads Hooks rings oblong links pear shaped links welded or mechanical coupling links and other attachments shall have a rated capacity at least equal to that of the alloy steel chain with which they are used or the sling shall not be used in excess of the rated capacity of the weakest component 11 3 3 1 Removal from Service Criteria Missing or illegible sling identification b Cracks or breaks Chapter 11 General DOE STD 1090 2007 Excessive wear nicks or gouges Minimum thickness on chain links shall not be below the values listed in Table 11 11 Stretched chain links or components Bent twisted or deformed chain links or components Evidence of heat damage Excessive pitting or corrosion Lack of ability of chain or components to hinge articulate freely Weld splatter For hooks removal criteria as stated in Chapter 12 Oth
337. lix having a left hand pitch similar to a left hand screw Right Lay Strand Strand in which the cover wires are laid in a helix having a right hand pitch similar to a right hand screw Rope Rope in which the strands are laid in a helix having a right hand pitch similar to a right hand screw LIFT Maximum safe vertical distance through which a hook can travel e The hoisting of a load DOE STD 1090 2007 LIFT CRITICAL A lift for which the application of provisions applicable to ordinary lifts would not adequately eliminate or control the likelihood or severity of the following personnel injury or significant adverse health impact onsite or offsite significant release of radioactivity or other hazardous material or other undesirable conditions undetectable damage that would jeopardize future operations or the safety of a facility damage that would result in delay to schedule or other significant program impact such as loss of vital data LIFT ORDINARY Any lift not designated as a critical lift or a preengineered production lift LIFT PREENGINEERED PRODUCTION Repetitive production type lifting operation independent of the nature of the load to be lifted in which the probability of dropping upset or collision is reduced to a level acceptable to the responsible manager by preliminary engineering evaluation specialized lifting fixtures detailed procedures operation specific traini
338. ll be given a complete inspection according to the requirements of Section 9 2 6 before being placed in service c Standby cranes shall be inspected at least semiannually according to the requirements of Section 9 2 6 Cranes exposed to adverse environments should be inspected more frequently d The determination supporting these alternate inspection frequencies and procedures shall be made by a qualified person for each affected crane Documentation supporting this determination shall be kept readily available Chapter 9 Mobile Cranes DOE STD 1090 2004 9 3 TESTING 9 3 1 OPERATIONAL TESTS The following shall be tested during an initial test a Load lifting and lowering mechanisms b Boom lifting and lowering mechanisms c Boomextension and retraction mechanism d Swinging mechanism e Travel mechanism f Safety devices 9 3 2 RATED LOAD TEST a Prior to initial use all cranes in which load sustaining parts have been modified replaced or repaired shall be load tested by a qualified inspector or under the direction of that inspector All rated load tests shall be performed in accordance with manufacturer s recommendations A 9 12 designated or authorized person shall determine if repairs made to a crane are extensive and require a rated load test or if repairs are routine maintenance and require only operational testing The replacement of rope is excluded from this requirement However a fu
339. llow the load to swing or roll to the lowest possible point against support members 2 Only operate shop cranes on hard level 11 Not adjust the height of portable A surfaces capable of sustaining the load frames when the unit is under load 3 Ensure the load does not drop suddenly 12 Secure trolley and hoist on portable A or swing during transportation frames in center of I beam before adjusting height 4 Whenever there is doubt as to safety consult with the responsible d If necessary to leave a shop crane or a management before operating portable A frame with a suspended load miscellaneous lifting devices unattended the immediate area at least 30 inches around the shop crane or portable A frame shall be posted or barricaded to restrict entry of unauthorized personnel 5 If adjustment or repairs are necessary or any other defects are known report Note Set flange to flange distance between wheels equal to rail width pius 1 8 DOE STD 1090 2007 Figure 16 4 Trolley Flange Distance Detail B I Beam with Canted Detail A I Beam with Crowr Flat Tread Wheel Acceptable Tread Wheel Preferred Detail C I Beam with Flat Tread Wheel Unacceptable Detail D Patented Rail Detail E Patented Rail with Flat Tread Wheel with Crown Tread Wheel Preferred Acceptable Figure 16 5 Trolley and Rail Compatibility Chapter 16 16 10 Miscellaneous Lifting Devices DOE STD 1090 2007 CHAPTER 17 REFE
340. load so that it will lift level and true Chapter 11 General 11 8 11 3 1 2 The following is an example of selecting a sling using the load angle factors shown in Figure 11 7 1 Load 1 000 lb 2 Sling 2 legged bridle 3 Angle with horizontal 45 degrees 4 Load angle factor from Figure 11 7 1 414 Each of the two legs would lift 500 Ib if a vertical lift were made However there is a 45 sling angle involved Therefore the 500 Ib load would be multiplied by the load angle factor in the chart giving a total of 707 lb 500 Ib x 1 414 tension in each sling leg Each sling leg therefore must have a rated capacity of at least 707 lb Safe Load The rated capacity or working load limit WLL of a sling varies depending on the type of hitch The rated capacity tables in this section show the applications for which the various safe loads apply when the slings are new All ratings are in pounds lbs Figures 11 8 and 11 9 provide information for determining the total rated capacity of 3 leg slings so as not to introduce a working load in direct tension in any leg greater than that permitted Two legs should be considered to carry the load because in normal lifting practice the load will not be uniformly distributed on all legs If rigging techniques verified by a qualified rigger ensure that the load is evenly distributed then full use of three legs is allowed Special rigging techniques verified by a
341. ltiple part tope legs 3 Three leg bridle slings 4 Four leg bridle slings 5 Special slings and combinations The total load that can be safely lifted with slings depends on the rating of the slings and the manner in which they are attached to the load Consult Tables 11 4 through 11 9 and Figure 11 10 Braided slings are made by braiding ordinary wire ropes together thus making them more flexible than wire rope slings The size of a braided sling is determined by the diameter of one wire rope and the number of ropes in the cross section of the slings 11 11 The design factor for wire rope slings shall be a minimum of 5 1 based upon breaking strength When a wire rope sling is used in a choker hitch the normal angle formed in the rope body as it passes through the choking eye is 120 degrees or greater do not confuse the choke angle with the angle of inclination of the load see Figure 11 10 Rated load in load capacity Tables 11 4 through 11 9 are for angles of 120 degrees or greater For smaller angles reduce the rated load to the percentages given in Figure 11 10 Chapter 11 General DOE STD 1090 2007 When legs are not of equal length use smallest H L ratio NOTE Load may be supported on only 2 legs while 3rd leg balances it Therefore the required SWL is determined by the following Total Rated Capacity WLL of single vertical hitch x H L x 2 Figure 11 8 Determination of capacity 3 leg
342. lude Proof Coil grade 28 Hi Test Grade 43 chain and Transport Grade 70 chain These grades are not recommended for overhead lifting and therefore are not covered in the applicable standards 2 Rating of multi leg slings adjusted for angle of loading between the inclined leg and the horizontal plane of the load 11 27 Chapter 11 General DOE STD 1090 2007 Table 11 11 Minimum allowable thickness at any point on a link Minimum Allowable Nominal Chain or Thickness at Any Point on Coupling Link Size the Link in mm in mm K 5 5 0 189 4 80 V 7 0 239 6 07 e 8 0 273 6 93 y 10 0 342 8 69 A 13 0 443 11 26 16 0 546 13 87 Y 20 0 687 17 45 VA 22 0 750 19 05 1 26 0 887 22 53 UA 32 1 091 27 71 Reprinted from ASME B30 9 2006 by permission of The American Society of Mechanical Engineers All rights reserved 11 3 3 3 Operation a The following shall apply to all personnel who use steel chain slings 1 Do not set a load on a sling or pull a sling from under a load Place wooden blocks or other supports under the load to provide sufficient clearance for the chain 2 Shorten chain slings by hooking back into the chain into the master link or with grab hooks Do not shorten by knotting twisting bolting or inserting the tip of the hook into a link 3 Do not hammer a chain to force it into position 4 Protect chain slings from sharp corners that might bend the links Use a suitable pad to prevent gougin
343. lude top running single or multiple girder bridge with top running trolley hoists Figure 7 1 top running single girder bridge with underhung trolley hoists Figure 7 2 and monorails underhung cranes Figure 7 3 7 1 1 OPERATOR TRAINING QUALIFICATION Operators of overhead cranes shall be trained and qualified as required in Chapter 6 Personnel Qualification and Training 7 1 2 RATED LOAD MARKING The rated capacity shall be marked on each side of the crane If the crane has more than one hoisting unit each hoist shall have its rated capacity marked on it or on its load block Markings on the bridge trolley and load block shall be legible from the ground or floor 7 1 8 MODIFICATION Cranes may be modified or rerated provided that the modifications or supporting structures are analyzed thoroughly by the crane manufacturer or a qualified engineer Modifications and reratings must be approved by the cognizant engineering organization A rerated crane or one whose load supporting components have been modified shall be tested in accordance with Section 7 3 Testing The new rated capacity shall be displayed in accordance with Section 7 1 2 Rated Load Marking 7 1 4 EGRESS On cab operated cranes there shall be at least two means of egress from the crane remote from each other and arranged to permit departure under emergency conditions 7 1 5 RAIL SWEEPS Bridge trucks shall be equipped with sweeps
344. ly extended and lowered before operation 5 Avoid fast swings hoists or sudden braking these can cause overloads 6 Do not handle large heavy loads in strong winds the wind can catch the load and create an unstable condition Test stability before lifting heavy loads Check outrigger footing Lift load slightly off the ground and stop Check the machine for movement ad check to be sure the brakes hold with the load elevated Never use machine stability to determine capacity If there are any indications of tipping the machine is already overloaded for that working radius Do not back crane away from the load while carrying a maximum load this may cause the crane to tip Always use outriggers when making lifts with pick and carry units and never lift a load forward of the front outriggers unless allowed on manufacturer s load chart Lower outrigger jacks until the tires clear the ground and level the unit to reach the machine s full capacity Recheck and if necessary reset outriggers between heavy lifts Always fully extend outrigger beams unless otherwise specified on the manufacturer s load charts for the crane Chapter 9 Mobile Cranes DOE STD 1090 2007 f Keep near capacity loads as close to the 9 5 1 4 Further Safety Considerations ground as possible a Make only vertical lifts never pull the load g Avoid hitting anything with the boom an sideways engineering analysis shall be made before p
345. m 166 Antimony 418 Bismuth 613 Brass cast 504 Brass rolled 523 Copper cast 550 Copper rolled 555 Gold 24 carat 1 204 Iron cast 450 Iron wrought 480 Lead commercial 712 Mercury 60 degrees F 846 Silver 655 Steel 490 Tin cast 458 Uranium 1 163 Zinc 437 Name of wood Ash 35 Beech 37 Birch 40 Cedar 22 Cherry 30 Chestnut 26 Cork 15 Cypress 27 Ebony 71 Elm 30 Fir Balsam 22 Hemlock 31 Maple Oak 62 Pine Poplar 30 Chapter 12 12 2 Rigging Hardware Name of Material Bluestone Brick pressed Brick common Cement Portland packed Cement Portland loose Cement slag packed Cement slag loose Chalk Charcoal Cinder concrete Clay ordinary Coal hard solid Coal hard broken Coal soft solid Coal soft broken Coke loose Concrete or stone Earth rammed Granite Gravel Lime quick ground loose Limestone Marble Plaster of paris cast Sand Sandstone Shale Slate Terra cotta Traprock Water Weight Ib ft 160 50 125 100 120 70 90 80 100 55 75 156 15 34 110 120 150 93 5 54 84 54 23 32 140 155 90 100 165 170 117 125 53 170 164 80 90 106 151 162 160 180 110 170 65 DOE STD 1090 2007 Good and Bad Rigging Practices Use of Chokers Hook Slings Good Hooks are turned out AT Good No cutting action on running lines Double slings shall be used running line ung when hoisting two or more can work action of eye pieces of mater
346. m the original fork supplier 10 3 4 3 Fork Repair Only the manufacturer of the fork or an expert of equal competence shall decide if a fork may be repaired for continued use and the repairs shall only be carried out by such authorities Surface cracks or wear should not be repaired by welding When resetting repairs are required the fork shall be subject to heat treatment 10 3 5 BATTERY MAINTENANCE a Facilities shall be provided for flushing and neutralizing spilled electrolyte for fire protection for protecting charging apparatus from damage by trucks and for adequate ventilation for dispersal of fumes from gassing batteries b Aconveyor overhead hoist or equivalent material handling equipment shall be provided for handling batteries c Reinstalled batteries shall be properly positioned and secured in the truck d Acarboy tilter or siphon shall be provided for handling electrolyte e When introducing electrolyte into batteries acid shall be poured into water water shall not be poured into acid f Trucks shall be properly positioned and brake applied before attempting to change or charge batteries g Care shall be taken to assure that vent caps are functioning The battery or compartment cover s shall be open to dissipate heat h Smoking shall be prohibited in the charging area i Precautions shall be taken to prevent open flames sparks or electric arcs in battery charging areas Chapter
347. mally hidden during inspection or maintenance procedures such as parts passing over sheaves these are points most subject to deterioration 5 Corroded or broken wires at end connections 6 Corroded cracked bent worn or improperly applied end connections Kinking crushing cutting or unstranding Table 8 1 Maximum allowable rope reductions Maximum allowable reduction from Nominal diameter Rope diameter Up to 5 16 in 8 mm 1 64 in 0 4 mm Over 5 16 in to 1 32 in 0 8 mm Vein 13 mm Over vein to 34in 3 64 in 1 2 mm 19 mm Over 3 4 in to 1 1 8 1 16 in 1 6 mm in 29 mm 3 32 in 2 4 mm Over 1 1 8 in to 1 vein 38 mm Reprinted from ASME B30 16 2007 by permission of The American Society of Mechanical Engineers All rights reserved b No precise rules can be given for determining the exact time to replace wire Chapter 8 Hoists rope because many factors are involved Safety depends largely on the use of good judgment by an appointed person in evaluating remaining strength in a used rope after allowance for deterioration disclosed by inspection Safety of rope operation depends on this remaining strength Conditions such as the following shall be reason for questioning rope safety and considering replacement 1 In hoist ropes 12 randomly distributed broken wires in one rope lay or 4 broken wires in one strand in one rope lay 2 Wear of one third of th
348. manufacturer unless otherwise recommended by the manufacturer due to working conditions Load chain links that pass over the load sprocket on edge alternate to those that lie flat in the pockets should be installed with the welds away from the center of the sprocket This precaution is not required on idler sprockets which change the direction but not the tension in the chain The chain shall be installed without any twist between the hoist and an anchored end on either the loaded side or the slack side When a chain is replaced disassemble and inspect the mating parts sprockets guides stripper for wear and replace if necessary Discarded load chain shall not be used for slings 7 2 7 4 Chain Roller a Test the crane under load in raising and lowering directions observing the operation of the chain and sprockets If the chain binds jumps or is noisy clean and properly lubricate it If the trouble persists inspect the chain and mating parts for wear distortion or damage If wear is observed or stretching is suspected the chain shall be measured according to the crane manufacturer s instructions If instructions are not available proceed as follows 1 Suspend the hoist in normal position and apply a light load of approximately 50 Ib 23 kg Chapter 7 7 10 Overhead and Gantry Cranes 2 Selecta 12 in 305 mm section of chain that normally travels over the load sprocket 3 Determine elongation
349. ment Control Horn Lights Back Up Alarm Hour Meter Daily Pre Shift Inspections are an OSHA requirement We recommend that you document that these inspections have been made Inspected by Custodian 10 31 Chapter 10 Forklift Trucks DOE STD 1090 2007 Page of 2 EXHIBIT Il SAMPLE FORM FORKLIFT LOAD TEST INSPECTED BY EQUIPMENT NUMBER LOCATION DATE INSPECTION Forklifts shall be inspected when assigned to service and at least every 12 months thereafter Prior to initial use all new modified or extensively repaired forklifts shall be inspected Craftsmen shall initial all tests work and inspections completed below Qualified inspector shall verify inspections have been complete prior to load test CRAFTSMAN INITIAL 1 Ensure capacity operation and maintenance instruction plates tags or decals are legible 2 Check all hydraulic systems including tilt cylinders valves and other similar parts to ensure drift has not developed 3 Check fuel system for leaks and condition of parts Special consideration shall be given in the case of a leak in the fuel system Immediate action shall be taken to take the forklift out of service until the leak is corrected 4 Check all parts of lift and tilt mechanisms and frame members to ensure safe operating conditions such as but not limited to hoist chain for damage and excessive wear 5 Check fo
350. monthly 3 Severe service daily to weekly In addition to the requirements of Section 7 2 4 Daily Preoperational Check these inspections shall include the following 1 Hoist braking system for proper operation 2 Rope or chain reeving for compliance with hoist manufacturer s recommendations 7 2 7 3 Operating mechanisms for proper operations proper adjustment unusual sounds or excessive wear Operators or other designated personnel shall examine deficiencies and determine whether the equipment should be removed from service or if a more detailed inspection is required PERIODIC INSPECTION A qualified inspector shall perform a complete inspection at the following intervals 1 Normal service yearly 2 Heavy service Semiannually to annually dependant upon the nature of the crane s critical components and the degree of their exposure to wear or deterioration 3 Severe service Monthly to quarterly The qualified inspector shall examine deficiencies and determine whether they constitute a safety hazard and whether the crane should be removed from service until it is repaired Dated and signed inspection records shall be kept on file and shall be readily available A sample load test form is included as Exhibit I which appears at the end of this chapter This form is intended to be a sample only and is not intended to be mandatory 7 2 7 1 Cranes In addition to the requirements o
351. most popular and versatile of all wire ropes and the most flexible is the 6 x 19F classification This rope is considered the perfect compromise between maximum abrasion resistance and maximum flexibility 2 6x 16F Slightly more abrasion resistant than the 6 x 19F the 6 x 16F makes an excellent rope for small draglines and similar uses The resistance to wear is gained by a slight sacrifice in flexibility 3 6x19 Seale The 6 x 19 Seale is a rugged wire rope for applications involving heavy wear Car pullers often use this rope and it is widely used for slushers and drag scrapers 4 6x19 Warrington The alternating large and small outer wires make this rope an all around performer The 6 x 19 Warrington is used for general purpose hoisting churn drills and miscellaneous slings 6 x 37 Classification When sheaves and drums are fairly small and abrasive conditions are not severe the ropes in this classification will show better performance than the coarser 6 x 19 construction Under conditions of repeated bending they will outlast a 6 x 19 rope when abrasion is severe the small outer wires quickly show the effect Figure 11 5 show three varieties of 6 x 37 wire rope with FC and IWRC cores Table 11 3 provides breaking strengths for 6 x 37 wire ropes with FC and IWRC cores The principal types of ropes in this classification include 1 6x37 2 operation A 6 x 37 2 operation strand has 18 outer wires This
352. multiple leg bridle slings assemblies shall be applied to the individual leg and shall be in accordance with paragraph a and b as applicable Master links to which multiple leg slings are connected shall be proof loaded to 200 percent times the force applied by the combined legs Welded end attachments shall not be used unless proof tested at 2 times rated capacity prior to initial use Test loads described above shall be accurate to within 5 percent 0 percent of stipulated values A written letter of certification by the manufacturer or a pull test witnessed and certified in writing by a qualified person is acceptable 11 3 2 3 Operation The following shall apply to all personnel who use wire rope slings 1 Start and stop slowly sudden starts and stops dramatically increase the stresses in hoist ropes and slings Lift slowly until the load is suspended to minimize swinging DOE STD 1090 2007 Loads shall be set on blocks Do not pull a sling from under a load that is resting on the sling Ensure that wire rope slings are protected against weather chemicals solvents and high temperatures Permanently remove from service fiber core rope slings that have been exposed to temperatures in excess of 180 degrees F 82 degrees C When wire rope slings of any grade are to be used at temperatures above 400 degrees F 204 degrees C or below 60 degrees F 51 degrees C the sling manufacturer should be consult
353. n HOLDING LINE Wire rope on a clamshell or orange peel bucket that holds the bucket while the closing line is released to dump the load HOOK LOAD The total live weight supported by the hook of a crane derrick or other hoisting equipment including the load slings spreader bars and other tackle not part of the load but supported by the hook and required for the handling of the load IDLER Sheave or roller used to guide or support a rope INDEPENDENT WIRE ROPE CORE Wire rope used as the core of a larger rope INNER WIRES All wires of a strand except surface or cover wires Chapter 1 Terminology and Definitions INTERNAL COMBUSTION ENGINE TRUCK A truck in which the power source is a gas or diesel engine INTERNALLY LUBRICATED Wire rope or strand having all wires coated with lubricant KINK Permanent distortion of wires and strands resulting from sharp bends LAGGING External wood covering on a reel of rope or a strand LANG LAY ROPE Wire rope in which the wires in the strands and the strands in the rope are laid in the same direction LAY LENGTH The lengthwise distance on a wire rope in which a strand makes one complete turn around the rope s axis see Figure 1 2 One rope lay nae Figure 1 2 Rope Lay Left Lay e Strand Strand in which the cover wires are laid in a helix having a left hand pitch similar to a left hand screw e Rope Rope in which the strands are laid in a he
354. n performing the procedure Revisions of procedures shall receive the same depth of review and level of approval as the initial versions received All procedures either new or revised shall be approved before use Chapter 3 Preengineered Production Lifts periodic intervals to ensure that their information and instructions are technically accurate and that appropriate human factor considerations have been included The frequency of reviews should be specified for each procedure it may vary with the type and complexity of the activity involved Applicable procedures should be reviewed after an incident During each review procedures should be compared to source documents to verify their accuracy 3 8 6 USE A copy of the current issue of the approved procedure shall be in the work area when the operation is performed Deviations from the approved procedure are not allowed during normal operations The requirements for use of procedures should be clearly defined and understood by all personnel If a procedure is determined to be deficient a procedure change shall be initiated before operations continue Personnel performing the procedure may take whatever action is necessary during emergency conditions to return the process to a safe and stable condition without first initiating a procedure change DOE STD 1090 2007 3 4 DESIGNATED LEADER Each time a preengineered production lift requiring more than one
355. n to the Table on Contents and on Figures 11 10 15 and Tables 11 10 11 14 15 16 Chapter 12 Provide ASME attribution at introduction to the Table on Contents and on Figures 12 2 3 4 5 6 7 8 10 12 13 Chapter 13 Provide ASME attribution at introduction to the Table on Contents and on Table 13 1 Chapter 14 Provide ASME attribution at introduction to the Table on Contents and on Figures 14 1 2 3 5 6 7 8 Chapter 16 Provide ASME attribution at introduction to the Table on Contents and on Figure 16 1 CONTENTS HISTORY AND BACKGROUND ACKNOWLEDGMENT INTRODUCTION CHAPTER 1 TERMINOLOGY AND DEFINITIONS 1 1 CHAPTER 2 CRITICAL LIE ES osorno 2 1 2 1 CRITICAL LIFT DETERMINATION tm 2 1 22 CRITIAL LIFT REQUIREMENTS eerte 2 2 CHAPTER 3 PREENGINEERED PRODUCTION LIFTS 3 1 31 PRENGINEERED PRODUCTION LIFT DETERMINATION 3 1 32 LIETING FIXTURES onore ee eae 3 2 SL DEM il A AAA 3 2 2 9 2 SS Pee Ede 3 2 33 3 Inspection and Testing suo tr 3 2 3 3 4 Storage Maintenance and Control 3 2 3 3 5 Modification and Repair cod ha te ud er e eet 3 3 33 PROCEDURES umi re HA NER dia 3 4 FJA l det as a Beat tae E ener Sia a ce eee 3 4 DAD Developed 3 4 3 4 3 Preparation and Revision i serie oer met Pene aea exe be ird 3 4 AA oU TU a 3 5 34 5 REVIEW eS 3 5 DAG Us ui
356. n two or more legs running on fixed rails or other runway Jib Crane A fixed crane with a vertical rotating member supported at the bottom also at the top in some types from which an arm extends to carry the hoist trolley Jib cranes are most commonly mounted on a vertical column supplied as part of the jib crane or on existing structural members e g a wall mounted jib crane Mobile Crane For the purposes of this chapter mobile cranes are defined as wheel mounted cranes truck cranes and crawler cranes A wheel mounted crane consists of a rotating structure with power plant operating machinery and boom mounted on a base or platform equipped with axles and rubber tired wheels for travel The base is usually propelled by an engine in the superstructure but it may be equipped with a separate engine controlled from the superstructure Chapter 1 Terminology and Definitions DOE STD 1090 2007 A truck mounted crane consists of a rotating superstructure with power plant that operates machinery and boom mounted on an automotive truck equipped with a power plant for travel Commercial truck mounted cranes are included in this category A crawler crane consists of a rotating superstructure with power plant operating machinery and boom mounted on a base equipped with crawler treads for travel Overhead Traveling Crane A crane with a movable bridge carrying a movable or fixed hoisting mechanism and traveling on
357. nce of preengineered production lifts This lift designation may be used at the discretion of the contractor for selected operations 3 1 PREENGINEERED PRODUCTION LIFT DETERMINATION 3 2 TTR TING FIXTURES 2320 See eiie medinm cond etatis 3 24 WDCSI BN aie ee epe edere eue E 35 2 2 ab ieren deed re RE HIP ocn b E I DI ER sats 3 2 3 gt A A nep e Uc E 3 2 4 Storage Maintenance and Control 3 2 3 Modification and Repair eee eee ott i Reed oi 3 3 PROCEDURES bec EO dob a edet eiie E WEE A TP T o DIR CORNERS 3 3 2 Developiment ecce RR e TROU o eg 3 3 3 Preparation and Revision ee ee e pese RORA 3 3 4 JApptovalucceceneacen RE RERO e TR DU e ON E ERES SR MEEWAu p S310 Ud A et 3 4 DESIGNATED LEADER cui liada 3 5 TRAINING de dS 3 6 1 Equipment Operation a O Procedure aan RON 3 1 Chapter 3 Preengineered Production Lifts DOE STD 1090 2007 INTENTIONALLY BLANK Chapter 3 3 ii Preengineered Production Lifts DOE STD 1090 2007 3 1 PREENGINEERED PRODUCTION LIFT DETERMINATION a An appointed person shall classify each lift into one of the DOE categories ordinary critical or preengineered production lift prior to planning the lift b A lift may be determined to be a preengineered production lift if all of the following criteria are met 1 The group of items to be lifted is identical in terms of dimensions weight center of gravity load path method of attachment to
358. ncies revealed by inspection or by the proof test be corrected and another proof test conducted 3 Any modification to the personnel lift platform or rigging requires retesting 4 Test reports kept on file and readily available to appointed personnel 5 A meeting with the qualified operator signaler persons to be lifted and the person responsible for overall worksite safety to plan is held prior to the trial lift to review the procedure 6 The procedures for entering and leaving the personnel platform and the points at which persons will enter and leave the device be reviewed This meeting shall be held at each new work location and shall be repeated for any employees newly assigned to the operation Chapter 4 Lifting Personnel 4 1 3 DOE STD 1090 2007 The designated leader and the crane operator shall determine that 1 The crane is uniformly level within 1 percent of level grade and firm footing exist under both crawler tracks or under each outrigger float Cribbing mats under tracks or blocks under outrigger floats are used as necessary to provide a firm and substantial footing 2 Cranes equipped with outriggers have outriggers extended in accordance with the manufacturer s instructions 3 Crane systems controls operator aids and safety devices are activated and functioning properly 4 No interferences exist 5 The total weight of the loaded personnel lift platform including personnel a
359. nctional test of the crane under a normal operating load should be made prior to putting it back in service Test weights shall not exceed 110 percent of the rated capacity and shall be accurate to within 5 percent 0 percent of stipulated values NOTE Load tests shall not be conducted in locations where the lift meets the definition of a critical lift see Chapter 1 Terminology and Definitions C A written report shall be furnished by the inspector showing test procedures and confirming the adequacy of repairs or alterations Test reports shall be kept on file and shall be readily available to appointed personnel Chapter 9 Mobile Cranes DOE STD 1090 2007 9 4 MAINTENANCE 9 4 1 PREVENTIVE MAINTENANCE A preventive maintenance program shall be established and based on the recommendation of the crane manufacturer If equipment maintenance procedures deviate from published manufacturer s recommendations the alternate procedures shall be approved in advance by the manufacturer or another qualified person and be kept readily available Dated maintenance records should be kept where readily available to appointed personnel Replacement parts shall be at least equal to the original manufacturer s specifications All moving parts of the crane for which lubrication is specified shall be regularly lubricated Lubricating systems should be checked for proper delivery of lubricant Operators and maintenance person
360. nd related rigging does not exceed 50 percent of the crane rating under the planned conditions of use 6 The personnel lift platform is not loaded in excess of its rated load capacity 7 The number of employees occupying the platform does not exceed the number required for the work being performed TRIAL LIFT Each shift before personnel initially enter the personnel lift platform the operator and signaler shall conduct a trial lift The trial lift shall include 1 Loading the unoccupied personnel platform to at least the maximum anticipated load Materials and tools to be used during the actual lift if secured to prevent displacement can be in the platform for the trial lift 2 Making the trial lift from the location where personnel will enter the platform to each location where the platform will be hoisted and positioned It is acceptable to perform a single trial lift on each shift for all locations to be reached from a single setup position Chapter 4 Lifting Personnel b The trial lift shall be repeated whenever 1 The crane mobile is moved and set up in a new location or returned to a previously used location 2 When the lift route is changed unless the operator determines that the safety of the hoisted personnel is not affected 3 Ifa different crane operator is assigned 4 1 4 LIFTING OPERATIONS 4 1 4 1 Pre Lift Meeting a A meeting attended by the operator the ground crew signale
361. ne is on the load hook except as noted in Chapter 4 Lifting Personnel Test the brakes each time a load approaching the rated capacity is handled by raising the load a few inches and applying the brakes Do not lower the load below the point where less than two full wraps of rope remain on the hoist drum Do not leave your position at the controls while the load is suspended unless required to do so by an approved emergency procedure If the load must remain suspended for any considerable length of time the operator shall hold the drum from rotating in the lowering direction by activating the positive controllable means of the operator s station 9 29 k Work on suspended loads is prohibited under normal conditions When the responsible manager decides that it is necessary to work on a suspended load guidelines for ensuring safety of the work shall be established through consultation with the appropriate safety organization Suspended loads that must be worked on shall be secured against unwanted movement L Tag lines should be used as required to guide snub or otherwise control the load 9 5 11 ORDINARY LIFTS a The requirements of all preceding paragraphs in Section 9 5 Operation also shall apply to ordinary lifts b An appointed person shall classify each lift into one of the DOE categories ordinary critical or preengineered production before the lift is planned c Hoisting and riggin
362. nel shall follow the manufacturer s recommendations as to the points and frequency of lubrication maintenance of lubricant levels and types of lubricant to be used 9 4 2 MAINTENANCE PROCEDURES Before starting adjustments or repairs on a crane maintenance personnel shall take the following precautions as applicable 1 Place the crane where it will cause the least interference with other equipment or operations in the area 2 Lower the lower load block to the ground or otherwise secure it against dropping 3 Lower the boom to the ground if possible or otherwise secure it against dropping 4 Place all controls in the OFF position and secure all operating features from inadvertent motion by brakes pawls or other means 5 Ensure starting means are rendered inoperative 9 13 6 Stop the power plant or disconnect it at the power takeoff 7 Relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components b Warning or out of order signs shall be placed on the crane controls Signs or flags shall be removed only by authorized personnel c After adjustments and repairs have been made the crane shall not be returned to service until all guards have been reinstalled trapped air has been removed from the hydraulic system safety devices are reactivated and maintenance equipment is removed d Forlocomotive cranes 1 Employ blue flag protection on each si
363. nergized place stops or signalers full time at a visual vantage point to observe the approach of active cranes and prohibit contact by the active cranes with the idle crane with persons performing maintenance or with the maintenance equipment 7 Install a guard or barrier between adjacent runways for the length of the established work area to prevent contact between persons performing maintenance and any crane on the adjacent runway 7 4 2 WIRE ROPE MAINTENANCE Personnel using wire rope shall ensure proper care by doing the following a Store rope to prevent damage or deterioration b Unreelor uncoil rope as recommended by the rope manufacturer and with care to avoid kinking or inducing a twist c Before cutting rope use some method to prevent unlaying the strands Heat affected zones of flame cut wire rope shall not be allowed to bear load d During installation avoid dragging the rope in dirt or around objects that will scrape nick crush or induce sharp bends in it e Maintain rope in a well lubricated condition to reduce internal friction and prevent corrosion Ensure that lubricant applied as part of a maintenance program is compatible with the original lubricant and is also a type that does not hinder visual inspection Those sections of rope located over sheaves or otherwise hidden during inspection and maintenance procedures require special attention when the rope is being lubricated 7 5 1 DOE S
364. nes or load 4 Non conductive barricades to restrict access to the crane work area Load control when required shall utilize tag lines of a non conductive type A designated signaler whose sole responsibility is to verify that the clearances established are maintained shall be in constant contact with the crane operator The person responsible for the operation shall alert and warn the crane operator and all persons working around or near the crane about hazard of electrocution or serious injury and instruct them on how to avoid the hazard All non essential personnel shall be removed from the crane work area No one shall be permitted to touch the crane or the load unless the signaler indicates it is safe to do so 9 22 9 5 2 4 Crane in Transit With No Load and Boom Lowered see Figure 9 4 a Cranes in transit with no load and boom lowered shall maintain clearance as specified in Table 9 3 b A designated signaler shall be assigned to observe the clearance and give warning before the crane approaches the above limits c When planning transit of the crane the effect of speed and terrain on the boom and crane movement shall be considered 9 5 2 5 Crane Operation Near Transmitter Towers see Figure 9 5 a Prior to work near transmitter towers where an electrical charge can be induced in the equipment or materials being handled the transmitter shall be deenergized or tests shall be made to determine
365. ng and independent review and approval of the entire process LIFTING SERVICE Whenever equipment governed by this standard is used to perform lifts LINE A rope used for supporting and controlling a suspended load LOAD The total weight superimposed on the load block or hook LOAD BLOCK The assembly of hook or shackle swivel bearing sheaves pins and frame suspended by the hoisting ropes LOAD BACKREST EXTENSION A device extending vertically from the fork carriage frame LOAD BEARING PARTS Any part of a material handling device in which the induced stress is influenced by the hook load A primary load bearing part is a part the failure of which could result in dropping upset or uncontrolled 1 7 motion of the load Load bearing parts which if failed would result in no more than stoppage of the equipment without causing dropping upset or loss of control of the load are not considered to be primary load bearing parts LOAD CENTER FORKLIFTS The horizontal longitudinal distance from the intersection of the horizontal load carrying surfaces and vertical load engaging faces of the forks or equivalent load positioning structure to the center of gravity of the load LOW LIFT TRUCK A self loading truck equipped with an elevating mechanism designed to raise the load only sufficiently to permit horizontal movement see Figure 10 3 MAGNET An electromagnetic device carried on a crane hook and used to pick
366. ng and rigging principles and good and bad rigging practices This is not a rigging textbook the information should be applied only by qualified riggers All manufacturer provided lift points designed for and installed on engineered or manufactured equipment are considered part of the equipment and are acceptable for their intended use Manufacturer supplied lift points shall 1 Meet manufacturer s pre operational inspection testing and maintenance criteria 2 Be inspected by a designated person prior to use 3 Be used in accordance with manufacturer s instructions In the absence of such information further qualified technical support may be needed Rigging accessories that have been damaged or removed from service shall be made unusable for hoisting and rigging operations before being discarded Determine the weight of the load 1 From markings on the load 2 By weighing if the load is still on the truck or railroad car From drawings or other documentation 4 By calculation using the load dimensions and the weights of common materials in Table 12 1 Determine the center of gravity of the load as accurately as possible 1 From drawings or other documentation 2 From markings on the load 3 By calculation Determine the best method to attach the load and 12 1 select the lifting devices e g eyebolts or shackles g Evaluate load stability i e evaluate load center of gravity with res
367. ng evaluated The actual or simulated operation shall enable trainees to demonstrate basic knowledge and skills at a level that ensures the safety of personnel and equipment 6 2 3 OPERATORS OF MOBILE CRANES Operators and operator trainees shall meet the following physical qualifications 1 Have vision of at least 20 30 Snellen in one eye and 20 50 in the other with or without corrective lenses 10 DOE STD 1090 2007 Be able to distinguish colors regardless of position if color differentiation is required for operation Have adequate hearing with or without a hearing aid for a specific operation Have physical strength coordination and sufficient reaction speed to meet the demands of equipment operation Show no evidence of physical defects or of emotional instability that could be a hazard to themselves or others or which in the opinion of the examiner could interfere with their safe performance such evidence may be sufficient cause for disqualification In these cases medical judgments and tests may be required Show no evidence of being subject to seizures or to loss of physical control such evidence shall be sufficient reason for disqualification Medical examinations may be required to determine these conditions Have normal depth perception field of vision manual dexterity coordination and no tendencies to dizziness or similar potentially hazardous characteristics Have no detectable
368. ng and rigging operations at their facilities Acknowledgment The Department of Energy DOE acknowledges the many organizations whose documents provided important source material for the standard They include American Society of Mechanical Engineers ASME B30 2 Overhead and Gantry Cranes Top Running Bridge Multiple Girder ASME B30 5 Crawler Locomotive and Truck Cranes ASME B30 9 Slings ASME B30 10 Hooks ASME B30 16 Overhead Hoists Underhung ASME B30 17 Overhead and Gantry Cranes Top Running Bridge Single Girder Underhung Hoist ASME B30 20 Below the Hook Lifting Devices ASME B30 21 Manually Lever Operated Hoist ASME B30 22 Articulating Boom Cranes ASME B30 23 Personnel Lifting Systems ASME B30 26 Rigging Hardware ANSI ITSDF B56 1 Low Lift and High Lift Trucks ANSI ITSDF B56 6 Rough Terrain Forklift Trucks ASME PALD Portable Automotive Lifting Devices Construction Safety Association CSA of Ontario The Rigging Handbook Society of Automotive Engineers Inc SAE SAE J1028 Mobile Crane Working Area Definitions Permission to reprint specific figures and illustrations was obtained from CSA and SAE Applicable sections of 29 CFR 1910 Occupational Safety and Health Standards for General Industry and 29 CFR 1926 Occupational Safety and Health Regulations for Construction have been paraphrased or reproduced verbatim throu
369. ng in the load block under T 4 Have identifications for controls to normal operating conditions indicate function or direction of motion 2 4 LOAD CONTROLLING MECHANISM 5 Bbe marked with identification as follows a Shall be equipped with a load controlling i Name of manufacturer ii Manufacturer s model or serial number 6 Have affixed to the hoist or load block in a readable position a label or labels displaying precautionary information concerning operating procedures Load sprockets shall have pockets or teeth to allow engagement of the load chain shall be guarded and provisions shall be made to guard against jamming of the load chain with the host mechanism under normal operating conditions 2 2 LOAD CHAIN a Load chain may be either roller or welded link type and shall be pitched so as to pass over all sprockets without binding A 3 mechanism which shall perform the following functions under normal operating conditions with test loads up to 125 percent of the rated load 1 Stop and hold the load when the lever force is removed and the lever stroke completed 2 Provide for incidental movement of the load when lifting or lowering 3 Friction brake shall have provision for adjustment where necessary to compensate for wear Manufacturer shall supply instruction manual for each hoist the manual shall include the following information and instructions 1 Operation 2 Inspection and
370. ng shall apply to all personnel j involved in forklift operations At the initial stage of the planning process an appointed person shall classify each lift into one of the DOE specified categories ordinary critical or preengineered production 10 5 1 CONDUCT OF OPERATOR The following requirements shall be observed by the operator when operating forklift trucks 10 5 1 1 General a Safe operation is the responsibility of the operator Report all accidents and near misses promptly b The operator shall develop safe working habits and also be aware of hazardous conditions in order to protect himself other k personnel the truck and other material c The operator shall be familiar with the operation and function of all controls and l instruments before operating the truck d Before operating any truck the operator m shall be familiar with unusual operating conditions which may require additional safety precautions or special operating instructions e Be certain the truck has successfully passed n a preuse inspection f Do not start or operate the truck any of its functions or attachments from any place other than from the designated operator s position g Keep hands and feet inside the operator s designated area or compartment Do not put any part of the body outside the operator compartment of the truck h Never put any part of the body within the reach mechanism of the truck or other at
371. ns 1 4 Wall Mounted Jib Crane See Cranes Types Of Jib Crane CRITICAL DIAMETER Diameter of the smallest bend for a given wire rope that permits the wires and strands to adjust themselves by relative movement while remaining in their normal positions CYLINDRICAL DRUM Hoisting drum of uniform diameter DECELERATION STRESS Additional stress imposed on a wire rope due to decreasing the load velocity DEFLECTION e Sag of a rope in a span usually measured at midspan as the depth from a chord joining the tops of the two supports Any deviation from a straight line DESIGN FACTOR Ratio of ultimate strength to the design working stress DESIGNATED Selected or assigned by the employer or the employer s representative as being qualified to perform specific duties DESIGNATED LEADER An individual assigned responsibility for safe handling of ordinary lifts The designated leader shall be present at the lift site during the entire lifting operation If the lift is being made by only one person that person assumes all responsibilities of the designated leader DIAMETER Distance measured across the center of a circle circumscribing the wires of a strand or the strands of a wire rope DIESEL ELECTRIC TRUCK An electric truck in which the power source is a generator driven by a diesel engine DOCKBOARD A portable or fixed device for spanning the gap or compensating for the difference in level between loading
372. ns if an accident or injury occurs f The operator or a designated person shall ensure that the crane is still within the inspection interval g The operator or a designated person shall visually examine the crane in accordance with Section 7 2 4 7 5 9 PLANNED ENGINEERED LIFTS Lifts in excess of the rated load may be required from time to time on a limited basis for specific purposes such as new construction or major repairs Every planned engineered lift exceeding the rated load shall be treated as a special and separate event Limitations and planned requirements shall be applicable as follows DOE STD 1090 2007 Planned engineered lifts shall be limited to powered cranes having a load rating of 5 tons and above When planned engineered lifts are made the load shall not exceed 125 of the crane load rating except as provided in para 7 5 9 d Planned engineered lifts shall be limited to two occurrences on any crane within any continuous 12 month period except as provided in para 7 5 9 d If greater lift frequency is desired consideration shall be given to rerating or replacing the crane The crane manufacturer shall be consulted if the planned engineered lift exceeds 125 of rated load or if the frequency of planned engineered lifts exceeds two during a continuous 12 month period Each planned engineered lift shall comply with the following requirements 1 A written review of the crane service histor
373. ntly deform before losing the ability to support the load at the temperatures at which the manufacturer has specified for use They are strong closed attachments that will not come unhooked The size is specified by the diameter of the body Side pulls on the shackle body are only permitted if the manufacturer has rated the shackle for that type of lift NOTE Round pin shackles restrained by cotter pin only shall not be used for lifting Types 1 Body types covered are anchor chain and synthetic sling see Fig 12 2 2 Pin types covered are screw pin and bolt type see Fig 12 2 3 Shackles other than those detailed in this chapter shall be used only in accordance with recommendations of the shackle manufacturer or a qualified person Shackle pins shall fit free without binding A bolt shall not be used as a substitute for a shackle pin Figure 12 3 shows the components and typical inspection points of shackles Each shackle body shall be permanently and legible marked by the manufacturer Raised or stamped letters on the side of the bow shall be used to show 1 Manufacturer s name and trademark 2 Size 3 Rated capacity Pins for shackles manufactured after May 20 2006 shall be marked by the manufacturer with raised or stamped letters showing 1 Name or trademark of manufacturer 2 Grade material type or load rating When shackles are side loaded the safe loading shall be reduced as specified by
374. ocumented training or technical experience in the hoisting and rigging discipline Instructors should attend recognized training courses workshops or seminars in order to remain current on industry practices and changes in applicable codes and standards 6 3 9 MAINTENANCE PERSONNEL Employees who operate cranes to perform crane maintenance shall be trained and qualified to operate the cranes on which maintenance is being performed Chapter 6 Personnel Qualification and Training DOE STD 1090 2007 6 4 REQUALIFICATION a Operator rigger and inspector qualification 1 Completion of a written or oral is for a period not to exceed 3 years unless evaluation relevant to the type of the qualification is revoked sooner by the equipment used or participation in a employee s manager refresher training program b The program for requalification shall 2 A performance evaluation include Chapter 6 6 12 Personnel Qualification and Training DOE STD 1090 2007 6 5 RECORDS A record of training and skill evaluations shall be kept on file and shall be readily available 6 13 Chapter 6 Personnel Qualification and Training DOE STD 1090 2007 CHAPTER 7 OVERHEAD AND GANTRY CRANES This chapter specifies operation inspection maintenance and testing requirements for the use of overhead and gantry cranes and implements the requirements of ASME B30 2 Overhead and Gantry Cranes Top Running Bridge Single or Multiple Girder
375. of distance and multiple contact points as viewed from the position of the operator and or position of the designated signaler The operator should avoid operating the crane with or without a load in this area The horizontal and vertical distance of movement of long span lines due to the wind shall be added to the minimum clearance Chapter 9 Mobile Cranes DOE STD 1090 2007 distance as specified in Table 9 3 A h Devices such as ribbons balls etc should qualified representative of the owner of the be attached by a qualified person to the lines or a designated representative of the power lines to improve visibility or electrical utility shall be consulted for equivalent means employed to aid in specific distances location of the prohibited zone Table 9 3 Safe working distance from power lines a When operating near high voltage power lines Normal voltage Minimum required phase to phase clearance Up to 50 kV 10 ft 3 1 m Over 50 to 200kV 15 ft 4 6 m Over 200 to 350kV 20 ft 6 1 m Over 350 to S00kV 25 ft 7 6 m Over 500 to 750kV 35 ft 10 7 m Over 750 to 1000 kV 45 ft 13 7m b While in transit with no load and boom or mast lowered Normal voltage Minimum required phase to phase clearance Up to 0 75 kV 4 ft 1 2 m Over 0 75 to 50 kV 6 ft 1 8 m Over 50 to 345 kV 10 ft 3 1 m Over 345 to 750 kV 16 ft 4 9 m Over 750 to 1000 kV 20 ft 6 1 m 9 20 Chapter
376. of load shall be equal to the rated capacity but shall not exceed i The wire rope or fitting manufacturers recommendations but in no case greater than 50 percent of the component wire rope s or structural strands nominal strength for all swaged socket and poured socket sling assemblies ii 125 percent of the vertical rated capacity of single leg hand tucked slings iii 200 percent of the vertical rated capacity for mechanical spliced single let slings and endless slings iv The proof load for multiple leg bridle slings assemblies shall be applied to the individual leg and shall be in accordance with paragraph I ii and iii as applicable v Master links to which multiple leg slings are connected shall be proof loaded to 200 percent times the force applied by the combined legs vi Test weights shall be accurate to within 5 percent 0 percent of stipulated values 3 Wire rope sling eyes with thimbles shall be made with a thimble having a ratio of thimble diameter D to rope diameter Chapter 11 General 11 24 d of 3 or more D d greater than or equal 3 Do not use wedge sockets or wire rope clips on slings used for critical lifts Ensure that working loads of wire rope slings do not exceed their rated capacities Do not splice slings together Use thimble eyes for slings to be joined end to end Locate sling eyes so that i Adequate clearance is maintained between the att
377. of the crane shall be retained throughout its service life Chapter 7 Overhead and Gantry Cranes DOE STD 1090 2007 7 2 INSPECTIONS 7 2 41 GENERAL There shall be no apparent damage excessive wear or deformation of any load bearing part of the equipment Brakes shall work satisfactorily and load brakes shall be designed to hold any load up to at least 125 percent of the rated capacity of the equipment without slipping or overheating All safety devices load indicators controls and other operating parts of the equipment shall be checked during each inspection and shall be in good working order Parts found to be defective during any inspection or nondestructive examination shall be replaced or repaired as directed by the responsible line manager or that person s designated representative 7 2 2 CRANE SERVICE Crane service is defined as follows a Normal service operating at less than 85 percent of rated load and not more than 10 lift cycles hr except for isolated instances b Heavy service operating at 85 to 100 percent of rated load or in excess of 10 lift cycles hr as a regular specified procedure C Severe service operating at normal or heavy service under abnormal operating conditions i e extreme temperatures corrosive atmospheres 7 2 3 INITIAL INSPECTION Prior to their initial use all new reinstalled modified or repaired cranes shall be inspected by a qualified inspector to ensure
378. of the responsible manager QUALIFIED INSPECTOR One whose competence is recognized by the responsible manager and whose qualification to perform specific inspection activities has been determined verified and attested to in writing QUALIFIED OPERATOR One who has had appropriate and approved training including satisfactory completion of both written and operational tests to demonstrate knowledge competence and skill in the safe operation of the equipment to be used DOE STD 1090 2007 QUALIFIED RIGGER One whose competence in this skill has been demonstrated by experience satisfactory to the appointed person NOTE The term rigger or qualified rigger in this standard refers to the function performed and in no way relates to the worker s classification in any union or bargaining unit RATED CAPACITY The maximum hook load that a piece of hoisting equipment is designed to carry also the maximum load that an industrial truck or a sling hook shackle or other rigging tackle is designed to carry NOTE At the option of the user a rated capacity can be assigned that is less than the design rated capacity REACH TRUCK A self loading truck generally high lift having load engaging means mounted so it can be extended forward under control to permit a load to be picked up and deposited in the extended position and transported in the retracted position see Figure 10 3 REEL The flanged spool on whic
379. om any cause 8 Reduction from nominal diameter greater than the amounts listed in Table 9 2 All rope that has been idle for a month or more due to shutdown or storage of a crane on which it is installed shall be inspected before it is placed in service This inspection shall be for all types of deterioration and shall be performed by an appointed person whose approval shall be required before further use of the rope A written and dated report of the rope condition shall be filed In order to establish data as a basis for judging the proper time for replacement a continuing inspection record shall be maintained Replacement rope shall be the same size grade and construction as recommended by the crane manufacturer unless otherwise recommended by a rope or crane manufacturer due to actual working condition requirements Never use discarded wire rope for slings 9 11 9 2 7 LOAD HOOKS LOAD BLOCKS Load hooks load blocks that have been changed out shall be inspected by a qualified inspector before returning the crane to service Inspection records shall be retained throughout the service life of the hook or load block and shall be readily available 9 2 8 CRANES NOT IN REGULAR USE a Acrane that has been idle for 1 month or more but less than 6 months shall be given an inspection according to the requirements of Section 9 2 5 before being placed in service b Acrane that has been idle for more than 6 months sha
380. ome egre det 6 5 TRAINING res be ae a e ds et AS UA 6 7 6 321 General ii e SUP eiecti gen s 6 7 6 3 2 Operators of Cab Operated Pulpit Operated and Floor Operated Cranes 6 7 6 3 3 Mobile Crane Operators x eee eese Uere ce metet Rege P RO s 6 8 6 3 4 Operators of Truck Mounted Cranes Capacity 1 Ton or Less sses 6 8 6 3 3 oke Truck Operators i ente eese mee eee RES 6 8 6 3 6 URIS GELS ca su eed eee P eee hee ER ert eee ERE 6 10 6 3 7 Inspectors te neq Qn PI E C Oe Cu eed es 6 10 6 3 8 A bn OE PERDU DH TR dede 6 11 6 3 9 Maintenance Personnel one pog e c qu tp D dete e 6 11 REQUALIEICATION nre t UR PO HD REOR OUS 6 12 RECORDS anr aa a r a E tee pou ei e Ho esed OR 6 13 6 i Chapter 6 Personnel Qualification and Training DOE STD 1090 2007 INTENTIONALLY BLANK Chapter 6 6 ii Personnel Qualification and Training DOE STD 1090 2007 6 1 GENERAL This chapter delineates the requirements for the qualification and training of operators riggers inspectors maintenance personnel trainers person in charge PIC designated leaders and first line supervisors Personnel who are designated to operate equipment or perform work covered by this standard shall be qualified and trained to the level of proficiency consistent with assigned tasks Chapter 6 Personnel Qualification and Training 6 2 1 DOE STD 1090 2007 GENERAL Only qualified personnel or
381. on After proof testing wire rope clips on a finished assembly shall be re tightened to the torque recommended by the wire rope clip manufacturer or a qualified person The compression hardware shall then be inspected in accordance with Section 12 11 6 Wire rope clips shall have the manufacturer s name or trademark and the saddle size either forged or die stamped into the saddle Wedge sockets shall have the manufacturer s name or trademark the size and model if required to match the wedge to the body either forged cast or die stamped into the wedge and socket body Compression hardware should not be in contact with the load or any obstruction during the lift 12 27 i Rigging using compression hardware should not be dragged on an abrasive surface or in contact with sharp edges j Wedge sockets should not be side loaded k Impacts can dislodge the wedge from the body and should be avoided 12 11 2 ASSEMBLY WIRE ROPE CLIPS a Before installing a wire rope clip on plastic coated or plastic impregnated wire rope consult the wire rope clip manufacturer wire rope manufacturer or a qualified person b For U bolt clips used to create end terminations the saddle shall be placed on the live end of the wire rope with the U bolt on the dead end side see Fig 12 12 c The minimum number of clips spacing turn back and torque values shall be as recommended by the manufacturer or a qualified person d A
382. on of latch if provided 5 Evidence of heat damage A designated person shall examine deficiencies and determine whether they constitute a safety hazard and whether a more detailed inspection is required 12 2 5 3 Frequent Inspection a The operator or other designated personnel shall visually inspect the hook at the following intervals records are not required 1 Normal service monthly 2 Heavy service weekly to monthly 3 Severe service daily to weekly Hook service is defined as follows 1 Normal service operation at less than 85 percent of rated capacity except for isolated instances 2 Heavy service operation at 85 to 100 percent of rated capacity as a regular specified procedure 3 Severe service operation at heavy service coupled with abnormal operating conditions These inspections shall in addition to the requirements of Section 12 2 5 2 Daily Inspection include the following 1 Wear 2 Hook attachment and securing means A designated person shall examine deficiencies and determine whether a more detailed inspection is required Chapter 12 Rigging Hardware DOE STD 1090 2007 12 2 5 4 Periodic Inspection a A designated inspector shall perform a complete inspection at the following intervals 1 Normal service yearly 2 Heavy service semiannually 3 Severe service quarterly A designated inspector shall examine deficiencies and d
383. on shall include those items specified in Section 14 5 4 2 Frequent Inspection in addition to the following 1 Deformation wear and corrosion of all members fasteners and lifting parts 2 Check for suspect counterfeit parts see Terminology and Definitions Chapter 1 3 Proper operation and condition of electrical components 4 Magnetic coil tested for ohmic ground readings and compared to manufacturer s standards d Dated inspection reports shall be prepared for each inspection Inspection records shall be kept on file and shall be readily available 14 5 5 TESTING 14 5 5 1 Operational Test a All new modified or repaired lifting magnets shall be tested prior to initial use Tests shall be performed by a qualified inspector or under the direction of that inspector Dated reports shall be kept on file Testing shall include the following 1 A check for proper operation of all electrical equipment 2 A visual inspection of the lifting magnet for visible defects 14 23 14 5 6 14 5 7 MAINTENANCE A preventive maintenance program shall be established and be based on the recommendations of the manufacturer or a qualified person Replacement parts shall be equivalent to original specifications Before maintenance is started on a lifting magnet or controls maintenance personnel shall take the following precautions Ensure that all sources of magnet power are disconnected and locked out
384. onditions indicate that disassembly should be done to permit detailed 14 3 4 1 Initial Inspection inspection Prior to their initial use a qualified inspector 3 Severe service quarterly Inspect shall inspect all new or repaired vacuum lifting equipment at site of use unless external devices to ensure their compliance with Section conditions indicate that disassembly 14 3 4 3 Periodic Inspection should be done to permit detailed inspection 14 3 4 2 Frequent Inspection 4 Special or infrequent service as a The operator or other designated person recommended by a qualified person shall inspect each vacuum lifting device at before the first use and as directed by the beginning of each shift or prior to use if the qualified person for any subsequent it has not been in regular service Occurrences b The inspection shall be for the following b Lifting device service is defined as follows records are not required 1 Normal operation with various 1 Deformation cracks and excessive weights within the rated load limit or wear of load bearing parts uniform loads less than 65 percent of rated load 2 Adequate vacuum generator output 2 Heavy operation within the rated load 3 Cuts tears excessive wear and foreign limit that exceeds normal service particles at vacuum pad seal rings 3 Severe operation under normal or 4 Leakage cuts kinks and collapsed heavy service with abnormal operating areas o
385. onfigurations the crane may be equipped to handle for the type crane for which qualification is being sought The operator shall complete a practical operating skill evaluation test actual or simulated demonstrating proficiency and basic knowledge in handling the specific type crane for which the operator is being evaluated including Pre start and post start inspection 2 Maneuvering skills 3 Shutdown 4 Securing the crane 5 Ability to use and respond to signals as found in Figure 9 6 Chapter 6 Personnel Qualification and Training DOE STD 1090 2007 f Qualification shall be limited to the type of equipment for which the operator is being evaluated g Trainee qualification requirements shall include but are not limited to the following 1 Satisfactory completing of a written examination covering safety operational characteristics and limitations and controls of the type crane for which they are being qualified 2 Demonstrate their ability to read write comprehend and exhibit arithmetic skills and load capacity chart usage in the language of the crane manufacturer s operations and maintenance instruction materials 3 Satisfactory completion of a combination written and verbal test on load capacity chart usage covering various crane configurations 6 2 4 OPERATORS OF TRUCK MOUNTED CRANES CAPACITY 1 TON OR LESS a Physical qualifications shall be based on specific job requirements
386. onnel Lift Platform Pre Lift Inspectpon cono ene 4 15 Exhibit II Personnel Lifting Planning and Authorization Form 4 16 4 i Chapter 4 Lifting Personnel DOE STD 1090 2007 INTENTIONALLY BLANK Chapter 4 4 ii Lifting Personnel DOE STD 1090 2007 4 1 GENERAL This chapter specifies the operation design testing and inspection requirements for the use of personnel lift platforms or baskets suspended from mobile or overhead cranes This chapter implements the requirements of 29 CFR 1926 550 g Cranes and Derricks and ASME B30 23 Personnel Lifting Systems 4 1 1 PERSONNEL LIFTING EVALUATION a The use of a crane to hoist employees on a personnel lift platform is prohibited except when the erection use and dismantling of conventional means of reaching the worksite such as a personnel hoist ladder stairway aerial lift elevating work platform or scaffold would be more hazardous or is not possible because of structural design or worksite conditions b The manager specifically responsible for the overall work function to be performed shall determine that the erection use and dismantling of conventional means of reaching the work site i e scaffold ladder stairway aerial lift or elevating work platform would be more hazardous or is not possible because of structural design or worksite conditions c For each personnel lifting procedure the manager responsible for the task shall authorize the us
387. ons performed when required by the inspector 11 Electrical apparatus for signs of pitting or any deterioration of controller contactors limit switches and push button switches 12 Supporting structures and trolleys if used for continued ability to support the imposed loads 13 Warning labels for illegibility or absence 8 2 5 2 Wire Rope a A qualified inspector shall inspect running rope at least annually This inspection shall include examination of the entire length of rope without detaching it from the hoist drum More frequent intervals shall be determined by a qualified person and shall be based on such factors as expected rope life as determined by experience on the particular installation or similar installations severity of environment percentage of capacity lifts frequency rates of operation and exposure to shock loads The qualified inspector shall carefully note any deterioration such as described below resulting in appreciable loss of original strength and determine whether further use of the rope constitutes an acceptable risk Chapter 8 Hoists 7 DOE STD 1090 2007 1 Reduction of rope size below nominal diameter whether due to loss of core support internal or external corrosion or wear of outside wires see Table 8 1 2 A number of broken outside wires and the distribution or concentration of such broken wires 3 Worn outside wires 4 Sections of rope that are nor
388. operation 5 Show no evidence of physical defects or of emotional instability that could be a hazard to themselves or others or Chapter 6 Personnel Qualification and Training which in the opinion of the examiner could interfere with their safe performance such evidence may be sufficient cause for disqualification In these cases medical judgments and tests may be required 6 Show no evidence of being subject to seizures or to loss of physical control such evidence shall be sufficient reason for disqualification Medical examinations may be required to determine these conditions 7 Have normal depth perception field of vision manual dexterity coordination and no tendencies to dizziness or similar potentially hazardous characteristics 8 Have no detectable or known disease or physical restriction that would render them incapable of safely operating equipment or carrying out rigging duties Where any deficiency of an upper or lower extremity exists the acceptability of a candidate shall be the decision of the supervisor after consulting with the designated physician Operators shall be required by the employer to satisfactorily pass a written examination covering operational characteristics controls and emergency control skills Operators shall be required by the employer to pass a practical operating skill evaluation Qualification shall be limited to the type of equipment for which the operator is bei
389. operation inspection testing and maintenance procedures that state specific requirements and acceptance criteria shall be prepared based on the hostile environment plan Chapter 5 Hostile Environments 5 2 HOSTILE ENVIRONMENT PLAN e The responsible manager shall ensure that the approved hostile environment plan is distributed as follows 1 DOE Site Office or equivalent 2 Equipment operators maintenance organizations and other organizations personnel affected by the plan 3 Equipment history file f Hostile environment plans in the equipment history file shall be readily available to appointed personnel 5 2 1 MARKING AND POSTING Equipment used under a hostile environment plan shall be posted with the following information Special Maintenance and Operating Instructions Required see Hostile Environment Plan 5 2 2 INSPECTION AND TESTING Handling fixtures and rigging accessories shall be qualified in accordance with Chapters 11 12 and 14 Wire Rope and Slings Rigging Accessories and Below the Hook Lifting Devices respectively of this standard prior to being exposed to the hostile environment Lifting equipment slings rigging accessories and fixtures that have been removed from hostile environments shall be inspected and maintained per the applicable provisions of this standard prior to their reuse outside of hostile environments Nylon rope or webbing slings should no
390. operator in order to provide a clear understanding of any special warning capacity information etc e Shop cranes shall have the rated capacity for each specified boom and leg position marked in a prominent location on the equipment e Small cranes 1 ton or less shall have a durable rating chart with legible letters and figures attached in a location accessible to the operator Each portable A frame shall have its rated capacity legibly marked on the structure on each side of the primary beam f The manufacturers name product serial number and model number must be permanently and legibly marked on each portable A frame g Operating instructions developed by the original manufacturer or supplier shall be maintained and readily available to the operator h For small cranes 1 ton or less operating instructions may be maintained on the vehicle on which the crane is installed i Safety instructions for shop cranes and portable A frames shall include the following Study understand and follow all instructions before operating this device 2 Do not exceed rated capacity 3 Useonly on hard level surface 4 Before moving lower the load to the lowest possible point NOTE For hoists used in conjunction with portable A frames see chapter 8 for hoist requirements 16 1 3 MODIFICATIONS a Miscellaneous lifting devices may be modified or re rated provided that the modifications of supporting s
391. operators to demonstrate basic knowledge and skills at a level that ensures the safety of personnel and equipment 6 2 7 OPERATORS OF FORKLIFT TRUCKS a Physical qualifications shall be based on specific job requirements b Operators shall be required by the employer to pass a practical operating skill evaluation Qualification shall be limited to the type of forklift for which the operator is being evaluated c The actual or simulated operation shall enable operators to demonstrate basic knowledge and skills at a level that ensures the safety of personnel and equipment 6 2 8 RIGGERS Riggers shall be required to pass a practical rigging skill evaluation that requires the use of rigging equipment in safe configurations The actual or simulated operation shall enable personnel to demonstrate basic knowledge and skills at a level that ensures the safety of personnel and equipment 6 2 9 PERSON IN CHARGE PIC DOE STD 1090 2007 The PIC shall have the necessary knowledge and experience of the specific type of equipment and completion of the operation The PIC shall understand the rules and procedures implemented at the site to ensure that the following are completed a Necessary administrative requirements b Personnel assignments and responsibilities c Selection of proper equipment tools d Recognition and control of hazardous or unsafe conditions e Job efficiency and safety f Critical lift documentation
392. or asterisked items In addition suspend operation when any unsafe condition is observed and immediately notify supervisor Other conditions not affecting safety shall be noted under Remarks and reported to supervisor REMARKS 7 27 Chapter 7 Overhead and Gantry Cranes DOE STD 1090 2007 Page 1 of 2 EXHIBIT Ill SAMPLE FORM PERIODIC CRANE INSPECTION REPORT MECHANICAL ITEMS MAKE CAPACITY LOCATION STATUS CODE SR Should be Replaced NR Needs Repair R Repaired SN See Notes N A Not Applicable ITEM OK CODE ITEM OK CODE Bridge Cam Followers Guide Alignment Runway End Stops Girders camber Railway Sweeps Safety Lugs Rails Energy Absorbing Bumpers Walks Ladders Railings Mono Rail Trucks to Girder Girders Connection Trucks Girder Supports Wheels Driver Sway Braces Wheels Idler Misc Wheels Bearings Clearances Overhead 3 Axles amp Coupling Clearances Lateral 2 Squaring Shaft Rated Load Markings Squaring Shaft Bearings Each Side of Crane Bridge Squaring Shaft Couplings Each Hoist Load Block Motor Coupling Trolley Drive Gear Reducer Wheels Driver Gear Reducer Oil Seals Wheels Idler Axle Pinion Wheels Bearings Axle Gear Axles amp Couplings Runway Alignment Motor Couplings Chapter
393. or known disease or physical restriction that would render them incapable of safely operating equipment or carrying out rigging duties Where any deficiency of an upper or lower extremity exists the acceptability of a candidate shall be the decision of the supervisor after consulting with the designated physician Shall successfully pass with a negative result a substance abuse test The level of testing will be determined by the standard practice for the industry where the crane is employed and this test shall be confirmed by a recognized laboratory service Operator physical examinations shall be required every three years or more 6 3 frequently if supervision deems it necessary Operators shall be required by the employer to satisfactorily pass a written examination covering operational characteristics controls and emergency control skills such as response to 1 Fire 2 Power line contact 3 Loss of stability 4 Control malfunction 5 As well as characteristic and performance questions appropriated to the crane type for which qualifications is sought Operators shall demonstrate their ability to read write comprehend and exhibit arithmetic skills and load capacity chart usage in the language of the crane manufacturer s operation and maintenance instruction materials Operators shall satisfactorily complete a combination written and verbal test on load chart usage that covers a selection of the c
394. ore it is lifted more than a few inches d Take care to make certain that the sling clears all obstacles 9 5 10 MOVING THE LOAD a The appointed person directing the lift shall make certain that the load is well secured and properly balanced in the sling or lifting device before it is lifted more than a few inches b Before starting to hoist not the following conditions 1 Hoist rope shall not be kinked 2 Multiple part lines shall not be twisted around each other Chapter 9 Mobile Cranes DOE STD 1090 2007 HOIST With forearm vertical forefinger pointing up move hand in small horizontal circles LOWER With arm extended downward forefinger pointing down move hand in small horizontal circles USE MAIN HOIST Tap fist on head then use regular signals y gt A t USE WHIPLINE Auxiliary Hoist Tap elbow with one hand then use regular signals RAISE BOOM Extend arm fingers closed thumb pointing upward LOWER BOOM Extend arm fingers closed thumb pointing downward Reprinted from ASME B30 5 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 9 6 Standard hand signals for controlling mobile crane operation 9 26 Chapter 9 Mobile Cranes DOE STD 1090 2007 MOVE SLOWLY Use one hand to give any motion signal and place other hand motionless above the hand giving the motion signa
395. orm loads less than 65 percent of rated load 2 Heavy operation within the rated load limit that exceeds normal service 3 Severe operation under normal or heavy service with abnormal operating conditions Chapter 14 Below the Hook Lifting Devices Chapter 14 Below the Hook Lifting Devices DOE STD 1090 2007 This inspection shall include those items specified in Section 14 4 4 2 Frequent Inspection in addition to the following initial use Tests and inspections shall be performed by a qualified inspector or under the direction of that inspector Test and 14 18 inspection results shall be documented and kept on file b General application magnets are required to 1 Deformation wear and corrosion of all satisfy the rated breakaway force test The members fasteners locks switches breakaway force measured in this test must warning labels and lifting parts exceed the rated load capacity by a factor of at least 2 2 Check for suspect counterfeit parts see Terminology and Definitions Chapter Cc Specified application magnets are required 1 to comply with the application breakaway force test The breakaway forces measured 3 Operation and condition of electrical in this test must exceed the specified components i e meters indicators and application load capacity by a factor of at alarms least 2 4 Magnet coil tested for ohmic ground d The rated breakaway force test shall readings
396. ortable A frames do not exceed the rated capacity of the unit 10 Verify required markings are installed and legible 11 Perform a function test of trolley and hoist installed on portable A frames to ensure proper operation b Operators or other designated personnel shall examine deficiencies and determine whether they constitute a safety hazard 16 2 4 PERIODIC INSPECTION a Miscellaneous lifting equipment shall be thoroughly inspected on a periodic basis in accordance with manufacturer s instructions If manufacturer s instructions are not available an engineering evaluation of the equipment shall be performed to establish the necessary inspection frequency and procedures b The qualified inspector shall evaluate identified deficiencies and determine whether they constitute a hazard c Dated and signed inspection records shall be kept on file and shall be readily available An external coded mark on the lifting device indicating the completion of the required inspection and the due date for the next inspection is also acceptable documentation d The following is a list of items frequently included in manufacturer s inspection instructions If manufacturer s instructions are unavailable these inspection items shall be considered in the engineering evaluation used to establish inspection procedures 1 Inspecting for bent broken damaged corroded cracked or missing parts 2 Verifying required markings are D
397. osition if color differentials required for operation 5 Have adequate hearing with or without a hearing aid for a specific operation 6 Have physical strength coordination and sufficient reaction speed to meet the demands of equipment operation 7 Show no evidence of physical defects or of emotional instability that could be a hazard to themselves or others or which in the opinion of the examiner could interfere with their safe performance such evidence may be sufficient cause for disqualification In these cases medical judgments and test may be required 8 Show no evidence of being subject to seizures or loss of physical control such evidence shall be sufficient reason for disqualification Medical examinations may be required to determine these conditions 9 Have normal depth perception field of vision manual dexterity coordination and no tendencies to dizziness or similar potentially hazardous characteristics 10 Have no detectable or known disease or physical restriction that would render them incapable of safely operating Chapter 15 Construction Hoisting and Rigging Equipment Requirements equipment Where any deficiency of an upper or lower extremity exists the acceptability of a candidate shall be the decision of the supervisor after consulting with the designated physician 11 Shall successfully pass with a negative result a substance abuse test The level of testing will be determined
398. oulder Shoulder machinery machinery Tapped through Untapped hole through hole Non shoulder Shoulder nut nut Installation Types In Qut of Plane Plane Good Bad Practice Practice 16 deg 90 deg E O deg 5 deg Loading Bc Angular Loading Reprinted from ASME B30 26 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 12 6 Eyebolts 12 13 Chapter 12 Rigging Hardware DOE STD 1090 2007 12 5 EYE NUTS 12 5 1 GENERAL a i This section specifies requirements for eye nuts that are used as rigging hardware during normal hoisting and rigging activities Eye nuts used for hoisting shall have sufficient ductility to permanently deform before losing the ability to support the load at temperatures at which the manufacturer has specified for use Each eye nut shall be marked to show 1 Name or trademark of manufacturer 2 Size or rated load Eye nuts shall have a minimum design factor of 5 1 Eye nuts shall be secured against rotation during the lift The threads of the eye nut shall be fully engaged See Fig 12 7 Eye nuts shall only be used for in line loads The plane of the eye may be positioned with a flat washer s or lock nut Shock loading should be avoided 12 5 2 EFFECTS OF ENVIRONMENT a When eye nuts are to be used at temperatures above 400 F 204 C or below 40 F 40 C the eye nut manufacturer or a qualified
399. oundslings shall be a minimum of 5 1 based on breaking strength f Rated capacities are affected by the type of hitch used and by the angle from the vertical when used as multi legged slings or in basket hitches The sling manufacturer shall supply data on these effects g Synthetic roundslings can be cut by repeated use around sharp cornered objects They eventually show sings of abrasion when they are repeatedly used to hoist rough surfaced products There are however protective devices offered by most sling manufacturers that minimize these effects h The roundsling capacities listed in Table 11 16 are approximate only The capacities are also based on a 5 1 design factor and assume that the end fittings are of adequate strength 11 3 6 1 Removal from Service Criteria Synthetic roundslings shall be removed from service if any of the following defects are visible a Missing or illegible sling identification b Acid or caustic burns c Evidence of heat damage d Holes tears cuts abrasive wear or snags that expose the core yarns e Broken or damaged core yarns f Weld splatter that exposes core yarns g Roundslings that are knotted h Discoloration and brittle or stiff areas on any part of the sling which may mean chemical or UV damage i Fittings that are pitted corroded cracked bent twisted gouged or broken j Hooks whose condition meets the removal criteria of Section 12 2 Chapter 11
400. over the connectors Chapter 15 15 10 Construction Hoisting and Rigging Equipment Requirements DOE STD 1090 2007 CHAPTER 16 MISCELLANEOUS LIFTING DEVICES This chapter provides requirements for the operation inspection testing and maintenance of miscellaneous lifting devices including portable A frames sometimes referred to as portable gantries Truck mounted cranes with a capacity of ton or less not covered in ASME B30 5 Mobile and Locomotive Cranes and self contained shop cranes as addressed by ASME PALD Portable Automotive Lifting Devices for latest ASME standards see http catalog asme org home cfm Category CS 16 1 GENERAL 16 1 16 1 1 Operator Training Qualifications seen eren rennen nne 16 1 16 1 2 Rated Load Markings Safety markings and Operating Instructions 16 1 D WE eene E 16 1 16 1 4 Load Ee CSS 16 2 16 1 5 Operating Controls cc certet aves ig ideas terr EPI EENS Ee 16 2 16 16 Load HOOK cuisine iii 16 2 16 67 c De EE 16 2 TOS GA ana aE NEE ES ENE AEE 16 2 INSPECTIONS M E 16 5 162 1 Generali ent eto eee repr e git pta tr e ES 16 5 16 2 2 Initial Inspection i iei rete ette re er ta ter oe reped 16 5 16 2 3 Daily Preoperational Inspecton een ene nemen 16 5 16 2 4 Periodic Inspection dene te dtt Pip T pet a RE onde rien sedans 16 5
401. ovisions for locking the device in the OPEN position unless the crane is the only load on a lockable switch or circuit breaker that is accessible from the floor One of the following types of floor remote and pulpit operated disconnects shall be provided 1 Anonconductive rope attached to the main disconnect device on a floor operated crane If this is selected the rope shall be suspended adjacent to the Chapter 7 Overhead and Gantry Cranes DOE STD 1090 2007 Overhead Traveling Crane NS Semi Gantry Crane Reprinted from ASME B30 2 2005 by permission of The American Society of Mechanical Engineers All rights reserved Figure 7 1 Top running single or multiple girder bridge with top running trolley hoist Chapter 7 7 2 Overhead and Gantry Cranes DOE STD 1090 2007 Bridge Girder Operator s Cab Outrigger Beam Overhead Cab Operated Crane Cantilever Gantry Crane Reprinted from ASME B30 17 2006 by permission of The American Society of Mechanical Engineers All rights reserved Figure 7 2 Top running single girder bridge with underhung trolley hoist 7 3 Chapter 7 Overhead and Gantry Cranes DOE STD 1090 2007 bw AM AR Cab operated crane Reprinted from ASME B30 11 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 7 3 Monorails and underhung cranes Chapter 7 7 4 Overhead and Gantry Cranes DOE STD 1090 2007 operating
402. pable of sustaining the proof load of the unit The load hooks shall be provided with a latching mechanism Shop floor cranes shall have required product warnings and markings DOE STD 1090 2007 LIFTING DEVICES 4 BELOW THE HOOK STRUCTURAL AND MECHANICAL 4 1 GENERAL a The design shall conform to requirements of ASME B30 20 and ASME BTH 1 NOTE Special lifting devices for shipping containers weighing 10 000 Ibs or more that are used for radioactive materials are governed by ANSI N14 6 Standard for Shipping Containers Weighing 10 000 Pounds or More for Nuclear Materials T E e e A load test not to exceed 125 percent of the rated load unless otherwise recommended by a manufacturer shall be provided Rated load should not be more than 80 percent of the maximum load sustained during the test A load test certificate indicating the date of load test amount of load applied and confirmation of lifter load rating shall be supplied Welding shall be in accordance with ANSI AWS D14 1 Guards for exposed moving parts such as but not limited to gearing projecting shafts and chain drives that constitute a hazard under normal operating conditions should be guarded A 5 Electrical equipment and wiring shall comply with Article 610 of ANSI NFPA 70 4 2 MARKINGS All new structural and mechanical lifting devices shall be marked with but not limited to the following information 1 Manufactur
403. pair them before operations begin 4 Do not load the lifting device in excess of its rated capacity except for test Chapter 14 Below the Hook Lifting Devices loads or handle any load for which it is not designed 5 Apply the lifting device to the load in accordance with established procedures 6 Before lifting ensure that lifting device ropes or chains are not kinked and multiple part lines are not interwoven 7 Ensure that the load is correctly distributed for the lifting device being used 8 Do notuse the lifting device for side pulls or sliding the load unless specifically authorized by a qualified person or by an approved procedure 9 Do not use a lifting device that is tagged Danger Do Not Operate or otherwise designated as nonfunctional 10 Do not remove Danger Do Not Operate tags from lifting devices without the approval of the person who placed them or an authorized person 11 Store the lifting device in a dry inside location when not in use 12 Ensure that markings or tags are not removed or defaced Replace missing or defaced markings or tags 14 2 10 CRITICAL LIFTS See Chapter 2 Critical Lifts for critical lift requirements a Structural and mechanical lifting devices for critical lift service shall have an initial proof load test of not less than 125 percent of its rated capacity or as specified by the design standard to which it was built If proof testing cannot
404. pect to lift points h Rigging equipment loading for applications other than vertical shall be evaluated as shown in Fig 12 4 1 Manufacturer specifications and requirements for use and application of rigging accessories shall be followed j Multiple slings or rigging hardware gathered in a link or ring shall not exceed a 120 included angle See Fig 12 4 k The horizontal angle of loading should not be less than 30 unless approved by a qualified person See Fig 12 4 l All rigging attachment points e g eyebolts imbedded anchor bolts shall be evaluated to ensure their capability to safely carry imposed rigging loads m The working load limit WLL of rigging hardware shall not be exceeded in its as configured application n Rigging hardware service is defined as follows for all types of rigging hardware other than rigging hooks for hooks see Section 12 2 5 3 b 1 Normal Service that involves use of loads at or below the rated load 2 Severe Service that involves normal service coupled with abnormal rigging or operating conditions 3 Special Service that involves operation other than normal or severe which is approved by a qualified person 12 1 1 GOOD AND BAD RIGGING PRACTICES Figure 12 1 illustrates some good and bad rigging practices Chapter 12 Rigging Hardware DOE STD 1090 2007 Table 12 1 Weights of Common Materials Name of Metal yes Aluminu
405. pection ees EERSTEN 13 2 13 3 yuz gu co x 13 4 13 4 NONDESTRUCTIVE TESTING ONDI eese rennen nennen 13 6 134 1 INDE Requirements eite ceret retirer trt tee et tii 13 6 134 2 INDF von jm P 13 6 1343 INDIE Methods surcar eerte teret et EE Eee REIR RECS OE REPE CHER E eeu 13 6 13 4 4 Acceptance Criteria IA 13 6 13 4 5 Discontinuity Removal sese ren rennen nre eret enne 13 6 13 5 MAINTENANCE sc rai ii 13 8 13 6 OPERATION tias 13 9 Exhibit I Hook Periodic Inspection Report 13 13 13 i INTENTIONALLY BLANK Chapter 13 Load Hooks 13 ti DOE STD 1090 2007 13 1 GENERAL 13 1 1 MARKING P Si The manufacturer s identification shall be forged cast or die stamped on a low stress and nonwearing area of the hook Hoisting hooks furnished by the original hoisting equipment manufacturer as an integral part the hoist assembly or by the original hoist manufacturer as replacement hooks are not required to have manufacturer markings 13 1 2 ATTACHMENTS P Si Hoisting hooks shall be fitted with a latch to bridge the throat opening to prevent the accidental release of slings or attachments Hooks without latches may be used in special applications where the latch would interfere with the proper use of the hook providing that 1 the use of the hook is restricted to the application for which it is approved and 2
406. per operation prior to making a lift 12 Before starting the lift lift the load a few inches to establish that it is securely attached to the magnet 13 Do not use a lifting magnet that is tagged Danger Do Not Operate or otherwise designated as nonfunctional 14 Do not remove Danger Do Not Operate tags from magnetic lifting devices without the approval of the person who placed them or an authorized person 15 Store the lifting device in a dry inside location when not in use 14 4 8 1 External Powered Electromagnets Before raising the load more than 2 in 50 mm ensure that any adjustable input control is switched to the FULL POWER or FULL ON position and remains in this position until the load is removed from the magnet Chapter 14 Below the Hook Lifting Devices 14 4 8 2 Battery Operated Electromagnets a Before lifting confirm that the device indicating correct current flow remains stable for a minimum of 5 seconds b For a lift of extended duration observe the device indicating correct current flow every 5 minutes c Open the ventilation lid before charging the battery d Before raising the load more than 2 inches 50 mm ensure that nay adjustable input control is switched to the FULL POWER or FULL ON position and remains in this position until the load is removed 14 4 8 3 Electrically Controlled Permanent Magnets Before raising the load check the
407. perator c Where voice direct or two way radio communication is used the signaler shall communicate directly with the operator not through a third person d The operator shall obey signals only from the designated signaler Obey a STOP signal no matter who gives it 7 5 5 SIZE OF LOAD a The weight of the load shall be determined prior to making the lift b Thecrane and rigging equipment shall not be loaded beyond its rated capacity except for authorized testing described in Section 7 3 7 5 6 ATTACHING THE LOAD Chapter 7 Overhead and Gantry Cranes a Ensure that the hoist rope is free from kinks or twists Do not wrap the hoist rope around the load b Ensure the load is attached to the load block hook by means of slings or other approved devices c Take care to make certain that the sling clears all obstacles 7 5 7 MOVING THE LOAD a The person appointed to direct the lift shall see that the load is well secured and properly balanced in the sling or lifting device before it is lifted more than a few inches b Before starting to hoist note the following conditions 1 Hoist rope shall not be kinked 2 Multiple part lines shall not be twisted around each other 3 The hook shall be positioned above the center of gravity of the load in such a manner as to minimize swinging when the load is lifted 4 If there is a slack rope condition it should be determined that the rope is properl
408. person is performed a designated leader shall be present at the lift site during the entire operation Leadership designation may be by written instructions specific verbal instruction for the particular job or clearly defined responsibilities within the crew s organizational structure The designated leader s responsibility shall include the following 1 Ensure that the personnel involved have received proper and current training and qualification for the procedure 2 Ensure that the equipment and accessories specified in the procedure are available 3 6 Survey the lift site for hazardous or unsafe conditions Ensure that equipment is properly set up and positioned Ensure that a signaler is assigned if required and identified to the equipment operator Direct the lifting operation to ensure that it is done safely and efficiently Stop the job when any potentially unsafe condition is recognized Direct emergency stabilization operations if an accident or injury occurs Chapter 3 Preengineered Production Lifts DOE STD 1090 2007 3 5 TRAINING Specialized training shall be conducted for personnel involved in performing preengineered production lifts This training shall be periodically reviewed and approved by the responsible operating and oversight organizations safety quality assurance etc 3 5 1 EQUIPMENT OPERATION a Personnel shall be trained and qualified on the specific types of
409. platforms and carriers DOG LEG Permanent short bend or kink in a wire rope caused by improper use DOE STD 1090 2007 DRAGLINE Wire rope used to pull an excavating or drag bucket DRIVE Motor coupling brake and gear case or gear cases used to propel bridge trolley or hoist DRIVE GIRDER A girder on which is mounted the bridge drive cross shaft walk railing and operator s cab DRUM A cylindrical flanged barrel of uniform cylindrical drum or tapering conical drum diameter on which a wire rope is wound for operation or storage It may be smooth or grooved ELASTIC LIMIT Limit of stress beyond which a permanent deformation takes place within the material This limit is approximately 55 65 percent of breaking strength of steel wire ropes ELECTRIC TRUCK A truck in which the principal energy is transmitted from power source to motor s in the form of electricity END CONTROL An operator control position that is located at the end opposite the load end of the truck EQUALIZER A device used to compensate for unequal length or stretch of a hoist rope EQUALIZING SLINGS Slings composed of wire rope and equalizing fittings EQUALIZING THIMBLES A special type of fitting used as a component part of some wire rope slings EYE OR EYE SPLICE A loop with or without a thimble formed in the end of a wire rope FAIL SAFE A provision designed to automatically stop or safely control any motion in wh
410. plied as part of a maintenance program is compatible with the original lubricant and is also a type that does not hinder visual inspection Those sections of rope in contact with sheaves or otherwise hidden during inspection and maintenance procedures require special attention when lubricating rope Chapter 11 General FC DOE STD 1090 2007 6 x 19 Warrington IWRC Figure 11 4 6 x 19 classification of wire rope Table 11 2 Breaking strength of wire rope 6 x 19 classification Breaking strength Breaking strength Rope Weight in tons of 2 000 Ib Rope Weight in tons of 2 000 Ib diameter Ib per diameter Ib per in ft Plow s Dod in ft Plow m oven steel pow steel ata steel steel 3 16 0 06 1 3 1 5 3 16 0 07 1 4 1 6 Ya 0 10 2 4 2 7 Va 0 11 2 6 2 9 5 16 0 16 3 8 4 1 5 16 0 18 4 1 4 4 3 8 0 23 5 4 6 0 3 8 0 25 5 8 6 5 7 16 0 31 7 0 8 0 7 16 0 34 7 5 8 6 Ye 0 40 10 0 11 0 Ve 0 44 10 8 11 8 9 16 0 51 11 7 13 3 9 16 0 56 12 6 14 3 5 8 0 63 15 0 16 5 5 8 0 69 16 1 17 7 Ed 0 90 21 5 23 8 Ya 0 99 23 1 25 6 7 8 1 23 28 3 32 0 7 8 1 35 30 4 34 4 1 1 60 38 0 41 7 1 1 76 40 8 44 8 1 1 8 2 03 48 5 53 0 1 1 8 2 23 52 1 57 0 1 2 50 60 0 65 0 1 2 75 64 5 70 4 1 3 8 3 03 73 5 81 0 1 3 8 3 33 79 0 87 1 1 3 60 88 5 96 0 1 3 96 95 1 103 0 1 5 8 4 23 103 0 113 0 1 5 8 4 65 111 0 122 0 134 4 90 119 0 130 0 134 5 39 128 0 140 0 1 7 8 5 63 138 0 152 0 17 8 6 19 148 0 163 0 2 6 40
411. pment Terminology and definitions Ropes and reeving Records and documentation Adjustments and repairs Rigging operating practices Sling loading Load indicating devices Personal protective equipment Below the hook lifting devices Rigging or hitch configuration D d ratio Sling types and application INSPECTORS a Employees who perform required documented inspections of equipment covered by this standard shall receive inspector training b Inspector training shall include basic inspection techniques and acceptance rejection criteria as specified in this standard and other applicable sources See Chapter 3 Preengineered Production Lifts DOE STD 1090 2007 The following equipment categories for general inspection are examples that should be considered 1 Overhead gantry and polar cranes 2 Monorail jib and other hoists 3 Mobile cranes hydraulic and lattice boom 4 Forklift trucks 5 Wire rope chain and synthetic web slings 6 Rigging accessories Employees who operate cranes to perform crane inspections shall be trained and qualified to operate the crane on which the inspection is being performed 6 11 6 3 8 INSTRUCTORS Instructors designated by management to be responsible for developing or presenting hoisting and rigging training programs shall develop technical competence by becoming familiar with the requirements of this standard and by satisfactorily completing d
412. pointed signal person and the riggers b Radios or equivalent shall be tested before lifting operations begin c Prior to commencing a lift the crane operator and the signal person shall contact and identify each other d All directions given to the crane operator by the signal person shall be given from the crane operator s direction perspective e g right swing e Each series of voice signals shall contain three elements stated in the following order 1 Function and direction 2 Distance and or speed 9 25 3 Function stop 9 5 7 SPECIAL SIGNALS For operations or crane attachments not covered by standard hand voice or audible signals additions to or modifications of the standard signal procedures may be required In all such cases the required special signals shall be agreed upon in advance by the manager person in charge crane operator signal person and riggers These special signals shall not be in conflict with the standard signals 9 5 8 SIZE OF LOAD The crane shall not be loaded beyond its rated capacity except of authorized testing described in Section 9 3 9 5 9 ATTACHING THE LOAD a Ensure that the hoist rope is free from kinks or twists Do not wrap the hoist rope around the load b Ensure that the load is attached to the load block hook by means of slings or other approved devices c Ensure the load is well secured and properly balanced in the sling or lifting device bef
413. production platform is not supplied by one manufacturer the manufacturers platform test shall be conducted at final assembly by the platform assembler or a qualified inspector 2 Slings wire rope or chain shall receive an initial load test before installation by applying a test load to each individual leg equal to twice the rated load of the leg If a master link or safety shackle is used in the suspension system it shall be tested to at least the weight of the platform plus the platform rating i Alltested components shall be visually inspected after testing ii Any components showing damage shall be replaced and the test procedure repeated 3 Non destructive testing of the platform s suspension system attaching points Chapter 4 Lifting Personnel a The platform manufacturer shall perform the a Atleast annually and at each new job site before personnel are hoisted the personnel platform and suspension system shall be load tested to 125 percent of the personnel platform s rated capacity b The platform shall be held in a suspended position for 5 minutes with the load suitably distributed c Load testing may be done concurrently with the trial lift d After load testing any deficiencies revealed during the inspection shall be corrected and another load test shall be conducted e Structural repair or modification to the platform requires load testing to 150 percent of the rated capacity f When fe
414. provided with a nameplate mane tag or other permanent marker displaying the following information 1 Manufacturer s name and address or if the magnet has been repaired or modified the name and address of the repairer modifier 2 Manufacturer s model or unit identification 3 Weight 4 Duty cycle if applicable 5 Cold current T Cases may exist where a lifting device cannot be marked with its rated capacity and weight This may be due to the security classification of the load to be lifted or other reasons approved by the responsible manager In these cases the lifting device shall be marked with an identification number and its documentation shall contain both its rated capacity and weight 14 5 3 INSTALLATION P Remote operated magnets shall be installed according to the manufacturer s recommendations cT Operators shall ensure that External power input is of the correct voltage and amperage 14 21 2 Power conductors and controls are of adequate rating and are insulated or otherwise protected against accidental interruption or damage 14 5 4 INSPECTIONS 14 5 4 Initial Inspection Prior to their initial use a qualified inspector shall inspect all new modified or repaired lifting magnets to ensure compliance with Section 14 5 4 3 Periodic Inspection 14 5 4 2 Frequent Inspection a The operator or other designated personnel shall visually inspect each magnetic lifting
415. qualification is sought under the direction of a qualified operator or instructor Instructor review of the applicant s knowledge shall include results of written and or oral evaluation and witnessing a demonstration of the operator s skills d Operators should be able to demonstrate knowledge of equipment operating characteristics capabilities limitations effects of variables safety features and operating procedures 6 3 5 FORKLIFT TRUCK OPERATORS a Only qualified and authorized operators shall be permitted to operate powered forklift trucks Operator trainees may operate powered forklift trucks under the direct supervision of a qualified operator or trainer and only where such operation does not endanger the trainee or other employees b The initial training of operators shall include 1 A combination of formal instruction e g lecture discussion interactive computer learning videotape written material 2 Practical training demonstrations performed by the trainer and practical exercises performed by the trainee 3 Evaluation of the operator s performance in the workplace including results of written and oral evaluation and witnessing a demonstration of the operator s skills c The following checklist contains basic factors with which a forklift truck operator should be familiar This checklist must be tailored to suit actual conditions 1 Operating instruction warnings and precautions for the
416. qualified engineer shall be required to prove that a load is evenly distributed over four or more sling legs DOE STD 1090 2007 GL CG cul cG Balanced Some unbalance Severe unbalance Note CL Centerline OG Center of Gravity Figure 11 6 Balancing Loads Vertical sling angle i P Tension Jason A 28 4 Ib Load 1 000 Ib Load on each sling 2 874 Ib Tension 500 Ib Tension 500 Ib Load 1 000 Ib Load on each sling 500 Ib Load angle factor Sling angle 90 1 000 50 45 40 35 30 25 Load 1 000 Ib Load on each sling 1 000 Ib Tension 707 lb Tension 707 Ib Load 1 000 Ib Load on each sling 707 Ib Figure 11 7 Relationship of load angle and lifting efficiency 11 9 Chapter 11 General DOE STD 1090 2007 11 3 1 3 Design Factor In general a design factor of 5 1 is maintained throughout this section with the exception of alloy steel chain slings Also certain sling fittings such as hooks which will deform beyond usefulness before breaking cannot be assigned a definite numerical design factor In such cases suitable safe loads are listed based on wide experience and sound engineering practice 11 3 1 4 Sling Care Proper care and usage are essential for maximum service and safety Wire rope slings shall be protected from sharp bends and cutting edges by means of corner saddles burlap padding or
417. r are of the same fiber the thread should also be of that fiber A 9 type When the core and cover are of different fiber types the thread should be of the same fiber type as the core All stitching shall be lock stitched type and should be continuous When not continuous they shall be back stitched or overstitched to prevent raveling The design factor for new synthetic roundslings and incorporating fittings shall be a minimum of five 5 Each synthetic roundsling shall be permanently marked or labeled showing 1 Name or trademark of manufacturer 2 Manufacturer s code or stock number 3 Rated capacities for the three basic hitches vertical choker vertical basket 4 Core fiber type if cover s is of a different fiber type both fiber types shall be identified 5 Length reach bearing point to bearing point Each manufacturer shall internally identify their product with name or trademark for traceability Appendix A Procurement Guidelines DOE STD 1090 2007 9 WIRE ROPE SLINGS P Si e e e ES gs Appendix A Wire rope slings shall meet or exceed the requirements of 29 CFR 1910 184 and ASME ANSI B30 9 Wire rope purchased to fabricate slings shall be made in the United States by a member of Wire Rope Technical Board Except stainless steel Stainless steel wire rope shall be made in the United States and shall be 302 or 304 grade stainless steel j W
418. r at other locations where vision is obstructed Slow down and sound horn at cross aisles and other locations where vision is obstructed Railroad tracks shall be crossed diagonally whenever possible Never travel with forks raised to unnecessary heights Approximately 4 to 6 inches 10 to 15 cm above floor level is adequate Chapter 10 Forklift Trucks DOE STD 1090 2007 Do not park closer than 6 ft 1800 mm to the nearest rail or a railroad track Face in the direction of travel except if the load being carried obstructs forward view In such cases travel with the load trailing When ascending or descending grades ramps and inclines 1 In excess of 5 percent grade drive loaded rider trucks with the load upgrade 2 Use low gear or slowest speed control 3 Operate unloaded trucks with the load engaging means downgrade 4 The load and load engaging means shall be tilted back if applicable and raised only as far as necessary to clear the road surface 5 Avoid turning if possible and normally travel straight up and down While turning be cautious of rear end swing and keep clear of the edge of loading docks Make starts stops turns or direction reversals in a smooth manner s as not to shift load and or overturn the truck Do no indulge in stunt driving or horseplay Slow down for wet and slippery floors Before driving over a dockboard or bridge plate be sure that it is properly secured
419. r proper tire inflation where applicable Check that tires are secured properly and are level with each other 6 Check batteries motors controllers limit switches protective devices electrical conductors and connections with special attention paid to the condition of electrical insulation 7 Check brakes steering mechanisms warning devices lights governors lift overload devices guards and safety devices Qualified inspector shall use the criteria for Items 8 9 and 10 to perform visual examination or as required by the manufacturer liquid penetrant examination or magnetic particle examination Acceptance No cracks linear indications laps or seams 8 Check for forks being secured properly and level with each other 9 Performs nondestructive test NDT on the right angle joint of the fork once every 12 months 10 Performs NDT on the load or stress bearing welds that attach the tines to the forklift once every 12 months Chapter 10 10 32 Forklift Trucks LOAD TEST NOTES l 2 3 DOE STD 1090 2007 Page 2 of 2 EXHIBIT Il continued FORKLIFT LOAD TEST Read all steps below prior to load test Forklifts in which load sustaining parts have been altered replaced or repaired shall be load tested prior to initial use Load test all forklifts at 100 rated capacity QUALIFIED INSPECTOR Shall verify all steps below EQUIPMENT NUMBER EQUIPMENT OPERATOR Qualified Inspector Ve
420. r s person s to be lifted and the designated leader shall be held each shift to plan and review procedures to be followed including Points at which persons will enter and leave the platform 2 Procedures for entering and leaving the platform 3 Special precautions if personnel will perform work from the suspended platform This meeting shall be held at each new work location and shall be repeated for any employees newly assigned to the operation 4 1 4 2 Pre Lift Inspection a After the trial lift prior to lifting personnel 1 A visual inspection of the crane rigging and personnel lift platform shall be conducted by a qualified inspector Any defects found that create a safety hazard shall be corrected prior to hoisting personnel 2 The platform shall be lifted a few inches and inspected to ensure that it is secure and properly balanced 4 1 4 3 Lifting Personnel a Prior to hoisting personnel in a personnel lift platform ensure that DOE STD 1090 2007 1 No hazardous conditions exist with the platform and its associated rigging 2 The hoist line is not wrapped around any part of the platform 3 Hoist ropes are free of kinks 4 Multiple part lines are not twisted around each other 5 The primary attachment is centered over the platform 6 Ropes are properly seated on drums and sheaves 7 The crane is within 1 percent of level 8 The crane has an anti two block device
421. rated capacities Synthetic web slings shall have a minimum design factor of 5 End fittings shall have sufficient strength to sustain twice the rated load of the sling without permanent deformation Each sling shall be permanently marked with the following 1 Manufacturer s name or trademark 2 Manufacturer s code or stock number A 8 Procurement Guidelines 3 Type of synthetic web material 4 Rated loads for the type of hitches used NOTE Hand written or ink embossed markings are not acceptable Sling tags shall be indelibly marked and the lettering shall not wear off with use The markings shall remain legible for the life of the sling The manufacturer shall have on file a written system of sling traceability as well as a quality control procedure Traceability should be specific mill lots Fabric wear pads should be sewn into the bearing points of the sling eyes Leather wear pads are not recommended Product warnings relative to the proper use care and maintenance shall accompany the shipment Single leg and endless synthetic web slings shall be proof tested to 200 percent of the rated load Multiple leg bridle slings shall have the proof load applied to the individual legs The proof load shall be two times the vertical rated load of a single leg sling A load test certificate LTC shall be provided for each lot of slings supplied The LTC shall reference as a minimum the PO number date o
422. rbe ler tee ide Dos ete 12 14 123 3 Removal Criteria eiie aede E diia 12 15 12 5 6 REPIS xc tote e eme nie re eei tu e Fa reta eegen gege eege cheers 12 15 12 37 Catia italia doi eerte 12 15 TURNBU CKLDBS 52 eniti tiit taiat 12 16 I EI 12 16 12 0 2 Operating Practices uode ttr tpe enne eet HE Stone EE dra desi erat 12 16 12 i Chapter 12 Rigging Hardware DOE STD 1090 2007 12 6 3 Effects of Envtronment neret nene tenete tenen e eterne 12 16 12 6 4 TEM iue eese eate A i REO HG HET 12 16 12 6 5 Inspections ein meet dee PR a E t er ER ER e aet 12 16 12 616 Removal Criteria ade ee I e aD eria dina sit 12 17 12 67 Repalts 5 egeta aio a RM RT Dat eod bat deridet ttd 12 17 12 6 8 Critical Lats citan a Rob Roe de Y DUREE 12 17 12 7 LINKS RINGS AND SWIVELS eeeeeeeeeeeene ettet entente tte nettes setate R A 12 19 12 FT EE 12 19 12 7 2 Operating Practices oe eet nt ee ait alates da d delete 12 19 12 7 3 Effects of Environment eee e ancien ia 12 19 12 7 4 Iraming nitet etes RR eee er be ect tt re Peer estie 12 19 12 7 5 Inspections o rhe rere P pa Ee B be Ri EE DES 12 19 12 tre Remoyal Citera renn eene ete d e dte s 12 20 12 717 Repaso a ee E e autos 12 20 12 7 8 Critical Lifts aee gna eati et d o e oe e a age 12 20 DS SWIVEL HOIST RINGS vecinal ii 12 21 12 8 E Generali aaa ii neo Mies 12 21 SL Effects of Environment nuca al aii i 12 2
423. re and rigging sketches shall be reviewed and approved by the responsible manager or designee and the responsible oversight organization such as safety quality assurance or quality control before the lift is made Subsequent revisions shall be approved per site specific procedures A pre lift meeting involving participating personnel shall be conducted prior to making a critical lift The critical lift plan procedure shall be reviewed and questions shall be resolved If required by the critical lift procedure a practice lift shall be done before the critical lift Conditions for a practice lift should closely simulate actual conditions involving weight rigging selection and configuration load movement path and other relevant factors Practice lifts should be done by the same crew using the same lifting equipment Although individual plans are generally prepared for critical lifts multi use plans may be employed to accomplish recurrent critical lifts For example a multi use plan DOE STD 1090 2007 may be used to lift an item or series of equipment or rigging must change to similar items that are handled repeatedly in accomplish the lift the critical lift plan must the same manner However if the lifting be revised and approved accordingly 2 3 Chapter 2 Critical Lifts DOE STD 1090 2007 CHAPTER 3 PREENGINEERED PRODUCTION LIFTS This chapter provides requirements for the design evaluation and performa
424. re selected and that rated capacity is not exceeded DOE STD 1090 2007 3 Survey the lift site for hazardous unsafe conditions 4 Ensure that equipment is properly set up and positioned 5 Ensure that a signaler is assigned if required and is identified to the operator 6 Direct the lifting operation to ensure that the job is done safely and efficiently 7 Stop the job when any potentially unsafe condition is recognized 8 Direct operations if an accident or injury occurs d The operator or other designated person shall visually examine the hoist in accordance with the requirements for a daily inspection described in Section 8 2 Inspections e A qualified person shall examine any deficiencies and determine whether they constitute a hazard Correct these deficiencies before operating the hoist f Load lines shall be checked after strain is put on them before the load is lifted clear of the ground If not plumb the slings or equipment shall be repositioned so the the lines are plum before continuing 8 5 7 PLANNED ENGINEERED LIFTS Lifts in excess of the rated load may be required from time to time on a limited basis for specific purposes such as new construction or major repairs Every planned engineered lift exceeding the rated load shall be treated as a special and separate event Limitations and planned requirements shall be applicable as follows a Planned engineered lifts shall be limite
425. red A qualified inspector shall conduct periodic documented inspections as required by the design organization In addition to looking for visible signs of wear deformation deterioration or damage these inspections shall verify the current configuration of the fixture against that specified in the approved design package Equipment to be used cranes hoists forklifts etc shall be inspected according to the appropriate section requirements in this standard for that type of equipment 3 2 4 STORAGE MAINTENANCE AND a CONTROL Lifting fixture users shall do the following 1 Store special lifting fixtures in an appropriate location to prevent damage or deterioration 2 Perform and document periodic preventive maintenance as required by the design organization 3 Establish controls to ensure that special lifting fixtures are used only in Chapter 3 Preengineered Production Lifts DOE STD 1090 2007 operations for which they were functionally designed 4 Maintain equipment to be used cranes hoists forklifts etc according to the appropriate section requirements in this standard for that type of equipment 5 If equipment maintenance procedures deviate from published manufacturer s recommendations the alternate procedures shall be approved in advance by the manufacturer or another qualified person and be kept readily available Chapter 3 Preengineered Production Lifts 3 3 3 2 5 MODIFICAT
426. rify Load Test Date Weight 1 Set forklift on solid level ground 2 Perform load test using the required weight see Note 3 3 Static Test Forklift trucks shall demonstrate ability to withstand the appropriate test load for a period of at least 10 min without permanent deformation or apparent damage Load slippage for this equipment shall not be greater than a maximum of 3 in vertically and 1 in horizontally at the cylinder 4 Check system for leaks while undergoing test 10 33 Chapter 10 Forklift Trucks CHAPTER 11 WIRE ROPE AND SLINGS This chapter provides requirements for the fabrication and use of wire rope and slings used in hoisting and rigging and implements the requirements of ASME B30 9 Slings for latest ASME standards see http catalog asme org home cfm Category CS 11 1 GENERAL ori AAA ES 11 1 11 2 WIRE eu 11 4 142 1 cd vp 11 4 1 2 2 Wire Rope Cores ede tiro p ee t Pr etr d d a te S D rr trn een 11 4 11 2 3 Wire Rope for General Durposges eese rene ener 11 4 11 2 3 1 AO AAA re e e rie Hat tn t 11 4 11 2 3 2 e O AA eee P ex e ripe Heiden ptt 11 5 11 2 4 Wire Rope Inspections nennen eem ren rennen tenete 11 5 11 2 5 Wiaire Rope Maintenance erect entrent tbe tar rna tpe ras eterni deu 11 5 11 3 MJBN Ccsp M2 11 8 11 31 Generale nica ERI RERO ERI
427. rocedures 10 Rigging 11 Lessons learned 12 Hand signals 13 Load dynamics 14 Applicable standards and regulations 15 Critical lifts 16 Safety features of equipment 17 Terminology and definitions 18 Ropes and reeving 19 Two blocking 20 Records and documents 21 Limit switches warning signals 22 Operating practices 23 Fire protection Chapter 6 Personnel Qualification and Training 6 3 3 6 3 4 Chapter 6 Personnel Qualification and Training DOE STD 1090 2007 24 Crane components 25 Access and egress 26 Warning devices MOBILE CRANE OPERATORS Only qualified and authorized operators or operator trainees under the direct supervision of a qualified operator shall be permitted to operate mobile cranes Operators shall meet the criteria specified in paragraphs 6 3 2 b and c and they should also be able to demonstrate an understanding of the following 1 Stability 2 Load charts 3 Crane setup 4 Refueling 5 Lifting operations involving multiple cranes 6 Assembly and disassembly 7 Outriggers 8 Operator aids OPERATORS OF TRUCK MOUNTED CRANES CAPACITY 1 TON OR LESS Only qualified and authorized operators or operator trainees under the direct supervision of a qualified operator shall be permitted to operate truck mounted cranes capacity 1 ton or less The initial training of operators shall include applicable training on equipment for which
428. rollers to the OFF position Become familiar with your equipment and its proper care If adjustments or repairs are necessary or any defects are known report them promptly to the responsible supervisor 7 15 7 5 2 Also notify the next operator of the defects at shift change Contacts with runway stops or other cranes shall be made with extreme caution If you are ordered to engage with or push other cranes do this with particular care for the safety of persons on or below the cranes and only after making certain that any persons on the other cranes are aware of what action is to be taken Secure outdoor cranes before leaving them When the wind indicating alarm is given anchor the bridge on outside cranes Lock and tag the main positive electrical control switch in the OPEN position before any crane maintenance is performed Operate all controls before beginning a new shift If any controls do not operate properly adjust or repair them before operations begin Do not hoist two or more separately rigged loads in one lift even though the combined load is within the crane s rated capacity Ensure that a 10BC or larger fire extinguisher is installed in the cab of cab operated cranes The extinguisher shall be maintained in a serviceable condition Do not lift lower or travel the crane while anyone is on the load or hook HOIST LIMIT SWITCH DEVICE At the beginning of each work shift or the first time
429. ropes if manual controllers are used or near the pendant push button station if magnetic controls are used 2 An under voltage trip for a main circuit breaker operated by an emergency stop button in the pendant push button station or the pulpit 3 A main line contactor operated by a switch or push button on the pendant push button station the remote control station or the pulpit 7 1 8 HOIST LIMIT SWITCH a The hoisting motion of all cranes shall have an overtravel limit switch device in the hoisting direction to stop the hoisting motion b Lower travel limit switches devices should be provided for all hoists where the load block enters pits or hatchways in the floor 7 1 9 MARKINGS a The arrangement of pendant push buttons stations and radio control transmitters should conform to Fig 7 4 Compass directions right left and forward reverse or other indicators may be substituted for W X Y and Z in Figure 7 4 b Master switches shall be labeled to indicate their function Main Auxiliary Bridge Trolley Hoist Hoist X Y Down Down Reprinted from ASME B30 2 2005 by permission of The American Society of Mechanical Engineers All rights reserved Figure 7 4 Typical Pendant Push Button Station 7 1 10 LOAD LIMITS The crane shall not be loaded beyond its rated capacity except for test purposes as described in Section 7 3 7 1 11 MAINTENANCE HISTORY The maintenance history
430. rtain weight that could be within 90 100 percent of the rated capacity of the equipment or maximum working load of any part of the tackle Use load indicating devices where the equipment tackle configuration could result in binding or friction of the load that could cause a greater stress in the hoist or tackle than would result from the apparent hook load The accuracy of load indicating devices shall depend on the requirements of the load system planned and shall not restrict the system requirements an accuracy of 2 percent of full scale reading within 10 70 percent of instrument range is recommended The device should be selected so that the estimated hook 12 25 load lies between 10 and 70 percent of the instrument range Load indicating devices shall have a design factor of not less than 3 1 Dynamometers and load cells shall be calibrated at least once a year and when specified in the critical lift procedure This also applies if they have not been used in the previous 6 months All calibrated devices shall have a tag affixed indicating date of calibration by whom they were calibrated and the date that the next calibration is due 12 9 CRITICAL LIFTS a See Chapter 2 Critical Lifts for critical lift requirements Load indicating devices used for critical lift service shall have an initial proof load test per the manufacturer s specifications confirming the load rating If proof testing cannot be verif
431. rucks DOE STD 1090 2007 Exhibits I and II are intended to be sample forms only The equipment manufacturer s inspection testing criteria supercede any other criteria In cases where the equipment manufacturer does not include inspection testing criteria other forms developed to facilitate required inspection testing are acceptable 10 28 DOE STD 1090 2007 INTENTIONALLY BLANK 10 29 Chapter 10 Forklift Trucks DOE STD 1090 2007 EXHIBIT SAMPLE FORM ONLY Typical Preuse Inspection Procedures sheet 1 of 2 OPERATORS PRE SHIFT INSPECTION ELECTRIC FORKLIFT Date Vehicle No Shift Type and Model Hour Meter OK NA VISUAL CHECKS Maintenance Needed Reported to Leaks Hydraulic Oil Battery Tires Condition and pressure Forks Top Clip retaining pin and heel Condition Load Backrest Extension solid attachment Hydraulic hoses Mast chains amp Stops Finger guards attached Safety warnings attached and legible Operators manual Located on truck and legible Capacity Plate attached information matches Model amp Serial Nos and attachments Seat Belt Buckle and retractor working smoothly OPERATONAL CHECKS Unusual Noises Must be Reported Immediately Accelerator Linkage Parking Brake Deadman Steering Drive Control Forward and Reverse Tilt Control Forward and Back Hoist amp Lowering Con
432. s Chapter 9 Mobile Cranes DOE STD 1090 2007 9 2 INSPECTIONS 9 2 1 GENERAL Equipment shall operate with a smooth regular motion without any hesitation abnormal vibration binding gross shimmy or irregularity There shall be no apparent damage excessive wear or deformation of any load bearing part of the equipment All safety devices load indicators boom angle and radius indicators controls and other operating parts of the equipment shall be checked during each inspection and shall be in good working order 9 2 2 INITIAL INSPECTION Prior to initial use all new or modified cranes shall be inspected as required in Section 9 2 6 Periodic Inspection by a qualified inspector to ensure compliance with the applicable provisions of this chapter Dated and signed inspection reports shall be kept on file and shall be readily available 9 2 3 DAILY PREOPERATIONAL CHECK a Operators or other designated personnel shall visually inspect items such as the following each day or prior to use if the crane has not been in regular service records are not required 1 All control mechanisms for maladjustment interfering with proper operation 2 Crane hooks and latches for deformation cracks and wear 3 Hydraulic systems for proper oil level 4 Lines tanks valves pumps and other parts of air or hydraulic systems for leakage 5 Hoist ropes for kinking crushing birdcaging and corrosion 6 Anti two
433. s Hold both fists in front of body thumbs pointing toward each other tapping chest EXTEND BOOM Telescoping Boom One hand signal Hold one fist in front of chest thumb RETRACT BOOM Telescoping Boom One hand signal Hold one fist in front of chest thumb pointing outward and heel of fist tapping chest Reprinted from ASME B30 5 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 9 6 continued 9 28 Chapter 9 Mobile Cranes DOE STD 1090 2007 3 The hook shall be positioned above the center of gravity of the load in such a manner as to minimize swinging when the load is lifted 4 Following any slack rope condition it should be determined that the rope is properly seated on the drum and in the sheaves 5 All personnel including the qualified rigger shall be clear of the load During hoisting take care to ensure that 1 There is no sudden acceleration or deceleration of the moving load 2 Load does not contact any obstructions A dry run shall be conducted in areas where clearance is limited Cranes shall not be used for side pulls except when specifically authorized by a designated person who has determined that the stability of the crane is not endangered and that various parts of the crane will not be over stressed Avoid carrying loads over people No hoisting lowering swinging or traveling shall be done while anyo
434. s and correct any deficiencies prior to returning the device to service MAINTENANCE A preventive maintenance program shall be established and be based on recommendations made by the vacuum lifting device manufacturer or a qualified person Replacement parts shall be equivalent to the original specifications The vacuum generator vacuum pads sealing rings mufflers and filters shall be maintained and cleaned according to the manufacturer s specifications TRAINING QUALIFICATION Vacuum lifting device operators shall be trained and qualified as specified in Chapter 6 Personnel Qualification and Training At a minimum instruction shall include the following as applicable DOE STD 1090 2007 Application of the lifting device to the load and adjustments of the device if any that adapt it to various sizes or kinds of loads Any special operations or precautions Condition of the load itself required for operation of the lifting device such as balance degree of order of stacked loads surface cleanliness bending and load thickness Procedure for storage of lifting device to protect it from damage Instructions for not exceeding the rated capacity of the lifting device or the capacity of the hoisting equipment by the combined weight of the load the lifting device and the rigging Charging of the battery if required The purpose of indicators meters or alarms on the vacuum lifting device
435. s and excessive chain stretch Steering braking and locking devices for malfunctioning Excessively worn or damaged tires Chapter 9 Mobile Cranes DOE STD 1090 2007 n Rust on piston rods and control valves when crane has been idle 9 2 6 2 Hydraulic and Pneumatic Hose Fittings and Tubing Inspect for a Evidence of leakage at the surface of the flexible hose or its junction with the metal couplings b Blistering or abnormal deformation of the outer covering of the hydraulic or pneumatic hose c Leakage at threaded or clamped joints that cannot be eliminated by normal tightening or recommended procedures d Evidence of excessive abrasion or scrubbing on the outer surface of a hose rigid tube or fitting means shall be taken to eliminate the interface of elements in contact or to otherwise protect the components 9 2 6 3 Hydraulic and Pneumatic Pumps and Motors Inspect for a Loose bolts or fasteners b Leaks at joints between sections c Shaft seal leaks d Unusual noises or vibration e Loss of operating speed f Excessive heating of the fluid g Loss of pressure 9 2 6 4 Hydraulic and Pneumatic Valves Inspect for a Cracks in valve housing b Improper return of spool to neutral position c Leaks at spools or joints d Sticking spools e Failure of relief valves to attain correct pressure setting relief valve pressures shall be checked as specified by the manufacturer
436. s been performed in accordance with specified requirements WEDGE SOCKET Wire rope fitting in which the rope end is secured by a wedge WHEEL BASE Distance between centers of outermost wheels for bridge and trolley trucks WHEEL LOAD The load on any wheel with the trolley and lifted load rated load positioned on the bridge to give maximum loading conditions WIRE ROPE Wire strands laid helically around an axis or a core WIRE ROUND Single continuous length of metal cold drawn from a rod WIRE SHAPED A single continuous length of metal either cold drawn or cold rolled from a rod Chapter 1 Terminology and Definitions Chapter 1 DOE STD 1090 2007 DOE HEADMARK LIST ANY BOLT ON THIS LIST SHOULD BE TREATED AS DEFECTIVE WITHOUT FURTHER TESTING ALL GRADE 5 AND GRADE 8 FASTENERS OF FOREIGN ORIGIN WHICH DO NOT BEAR ANY MANUFACTURE S HEADMARKS ES GRADE 5 GRADE 8 GRADE 5 FASTENERS WITH THE FOLLOWING HEADMARKS MARK MANUFACTURER MARK MANUFACTURER Y J Jinn Her TW KS Kosaka Kogyo JP GRADE 8 FASTENERS WITH THE FOLLOWING HEADMARKS MARK MANUFACTURER MARK MANUFACTURER CA A Asahi Mfg JP Es KS Kosaka Kogyo JP EE E Ddai JP Em M Minamida Sleybo JP FM Fastener Co of Japan JP MS Minato Kogyo JP H hinamoto Metal JP NF Nippon Fasteners JP ES J JinnHer TW RT Takai Lid JP Cx KY Kyoel Mig JP Q9 UNY Unite JP C Maio Inlasco CA TW JP YU Greater than 1 2inch diameter GRADE
437. s in Chapter 11 General 11 40 excess of 150 degree F 66 degree C or below 40 degree F 40 degree C The sling manufacturer should be consulted for the temperature range of slings made from other synthetic yarns n Do not use aluminum fittings where acid or caustic fumes vapors sprays mists or liquids are present o Ensure that each sling is permanently marked to show 1 Name or trademark of manufacturer 2 Manufacturer s code or stock number 3 Rated capacity for types of hitches used 4 Type of synthetic web material p Synthetic web slings e g Kevlar K Spec nylon polyester may be used in radiation areas only when a qualified person ensures that the absorbed dose does not exceed 100 000 rad during the life of the sling 11 3 5 4 Critical Lifts See Chapter 2 Critical Lifts for critical lift requirements a Synthetic web slings used for critical lift service shall have an initial proof test of 200 percent of the vertical rated capacity If proof testing cannot be verified the sling s shall be proof tested before being used to make a critical lift b Prooftesting shall be performed in accordance with Section 11 3 5 2 Proof Testing 11 3 6 SYNTHETIC ROUNDSLINGS a Synthetic roundslings shall possess the following qualities 1 Core yarn shall be of a synthetic fiber wound together on a plurality of turns for even distribution of the load DOE STD 1090 2007 2 In genera
438. s of this chapter Written records are not required Frequent Inspection 1 A visual inspection shall be performed by the user or other designated person each shift before the eyebolt is used Semi permanent and inaccessible locations where frequent inspections are not feasible shall have periodic inspections performed Chapter 12 Rigging Hardware DOE STD 1090 2007 2 Conditions such as those listed in Section 12 4 5 or any other condition that may result in a hazard shall cause the eyebolt to be removed from service Eyebolts shall not be returned to service until approved by a qualified person 3 Written records are not required c Periodic Inspection 1 A complete inspection of the eyebolt shall be performed by a designated person The eyebolt shall be examined for conditions such as those listed in Section 12 4 5 and a determination made as to whether they constitute a hazard 2 Periodic inspection intervals shall not exceed one year The frequency of periodic inspections should be based on v Frequency of use vi Severity of service conditions vii Nature of lifts being made viii Experience gained on the service life of eyebolts used in similar circumstances 3 Guidelines for the time intervals are i Normal service yearly ii Severe service monthly to quarterly 111 Special service as recommended by a qualified person 4 Written records are not required 12 4 5 REMOVAL CRITER
439. s or fumes The link ring or swivel manufacturer or a qualified person 12 19 should be consulted before links rings or swivels are used in chemically active environments 12 7 4 TRAINING Link ring or swivel users shall be trained in the selection inspection cautions to personnel effects of environment and rigging practices as covered by this standard 12 7 5 INSPECTIONS a Initial Inspection 1 Prior to use all new altered modified or repaired link ring or swivel shall be inspected by a designated person to verify compliance with the applicable provisions of this chapter Written records are not required Frequent Inspection 1 A visual inspection shall be performed the user or other designated person each shift before the link ring or swivel is used Semi permanent and inaccessible locations where frequent inspections are not feasible shall have periodic inspections performed 2 Conditions such as those listed in Section 12 7 6 or any other condition that may result in a hazard shall cause the link ring or swivel to be removed from service Links rings or swivels shall not be returned to service until approved by a qualified person 3 Written records are not required Periodic Inspection 1 A complete inspection of the link ring or swivel shall be performed by a designated person The links rings or swivels shall be examined for conditions such as those listed in Section 12 7 6 and a det
440. s test should be supplied by the manufacturer of the lifting Testing shall include the following magnet 1 A check to ensure that the lifting 14 4 6 MAINTENANCE magnet contains no visible defects a A preventive maintenance program shall be 2 A check for proper operation of all established and be based on electrical protective equipment meters recommendations made by the manufacturer indicators alarms etc or a qualified person 14 4 5 2 Rated Load Test b Replacement parts shall be equivalent to the original specifications All new modified or repaired lifting magnets shall be tested and inspected before c Before adjustment and repairs are started on a lifting magnet or its controls maintenance personnel shall take the following precautions DOE STD 1090 2007 Ensure that all sources of magnet power are disconnected and locked out tagged out or flagged Ensure that a magnet removed for repair is tagged as defective d Only qualified personnel shall work on equipment when adjustments and tests are required e After adjustments and repairs have been made the lifting magnet shall not be returned to service until it has been inspected according to Section 14 4 4 3 f Dated records of repairs and replacements shall be available g Maintenance personnel shall ensure that any defective condition disclosed by the inspection is corrected before operation of the lifting magnet is resumed Repairs shall b
441. sition Example sees A 18 Appendix A A ii Procurement Guidelines DOE STD 1090 2007 1 MANUAL ELECTRIC AND AIR OPERATED HOISTS 1 1 GENERAL P Si e e e Manual electric and air operated hoists shall meet or exceed the requirements of ASME ANSI B30 16 To the extent that the desired configuration and capacity of electric or air operated hoist is available with a Nationally Recognized Testing Laboratory s listing it should be specified to have such a listing If not the procurement procedures for such hoists should be coordinated with the site s authority having jurisdiction responsible for interpretation and enforcement of applicable codes For hoists designated a Safety Class or Safety Significant per applicable DOE nuclear safety rules or Orders application of ASME NUM 1 requirements should be considered during procurement The rated load shall be marked on the hoist or load block The hoist shall be marked with identification as follows 1 Hand Chain Operated i Name of manufacturer ii Manufacturer s model or serial number 2 Electric Powered Hoist i Name of manufacturer ii Manufacturer s model or serial number iii Voltage of AC or DC power supply and phase and frequency of AC power supply iv Circuit ampacity v Warning labels per ANSI Z535 4 3 Air Powered Hoist i Name of manufacturer ii Manufacturer s model and serial number ii Rated air pressure Al
442. slings have more than one leg b ensure that the tag is affixed to the master link 17 Ensure that the working load does not c exceed the rated capacity of the sling 11 3 3 4 Critical Lifts See Chapter 2 Critical Lifts for critical lift requirements a Single leg and endless alloy steel chain slings 11 3 4 Heavy duty Medium duty Light duty used for critical lift service shall have an d initial proof test of 200 percent of the vertical rated capacity If proof testing cannot be verified the sling s shall be proof tested before being used to make a critical lift The proof load for multiple leg bridle slings shall be applied to the individual legs and shall be 200 percent of the vertical rated e capacity of a single leg sling Master links to which multiple leg slings are connected shall be proof loaded to 200 percent multiplied by the force applied by the combined legs METAL MESH SLINGS Metal mesh slings Figure 11 15 shall be f classified with the designations shown in Table 11 12 based on types of duty and material classification Table 11 12 Metal mesh sling Designations g Type Classification Designation 35 CS 35 SS Carbon steel Stainless steel 43 CS 43 SS i Carbon steel Stainless steel 59 CS 59 SS Carbon steel Stainless steel 11 29 The carbon steel used in metal mesh slings shall be processed to produce the required mechanical properties
443. spection and shall be in good working order 16 2 2 INITIAL INSPECTION A qualified inspector shall inspect all miscellaneous lifting devices prior to initial use after disassembly and reassembly and after load testing The inspection shall be performed in accordance with manufacturer s requirements If manufacturer s instructions are not available an engineering evaluation of the equipment shall be performed to establish necessary inspection procedures Dated and signed inspection reports shall be kept on file and shall be readily available 16 23 DAILY PREOPERATIONAL CHECK a Operators or other designated personnel shall visually inspect miscellaneous lifting equipment each day or prior to use if the equipment has not been in regular service records are not required The inspection shall include but not be limited to inspecting the following 1 All control mechanisms for maladjustment interfering with proper operation 2 Hook and latch for deformation cracks and wear 3 Hydraulic systems for proper operation 4 Wire rope for kinking crushing birdcaging and corrosion 5 Chain for bent links stretched links cracks scores abrasions or heat damage 6 All safety devices for malfunction 7 Inspection items identified in manufacturer s operating instructions 8 Visually inspect for bent broken damaged corroded cracked or missing parts 9 Verify the hoist and all components installed on p
444. sumes all responsibilities of the designated available to the operator leader c A qualified operator Leadership designation may be by written instructions specific verbal instructions for d Proper type designation for working in a the particular job or clearly defined responsibilities within the crew s organizational structure The designated leader s responsibility shall include the following Ensuring that personnel involved understand how the lift is to be performed 2 Ensuring that the weight of the load is determined that proper equipment and accessories are selected and that rated capacity is not exceeded 10 25 classified hazardous area if applicable Chapter 10 Forklift Trucks DOE STD 1090 2007 RAISE THE TINES With forearm vertical forefinger pointing up move hand in small horizontal circle LOWER THE TINES With arm extended palm down lower arm vertically TILT MAST BACK With forearm vertical thumb extended jerk thumb over shoulder TILT MAST FORWARD With arm extended thumb down lower arm vertically MOVE TINES IN DIRECTION FINGER POINTS With arm extended palm down point forefinger in direction of movement DOG EVERYTHING Clasp hands in front of body STOP Extend both arms palms down Chapter 10 Forklift Trucks 10 26 DOE STD 1090 2007 INTENTIONALLY BLANK 10 27 Chapter 10 Forklift Trucks Chapter 10 Forklift T
445. sure that slings with end fittings that are used in a choker hitch have sufficient length so that the choking action is on the body f the sling In slings used in a basket hitch balance the load to prevent slippage Do not drag slings across the floor or over any abrasive surface Do not twist or tie slings into knots Protect slings from being cut by sharp corners sharp edges and highly abrasive surfaces Do not pull slings from under loads when a load is resting on a sling Do not use roundslings to lift loads in excess of the rated capacity properly derated for other than straight pull configuration When not in use store slings to prevent mechanical chemical or environmental damage Personnel should never stand in line with or next to a roundsling that is under tension If extreme temperatures are involved ensure the guidance in 11 3 6 d is followed Do not allow the load hook or any fitting to constrict bunch or pinch roundslings Ensure that roundslings are not used as bridles on suspended personnel platforms For multiple leg roundslings used with non symmetrical loads an analysis should be performed by a qualified person to prevent overloading of any leg Ensure that each sling is permanently marked to show 1 Name or trademark of manufacturer 2 Manufacturer s code or stock number DOE STD 1090 2007 3 Rated loads for the type s of hitch es 11 3 6 4 Critical Lifts used and the
446. t be used in a radiation area unless absolutely necessary When it is necessary to use a nylon or polyester sling in a radiation area the responsible manager shall ensure that radiation exposure does not exceed 100 000 rad during the life of the sling DOE STD 1090 2007 EXHIBIT HOSTILE ENVIRONMENT PLAN Building Location Type crane hoist e g overhead top running bridge and trolley top running bridge with underhung hoist jib crane monorail hoist overhead hoist Capacity Auxiliary Power method Manufacturer l a H amp R standard requirement that will not be met Section number copy the applicable section 1 b Difference between standard requirement and what is to be allowed by this plan l c Justification for not meeting the standard requirement 1 d Actions or features to compensate for differences L e Actions to be taken e g inspections maintenance for lifting equipment slings rigging accessories and fixtures that will be removed from hostile environments and subsequently reused to ensure compliance with this standard applicable regulatory requirements and manufacturer s recommendations prior to their reuse if applicable Include information regarding replacement or retirement criteria for this equipment Include information regarding any special design maintenance or test considerations that apply to this equipment
447. t mandatory at all DOE sites and locations this standard has been used for many years by DOE and its contractors as a valuable resource for conducting hoisting and rigging safely and efficiently It is felt that the full implementation of the provisions of this standard will dramatically strengthen hoisting and rigging programs throughout the DOE complex and will significantly decrease the probability of serious accidents resulting in personnel injury or death or severe property damage It should be noted that not all hoisting and rigging equipment or operational methods could be covered comprehensively by this standard Hoisting and rigging equipment fabricated onsite or operated in manner not envisioned by this Standard shall be designed constructed operated inspected and tested in accordance with the design engineer of record and applicable design standards This Standard does not address elevators drilling rigs or the lifting loads with construction equipment not normally intended for lifting purposes e g excavators payloaders Also this Standard does not repeat other DOE nuclear regulations orders or standards e g 10 CFR 830 Nuclear Safety Management with respect to safety analysis technical safety requirements or safety classifications of hoisting equipment The applicable regulatory documents should be consulted to ensure conformance with these requirements during hoisting and rigging activities To propose improvements to t
448. t if you are physically or mentally unfit Familiarize yourself with the equipment and its proper care If adjustments or repairs are necessary or any damage is known or suspected report it promptly to the appointed person Notify the next operator of the problem upon changing shifts Correct deficiencies before resuming normal operation Test all controls before beginning a shift If any controls do not operate properly adjust or repair them before beginning operations Operators are responsible for those operations under their direct control Whenever there is doubt as to safety consult with responsible management before handling the load Do not operate a hoist that bears an out of order sign or is otherwise tagged out of service If there is a tag sign or lock on electric or air powered equipment do not energize the equipment until the tag sign or lock is removed by the person who placed it there or by an authorized person Do not close the main line disconnect device on powered equipment until you are certain that no one is on or adjacent to the hoist or carrier 8 17 8 5 2 SIZE OF LOAD Know the weight of the load and do not load the hoist beyond the rated capacity except as provided for in Section 8 3 Testing 8 5 3 ATTACHING THE LOAD a The supporting structure or anchoring means shall have a load rating at least equal to that of the hoist b Use hoists only in areas that will allow you to
449. t of low sling angle l Synthetic web slings shall be used in accordance with the sling manufacturer s recommendation m Conventional three strand natural or synthetic fiber rope slings are NOT recommended for lifting service and should be used only if conventional sling types are not suitable for a unique application The requirements of ASME B 30 9 Slings Section 9 4 and 29 CFR 1910 184 h shall be followed n Tiedown and or ratchet strap shall not be used as synthetic web slings Only synthetic web slings constructed from webbing approved for sling construction by the manufacturer or other qualified person shall be used at DOE locations 11 3 5 1 Removal from Service Criteria Slings shall be immediately removed from service if any of the following defects are visible a Acid or caustic burns Chapter 11 11 36 General b Melting or charring of any part of the surface c Snags punctures tears or cuts d Broken or worn stitching in load bearing splices e Excessive abrasive wear f Knots in any part of the sling g Excessive pitting or corrosion or cracked distorted or broken fittings h Discoloration brittle or stiff areas on any part of the sling that may indicate chemical or UV damage i Other visible damage that causes doubt as to the strength of the sling Missing or illegible sling identification c 11 3 5 2 Proof Testing a Forsingle or multiple leg sl
450. t of the filled capacity Vehicles with mufflers having screens or other parts that may become clogged shall not be operated while such screens or parts are clogged Any vehicle that emits hazardous sparks or flames from the exhaust system shall immediately be removed from service and not returned to service until the cause for the emission of such sparks and flames has been eliminated a When temperature of any part of any truck is found to be in excess of its normal operating 10 16 Forks used in pairs the normal arrangement shall have a rated capacity of each fork at least half the manufacturer s truck rated capacity at the center distance shown on the forklift truck nameplate 10 3 4 2 Fork Inspections Forks in use single shift operation shall be inspected at intervals of not more than 12 months or whenever any defect or DOE STD 1090 2007 permanent deformation is detected Severe use applications require more frequent inspection at an interval set by facility management Fork inspection shall be carried out by a qualified inspector with the aim of detecting any damage failure deformation or other condition that might impair safe use A fork that shows any of the following defects shall be withdrawn from service and shall not be returned to service until it is satisfactorily repaired by the fork manufacturer or an expert of equal competence Fork inspection shall include 1 Surface Cracks A thorough
451. t ratings 2 A work area chart for which capacities are listed in the load rating chart see sample in Figure 9 1 3 Where ratings are limited by structural hydraulic or factors other than stability the limitations shall be shown and emphasized on the rating charts 4 In areas where no load is to be handled the work area figure and load rating chart shall state that information 5 Recommended reeving for the hoist lines shall be shown In addition to the data required on the load rating chart the following information shall be shown either on the rating chart or in the operating manual 1 Recommended parts of the hoist reeving and size and type of rope for various crane loads 2 Recommended boom hoist reeving diagram where applicable size type and length of rope 3 Tire pressure where applicable 4 Cautionary or warning notes relative to limitations on equipment and operating procedures including indication of the least stable direction 5 Position of the gantry and requirements for intermediate boom suspension where applicable 6 Instructions for boom erection and conditions under which the boom or boom and jib combinations may be raised or lowered 7 Whether the hoist holding mechanism is automatically controlled or manually Chapter 9 Mobile Cranes DOE STD 1090 2007 controlled whether free fall is 8 The maximum telescopic travel length available and whether any combination o
452. tachments i Avoid reaching through the mast for any purpose Chapter 10 10 20 Forklift Trucks To safeguard pedestrians understand the truck s limitations and observe the following precautions 1 Do not drive a truck up to anyone standing in front of an object 2 Ensure that personnel stand clear of the rear swing area before conducting turning maneuvers 3 Exercise particular care at cross aisles doorways and other locations where pedestrians may step into the path of travel of the truck 4 Do notallow anyone to stand or pass under the elevated portion of any truck whether empty or loaded Do not permit passengers to ride on powered industrial trucks unless a safe place to ride has been provided by the manufacturer Ensure that fire aisles access to stairways and fire equipment is kept clear A powered industrial truck is considered unattended when the operator is more than 25 ft 7 6 m from the truck which remains in his view or whenever the operator leaves the truck and it is not in his view Before leaving the operator s position the operator shall perform the following 1 Bring truck to a complete stop 2 Place directional controls in neutral 3 Apply the parking brake 4 Fully lower load engaging means unless supporting an elevated platform In addition when leaving the truck unattended the operator shall perform the following 1 Stop the engine or turn off the controls
453. te the crane so that lowering will be power controlled no free fall 4 Ensure movement of the personnel lift platform is performed in a slow controlled cautious manner with no sudden movements of the crane or the platform The lifting or lowering speed shall not exceed 100 ft min 30m min 5 After the personnel lift platform is positioned set all brakes and locks on the lift crane before personnel perform any work 6 Ifthe personnel lift platform cannot be landed ensure it is tied to the structure before personnel get off or on 7 Ensure that lifts are not made on another of the crane s load lines while personnel are suspended on the personnel lift platform Suspended personnel lift platforms shall be used only for personnel their tools and sufficient materials to do their work They shall not be used for transporting bulk materials Personnel lift platforms should not be used in winds greater than 20mph 32 2 km hr electric storms snow ice sleet or other adverse weather conditions that could affect the safety of personnel Use tag lines to control motion of occupied personnel lift platforms unless their use creates an unsafe condition Chapter 4 Lifting Personnel DOE STD 1090 2007 g Cranes shall not travel while personnel overall work function and precautions are in the platform Exceptions to this to be taken documented in the personnel provision shall be approved by the lift plan manager specif
454. ted from ASME B30 26 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 12 12 Wire Rope Clips Socket Body j r Wedge E EI Pin Wrong Installation L Components Right Installation Reprinted from ASME B30 26 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 12 13 Wedge Sockets 12 29 Chapter 12 Rigging Hardware DOE STD 1090 2007 CHAPTER 13 LOAD HOOKS This chapter provides safety standards for the inspection testing and maintenance of load hooks installed on cranes or hoists and implements the requirements of ASME B30 10 Chapter 10 1 Hooks See Chapter 12 Rigging Accessories for rigging hook requirements for latest ASME standards see http catalog asme org home cfm Category CS 13 1 GENERAL EE 13 1 13 1 1 Marking aom tii 13 1 13 1 2 Attachments unire rar ii Eres USE 13 1 13 1 3 Load LIMIS zit m a UNTER dirias 13 1 13 1 4 Hook Standards ue eiii weed ta near 13 1 13 2 TINSPECTIONS c 13 2 132 1 Hook Serviee ii iet eo er reb eap uses hr eee vb ahead Ana Rasa 13 2 13 2 2 Initial Inspection teer ett rapere E ep tbe a easet e ara 13 2 1323 Daily Inspection perro een rere e ep b EEN 13 2 13 2 4 Frequent Inspection ec t bep IE ep rb eta rasa p rait oe RR tpe Rede 13 2 13 2 5 Periodic Ins
455. ter testing unloaded apply a load of at least 50 Ib 23 kg multiplied by the number of load supporting parts of chain to the hoist to check proper load control 8 3 1 3 Manual Lever Operated Hoists Check all functions of the hoist with the hoist suspended in an unloaded state After testing unloaded apply a load of at least 100 Ib 46kg multiplied by the number of load supporting parts of load line to the hoist to check proper load control 8 3 2 RATED LOAD TEST Test anchorages or suspensions shall be approved by a qualified person 8 3 2 1 Electric or Air Powered Hoists a The manufacturer shall dynamically test new hoists as specified in Section 8 3 1 1 Chapter 8 Hoists Electric or Air Powered Hoists steps a and b with a test load of at least 125 percent of the rated load If the manufacturer cannot test the hoist the user shall be notified and the test shall be accomplished at another location or job site by a qualified inspector or under the direction of that inspector A qualified inspector shall test hoists in which load suspension parts have been modified replaced or repaired as specified in Section 8 3 1 1 steps a and b by or under the direction of a qualified inspector and a record of the test should be made A designated or authorized person shall determine if repairs made to a hoist are extensive and require a rated load test or routine maintenance and require only an operational
456. test The applied test load shall not be less than 100 percent of the rated capacity of the hoist or more than 125 percent of the rated capacity of the hoist unless otherwise recommended by the manufacturer or a qualified person The replacement of load chain and rope is specifically excluded from this hoist test however a functional test of the hoist under a normal operating load should be made in accordance with 8 3 1 Operational Tests prior to putting the hoist back in service 8 3 2 2 Hand Chain Operated or Manual Lever Operated Hoists The manufacturer shall dynamically test new hoists with a test load of at least 125 percent of the rated capacity If the manufacturer cannot test the hoist the user shall be notified and the test shall be accomplished at another location or job site by a qualified inspector or under the direction of that inspector Hoists in which load suspension parts have been modified replaced or repaired shall be tested statically or dynamically by or under the direction of a qualified inspector and a record of the test should be kept A designated or authorized person shall determine if repairs made to a hoist are extensive and require a rated load test or are routing maintenance and require only an DOE STD 1090 2007 operational test The applied test load shall not be less than 100 percent of the rated capacity of the hoist or more than 125 percent of the rated capacity of the hoist un
457. th forks elevated except to pick up or deposit a load over a rack or stack When stacking or tiering use only enough backward tilt to stabilize the load Rigging loads from the tines of a forklift attaching rigging to the forks to support a suspended load shall only be performed by qualified personnel in accordance with approved site procedures Never lift with one fork without an engineering analysis and approval Use guides and signalers as necessary If in doubt check the conditions personally before proceeding Standard hand signals are shown in Figure 10 5 Hand Signals Do not block fire extinguishers fire protection sprinklers or alarm stations when stacking loads 10 23 10 5 2 LIFTING OF PERSONNEL Only the operator up high lift trucks have been designed to lift personnel If a work platform is used on forklift trucks designed and intended for handling materials take the following precautions a Usealift platform manufactured for the purpose of lifting personnel with a forklift truck The platform shall include 1 A4in 10 cm minimum height toe plate provided on the work platform 2 The floor of the platform located not more than 8 in 20 cm above the upper face of the supporting truck fork blade 3 Arestraining means such as a guard rail having a height above the platform floor of not less than 36 in 90 cm or more than 42 in 110 cm around its upper periphery and including a midr
458. the crane is used during a shift test the upper limit switch device of each hoist under no load Exercise extreme care to avoid two blocking inch the block into the limit switch or run it in at slow speed If the switch device does not operate properly immediately notify the supervisor If a lift is in progress during a shift change this testing requirement is considered to have been satisfied for the completion of Chapter 7 Overhead and Gantry Cranes DOE STD 1090 2007 that lift However test the limit switch again before the next lift c Do not use the final hoist limit switch device that controls the upper limit of travel of the load block as an operating control 7 5 3 STANDARD HAND SIGNALS The standard hand signals for DOE use shall be as specified in the latest edition of the ASME B30 standards for the particular type of crane or hoist being used see Figure 7 5 7 5 4 IDENTIFICATION OF SIGNALERS a All personnel acting as signalers during the crane operations shall be clearly identified to the crane operator Options for improving signaler visibility include using an orange hardhat orange gloves or orange vest b Inthose cases where the crane operator cannot see the signaler a second person relay signaler shall be stationed where he or she can see both the signaler and the crane operator and signals can be relayed to the operator The relay signaler shall also be clearly identified to the crane o
459. the following additional precautions to protect personnel 1 Means shall be provided whereby personnel on the platform can shut off power to the truck Means shall be provided to render inoperative all operating controls on the elevating platform when the controls on the elevating platform have been selected for use only one location of controls shall be capable of being operated at one time Emergency lowering means available at ground level should be provided such means shall be protected against misuse d Take the following precautions whenever personnel are elevated with a forklift truck 1 Ensure the truck has a firm and level footing 2 Place all travel controls in neutral and set parking brake 3 Before elevating personnel mark area with cones or other devices to warn of work by elevated personnel 4 Lift and lower personnel smoothly with caution and only at their request 5 Avoid overhead obstructions and electric wires Chapter 10 Forklift Trucks 10 24 10 11 12 13 14 15 16 17 18 Keep hands and feet clear of controls other than those in use Move truck and or platform slowly only for minor adjustments in horizontal positioning when personnel are on the platform and only at their request Ensure the mast is vertical do not operate on a side slope The platform is horizontal and never tilted forward or rearward when elevated Personnel are to
460. the lifting equipment and selection of lifting equipment Chapter 3 Preengineered Production Lifts 3 1 2 All items must be lifted in adherence to a specific step by step procedure that eliminates job rigging decisions or calculations by lift personnel The lifting procedure shall address the specific operation and attachment of all lifting equipment fixtures and accessories 3 Training procedures are in place to ensure specialized training is provided to personnel involved in preengineered production lifts DOE STD 1090 2007 3 2 LIFTING FIXTURES 3 2 1 DESIGN a Special lifting fixtures e g below the hook lifting devices and rigging accessories shall be designed according to recognized consensus standards 29 CFR 1910 Occupational Safety and Health Standards for General Industry 29 CFR 1926 Occupational Safety an Health Regulations for Construction ASME B30 9 Slings B30 10 Hooks B30 20 Below the Hook Lifting Devices etc and the lifting fixture design requirements in Chapters 12 and 14 Rigging Accessories and Below the Hook Lifting Devices respectively b Special lifting fixtures shall be designed by a qualified engineer c The designer shall determine the requirements for initial and periodic inspections or tests including acceptance rejection criteria and periodic inspection test intervals d Special lifting fixture designs shall receive a documented revi
461. the plane of the unbent hook shall be replaced Hooks having more than 1096 wear in the throat section or 596 elongation of the shank shall be replaced Lubricate hook bearing and latch pin as applicable Establish three marks A B and C with center punch For ease in measuring set distances on an even number of inches Chapter 7 Overhead and Gantry Cranes 7 24 DOE STD 1090 2007 BEFORE LOAD TEST Length AB in Length BC in AFTER LOAD TEST Length AB in Length BC in Check for 1 Wear and deformation 2 Cracks and twisting 3 Signs of opening between Point A and Point B Load Test Inspection Date Qualified Inspector Operated By Actual Load Test 7 25 Page 4 of 4 Chapter 7 Overhead and Gantry Cranes DOE STD 1090 2007 Page 1 of 2 EXHIBIT Il SAMPLE FORM OVERHEAD CRANE PRE OPERATIONAL CHECKLIST Records Are Not Required CRANE NO CAPACITY TYPE LOCATION SHIFT 2 OPERATORS NAME INSTRUCTIONS Check all items Inspect and indicate as Satisfactory S Unsatisfactory U or Not Applicable NA Overhead and Gantry Cranes 1 WALK AROUND INSPECTION S U 2 MACHINERY INSPECTION S U NA NA a Foundations a Holding Brake m b Access b Load Control Brake c Secured Items C Covers Secured d Walkways Handrails d Upper Sheaves ii e Bridge Drive Motor e Wire Rope E
462. the type of forklift truck permitted see Figure 10 2 or the truck shall be clearly marked as to the area s it is not to enter 10 2 1 1 Non Hazardous Areas The following units are not suitable for use in hazardous areas since they include only minimum safeguards against inherent fire hazards a Type D Forklifts diesel powered units having minimum acceptable safeguards against inherent fire hazards b Type E Forklifts electrically powered units having minimum acceptable safeguards against inherent fire and electrical shock hazards c Type G Forklifts gasoline powered units having minimum acceptable safeguards against inherent fire hazards d Type LP Forklifts liquefied petroleum gas powered units having minimum acceptable safeguards against inherent fire hazards 10 2 1 2 Hazardous Areas The following units are suitable for use in hazardous areas since they are equipped with additional safeguards 1 e special exhaust fuel or electrical systems or other modifications against inherent fire hazards a Type DS Forklifts diesel powered units that are provided with all the requirements for the type D units and that have additional safeguards to the exhaust fuel and electrical systems b Type DY Forklifts diesel powered units that have all the safeguards of the type DS units except that they do not have any electrical equipment including ignition they are equipped with temperature limit
463. ting condition e Carefully inspect all parts of lift and tilt mechanisms and frame members and maintain them in a safe operating condition Chapter 10 Forklift Trucks Chapter 10 Forklift Trucks DOE STD 1090 2007 Check for suspect counterfeit parts see Terminology and Definitions Chapter 1 For special trucks or devices designed and approved for operation in hazardous areas ensure that the original approved safe p operating features are preserved by maintenance Check fuel systems for leaks and for the proper condition of the parts Give special consideration in the case f a fuel system leak Take action to prevent use of the truck until the leak has been corrected Inspect and maintain all hydraulic systems q Check tilt cylinders valves and other similar parts to ensure that drift or leakage has not developed to the extent that it would create a hazard Maintain capacity operation safety and maintenance instruction plates tags or decals in legible condition Inspect and maintain batteries motors controllers limit switches protective devices electrical conductors and connections Pay special attention to the condition of electrical insulation Those repairs to the fuel and ignition s systems of industrial trucks which involve fire hazards shall be conducted only in locations designated for such repairs Trucks in need of repairs to the electrical system shall have the battery disconn
464. to handle material having sharp edges They can be positioned on the sling where required do not move when the sling stretches adjust to the load and cover both sides of the sling 4 Eye buffers can be attached at the bearing point of the sling eye This attachment increases the longevity of the fabric sling 5 Coatings can be applied to provide added resistance to abrasion and chemical damage These treatments also increase the coefficient of friction affording a better grip when loads with slippery surfaces are to be handled The synthetic web sling capacities listed in Tables 11 14 and 11 15 are approximations only and are based on nylon or polyester webbing having breaking strengths between 6 800 and 9 800 Ib in of webbing width The capacities are also based on a 5 1 design factor and assume that the end fittings are of adequate strength DOE STD 1090 2007 Endless or Grommet Slings Standard Eye and Eye Slings Y Reverse Eye Wide Body Cargo Twisted Eye Figure 11 17 Synthetic web sling types 11 35 Chapter 11 General DOE STD 1090 2007 k Although safe working loads for bridle hitches in the choker or double basket configuration are provided they should be used only with extreme caution because as the sling angle decreases one edge of the web will take all the load producing a risk of tearing see Figure 11 18 EU mum dr NM 33 ker A CEA M Kee LA lite Figure 11 18 Effec
465. topping motion by fiction or electromagnetic means BRAKE DRAG A brake that provides stopping force without external control BRAKE HOLDING A brake that sets automatically and that prevents motion when power is off BRAKE PARKING A device to prevent the movement of a stationary vehicle BRAKING COUNTER TORQUE A method of stopping motion in which the power to the Chapter 1 Terminology and Definitions DOE STD 1090 2007 motor is reversed to develop torque in the opposite direction BRAKING DYNAMIC A method of controlling crane motor speeds when in the overhauling condition to provide a retarding force BRAKING MECHANICAL A method of slowing motion by friction BRAKING REGENERATIVE A form of dynamic braking in which the electrical energy generated is fed back into the power system BREAKING STRENGTH The measured load required to break a wire rope or chain BRIDGE The part of a crane consisting of girders walkways railings trucks and drive mechanisms that carries the trolley or trolleys BRIDGE TRAVEL Horizontal travel of the crane parallel with runway rails BRIDLE SLING A sling composed of multiple legs branches the top ends of which terminate in a fitting that latches onto the lifting hook BULL RING The main large ring of a sling to which sling legs are attached BUMPER BUFFER An energy absorbing device for reducing impact when a moving overhead crane or trolley reaches the
466. trainees under the direct supervision of qualified personnel who meet the following requirements shall be allowed to rig operate inspect or perform maintenance on cranes hoists or powered forklift trucks a b Be at least 18 years old Understand spoken and written English or a language generally in use at the work location At the site s discretion crane operator certification by the National Commission for the Certification of Crane Operators NCCCO an OSHA recognized certification body or a state licensing agency may be used to verify compliance with qualification requirements described hereunder for covered classes of equipment 6 2 2 OPERATORS OF CAB a OPERATED AND PULPIT OPERATED CRANES Operators and operator trainees shall meet the following physical qualifications 1 Have vision of at least 20 30 Snellen in one eye and 20 50 in the other with or without corrective lenses Operators whose jobs do not require binocular vision operation of cranes with television cameras or periscope optics shall have distant visual acuity of 20 30 in one eye and no specific visual requirement for the other eye 2 Beable to distinguish colors regardless of position if color differentiation is required for operation 3 Have adequate hearing with or without a hearing aid for specific operation 4 Have physical strength coordination and sufficient reaction speed to meet the demands of equipment
467. trol Attachment Control Horn Lights Back Up Alarm Hour Meter Battery Discharge Gauge Chapter 10 Daily Pre Shift Inspections are an OSHA requirement We recommend that you document that these inspections have been made Inspected by Custodian 10 30 Forklift Trucks DOE STD 1090 2007 EXHIBIT SAMPLE FORM ONLY Typical Preuse Inspection Procedures sheet 2 of 2 OPERATORS PRE SHIFT INSPECTION GAS LP or DIESEL FORKLIFT Date Vehicle No Shift Type and Model Hour Meter NA VISUAL CHECKS Maintenance Needed Reported to Fluid Levels Oil Radiator Hydraulic Leaks Hydraulic Oil Battery Fuel Tires Condition and pressure Forks Top Clip retaining pin and heel Condition Load Backrest Extension solid attachment Hydraulic hoses Mast chains amp Stops Finger guards attached Safety warnings attached and legible Operators manual Located on truck and legible Capacity Plate attached information matches Model amp Serial Nos and attachments Seat Belt Buckle and retractor working smoothly OPERATONAL CHECKS Unusual Noises Must be Reported Immediately Accelerator Linkage Parking Brake Steering Drive Control Forward and Reverse Tilt Control Forward and Back Hoist amp Lowering Control Attach
468. trucks boxcars unfamiliar ramps or platforms before start of operation Other workers should not be inside the truck when the forklift truck is performing loading or unloading operations Load arrangements 10 21 and spacing issues should be determined before the forklift enters the truck Fixed jacks or supports may be needed to prevent upending or corner dipping when powered industrial trucks are driven on and off semitrailers that are not coupled to the tractor The brakes of highway trucks shall be set and wheel chocks placed under the rear wheels to prevent the trucks from rolling while they are boarded Care shall be taken to not contact overhead installations such as lights wiring pipes sprinkler systems etc If in doubt measure Motorized hand trucks shall not be ridden unless they are of the hand rider design 10 5 1 2 Traveling a Observe all traffic regulations and under all travel conditions operate the truck at a speed that will permit it to be brought to a stop in a safe manner Unless facility specific procedures state otherwise the guideline is within plant buildings 5 mph on plant roads 15 mph Drive slowly around curves Yield the right of way to pedestrians and emergency vehicles Whenever possible establish eye contact with approaching pedestrians or vehicle drivers before continuing Do not pass another truck traveling in the same direction at intersections blind spots o
469. tructures are analyzed thoroughly by a qualified engineer or by the manufacturer of the lifting device b Are rated lifting device or one whose load supporting components have been modified shall be tested in accordance with Section 16 3 Testing The new rated capacity shall be displayed in accordance with Section 16 1 2 Rated Load Marking Safety Markings and Operating Instructions DOE STD 1090 2007 16 1 4 LOAD LIMITS Miscellaneous lifting devices shall not be loaded beyond its rated capacity except for test purposes as described in Section 16 3 16 1 5 OPERATING CONTROLS a Operating controls shall be readily visible and accessible to the operator and shall not subject the operator to pinch points sharp edges or snagging hazards b The release system for shop cranes shall require intentional positive action by the operator for release to prevent accidental lowering 16 1 6 LOAD HOOK a Shop cranes shall be equipped with load hooks and or chain capable of sustaining the proof load of the crane b Latch equipped hooks shall be used for all operations unless the application makes using the latch impractical unnecessary or unsafe The absence of a hook throat latch is not indiscriminately allowed 16 1 7 WIRE ROPE a Wire rope single line capacity used on small cranes 1 ton or less shall have a minimum design factor of 3 5 1 based upon breaking strength b Smallcranes 1 ton or less shall
470. ttachment points 3 Attachment mechanisms i Master links shackles slings bolt ups etc 4 Special purpose items i Overhead protection ii Platform controls c For frequent inspections dated records for the hoisting equipment and personnel lift platform shall be made and kept by the platform user for the duration of the personnel lift operation 4 5 2 PERIODIC INSPECTION 4 5 2 1 Personnel Lift Platform a Atleast once every 12 months or as required by the personnel lift platform manufacturer a periodic inspection of the platform shall be performed by a qualified inspector in accordance with the instructions provided by the manufacturer b Platforms which have been out of service for 12 or more consecutive months shall receive a periodic inspection prior to use c Dated inspections records for the platform shall be made The last periodic inspection records shall be kept with the platform and available for review 4 5 2 2 Hoisting Equipment a Hoisting equipment shall be inspected in accordance with requirements of Chapter 7 Overhead amp Gantry Cranes or Chapter 9 Mobile Cranes Chapter 4 Lifting Personnel DOE STD 1090 2007 4 6 TESTING 4 6 1 PLATFORM MANUFACTURER TEST 4 6 2 RATED LOAD TEST following testing 1 Test the personnel lift platforms i Suspension mechanisms or attachment components ii Occupant safety features iii Platform rating iv When the complete
471. ty Test SAE J874 Center of Gravity Test Code SAE J987 Crane Structure Method of test Underwriters Laboratories UL 558 Internal Combustion Engine Powered Industrial Trucks UL 583 Electric Battery Powered Industrial Trucks DOE STD 1090 2007 APPENDIX A PROCUREMENT GUIDELINES This appendix provides reference guidance in preparing purchase requisitions for hoisting and rigging materials and equipment Nationally recognized standards and specifications are referenced for listed items However caution should be used prior to procurement of special items in order to verify appropriate specification or standard reference and requirements Some specific requirements listed in this appendix are more restrictive than consensus standard requirements but are recommended to ensure materials of adequate quality and workmanship are provided Quality receipt inspections should be provided for all received materials in order to verify compliance of all requirements stated on the purchase order This appendix primarily contains procurement criteria for off the shelf type items If the information provided in this appendix is used in the development of specifications for purchase of cranes or other special handling equipment the appropriate engineering group should be consulted Since this appendix contains only a partial listing of commonly used rigging hardware the requisitioner shall review applicable standards or specifications and
472. ualified person 1 Missing or illegible manufacturer s name or trademark and or rated load identification 2 Indications of heat damage including welding spatter or arc strikes 12 8 3 Excessive pitting or corrosion 4 Bent twisted distorted stretched elongated cracked or broken load bearing components 5 Excessive nicks or gouges 6 A 10 reduction of the original or catalog dimension at any point around the body or pin 7 Incomplete pin engagement 8 Excessive thread damage 9 Evidence of unauthorized welding 10 Other conditions including visible damage that cause doubt as to the continued use of the shackle 12 3 6 REPAIRS a Repairs alterations or modifications shall be as specified by the shackle manufacturer or a qualified person Replacement parts shall meet or exceed the original equipment manufacturer s specifications 12 3 7 CRITICAL LIFTS a See Chapter 2 Critical Lifts for critical lift requirements Shackles used for critical lift service shall have an initial proof load test of 200 percent of the rated capacity Test loads shall be accurate to within 5 percent 0 percent of stipulated values If proof testing cannot be verified the shackle s shall be proof tested before being used to make a critical lift DOE STD 1090 2007 pe Se e gt AK C y E Screw pin type Screw pin type Bolt type Bolt type Bolt type Anchor Shackles Chain Shackles Synth
473. uirements of all preceding paragraphs in Section 7 5 Operation also shall apply to ordinary lifts b An appointed person shall classify each lift into one of the DOE categories ordinary critical or preengineered production before the lift is planned c Hoisting and rigging operations for ordinary lifts require a designated leader who shall be present at the lift site during the entire lifting operation If the lift is being made by only one person that person assumes all responsibilities of the designated leader Chapter 7 Overhead and Gantry Cranes d Leadership designation may be by written instructions specific verbal instructions for the particular job or clearly defined responsibilities within the crew s organizational structure e The designated leader s responsibility shall include the following 1 Ensure that personnel involved understand how the lift is to be made 2 Ensure that the weight of the load is determined that proper equipment and accessories are selected and that rated capacity is not exceeded 3 Survey the lift site for hazardous unsafe conditions 4 Ensure that equipment is properly set up and positioned 5 Ensure that a signaler is assigned if required and is identified to the operator 6 Direct the lifting operation to ensure that the job is done safely and efficiently 7 Stop the job when any potentially unsafe condition is recognized 8 Direct operatio
474. ut of the area between the sling and the load Ensure that all personnel stand clear of the suspended load Avoid shock loading Do not pull metal mesh slings from under a load when the load is resting on the sling Do not store metal mesh slings in an area where they will be subjected to mechanical damage or corrosive action DOE STD 1090 2007 l Avoid twisting and kinking of the legs m Inachoker hitch ensure that metal mesh slings are long enough so that the female handle chokes freely on the mesh never on the handle n Ina choker hitch ensure that the load is balanced When this cannot be done consult the manufacturer for a derating factor or for other means of handling this type of load o Ina basket hitch ensure that the load is balanced to prevent slippage p Do not use metal mesh slings in which the spirals are locked or are without free articulation q Never hammer a sling to straighten a spiral or cross rod or to force a spiral into position r Metal mesh slings used in pairs should be attached to a spreader beam s Ensure that all metal mesh slings have a permanently affixed metal identification tag or tags containing the following information 1 Manufacturer s name or trademark 2 Rated load for the type s of hitch es used and the angle upon which it is based 3 Width and gauge 11 3 4 4 Critical Lifts See Chapter 2 Critical Lifts for critical lift requirements a
475. utting the crane back in service if this b Keep speed slow in lifting and lowering occurs loads 9 5 2 OPERATING NEAR POWER c Swing carefully and slowly and avoid boom LINES AND TRANSMITTER or jib whipping check counterbalance TOWERS clearance It is recognized that operating mobile cranes d Do not let the load strike the boom or where they can become electrified from electric outriggers power lines is an extremely hazardous practice It is advisable to perform the work so there is no e Allow maximum clearance between the possibility of the crane load line or load hook block and boom point sheaves becoming a conductive path Figure 9 2 THisareasoun BE AVOIDED PROHIBITED ZONE SEE TABLE 9 3 CRANE SHALL NOT BE USED TO HANDLE MATERIALS IN THIS AREA Reprinted from ASME B30 5 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 9 2 Danger zone for cranes and lifted loads Operating near electrical transmission line 9 18 Chapter 9 Mobile Cranes DOE STD 1090 2007 The following steps shall be taken to minimize the hazard of electrocution or serious injury as a result of contact between the energized power lines and the crane load line or load a The electric Power Marketing Administrations in DOE may deviate from the requirements of Table 9 3 providing the work is done according to line management approved procedures that do not conflict w
476. ved by a qualified person for conformance to applicable design criteria The hoist support shall be inspected and any deterioration or damage shall be taken into consideration in design calculations for the load to be lifted 4 The hoist shall be inspected in accordance with para Section 8 2 5 just prior to making the lift 5 The lift shall be made under controlled conditions under the direction of a designated person in accordance with a previously prepared lift plan All persons in the area of the hoist shall be alerted that the lift is being made 6 The operator shall test the hoist at the planned engineered load by lifting the load a short distance and setting the brakes The lift shall only be continued if the brakes stop and hold the load Any Chapter 8 Hoists DOE STD 1090 2007 failure to hold the load shall be corrected before proceeding with the lift f The rated load test specified in Section 8 3 2 is not applicable to planned engineered lift 7 The hoist shall be inspected in accordance provisions with Section 8 2 5 after the lift is completed and prior to being used for the lifting of any other load 8 5 8 CRITICAL LIFTS 8 A record of the planned engineered lift See Chapter 2 Critical Lifts for critical lift including calculations inspections and all requirements distances moved shall be placed on file for availability to appointed personnel INTENTIONALLY BLANK Chapter 8 8 20 Hoists
477. veling type they should rotate freely Hooks shall be equipped with latches unless the application makes the use of the latch impractical When required a latch shall be provided to bridge the throat opening of the hook and retain under slack conditions such items as but not limited to slings chains etc Refer to ASME ANSI B 30 10 1 4 LOAD BLOCKS a On hand chain operated hoists a means shall be provided to guard against load chain jamming in the load block under normal operating conditions b On electric or air powered hoists load blocks shall be of the enclosed type and means shall be provided to guard against rope or load chain jamming in the load block under normal operating conditions 1 5 HOIST BRAKES a Hand chain operated hoist s shall be so designed that when the actuating force is removed it will automatically stop and hold any test load up to 125 percent of the rated load b Electric powered hoist under normal operating conditions with rated load and test conditions with test loads up to 125 percent of rated load the braking system shall perform the following functions Appendix A Procurement Guidelines A 2 1 Stop and hold the load hook when controls are released 2 Limitthe speed of load during lowering with or without power to a maximum speed of 120 percent of rated lowering speed for the load being handled 3 Stop and hold the load hook in the event of a complete power failure
478. vices anti two block devices and load moment indicators where required 4 Air hydraulic and other pressurized lines for deterioration or leakage particularly those which flex in normal operation 5 Hooks and latches for deformation chemical damage cracks or wear 6 Wire rope reeving for compliance with hoisting equipment manufacturer s specifications 7 Electrical apparatus for malfunctioning signs of excessive deterioration dirt or moisture accumulation 8 Hydraulic system for proper fluid level 9 Tires for proper inflation and conditions 10 Ground conditions around the hoisting equipment for proper support including ground settling under and around outriggers ground water accumulation or similar conditions 11 The hoisting equipment for level position and 12 The hoisting equipment for level position after each move and setup If any deficiency is identified an immediate determination shall be made by the competent person as to whether the deficiency constitutes a hazard If the deficiency is determined to constitute a hazard the hoisting equipment shall be removed from service until the deficiency has been corrected The operator shall be responsible for those operations under the operator s direct control Whenever there is any doubt as to safety the operator shall have the authority DOE STD 1090 2007 to stop and refuse to handle loads until safety has been assured 15
479. visual examination for cracks and if considered necessary non destructive crack detection with special attention to the heel and to the welds that attach the mounting components to the fork blank Inspection for cracks shall include any mounting mechanisms of the fork blank to the fork carrier Forks shall not be returned to service if surface cracks are detected 2 Fork Tine Inspection Examination for straightness of blade and shank fork angle upper face of blade to load face of the shank fork blade and shank wear Difference in height of fork tips may vary from manufacturer to manufacturer and with tine length For these reasons fork tine inspections shall be done in accordance with manufacturers requirements 3 Positioning Lock Confirm that the Positioning Lock when provided is in good repair and in correct working order If any fault is found the fork shall be withdrawn from service until satisfactory repairs are made 4 Fork Hooks Wear When fork hooks are provided the support face of the top hook and the retaining faces of both hooks shall be checked for wear crushing and other local deformations If clearance between the fork and the fork carrier becomes excessive the fork shall not be returned to service until repaired in accordance with paragraph 10 3 4 3 10 17 5 Fork Marking When fork marking is not clearly legible it shall be renewed Marking shall be renewed per instructions fro
480. vities on equipment covered by this standard should have an understanding of 5 Maintenance and repair procedures the following criteria recommended by the manufacturer or responsible maintenance engineering The tools to safely accomplish their organization work 6 Wiring diagrams 2 Access to operating instructions to perform adjustments 7 Documentation requirements for maintenance and repair 3 Parts information furnished by the manufacturer or the responsible maintenance engineering organization Chapter 6 6 6 Personnel Qualification and Training DOE STD 1090 2007 6 3 1 GENERAL Organizations that employ personnel who operate rig inspect or perform maintenance on equipment covered in this standard shall provide training programs including a means of evaluation to ensure that the personnel are competent to perform the operations This training shall also include applicable site specific hoisting and rigging procedures which address abnormal or emergency operations as well possible equipment failure The training organization shall use training methods best suited for the students and the subject material This may include but is not limited to computer aided training classroom training simulated field training on the job training OJT and training by equipment manufacturer or commercial training companies Score standards shall be set for each examination by the training organization The minimum
481. wing Visually inspect rope in accordance with Section 9 2 6 9 34 Chapter 9 Mobile Cranes DOE STD 1090 2007 Page 3 of 4 EXHIBIT continued SAMPLE FORM MOBILE CRANE LOAD TEST AND FOLLOW UP CHECKS DEFECTIVE OK NA a Rope diameter Previous Present b Wear C Kinks d Broken wires e Other signs of deterioration Visually inspect the rope drum for a Wear b Deformation C Deterioration d Have qualified inspector perform nondestructive tests on hook by visual examination liquid penetrant examination or magnetic particle examination Acceptance No cracks linear indications laps or seams Hooks with more than 596 normal new hook throat opening not to exceed 1 4 in or as recommended by the manufacturer shall be replaced Hooks with any visibly apparent bend or twist from the plane of the unbent hook new hook shall be replaced Hooks having more than 1096 wear in the bowl section or 5 elongation of the shank shall be replaced Lubricate hook bearing and latch pin as applicable Establish three marks A B and C with a center punch For ease in measuring set distances on an even number of inches BEFORE LOAD TEST Length AB in Length BC in AFTER LOAD TEST WE Length AB in Length BC in e Check for 1 Wear and deformation 2 Cracks and twisting 3 Signs of opening between Point A and Point B 9 35 Chapter 9 Mobile Cranes DOE STD 1090 2007 Page 4 of 4 EXHIB
482. wood blocking Overloading shall be avoided as shall sudden dynamic loading that can build up a momentary overload sufficient to break the sling 11 3 1 5 Sling Storage Personnel using slings shall ensure that they are stored properly as follows a Slings should be stored in racks preferably vertical and in designated locations when not in use Do not store slings in a location where they will be subjected to mechanical damage corrosive action moisture extreme heat or kinking Slings may require segregated storage as determined on a case by case basis b Before storage and periodically during storage wipe slings clean to remove as much dirt and abrasive grit as possible and relubricate wire rope and chain slings to extend their useful life Chains should not be lubricated when in use c Do not store metal mesh slings in areas where the temperature exceeds 550 degrees F 288 degrees C or 200 degrees F 93 degrees C if elastomer covered d Do not store synthetic web slings where the temperature exceeds 200 degrees F 93 degrees C Chapter 11 General 11 3 1 6 Inspections a Sling users shall visually inspect all slings each day they are used or prior to use if the sling has not been in regular service records are not required In addition a periodic inspection shall be made at least annually by a qualified inspector More frequent intervals for periodic inspections should be established if necessary as
483. xle bogie Carrier on tires Over side tracks 366 of carrier idler tumbler drive tumbler Crawler type lower Note These lines determine the limiting position of an load for operation within working areas indicated Reprinted from ASME B30 5 2004 by permission of The American Society of Mechanical Engineers All rights reserved Figure 9 1 continued 9 5 Chapter 9 Mobile Cranes DOE STD 1090 2007 10 The sequence and procedure for extending and retracting the telescopic boom section 11 Maximum loads permitted during the actual boom extending operation and any limiting conditions or cautions 12 Hydraulic relief valve settings specified by the manufacturer 9 1 4 LOAD HOIST BRAKES When power operated brakes that have no continuous mechanical linkage between the actuating and braking means are used an automatic means shall be provided to set the brake to prevent the load from falling in event of loss of brake actuating power 9 1 5 POWER CONTROLLED LOWERING A power controlled lowering system shall be provided and shall be capable of handling rated loads and speeds as specified by the manufacturer of the crane 9 1 6 BOOMS a Booms boom sections and jibs shall be clearly identified and shall be used only for the purpose recommended by the manufacturer b Lattice booms shall meet the performance requirements of SAE J987 Crane Structure Method of Test see Chapter
484. y assurance etc shall participate in the review process Before its first use in the actual production process the procedure shall undergo a formal verification and validation process using walk throughs or similar methods to ensure that the steps are appropriate and correct Any discrepancies found during this process shall be corrected and the process repeated until the procedure is correct Any changes to an existing approved procedure shall be performed according to the process specified above The change shall be evaluated to determine whether the revised procedure must be revalidated and reverified Chapter 3 Preengineered Production Lifts DOE STD 1090 2007 3 3 5 REVIEW 3 3 4 APPROVAL a Approved procedures should be reviewed at Before each procedure is validated it shall be reviewed and approved by the following personnel 1 Author of the procedure 2 Representative of a qualified engineering organization 3 Representatives of the responsible oversight organizations e g safety quality assurance After each procedure is validated it shall be reviewed and approved by the following personnel 1 Author of the procedure 2 Representative of a qualified engineering organization 3 Representatives of the responsible oversight organizations 1 e safety quality assurance 4 Management of the facility where the procedure will be performed 5 Management of the production organizatio
485. y issue and distribute the manual under controlled distribution an arrangement where the manual must be specifically requested from the originating source however once requested updates are automatically received through an actively maintained distribution list In 1982 the manual was included as a reference standard in DOE 5480 4 Environmental Protection Safety and Health Protection Standards Updates and improvements have been made over the years on an approximately annual basis Revisions have occurred in 1984 1985 1986 1988 1989 1993 1995 1996 1999 2001 2004 and 2007 to clarify intent comply with OSHA and ANSI B 30 changes improve format strengthen wording delete needless redundancy eliminate obsolescence and the like Prior to inclusion in the manual all changes must be approved by the DOE Hoisting and Rigging Committee which meets annually and by the Headquarters Office of Worker Safety and Health Policy which has safety responsibility for DOE hoisting and rigging The Committee is also a major source for input into the manual particularly concerning those areas that are not defined or are only generally defined by Federal and national standards such as training and qualification and those concerning the DOE s unique operational environment such as hoisting and rigging over nuclear reactors and other locations containing critical equipment In the years that minor revisions occur only the changed pages usually 8 to
486. y other condition that may result in a hazard shall cause the swivel hoist ring to be removed from service Swivel hoist rings shall not be returned to service until approved by a qualified person 3 Written records are not required Periodic Inspection 1 A complete inspection of the swivel hoist ring shall be performed by a designated person The swivel hoist ring shall be examined for conditions such as those listed Chapter 12 Rigging Hardware DOE STD 1090 2007 in Section 12 8 5 and a determination made as to whether they constitute a hazard 2 Periodic inspection intervals shall not exceed one year The frequency of periodic inspections should be based on i Frequency of use ii Severity of service conditions iii Nature of lifts being made iv Experience gained on the service life of swivel hoist rings used in similar circumstances 4 Guidelines for the time intervals are i Normal service yearly ii Severe service monthly to quarterly 111 Special service as recommended by a qualified person 5 Wiritten records are not required 12 8 5 REMOVAL CRITERIA Swivel hoist rings shall be removed from service if damage such as the following is visible and shall only be returned to service when approved by a qualified person a Missing or illegible manufacturer s name or trademark and or rated load identification b Indications of heat damage including welding spatter or arc
487. y seated on the drum and in the sheaves 5 All personnel including the qualified rigger shall be clear of the load c During hoisting take care to ensure that 1 The load is lifted slowly until it clears the ground or other support to minimize swinging 2 There is no sudden acceleration or deceleration of the moving load 3 The load does not contact any obstructions A dry run shall be conducted in areas where clearance is limited DOE STD 1090 2007 HOIST With forearm vertical forefinger pointing up move hand in small horizontal circles LOWER Extend arm downward forefinger pointing down and move hand in small horizontal circles BRIDGE Arm extended forward hand open and slightly raised make pushing motion in direction of travel TROLLEY TRAVEL Palm up finger closed thumb pointing in direction of motion jerk hand horizontally STOP Extend arm palm down hold position rigidly EMERGENCY STOP Extend arm palm down moving hand rapidly right and left MULTIPLE TROLLEYS Hold up one finger for block marked 1 and two fingers for block marked 2 Regular signals follow MOVE SLOWLY Use one hand to give any motion signal and place other hand motionless above hand giving the motion signal Hoist slowly shown as example MAGNET IS DISCONNECTED Crane operator spreads both hands apart palms up Reprinted from ASME B30 2 2005 by permission o
488. y shall be prepared including reference to previous planned engineered lifts structural repairs and modifications of original design 2 The design of the structural mechanical electrical pneumatic and hydraulic components of the crane shall be reviewed by means of applicable calculations for the load to be lifted and approved by the crane manufacturer or a qualified person in accordance with accepted crane design standards if the load to be lifted exceeds 125 of rated load or if the frequency of planned engineered lifts exceeds two during a continuous 12 month period 3 The design of the crane supporting structure shall be reviewed and approved by a qualified person for conformance to applicable design criteria The crane support shall be inspected and any deterioration or damage shall be taken into consideration in design calculations for the load to be lifted 4 The crane shall be inspected in accordance with para Section 7 2 7 just prior to making the lift 5 The lift shall be made under controlled conditions under the direction of a designated person in accordance with a previously prepared lift plan All persons in the area of the crane shall be alerted that the lift is being made 6 The operator shall test the crane at the planned engineered load by lifting the load a short distance and setting the brakes The lift shall only be continued if the brakes stop and hold the load Any failure to hold the lo

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