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Hoisting & Rigging Assessment Plan

By Donna Roberts,2014-07-01 01:22
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Hoisting & Rigging Assessment Plan

    HOISTING & RIGGING

    Assessment Plan

    NNSA/Nevada Site Office Facility Representative Division

    Performance Objective: To determine that hoisting and rigging operations are conducted according to “industry best standards” for increasing equipment reliability

    while assuring worker safety, and to verify issues being addressed in BN Hoisting assessment.

Criteria:

    Lifts are identified and categorized appropriately for scheduled maintenance. DOE-STD-1090-2001

    An integrated process ensures safety issues are identified and controls established. DOE-STD-1090-2001

    Personnel operating and maintaining the hoisting equipment are trained; they understand their roles and responsibilities. DOE-STD-1090-2001

    Maintenance conducts safety inspections of hoisting and rigging equipment on a scheduled basis, certifying that safe operations are in compliance with good conduct of operations. DOE-STD-1090-2001

Equipment operators comply with industry best standards for operating hoisting and

    rigging equipment. DOE-STD-1090-2001

    Management ensures that all personnel operating hoists have been medically xamined and certified as fit to perform their duties. DOE-STD-1090-2001

References:

    Title 29 CFR 1910.179, “Overhead and Gantry Cranes”

    Title 29 CFR 1910.180, “Crawler Locomotive and Truck Cranes”

    Title 29 CFR 1910.184, “Slings”

    Title 29 CFR 1926.251, “Rigging Equipment for Material Handling”

    Title 29 CFR 1926.550, “Cranes and Derricks”

    Title 29 CFR 1926.553, “Base-Mounted Drum Hoists”

    Title 29 CFR 1926.554, “Overhead Hosts”

    Title 29 CFR 1926.555, “Conveyors”

    Title 30 CFR Part 57, Subpart D, "Personnel Hoisting"

    ANSI A10.28, “Work Platforms Suspended from Cranes and Derricks

    ANSI B20.1-1957, “Safety Code for Conveyors, Cableways and Related Equipment

    ANSI B30.2, “Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist”

    ANSI B30.5, “Mobil and Locomotive Cranes”

    ANSI B30.7, “Base-Mounted Drum Hoist”

    ANSI B-30.9, “Slings”

    ANSI B30.10, “Hooks”

ANSI B30.11, Monorail and Underhung Cranes”

    ANSI B30.16, “Overhead Hoists (Underhung)

    ANSI B30.17, “Overhead and Gentry Cranes (Top Running Bridge, Single Girder,

    Underhung Hoists)

    ANSI B30.21, “Manually Lever-Operated Hoists”

    ASTM A-391, “Alloy Steel Chain”

    DOE-STD-1090-2001, Hoisting and Rigging (Formerly Hoisting and Rigging Manual)

    BN CD-0444.001, “General Safety Rules”

    BN CD-0444.006, “Formal Workplace Inspection Program (FWIP).

    BN CD-0444.063, “Lockout/Tagout”

    BN CD-0444.071, “Chains and Slings”

    BN CD-0444.70, Hoisting Apparatus, Cranes and Conveyors BN-0029, “Inspection Log Alloy Steel Chains & Load Binders”

    BN-0030, “Inspection Log Natural & Synthetic Fiber Rope Slings”

    BN-0031, “Inspection Log Synthetic Web Straps & Slings”

    BN-0032, “Inspection Log Wire Rope Slings”

    Purchasing Requisition

    BN OP-2110.121, “Crane Inspections and Certification”

    BN OP-2110.008, “Inspections of Slings and Chains”

    BN OP-21110.061, “Hoist Operator Qualification”

    BN OP-2100.042, “Rigging Work Operations”

    BN OP-2110.018, “Use of Rigging and Lifting Fixtures”

    BN CD-0444.072, “Powered Industrial Trucks”

    BN CD-0444.073, “Aerial Work Platforms/Lifts”

Approach:

    Document Review

Interviews:

    Fleet & Equipment personnel / Signalers Qualified Crane or Hoist Operators (Operators) Facility Manager / Supervisors / Employees Qualified Crane or Hoist Inspectors (Inspectors) Safety & Industrial Hygiene Department Manager Procurement & Property Management Department Manager

Observations:

    Operations/Work

    Lines of Inquiry

    HOISTING & RIGGING

    NNSA/Nevada Site Office Facility Representative Division

     YES NO N/A COMMENTS

     Hoisting Apparatus, Cranes and Conveyors BN CD 0444.070

     Initial Inspections BN CD-0444.070, 4.1

    1. Have Fleet & Equipment personnel performed a thorough

    inspection of the crane, conveyor or hoist and all associated

    components after:

     a. Initial installation?

     b. Any alteration, modification or reassembly? 2. Have the results of each inspection been recorded according to

    the requirements in Title 29 CFR 1910.179, 1910.180,

    1926.550, or ANSI B30.2 or B30.10 standards?

     Pre-operation Inspections BN CD-0444.070, 4.2

    3. Are Operators using an appropriate pre-operation inspection

    checklist and performing a visual inspection at the beginning of

    each shift or prior to start-up?

     Inspections - BN CD-0444.070, 4.3

    4. Are Inspectors performing routine inspections according to

    Title 29 CFR 1910.179, 1910.180, 1926.550 and the

    appropriate ANSI B30 series standards?

    5. Are they performing inspections, when appropriate, at floor

    level?

    6. Are they recording the results of each inspection according to

    the requirements in Title 29 CFR 1910.179, 1910.180,

    1926.550 or ANSI B30.2 or B30.10 standards?

     Technical Inspections of Device-Handling Crane/Hoists

    BN CD-0444.070, 4.4

     YES NO N/A COMMENTS

     7. Are Fleet & Equipment personnel in concert with a device

    owner or designee, performing technical inspections of

    device-handling cranes according to DOE, BN. LANL, LLNL,

    SNL or other customer requirements as deemed appropriate by

    the Safety & Industrial Hygiene Department Manager?

    8. Are they documenting the results of each inspection according

    to the requirements in Title 29 CFR 1910.179, 1910.180,

    1926.550 or ANSI B30.2 or B30.10 standards?

     Operating Cranes or Hoists and Using Standard Hand Signals

    - BN CD-0444.070, 4.5

    9. Are Supervisors classifying each lift as ordinary or critical

    during the planning phase of each lift?

    10. Are Supervisors designating a signaler for each crane or hoist

    operation when a signaler is required?

    11. Are Supervisors ensuring that the crane/hoist operator and

    signaler are familiar with standard hand signals before the

    operation begins?

    12. Are the Signalers using standard hand signals to direct crane

    or hoist operations?

    13. Do the Signalers remain clearly visible to the operator and

    close enough so that had signals are distinctly apparent to the

    operator?

    14. Do the Signalers use a radio or telephone communication

    system when unable to remain clearly visible to the operator?

    15. Do the Signalers communicate directly with the operator when

    using radio or telephone communications without going

    through a third person?

    16. Do they cease operations if the operator cannot clearly see a

    hand single, hear a radio or use the telephone communication

    system?

    17. Do they ensure that communications have been reestablished

    before resuming the operation?

     YES NO N/A COMMENTS

     Personnel Hoist - BN CD-0444.070, 4.6

    18. Has the Facility Manager ensured that hoist or cranes used for

    transporting personnel have been previously approved to

    perform these operations by the Safety & Industrial Hygiene

    Department Manger?

    19. Has the Facility Manager made the personnel hoisting

    operations support execution plan (SEP) readily available on

    the site?

    20. Has the Facility Manager submitted a copy of the SEP to the

    Safety & Industrial Hygiene Department Manager for review

    and approval?

    21. Does the SEP show the approval signature of the Safety &

    Industrial Hygiene Department Manager?

    22. Does the Facility Manager have a copy of the SEP at the

    worksite?

    23. How does the Facility Manager enforce compliance with the

    SEP?

     Conveyors - BN CD-0444.070, 4.7

    24. How has the Facility Manager ensured that conveyors used for

    transporting bulk materials have been previously approved to

    perform their respective operations in a safe manner?

    25. Is there a copy of the SEP at the worksite? 26. Does the SEP identify the method used to safely operate

    conveyors?

     General Conveyor Requirements - BN CD-0444.070, 4.8

    27. Are there means at the operator’s station for stopping the motor

    or engine of any conveyor system?

    28. Is the conveyor system equipped with audible warning signal

    which sounds immediately before starting up the conveyor?

    29. Are there suitable guards provided to protect employees

    required to work below the conveyors where a conveyor

    passes over work areas, aisles or thoroughfares?

     YES NO N/A COMMENTS 30. Are conveyors locked out or otherwise rendered inoperable

    and tagged out with a “Do Not Operate” tag during repairs or

    when operation is hazardous to employees performing

    maintenance work?

    31. Do all the conveyors meet the requirements for design,

    construction, inspection, testing, maintenance and operation

    as prescribed in ANSI B20.1-1957, “Safety Code for Conveyor,

    Cableways and Related Equipment.”?

    32. Do the operators perform a visual inspection, using appropriate

    pre-operation inspection checklist, at the beginning of each

    shift or before start up of any conveyor system?

    33. Are operators aware that they should cease operations of any

    conveyor system at the first sign of an unsafe condition and

    immediately notify their supervisor?

    34. Are inspectors performing routine inspections of conveyor

    systems according to Safety Directive BN CD-0444.006,

    “Formal Workplace Inspection Program (FWIP).”?

    35. Do they place special emphasis on:

     a. Conveyor design and construction?

     b. Guards along the conveyor’s entire length?

     c. Gears, sprockets, sheaves and other moving parts are

    protected either by standard guards or are positioned in such

    manner as to protect employees from injury?

     d. Lubrication of moving parts?

     e. Excessive wear on conveyor components?

     f. Guards along travel ways?

     g. Lighting, ventilation and drainage? 36. Are the results of the inspections being recording per BN

    Safety Directive CD-0444.006?

    37. Do the Inspectors cease operations of any conveyor system at

    the first sign of an unsafe condition and immediately notify the

    manager?

     YES NO N/A COMMENTS

     Disqualifying Operators and Inspectors BN CD-0444.070, 4.9

    38. Are Facility Managers aware that they should disqualify a

    crane, hoist or convey operator or inspector for unsafe work

    practices, physical incapacity, accidents, failure to pass a skill

    evaluation, or other reasons that indicate the employee is not

    capable of competently and safely performing assigned tasks?

     Training - BN CD-0444.070, 5.0

    39. Have Managers scheduled overhead and gantry crane

    operators and hoist operators to attend course 1E000371,

    “Hoist and Overhead Cranes”, or an equivalent course?

    40. Have Facility Managers scheduled mobile crane operators to

    attend course 1E000373, “Mobile Cranes”, or an equivalent

    course?

    41. Has the Facility Manager required crane or hoist operators to

    demonstrate knowledge by completing a daily inspection?

    42. Has the Facility Manager required crane or hoist operators to

    demonstrate skill in manipulating and controlling the crane or

    hoist through all phased of standard operations?

    43. Has the Facility Manager scheduled employees who perform

    monthly overhead crane or hoist inspections to attend course

    1E00P371, “Practical Operations and Monthly Inspection of

    Hoist Overhead Cranes”, or an equivalent course?

     Chains and Slings BN CD 0444.071

     General - Slings BN CD-0444.071.4.1.1

    44. Are all slings individually identified by the manufacture or by

    the user organization before use?

    45. Is each sling and fastening inspected before use for damage or

    defects?

    46. Are all slings tested, maintained, inspected, and certified

    according to the most recent edition of ANSI Standard B-30.9

    and Title 29 CFR 1910.184?

     YES NO N/A COMMENTS 47. Is each sling purchased certified as proof tested by the

    manufacturer according to the appropriate ANSI B30.9 and

    Title 29 CFR 1926.251, “Rigging Equipment for Material

    Handling”?

    48. Does each sling purchased meet the requirements of Title 29

    CFR 1910.184, “Slings” and Title 29 CFR 1926.251, Rigging

    Equipment for Material Handling”?

    49. Does BN Procurement & Property Management Department

    maintain a copy of the certification issued with each sling?

    50. Does the user organization have a copy of each certification?

    51. Are slings stored in an area not near acids or alkalies and in an

    area where they are safe from being struck by tools or

    equipment?

     Alloy Steel Chains and Slings - BN CD-0444.071.4.1.2

    52. Do all hooks, rings, oblong links, pear-shaped links, or

    mechanical coupling links or other attachments when used with

    alloy-steel chains have a rated capacity of at least equal to that

    of the chain. Job or shop hooks or links, makeshift fasteners,

    or other such attachments formed from bolts, rods. Steel plate,

    etc. shall not be used. Nonstandard end fittings designed by

    the designated engineer may be used but they must be proof

    tested to two times their rated load?

    53. Do all alloy steel chains have a permanently affixed durable

    metal identification tag stating the following information:

     a. Size?

     b. Manufacturer’s grade?

     c. Rated load and the angle upon which the rating is based?

     d. Reach?

     e. Number of legs?

     f. Sling manufacturer?

    54. Are all chains used for hoisting alloy grade 80 steel and do they

    have markings as shown in the table 1 on page 4 of

     YES NO N/A COMMENTS

    CD-0444.071?

    55. Are slings stored in racks or in designated locations when not

    in use?

    56. Are the slings wiped clean periodically to remove as much dirt

    and grit as possible and are they not lubricated when in use?

     Synthetic Web Slings - BN CD-0444.071.4.1.3

    57. Is each synthetic web sling permanently marked by the

    manufacturer showing the following information:

     a. Manufacturer’s name or trademark?

     b. Manufacturer’s code or stock number?

     c. Rated loads for the type of hitches used?

     d. Type of natural or synthetic material? 58. Is each sling marked with an identifying number and inspection

    due date?

    59. Are the synthetic web slings stored, preferable vertical, in racks

    or in designated locations?

    60. Are slings stored in a location that protects them from direct

    sunlight or ultraviolet light?

    61. Are the slings wiped clean periodically to remove as much dirt

    and abrasive grit as possible?

    62. Are slings stored in areas that are not dame or dirty or exposed

    to corrosive materials or adverse weather conditions?

     Natural and Synthetic Fiber Rope Slings

    BN CD-0444.071.4.1.4

    63. Are the natural or synthetic fiber rope slings marked to show

    the following information:

     a. Manufacturer’s name or trademark?

     b. Manufacturer’s code or stock number?

     c. Rated loads for the type of hitches used?

     d. Type of natural or synthetic material?

     e. Date of manufacture?

     YES NO N/A COMMENTS 64. Do operators ensure that natural or synthetic fiber rope slings

    are not subjected to a sustained load equal to the rated load for

    more than three days?

    65. Are natural or synthetic fiber rope slings inspected to ensure

    they are made from new rope and have not been repaired or

    reconditioned?

    66. Are natural or synthetic fiber rope slings stored in an area

    where they will not be subjected to any of the following:

     a. Mechanical damage or corrosive action?

     b. Extreme temperatures lower than 20F (-6.6C) and higher

    than 150F (65.5C)?

     c. Excessive moisture higher than 80% relative humidity?

     d. Excessive dryness lower than 10% relative humidity?

     Wire Rope Slings - BN CD-0444.071.4.1.5

    67. Is each wire rope sling permanently marked with its rated

    capacity on a swage or socket either by stamping or etching?

    68. Do all wire rope slings have a means of individual identification

    for use in recording the required periodic inspection? It may be

    the manufacturer’s tag (purchase order number, item number),

    organization tag, etching on the swage or socket, or stamping

    according to the manufacturer’s directions.

    69. If the manufacturer’s tag has been lost has the user

    organization used an etching or stamping system in its place?

    70. If the organization does not have an etching or stamping

    system has a qualified engineer performed a proof test

    according to ANSI B30.9, Section 9.2.3 and documented the

    results on the BN-0032 “Inspection Log Wire Rope Slings”?

    71. Are wire rope slings stored in racks (preferably vertical) or in

    designated locations when not in use?

    72. Are wire rope slings cleaned periodically to remove as much

    dirt and abrasive grit as possible?

     Slings - BN CD-0444.071.4.2

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