Attachment_(1.2)retract.pdf

U.S. Coast Guard Naval Engineering Technical Standard

Title

Prepared by:

Author Date

Reviewed by:

Chief, Engineering Services Division Date Surface Forces Logistics Center

Approved by:

Chief Office of Naval Engineering (CG-45)

Date

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Published by Commander, Surface Forces Logistics Center

REV

Technical Standard 583-4 Shore Based Boat Hoisting Systems

18 March 2013

3/22/2013

07/19/2013

TILYOU.MARK.

R.1271107117

Digitally signed by TILYOU.MARK.R.1271107117 DN: c=US, o=U.S. Government, ou=DoD, ou=PKI, ou=USCG, cn=TILYOU.MARK.R.1271107117 Date: 2013.03.18 17:08:11 -04'00'

Digitally signed by KAPLAN.JOHN.

F.1088265161 Reason: I have reviewed this document Date: 2013.03.22 13:49:37 -04'00'

MOORE.NATHAN.

A.1111797370

Digitally signed by MOORE.NATHAN.A.1111797370 DN: c=US, o=U.S. Government, ou=DoD, ou=PKI, ou=USCG, cn=MOORE.NATHAN.A.1111797370 Date: 2013.07.19 15:52:07 -04'00'

SFLC TECHNICAL STANDARD 583-4

REV - 1 583-4

SHORE BASED BOAT HOISTING SYSTEMS

1. SCOPE

1.1 Intent. Ownership and technical cognizance over some shore based boat hoisting systems (davits and mobile boat hoists) has been transferred to SFLC-Industrial Operations Division (SFLC-IOD) and to SFLC-Small Boat Product Line (SFLC-SBPL) from the Shore Infrastructure Logistics Center (SILC). The Platform Authority for SFLC owned or maintained devices is the SFLC-IOD or SFLC-SBPL. The Platform Authority for SILC owned devices is the Weight Handling Systems Subject Matter Expert (SME) within SILC. Whether owned by SFLC or SILC, the following Technical Standard applies to all shore based boat hoisting systems.

NOTE:

Shore based mobile boat hoists and cranes require certification per SFLC Technical Standard 997 Docking Instructions for Cutters and Boats prior to lifting USCG Cutters and Boats. The required processes for these certifications are provided in SFLC CGTO PG-85-00-870-S Drydock Certification Review Process Guide.

1.2 Appendices.

SUB-STANDARD APPENDIX

OSHA DOCUMENTATION A

STANDARD BOAT WEIGHTS FOR LIFTING BY SHORE

BASED DAVITS AND TRAVEL-LIFTS

B

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction Manual (COMDTINST) M11000.11 (series), Civil

Engineering Manual

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 29, Part 1910, Section 178 – Powered Industrial

Trucks, 2010

Code of Federal Regulations (CFR) Title 29, Part 1910, Section 179 – Overhead and Gantry Cranes, 2001

REV - 2 583-4

Code of Federal Regulations (CFR) Title 29, Part 1910, Section 180 – Crawler and Truck Cranes, 2001

Code of Federal Regulations (CFR) Title 29, Part 1910, Section 184 – Slings, 1998

Code of Federal Regulations (CFR) Title 29, Part 1910, Gear Certification, 1999

Naval Facilities Engineering Command (NAVFAC) P-307 – Management of Weight Handling Equipment, 2009

3. REQUIREMENTS

3.1 Shore Based Davits and Mobile Boat Hoists.

3.1.1 General Information.

3.1.1.1 The organization with technical responsibility and the organization with repair and maintenance responsibility shall be identified on the equipment. A maintenance and OSHA documentation label plate, identifying the responsible authorities shall be installed on the equipment; see Appendix A.

3.1.1.2 Shore based davits and mobile boat hoists shall have a posted Working Load Limit (WLL). Davits and mobile boat hoists shall NOT be used to lift loads in excess of the posted WLL, except under controlled test conditions. The Working Load Limit represents the lowest Safe Working Load (SWL) of a series of components working together. Example: If the hook SWL is 5 tons, and the davit structure SWL is 4 tons, the WLL of the system is 4 tons.

3.1.1.3 Shore based davits and mobile boat hoists are subject to inspection by OSHA or USCG inspectors.

3.1.1.4 It is the responsibility of the davit or mobile boat hoist operator to know the weight of the boat being lifted. Some generic boat weights can be found in Appendix B Table 1. Boats shall not be lifted with personnel on board.

3.1.2 Safety.

3.1.2.1 Mobile boat hoists have been codified by SILC as Special Purpose Motor Vehicles.

Requirements for their operation are promulgated by SILC. Mobile boat hoist operators shall be qualified for moving the mobile boat hoist on land.

3.1.2.2 Prior to conducting lifts, the operator shall:

• Verify that the davit or mobile boat hoist has been inspected within the prior year, and all control and safety accessories are functional.

• Visually inspect the rigging and slings for alignment and obvious wear.

REV - 3 583-4

• If lifting with slings, visually inspect the placement of the slings to ensure that they align with boat structure.

• Ensure a Safety Supervisor is present.

3.1.2.3 The davit or mobile boat hoist shall have an overload alarm system. When the load exceeds 90% of system WLL, the alarm system shall audibly and visually alarm. The audible alarm shall have an acknowledge/silence feature; visual alarms shall remain until the alarm condition is cleared.

3.1.2.4 A portable fire extinguisher shall be provided in an easily accessible location on the davit or mobile boat hoist.

3.1.3 Operating Principles.

3.1.3.1 All davit and traveling lifts shall have a posted Working Load Limit (WLL). Davits and mobile boat hoists shall not be used to lift load in excess of the posted WLL, except under controlled test conditions.

3.1.3.2 It is the responsibility of the davit or mobile boat hoist operator to know the weight of the boat being lifted. The operator shall maintain a log of all boats lifted (date/size/weight) with notation of special issues; the log shall be updated at least once weekly. The intent is to document equipment usage, and provide data for evaluation of the need for maintenance, repair or replacement. A Davit or Mobile Boat Hoist Usage Report (consolidated number of hours of operation, number of lifts, maximum weight / typical weight, and special notes) shall be generated annually, and incorporated into annual Unit Reports.

3.1.4 Inspection. Davits and mobile boat hoists shall be subject to Frequent and Periodic inspections in accordance with OSHA requirements, and in accordance with the Equipment Maintenance Manual.

3.1.4.1 Frequent inspection shall include observation during routine operation for any defects which might appear between regular inspections. Such defects shall be reviewed for determination if they are a safety hazard. Frequent inspections shall include:

• Daily review of all functional operating mechanisms for any maladjustment which could interfere with proper operation of the equipment.

• At least quarterly inspection for deformation of hooks.

• At least quarterly inspection for excessive wear, twist or distortion of hoist chains, wires, ropes, and straps.

• At least quarterly inspection of all slings.

• At least quarterly inspection for excessive wear of functional operating mechanism components.

• At least quarterly inspection of travel-lift tires for proper inflation and wear patterns.

• At least semi-annual sampling of hydraulic oil from system reservoirs for cleanliness/ particulate count and water content. Davits and travel-lifts which are used on daily

REV - 4 583-4

basis or the equipment is operating more than 40 hours per quarter (3 months), shall be tested quarterly. Spectrographic analysis is not required at this frequency unless high levels of contamination are evident. Water content shall not exceed 0.05 percent by weight. The target contamination limit shall be no dirtier than ISO 4406 Code 18/16/13, unless specific contamination limits (in ISO 4406 reporting format) have been established by the davit or mobile boat hoist manufacturer.

3.1.4.2 Periodic Inspections – Annual: Annual inspection shall be conducted annually, not to exceed 15 months without SILC SME, or SFLC–SBPL Engineering Officer or SFLC-IOD Engineering Officer approval. It is intended that the inspection be accomplishable at the unit level, without contractor assistance. Annual inspection may include the use of ladders and/or a man-lift as necessary to access components for close inspection. Annual inspection shall include the following generic requirements; additional specific requirements may be promulgated as part of Maintenance Procedure Cards, or may be contained in the Equipment Maintenance Manual.

• Inspection to determine if there are deformed, cracked, or corroded members.

• Inspection for loose bolts and rivets.

• Inspection for cracked or worn sheaves or drums.

• Inspection of worn, cracked, or distorted parts such as pins, linings, pawls, and ratchets.

• Inspection of sensors and indicators over their full range, and for any significant inaccuracies.

• Performance and compliance inspection with safety requirements for gasoline, diesel, electric or other power plants.

• Inspection of power trains (lifting and propulsion) for improper performance or non-compliance with applicable safety requirements, including excessive wear of drive train and steering components.

• Inspection of hooks for cracking or bending/distortion.

• Inspection of hydraulic and pneumatic hoses and fittings for leakage or abrasion.

• Inspection of hydraulic and pneumatic pumps and motors for loose fasteners, joint leaks, seal leaks, or loss of pressure.

• Inspection of hydraulic and pneumatic valves for improper operation, relief valve set pressures, and sticking spools.

• Inspection of hydraulic and pneumatic cylinders for drafting, seals leakage, scored rods, and deformed joints.

• No-load demonstration of all safeties and control features, and operation with a generic weight (as available) to demonstrate application and release of brakes.

• Inspection of electrical apparatus for signs of pitting or deterioration of controller contactors, limit switches, and pushbutton stations.

• Lubricants and hydraulic oils shall be changed for cause, not based on a set annual basis. The objective is to achieve multi-year service life, if possible. A spectrographic analysis of hydraulic oil sample shall be taken annually, specifically looking at degradation of additive packages, and material content of contamination.

• Conduction of Operational testing; (para 3.1.7.1).

REV - 5 583-4

3.1.4.3 Periodic Inspections – Biennial (2 years): More intensive inspections shall be conducted biennially, and after overhauls. The period between inspections shall not exceed 27 months without SILC SME, or SFLC-SBPL or SFLC-IOD SME approval. The weight test portions of this inspection shall be accomplished as part of acceptance. The inspections shall be more formal, with certified test weights, and may require outside or contractor assistance. This inspection shall include accomplishment or completion of Annual Testing, and at least the following generic requirements; additional specific requirements may be promulgated as part of Maintenance Procedure Cards, or may be contained in the Equipment Maintenance Manual.

• More detailed inspection of brake system parts, linings, and settings. Some minor disassembly may be required.

• More detailed inspection of power trains, including hydraulic systems, for wear and degradation. Some minor disassembly may be required, but disassembly to bare frame or manifold is not required unless there is evidence of failure.

• General lubricants may be changed on a biennial basis. Hydraulic oils shall be evaluated for continued use and replacement on a 4 year cycle.

• Conduction of Rated Load testing; (para. 3.1.7.4).

3.1.4.4 Davits and mobile boat hoists shall be inspected and technically evaluated for remaining service life at not more than 20 years of service and again in not more than 10 year intervals.

The evaluation shall identify corrosion and structural issues, and any mechanical discrepancies.

The safety systems shall be evaluated, and reviewed for update. A Remaining Service Life report shall be prepared and filed with the OSHA documentation. The Report shall estimate the remaining service life of the equipment, and options for Service Life Extension.

3.1.5 Repair. Davits and mobile boat hoists shall be kept in good repair. Problems identified during frequent and periodic inspections shall be evaluated, light repairs accomplished, and request for heavy repairs initiated in a timely manner. Unsafe conditions shall be corrected before the equipment is returned to service:

3.1.5.1 When wire ropes are changed or when winch brakes are overhauled or adjusted, the davit or mobile boat hoist shall be given a Wire Rope/Brake Overhaul Weight Test (para. 3.1.7.3). It is intended that the inspection be accomplishable at the unit level, without contractor assistance.

3.1.5.2 Overhauls shall be scheduled on an as-needed basis. Overhauls of critical components should not generally be required more than once every 4 to 5 years. If component overhauls are more frequent, the root cause of such component failures shall be sought.

3.1.6 Maintenance. A preventive maintenance program based on the davit or mobile boat hoist manufacturer’s recommendations shall be established and documented. Evidence of compliance with the preventive maintenance program shall be maintained. A copy of the maintenance program shall be maintained with the maintenance and OSHA documents (Appendix A).

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3.1.7 Tests/Inspections. Operational/No-Load tests shall be conducted prior to Annual or Rated Load tests. Annual weight tests shall be conducted once a year. Rated load tests shall be conducted biennially (every 2 years) or after overhaul. Winch and Wire tests shall be conducted after changing wire rope or servicing the brakes. At the conclusion of all but the no Operational/ No-Load test, a test report shall be generated, and a copy of the test report shall be filed in the maintenance and OSHA documents (Appendix A).

3.1.7.1 Operational Test: Tests shall include demonstration of the following functions over the entire range of motion of the equipment w/o a test load:

• Load lifting and load lowering mechanisms.

• Boom lifting and lowering mechanisms.

• Boom extension and retraction mechanisms.

• Swinging mechanisms.

• Travel and travel steering mechanisms.

• Safety Devices.

• Operational Aids.

3.1.7.2 Annual Weight Test: A test conducted with a weight of opportunity (nominally 25% to 50% of the crane or mobile boat hoist WLL). The test shall consist of moving the load several feet, several times each to demonstrate the following:

• Operation and release of all wire rope brake devices,

• Operation and release of hydraulic cylinder brake devices,

• Operation and release of all mechanical braking mechanisms,

• Operation and release of all parking brake mechanisms, and

• Operation and release of traveling brake mechanisms.

3.1.7.3 Winch and Wire Test: When wire rope is replaced, or when winch brake systems are adjusted, at least the following shall be accomplished.

• No-load operation of the winch to ensure the wire is spooling properly on the drum.

• Weight of opportunity (nominally 50% of the crane or mobile boat hoist WLL) demonstration of operation and release of the winch brake mechanisms.

3.1.7.4 Rated Load Tests shall include conducting the Operational Tests (as a preliminary) and then a Weight Test with a test load of 110% of the WLL of the davit or mobile boat hoist.

Weight Tests shall be conducted without components being in overload condition, and without adjustment to any system pressure or limiting devices; winch overload alarms shall indicate and may be temporarily silenced (audible only) for conducting the test. Each of the following functions shall be demonstrated at no specified speed:

• Load lifting and load lowering mechanisms.

• Boom lifting and lowering mechanisms.

REV - 7 583-4

• Boom extension and retraction mechanisms.

• Swinging mechanisms.

• Travel and travel steering mechanisms.

3.2 Loose Cargo Gear.

3.2.1 General Information. Loose Cargo Gear shall include cargo gear and davit or mobile boat hoist accessories which are not attached to or inspected as part of the davit or mobile boat hoist. Loose Cargo Gear shall be tested and inspected in accordance with 46 CFR (OSHA) Part 1919.

3.2.2 Safety. Safe Working Loads (SWL) shall be identifiable on all loose cargo gear. All loose cargo gear shall be delivered with pull test certificates, which shall be maintained with the cargo gear inventory in the OSHA and Maintenance Documentation (Appendix A-3).

3.2.3 Operating Principles. All loose cargo gear used with the davit or mobile boat hoist shall have adequate SWL for the application.

3.2.4 Inspection. Loose cargo gear shall be visually inspected and inventoried annually.

The inspection report and inventory shall be maintained in the OSHA and maintenance documentation (Appendix A).

3.2.5 Repair. Loose cargo gear which is repaired shall be proof loaded prior to being returned to service.

3.2.6 Maintenance. Loose cargo gear shall be maintained in working order. Components removed from service for repair, testing, or replacement shall be clearly tagged as not available for service, and shall be segregated from working components.

3.2.7 Tests/Inspections. Loose cargo gear shall be thoroughly examined at least once every 5 years by a competent authority. Loose cargo gear shall be proof load tested in accordance with 46 CFR 1919.27. For equipment rated less than 20 tons, the proof load shall be to 125% of Working Load Limit.

4. NOTES

4.1 Modifications. Modifications to davits and mobile boat hoists shall be approved by the SILC SME, or by SFLC-ESD-NAME via the Engineering Change Process. Modifications shall be documented with distribution of official USCG drawings, or with drawings certified by a Professional Engineer (OSHA requirement); see 29 CFR OSHA 1910.179/180/181 as applicable.

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APPENDIX A

OSHA DOCUMENTATION

A1. SCOPE

A1.1 Intent. Documentation on shore based davits and mobile boat hoists shall be maintained on site and available to an inspector, on demand. Additional information on Equipment History Files and document retention may be found in NAVFAC P307.

A2. REQUIREMENTS

A2.1 OSHA Documentation. A hard copy file to document the ratings and technical information for shore based davits, mobile boat hoists, and related loose cargo gear shall be maintained by the applicable operating UNIT or by the BASE on which the equipment is located.

The file shall include the following:

• Ratings of equipment, and all authorized modifications thereof.

• Identification of the Activity having Technical Authority, and identification of the

Activity having Maintenance and Repair responsibility for the davit or traveling lift.

• A copy of the Maintenance Plan.

• Copies of inspection reports.

• Copies of overhaul reports and major component replacements, including replacement of wire ropes and slings.

• Test reports.

The file shall be maintained on-site, and shall be available “on-demand” to an inspector (OSHA, USCG, or contractor).

A3. NOTES

A3.1 Label Plate. A weatherproof label plate shall be posted on each davit and mobile boat hoist adjacent to the manufacturer’s label plate to ensure that the user, maintenance personnel, and inspectors are aware of and can access documentation on demand. The plate shall include the title “MAINTENANCE AND OSHA DOCUMENTS” and shall identify:

• That maintenance and OSHA documentation is available on-site.

• The command or activity with Technical Authority over the device, and the command or activity responsible for maintenance.

• The location (building and office code) of the technical and maintenance documentation, and

• The telephone number or extension of the POC to obtain the documents.

A3.2 Plate Size. The size of the plate shall be appropriate to the equipment; the suggested minimum size of the label plate is 3 inches high by 5 inches wide. The color of the plate shall be

REV - Appendix A - 2 583-4 in high contrast to the color of the equipment, and the location shall be visible by the operator on start-up.

A3.3 Plate Lettering. The label plate title shall be in not less than 3/8 inch lettering; text shall be in not less than ¼ inch lettering. The title and text shall be in high contrast to the background color. The label plate shall be secured with threaded fasteners, and shall be suitable for exposed installation in the weather.

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APPENDIX B

STANDARD BOAT WEIGHTS FOR LIFTING BY

SHORE BASED DAVITS AND TRAVEL-LIFTS

B1. SCOPE

B1.1 Intent. This appendix provides a listing of generic boat weights for standard Coast Guard boats in Table 1.

B2. REQUIREMENTS

B2.1 General. The shore based davit or mobile boat hoist operator shall identify the lifting weight of the boat to be lifted prior to beginning the lift. Generic boat weights are shown in Table 1. If this weight is more than 80 percent of the rated capacity of the crane or mobile boat hoist, the operator should verify the actual weight of the boat to be lifted prior to proceeding.

B2.1.1 Lifting Weight - Small Boats. Small boats will generally have a Lifting Weight plate attached to the stern of the boat, documenting the boat weight in a ready to lift condition (full load and fuel, no personnel).

B2.1.2 Lifting Weight - Large Boats. For larger boats with tankages, and for small cutters the operator should consult the applicable Stability and Loading Booklet for the cutter or boat (See the Naval Engineering Technical Information Management System (NETIMS)). The lifting weight of the boat and weight distribution will vary with the fluids on board.

B2.1.3 Multi-Point or Multi-Strap Lift. When conducting a multi-point or multi-strap lift, the operator shall be aware that weight distribution is not evenly spread within boats; the aft weight concentration can be 60 percent or more of the total boat weight. The location of straps shall also take into consideration the location of framing within the cutter or boat.

TABLE 1 - STANDARD BOAT WEIGHTS FOR LIFTING

BY SHORE BASED DAVITS AND MOBILE BOAT HOISTS

BOAT DESCRIPTION WEIGHT

13' CB-S Cutter boat Small (Zodiac H472) tbd 16' AB-SKF ATON boat skiff 1,146 17' CB-M Cutter boat Medium (Zodiac H540) 2,300 18' ATON-M Cutter boat ATON Medium (Metal Shark) tbd 20' AB-S ATON boat small 2,765 23' CB-OTH Cutter boat OTH (Zodiac H733) 4,500 23' SRP Short Range Prosecutor (Zodiac H770) 5,435 23' UTL Utility Boat Light (SAFE BOATS) tbd

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BOAT DESCRIPTION WEIGHT

24' CB-L Cutter boat Large (ACB) 3,815 24' SPC-SW Special Purpose Craft - Shallow Water tbd 24' ATON-L Cutter Boat ATON Large (Metal Shark) tbd 25' UTM Utility Boat Medium (SAFE BOATS) tbd 25' TPSB Trailerable Port Security Boat 5,325 25' RBS Response Boat - Small 8,660 26' MSB Motor Surf Boat (OTECH) tbd 26' TANB Trailerable Aids to Navigation Boat 7,380 29' RB-S II 29' Response Boat - Small II tbd 32' TPSB Transportable Port Security Boat (KMI) tbd 33' SPC-LE Special Purpose Law Enforcement Boat (SAFE) tbd 36' LRI Long Range Interceptor (Williard) 24,000 36' SPC-BTD Boarding Team Delivery - Special Purpose tbd 38' ASB Arctic Survey Boat (Munson) tbd 38' LCVP Landing Craft (Munson) tbd 41' UTB Utility Boat 30,000 42' SPC-NLB Near Shore Lifeboat (SAFE) 33,100 44' MLB Motor Life Boat 39,500 45' RBM Response Boat Medium 36,500 45' BU Buoy Boat 47,800 47' MLB Motor Life Boat 40,000 49' BUSL Buoy Boat Stern Loading 87,000 52' SPC-HWX Heavy Weather - Special Purpose Craft 78,940 55' ANB Aids to Navigation Boat 78,400 64' SPC-SV Special Purpose Craft - Screening Vessel tbd

B3. NOTES None.