Attachment 1_Appendix 4_GA Lift Procedure.pdf

DIII-D Hoisting and Rigging Compliance Standard Pg 1 of 20 11/18/22

General Introduction: This standard highlights the DIII-D crane program for compliance to DOE H&R and the GA S10 Crane Safety procedures.

DIII-D Specific Safety Practices

1. General

a. Promptly report any crane malfunctions to the attention of your supervisor or the

Facilities Manager.

b. Hard hats are to be worn by all crane associated team members and by anyone within 20 feet of an active load operation.

c. Lock Out and Tag Out the crane upon any crane malfunction or out of date inspection dates.

2. Crane operation

a. Crane operator performs daily inspection; check proper control functions, upper hook limit operation, and survey the rails for any obstructions are minimum requirements.

b. Crane specific qualified operators need specific check out on cranes > 5 ton capacity and are posted adjacent to the cranes (e.g. high bay cranes) all trained operators are qualified to operate cranes < 5 tons. Specific areas like the Fast Wave and ECH vault require orientation and permission from the area supervisor.

c. Blind start and north (pit) crane movement from its parking space (at north end of pit) is prohibited. The operator must have line of sight of the moving crane at all times, including over-the-wall lifts.

d. Over –the-wall into the pit and pit crane operation require the checkout and approval of the pit coordinator and DIII-D Safety Officer. A list is posted in the high bay listing the approved pit and over-the-wall crane operators.

e. Typical crane paths in the high bay are down the east side then crossing west to the landing point.

f. The horn on all cranes having one shall be sounded upon crane start up and occasionally while the bridge amd/or trolley are traveling, not incessantly though.

g. Crane operator is responsible for the safety of all personnel near the lifting area, not moving a load over personnel, and ensuring hard hats are worn by all personnel that the crane will travel over, including without a load.

h. Crane operator distractions are to be kept to a minimum; upon interruption the lift operation shall stop until interruptions are cleared. This includes cell phone calls or pages etc.

i. No riding on a cranes, hooks, slings, or loads is allowed. Special situations where the crane maintenance personnel ride the high bay crane as part of their preventative or corrective maintenance is allowed. The pit coordinator can authorize or run the crane with riders on the bridge in the high bay for special needs e.g. overhead photography, work on ceiling lights, etc.

3. Rigging

a. Only rigging with yearly inspection tags is allowed to be used to lift a load. Rope is only to be used as tag lines, not to lift any part of a load.

Appendix 4

DIII-D Hoisting and Rigging Compliance Standard Pg 2 of 20

b. Swivel eyes are preferred over eye hooks for attaching slings to a load.

c.

Types of Lifts Lift Category Risk

Criteria/determined By Responsible Line Manager

Procedure Crane Operator Req.

Critical a. potential serious personnel injury

b. potential 3 month loss of time $50k damage

Yes--- written and approved by: equipment owner, area supervisor, Safety Officer, and DIII- D Director or designee

Critical Lift Crane Operator---one who has > 5 years experience as crane operator and appointed by management for this lift.

Ordinary Lift

Does not meet the critical or production lift criteria

None required Trained crane operators

Production repetitive lifts

Lift is controlled by procedure and is part of a repetitive process.

This maybe a repetitive critical lift as well.

Yes--- written and approved by: equipment owner, area supervisor, Safety Officer, and DIII- D Director or designee

Trained Lift Operator

Special Over-the-Wall No, training and approval by Pit Coordinator and Safety Officer

Highbay/Pit crane operation approved

Lift Procedures Type Form Signoffs Critical See Safety Web

Site Equipment Responsible Person (RP), their supervisor, and DIII-D Director

Production Lift See Safety Web Site

Engineer, and supervisor, plus Facility Director if it is a repetitive critical lift.

DIII-D Overhead Cranes Capacity (Ton)

Location Maintenance Schedule Operator Qualification/Training

20 North Wall Pit, Bldg 34 Yearly Crane/Special Orientation in pit and over wall*

20 South Wall High Bay, Bldg 34

Yearly Crane

1.5 Fast Wave Area Yearly Crane and orientation

2 North Wall, under pit Yearly Crane/Special Orientation

DIII-D Hoisting and Rigging Compliance Standard Pg 3 of 20 shield roof

1.5 North ECH Vault Yearly Crane + Orientation

1.5 x2 Old ECH Vault Serviced??? Crane + Orientation

1.5 Mezzanine 1 Yearly Crane

*List of qualified crane operators for pit and over-the-wall located in high bay adjacent to wireless pendant charging station.

Crane and Hoisting and Rigging Training Requirements Job classification Required Training (3 yrs retraining) Trainer

Critical Crane Operator

Crane, and Hoisting &Rigging (CH&R) + experience

Designated by RLM

Crane Operator > 2 T Crane Course Over-the-Wall Crane Operator

CH&R

Pit Coordinator + designated experienced personnel

Pit Crane Operator CH&R Pit Coordinator Crane Operator <2T CH&R Periodic Crane course

DIII-D Hoisting and Rigging Compliance Standard Pg 4 of 20

Hoisting and Rigging Equipment Maintenance Item

Inspection Type

Inspector Frequency Documentaion

Crane Rope Inspection per

DOE H&R

section

Monthly Yes

Crane General Overall inspection and maintenance

Crane Vendor

Biannual/yearly Yes

Crane Load Test Crane Vendor

Yearly (not required by DOE/OSHA unless load elements have been changed)

Yes

Slings, Shackles, Rigging, etc.

Load Test Crane Vendor

Yearly Yes and noted on item by tag.

Slings, Shackles, Rigging etc.

Visual Inspection

Crane Operator and Rigger

Prior to each use No

Lift Fixtures

Load Test Qualified Rigger/Lift Engineer

Change in equipment configuration, expiration of valid period.

Yes, maintained in file, load test number on fixture

DIII-D Hoisting and Rigging Compliance Standard Pg 5 of 20

Back This procedure sets forth Company requirements to comply with the Overhead Crane Safety Standards of Occupational Safety and Health Administration (OSHA) general industry rules (29CFR 1910.179) and Department of Energy (DOE) Hoisting and Rigging Standard 1090-2007.

It applies to Company use of overhead and gantry cranes including semi-gantry, cantilever gantry, wall cranes, storage bridge cranes, and other cranes having similar trolley and travel characteristics.

[Note: The term “hoist” refers to an integral part of a crane and not to a separate lifting system.

“Hoisting” and “lifting” have the same meaning as used in this procedure and are used interchangeably.]

Definitions

Crane A machine for lifting and lowering a load and moving it horizontally, with the hoisting mechanism an integral part of the machine. Whether fixed or mobile, cranes are driven manually or by power.

Designated person or personnel Selected, assigned, or authorized by the Company as qualified to perform specific duties.

Gantry crane A crane similar to an overhead crane except that the bridge for carrying the trolley or trolleys is rigidly supported on two or more legs running on fixed rails or other runway.

Hoist A device integral to a crane used for lifting or lowering a load by means of a drum or lift-wheel around which rope or chain wraps. It may be manually, electrically, or pneumatically driven and may use chain, fiber, or wire rope as its lifting medium.

Mobile crane A crawler crane, locomotive crane, wheel-mounted cranes of both the truck and self-propelled wheel type, and any variation that retains the same fundamental characteristics.

It includes only cranes powered by internal combustion engines or electric motors and that utilize drums and ropes.

Overhead crane A crane with a movable bridge carrying a movable or fixed hoisting mechanism and traveling on an overhead fixed runway structure.

Rigging

DIII-D Hoisting and Rigging Compliance Standard Pg 6 of 20

The hardware or equipment used to safely attach a load to a lifting device. The process of safely attaching a load to a hook by means of adequately rated and properly applied slings and related hardware.

Wall crane A crane having a jib with or without trolley and supported from a side wall or line of columns of a building. It is a traveling type and operates on a runway attached to the side wall or columns.

Procedure

I. Crane Operation General Requirements

a) The Company allows only designated employees who have been authorized and trained in the safe operation of cranes to operate such equipment. Trainees may be authorized to operate cranes provided they are under the direct supervision of a qualified operator.

b) Company business unit management must ensure that an operating manual supplied by the manufacturer is readily available to the operator at all times.

c) Crane operators must perform and follow the work practices as listed below:

• Safely operate equipment.

• Follow the equipment operating guidelines.

• Perform the pre-use and frequent equipment inspection.

• Ensure that the load will not exceed the rated capacity of the equipment.

• Abide by any restrictions placed on the use of the equipment.

• Ensure inspections are current via inspection sticker, other documentation, or verbal confirmation from the equipment custodian.

• Respond to signals from the appointed signal person.

• Obey a STOP signal no matter who gives it.

• Stop work and do not handle a load if there is any question as to the safety of the activity until the matter has been resolved with Company business unit management.

• Sound a warning signal (if furnished) during travel, particularly when approaching personnel.

• Notify the next operator of any defects in equipment or operating problems at shift change.

• Make contacts with runway stops or other cranes with extreme caution. If engaging with or pushing other cranes, proceed 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.

• Do not load the crane beyond its rated load except for test purposes.

• Do not engage in any attention-diverting activity while operating the crane.

• Do not engage in operation of cranes when physically or mentally unfit to do so.

• Do not hoist two or more separately rigged loads in one lift, even though the combined load is within the crane’s rated capacity.

DIII-D Hoisting and Rigging Compliance Standard Pg 7 of 20

• Do not lift, lower, or travel the crane while anyone is on the load or hook.

d) Emergency Switch

• If the crane’s main or emergency switch is open when starting on duty, operators may not close it until it has been determined that no one is on or close to the crane.

• Operators may not close the switch if any warning labels are present, and only close the switch after any such labels are properly removed by the person placing 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 controllers to the

OFF position.

e) Hoisting Company business unit management must ensure accurate determination of the weight of the load before hoisting. The crane and rigging equipment must not be loaded beyond its rated capacity, except for authorized testing.

Pre-Lift Check Before the lift is performed, the operator must ensure that:

• The load to be lifted is within the rated load capacity limits for the crane.

• The load is attached to the hook by means of slings or other approved devices.

• The load is well secured and properly balanced in the sling or lifting device before it is lifted more than a few inches.

• The hoist rope is not kinked.

• Multiple-part lines are not twisted around each other.

• The hook must be positioned above the center of gravity of the load in such a manner as to minimize swinging when the load is lifted.

• If there is a slack-rope condition, it should be determined that the rope is properly seated on the drum and in the sheaves.

• All personnel, including the qualified rigger, must be clear of the load.

f) Prohibitions on Hoisting Crane operators must comply with the following hoist prohibitions:

• The load must not be lowered below the point where less than two full wraps of rope remain on the hoisting drum.

• During hoisting, ensure there is no sudden acceleration or deceleration of the moving load and the load does not contact any obstructions.

• Do not hoist, lower, or travel while anyone is on the load or hook.

• Do not carry loads over people.

g) Hoist Limit Switch

The first time the crane is used during a shift, test the upper-limit switch/device of each hoist under no load. Avoid two-blocking; “inch” the block into the limit switch or run it

DIII-D Hoisting and Rigging Compliance Standard Pg 8 of 20 in at slow speed. If the switch/device does not operate properly, immediately notify responsible Company business unit management.

Never use the final hoist-limit switch that controls the upper limit of travel of the load block as an operating control.

h) Attaching the Load Ensure the load is attached to the load-block hook by means of slings or other approved devices. Ensure that the sling clears all obstacles.

i) Moving the Load The person appointed to direct the lift must 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. Ensure that:

• The load is lifted slowly until it clears the ground or other support to minimize swinging.

• There is no sudden acceleration or deceleration of the moving load.

• The load does not contact any obstructions.

• A “dry run” is conducted in areas where clearance is limited.

j) Side Pulls Cranes must 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.

k) Holding a Suspended Load The operator must not leave his or her position at the controls while the load is suspended.

No person is allowed to stand or pass under a load on the hook.

If the load must remain suspended for any considerable length of time, the operator must hold the drum from rotating in the lowering direction.

l) Cab Housekeeping Necessary clothing and personal belongings must be stored in such a manner as to not interfere with access to the crane or its operation.

Tools, oil cans, waste, extra fuses, and other necessary articles must be stored in the toolbox and must not be permitted to lie loose in or about the cab.

m) Unattended Crane Before leaving the crane unattended, the operator must perform the following tasks:

1. Land any load, bucket, lifting magnet, or other device.

2. Set travel brakes and other locking devices.

3. Put controls in the off or neutral position.

4. Secure the crane against accidental travel.

n) Power Failure Procedure

DIII-D Hoisting and Rigging Compliance Standard Pg 9 of 20

If power to the crane fails during a lift operation:

• Set all brakes and locking devices.

• If practical, land the suspended load under brake control.

o) Crane Breakdown Procedure

In the event a crane breaks down with a suspended load intact and the operator cannot lower the load safely, the operator must:

• Cordon off the area under the load to prevent personnel from entering.

• Contact the supervisor or other designated person immediately and inform him or her of the situation.

• Assist with or take charge of the situation if a supervisor or other designated person is not available, and ensure that the area under the suspended load is suitability cordoned off and posted.

• Not leave the suspended load unattended at any time.

II. Personal Protective Equipment (PPE)

Company business unit management responsible for the work areas where cranes will operate must ensure that appropriate PPE are worn by crane operators. Company management, with assistance as needed from the LSNC Department or local safety organization, must evaluate work conditions and determine what hazards are present, or are likely to be present, which necessitate the use of PPE to protect affected employees.

Minimum PPE requirements for all crane operators include:

a) Fall Prevention and Fall Arrest

When an employee is performing maintenance, repair, or inspection of a crane six (6) feet or more above the ground or lower level and a standard barrier or platform is not provided, the employee must wear an approved safety harness and lanyard or a fall arrest device and fasten the lanyard or device to a secure anchor.

a) Safety Shoes All personnel participating in lifts involving cranes or hoists must wear approved safety shoes.

b) Hard Hats All personnel must wear approved hard hats when such personnel operate a crane, or participate in a lift or are within fifteen (15) feet of the vertical plane of the load.

If the top of the load is lifted to a height greater than five (5) feet, the load is considered an overhead hazard and head protection must be worn.

c) Gloves Employees who handle wire rope or loads with rough or sharp edges or splinters must wear sturdy work gloves.

DIII-D Hoisting and Rigging Compliance Standard Pg 10 of

11/18/22 III. Critical Lift

Circumstances may arise where, due to reasons of equipment importance, cost, consequences, or other criteria, a particular lift is designated as “critical.” Responsible Company business unit management must evaluate and designate such critical lifts in advance of the lift so that additional precautions may be taken.

a) The following criteria establish a lift as a “Critical Lift”:

• When a crane is lifting more than 75 percent of its rated capacity

• The load item, if damaged or upset, would result in a hazardous material spill or release to the environment

• The load item is unique and, if damaged, would be irreplaceable or not repairable and is vital to a system, facility, or project operation.

• The cost to replace or repair the load item, or the delay in operations of having the load item damaged, would have a negative impact on facility or organizational budgets to the extent that it would affect program commitments.

• A lift not meeting the above criteria must also be designated critical if mishandling or dropping 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 that 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.

a) Critical Lift Requirements The following additional precautions must be instituted for performing Critical Lifts:

• Responsible business unit management shall appoint a qualified Person-In-Charge (PIC) for the entire operation. This person 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:

o Identification of the items to be moved, the weight, dimensions, and center of gravity of the load, and any hazardous or toxic materials that are present.

o Identification of operating equipment to be used by type and rated capacity.

o Operating procedures and special instructions to operators including rigging precautions and safety measures to be followed as applicable.

o Rigging sketches that include (as applicable):

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.

Load-indicating devices.

Load vectors.

Lifting points.

Sling angles.

DIII-D Hoisting and Rigging Compliance Standard Pg 11 of

11/18/22 Boom and swing angles.

Methods of attachment.

Crane orientations.

Other factors affecting equipment capacity (i.e. load path sketch, key point heights, floor or soil bearing capacity).

• All rigging equipment used in critical lifts (i.e., slings, below-the-hook lifting devices, and rigging hardware) shall have proof load certificates.

• 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 procedure 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 may be used to lift an item or series of similar items that are handled repeatedly in the same manner. However, if the lifting equipment or rigging must change to accomplish the lift, the critical lift plan must be revised and approved accordingly.

IV. Inspections

Company business unit management must perform and document crane inspections, as described below. Any deficiencies discovered during the inspection of a crane must be corrected before the crane is returned to service. Required inspections include:

a) Initial Inspection New, reinstalled, altered, modified, or extensively repaired cranes must be inspected and tested before initial use according to the written procedures outlined in the crane manufacturer’s manual and in this procedure. All safety devices, controls, and other operating parts of the equipment must be inspected and must be in good working order before operating a crane. (See Section IV of this procedure for testing requirements of new or modified cranes.)

b) Daily Preoperational Inspection

DIII-D Hoisting and Rigging Compliance Standard Pg 12 of

Each crane must be inspected by a qualified crane operator before daily use or before each work shift (see Appendix A for sample Inspection Form). The operator must determine whether equipment must be removed from service or if a more detailed inspection is required, by performing the following steps:

• Test all controls. If any controls do not operate properly, they should be adjusted or repaired before operations begin. Check that motions are smooth and regular, with no hesitations, vibration, binding, weaving, unusual noise, or other irregularity.

• The trip-setting of primary upper-limit switches must be checked under no-load conditions by inching the block into the limit.

• Visually inspect all ropes and load chains for damage.

• Inspect all functional operating mechanisms for maladjustment that can interfere with proper operation, including:

o Deterioration or leakage in lines, tanks, valves, drain pumps, and other parts of air or hydraulic systems o Hooks with deformities, cracks, chemical damage, or excessive wear o Hoist chains and end connections for excessive wear, twist, distorted links interfering with proper function, or stretch beyond manufacturer’s recommendations o Wire rope for wear, corrosion, kinking, crushing, or broken wires or strands o Rope and chain reeving system o Hoist braking system

• Ensure that inspections of all components, including wire rope, chains, and crane, are current via inspection sticker or other documentation from the designated inspector.

The daily inspection may be documented on a tag attached to the crane controls, or it may be documented in a log that is kept with the key that unlocks the crane controls. Responsible management must ensure that inspection tag or log book records are collected and maintained.

c) Monthly Inspection Signed and dated inspection records must be kept on file and must be readily available upon request for purposes of audit or regulatory inspection. Monthly inspection must be performed for the following crane components:

• Hooks and hoist chains, including end connections, with a certification record that includes the date of inspection, the signature of the person who performed the inspection, and the serial number or other identifier of the hook inspected

• All functional operating mechanisms for excessive wear of components

• Rope reeving for noncompliance with manufacturer’s recommendations

• Hoist braking system for proper operations

• Operating mechanisms for proper operation, adjustment, unusual sounds, or excessive wear

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11/18/22

Any deficiencies discovered by a designated inspector during the inspection of wire rope that could reduce its load capacity or adversely affect its performance must be corrected before the rope is returned to service, or the rope must be removed from service. The inspection must include examination of the entire length of the rope without detaching it from the drum.

Some of the conditions that could result in an appreciable loss of strength are:

• Reduction of rope diameter below nominal diameter due to loss of core support, internal or external corrosion, or wear of outside wires

• A number of broken outside strands and the degree of distribution or concentration of such broken wires

• Worn outside strands

• End connections with corroded or broken wires or that are cracked, bent, worn, or improperly applied

• Sections of the rope at or near terminal ends where corroded or broken wires may protrude

• Severe kinking, crushing, cutting, or unstranding of wire(s)

• Ropes with saddles or with heavy wear and/or broken wires at sections in contact with equalizer sheaves or other sheaves where rope travel is limited

d) Periodic Inspection

Complete inspections of all cranes must be performed by a qualified inspector at 3 month intervals.

The annual certification, as required in the “Testing Section” below, can serve as one of the required periodic inspections. Periodic inspections shall be evenly spaced throughout the year, and cranes shall not be operated more than 750 hours between inspections.

The qualified inspector must examine the following items:

• Deformed, cracked, or corroded members

• Loose bolts or rivets

• Cracked or worn sheaves and drums

• Worn, cracked, or distorted parts, such as pins, bearings, shafts, gears, rollers, locking and clamping devices

• Excessive wear on brake system parts, linings, pawls, and ratchets

• Load, wind, and other indicators over their full range, for any significant inaccuracies

• Gasoline, diesel, electric, or other power plants for improper performance or noncompliance with applicable safety requirements

• Excessive wear of chain drive sprockets and excessive chain stretch

• Electrical apparatus for signs of pitting or any deterioration of controller contactors, limit switches, and push-button stations Dated and signed inspection records must be kept on file and must be readily available for review by designated personnel.

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11/18/22

e) Annual Inspection A designated inspector must inspect wire ropes at least annually. The inspector must carefully note any deterioration that results in appreciable loss of original strength and determine whether further use of the rope constitutes an acceptable risk. The inspection must include examination of the entire rope length without detaching it from the drum.

Inspection Requirements for Irregularly Used Wire Rope All rope that has been idle for a month or more due to shutdown or storage of a crane must be thoroughly inspected before it is used. This inspection must be for all types of deterioration and performed by a designated inspector whose approval must be required for further use of the rope.

Non-rotating rope must be carefully inspected.

Operators must keep a certification record of wire rope inspections on file and readily available.

The certification must include the date of inspection, the signature of the person who performed the inspection, and an identifier for the ropes that were inspected.

Load Hooks and Blocks A designated inspector must inspect load hooks and load blocks that have been changed out before returning the crane to service. Inspection records must be retained on file throughout the service life of the hook or load block.

Inspection Requirements for Irregular Service Cranes:

Crane Idle 1 Month to 6 Months A crane that has been idle for 1 month or more but less than 6 months must be given an inspection of all crane items that require a daily or frequent inspection, including rope inspections, before placing it in service.

Crane Idle More Than 6 Months A crane that has been idle for more than 6 months must be given a complete inspection of all items required for daily/frequent and periodic inspections, including rope inspections, before placing it in service.

Standby Crane Standby cranes must be inspected at least semiannually according to the requirements for frequent inspections and rope inspections. Inspection of wire ropes must be completed at least semiannually. Standby cranes that are exposed to adverse environmental conditions must be inspected according to the requirements for frequent crane inspections.

V. Maintenance

Company business unit management must establish a crane preventive maintenance program on the basis of recommendations of the crane manufacturer.

DIII-D Hoisting and Rigging Compliance Standard Pg 15 of

11/18/22 Company business unit management must allow only trained and qualified employees to operate cranes for the purpose of crane maintenance. Crane operation by maintenance personnel must be limited to those crane functions necessary for performing maintenance on the crane or for verifying the performance of the crane after maintenance has been performed.

a) Pre-Maintenance Procedures Before starting adjustments or repairs on a crane, maintenance personnel must take precautions in the following chronological order:

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. Place all controls in the OFF position and secure all operating features from inadvertent motion by brakes or other means.

4. Lock out the means of starting crane operating equipment.

5. Stop the power source or disconnect it at the power takeoff.

6. “Warning” or “Out-of-Order” signs must be placed on the crane controls and underneath the crane where overhead work may create a hazard. Signs or flags must be removed only by authorized personnel.

7. Guard adjacent runways for the length of the work area to prevent contact with another crane.

b) Adjustments and Repairs Any hazardous conditions disclosed by inspection or during operation must be corrected before operation of the crane is resumed. Adjustments and repairs must be done only by designated personnel.

Adjustments must be maintained to ensure correct functioning of components, which include:

• Functional operating mechanisms

• Safety devices

• Control systems

• Power plants

• Braking systems

Repairs or replacements must be provided promptly as needed for safe operation.

c) Post-Maintenance Procedures After adjustments and repairs have been made, the crane must not be operated until:

• All guards have been reinstalled.

• Safety devices have been reactivated.

• Maintenance equipment has been removed.

d) Maintenance Records Company business unit management must maintain a file of all crane inspection and maintenance records. Records must be readily accessible and available upon request to the

DIII-D Hoisting and Rigging Compliance Standard Pg 16 of

11/18/22 LSNC Department or local safety organization. Records must be maintained for lifetime of the crane’s use at the Company.

VI. Testing

a) Operational Tests Prior to initial use, all new, reinstalled, repaired, or modified cranes shall be tested by a qualified crane operator to include the following functions:

• Lifting and lowering

• Trolley travel

• Bridge travel

• Locking, limiting, and indicating devices, if provided

• 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 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

b) Equipment Over 3 Ton Rated Capacity

All cranes used in lifting service, exceeding three tons rated capacity, and their accessory gear shall not be used until the employer has ascertained that such equipment has been certificated as evidenced by current and valid documents attesting to compliance with the following:

• Tests and examinations shall be conducted annually by a currently licensed certificating agency or designee listed in the certificating agency license, and a certificate shall be issued by the certificating agency;

• Certificates (annual and quadrennial) attesting to current compliance with testing and examination standards of requirements shall be maintained for each crane and shall be in a form acceptable to the regulatory division.

c) Rated Load Tests 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 a qualified inspector, as follows:

• 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:

o Hoist the test load a sufficient distance to ensure that the load is supported by the crane and held by the hoist brakes. Personnel shall be kept clear of the test load while it is suspended.

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11/18/22 o Transport the test load by means of the trolley for the full length of the bridge.

o 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.

o Lower the test load, stopping by the brakes.

• If wire rope clips or wedge socket end connection are installed during wire rope installation:

o 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.

o If wire rope clips are used, then check and retighten nuts to the wire rope clip or wire rope manufacturer’s recommended torque value.

o If a 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 operator.

• The transporting of test loads shall be done as far as interfering equipment/structures permit, and in accordance with recommendations from the manufacturer. Ttest loads should not be carried over critical systems or components.

• Test loads shall be accurate to within -5 percent, +0 percent of stipulated values.

VII. Training Company business unit management must ensure that all employees who operate, rig, inspect, or perform maintenance on cranes and related equipment covered under this procedure are provided with training, including a means of evaluation, to ensure that they are competent to perform their tasks safely. Qualification must be limited to the type of equipment for which the operator is being evaluated.

This training must also include applicable site-specific lifting and rigging procedures that address abnormal or emergency operations as well as possible equipment failure. The LSNC Department is available to assist Company business unit management with training.

a) Crane Operators

The training required for all employees who operate overhead cranes shall be classroom (instructor lead) and on-the-job type. Operators and operator trainees must satisfactorily pass a written examination covering operational characteristics and controls, along with emergency control skills, such as response to fire, power line contact, loss of stability, and control malfunction. The exam should also include characteristic and performance questions appropriate to the crane type for which qualification is sought.

Operating skill evaluation: The operator must 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, that includes:

DIII-D Hoisting and Rigging Compliance Standard Pg 18 of

11/18/22

• Prestart and post-start inspection

• Maneuvering skills

• Shutdown

• Securing the crane

b) Riggers Riggers must pass a practical rigging skill evaluation that requires the use of rigging equipment in safe configurations. The actual or simulated operation must enable personnel to demonstrate basic knowledge and skills at a level that ensures the safety of personnel and equipment.

d) Requalification Crane operator and rigger qualification is for a period not to exceed three (3) years, unless the qualification is revoked sooner by Company business unit management. Requalification of all crane-related personnel must include:

• Completion of a written or oral evaluation relevant to the type of equipment used or participation in a refresher training program

• A performance evaluation

e) Previous Training and Qualification Personnel involved in crane operations who have documented evidence of previous related training or experience may be accepted as meeting training requirements.

Previous training deemed acceptable may include:

• Vendor or equipment manufacturer training

• Completion of an apprenticeship program

• Journeyman status in an applicable trade

For previous training to be acceptable for qualification, documented evidence must include type and class of equipment and hours of experience. For qualifications not related to equipment operation, personnel must have documented evidence of training and experience related to an activity covered by this Plan. Documented evidence may be any of the following:

• Certificates of training

• Journeyman card or documents issued by a trade union

• Degree or accreditation from a college or trade school

When previous training and experience are accepted, personnel involved in crane operations will be considered qualified when they have passed a written and oral examination, passed a performance evaluation.

VIII. Contractors and the Crane Safety Program

Contractors are required to have an OSHA-compliant crane safety program in place for their employees, including documented safety training. Company business unit management this is

DIII-D Hoisting and Rigging Compliance Standard Pg 19 of

11/18/22 responsible for the hiring of contractors to perform crane activities on Company sites, must confirm that the contractor is in compliance with these requirements.

Contractor employees are not allowed to use Company cranes or equipment, unless they have received specific instruction and approval from responsible Company business unit management.

DIII-D Hoisting and Rigging Compliance Standard Pg 20 of

11/18/22 Appendix A

Daily Crane Inspection Checklist (Prior to Each Daily Use)

Date_ Time Inspector__________________________________

Crane (Make, Model & SN) Location____________________________

Item

Pass

Fail

Action Taken

1. Check functional operating / control mechanisms for maladjustment.

2. All control mechanisms for contamination.

3. Check for deterioration or leakage in lines, tanks, valves, drain pumps, and other parts of air or hydraulic systems.

4. Visually inspect hooks for deformation and cracks. Hooks having a throat opening in excess of 15% of what it should be, and/or more than a 10 degree twist from the plane of the unbent hook need to be replaced.

5. Visually check hoist chains, including end connections, for excessive wear, twist, distorted links interfering with proper function, or stretch beyond manufacturer’s recommendations.

6. Perform a thorough inspection of any running ropes that have been idle for a period of one or more months.