CARDEROCKDIVINST 11262.2D Weight Handling Program Management.pdf

CARDEROCKDIVINST 11262.2D

Code 102 29 Sep 2020

CARDEROCKDIV INSTRUCTION 11262.2D

From: Commanding Officer

Subj: WEIGHT HANDLING PROGRAM MANAGEMENT

Ref: (a) NAVFAC P-307

(b) NUWCHQINST 3100.1a

(c) NAVFACINST 11230.1F

(d) OPNAVINST 5100.23H

(e) CARDEROCKINST 4855.2B

(f) CARDEROCKDIVINST 5100.1B

1. Purpose

a. To update policy, procedures, and responsibilities for Weight Handling Program (WHP) Management at the Naval Surface Warfare Center, Carderock Division (NSWCCD), West Bethesda, Maryland Site and all Detachments or other designated NSWCCD site locations.

b. To promote safe operation and maintenance of Weight Handling Equipment (WHE), and to ensure WHE is reliable and available when needed to support the NSWCCD mission.

c. To provide procedures for reporting WHE accidents, near misses, and other unplanned occurrences.

2. Cancellation. CARDEROCKDIVINST 11262.2C of 16 June 2014.

3. Scope. This instruction applies to NSWCCD West Bethesda, Maryland and all Detachments/Sites personnel who operate WHE.

4. Discussion. A safe and reliable WHP is critical to U.S. Navy operations. Reference (a), paragraph 2.3, requires that Navy activities with WHE develop written instructions for managing their WHP. NSWCCD’s WHP is managed by the Weight Handling Program Manager (WHPM), who is part of the Facilities Branch (Code 1021) within the Infrastructure Division (Code 102).

DEPARTMENT OF THE NAVY

NAVAL SURFACE WARFARE CENTER

CARDEROCK DIVISION

9500 MACARTHUR BOULEVARD

WEST BETHESDA MD 20817-5700

IN REPLY REFER TO:

5. Responsibilities

a. Commanding Officer (Code 00). The CO is responsible for ensuring the safety of the WHP for NSWCCD, West Bethesda, Maryland and all Detachments/Sites. This responsibility includes certification of equipment, training, and qualification of personnel.

(1) The CO will designate the following in writing:

(a) NSWCCD Weight Handling Program Manager.

(b) Certifying Official and Alternates.

(c) Licensing Program Official.

(d) Trackage Certifying Official.

(2) The CO is responsible for reporting crane and rigging gear accidents, external audits, and external evaluations to the Naval Surface Warfare Center Commander and Executive Director, per reference (b).

b. The Facilities Branch Manager (Code 1021), Infrastructure Division has overall responsibility to establish a WHP that meets the applicable requirements of reference (a), section 2, and will develop supplemental weight handling procedures to address the various parts of the program. In addition, the Division Head, Infrastructure Division (Code 102) will ensure NSWCCD WHP policy and procedures are implemented Command-wide. For purposes of clarity and consistency within this instruction, the Division Head, Infrastructure Division (Code

102) will be considered a Site Director for the West Bethesda, Maryland location.

c. WHPM

(1) Is responsible for implementation of the WHP at NSWCCD West Bethesda, Maryland, and each respective Detachment/Site.

(2) Provides oversight to ensure Command-wide compliance with the provisions of this instruction and all applicable references.

(3) Will provide the Facilities Branch Manager (Code 1021), Infrastructure Division with supplemental procedures for WHP management, as necessary.

d. WHE Certifying Official and Alternate Officials will ensure that WHP requirements are implemented at NSWCCD West Bethesda, Maryland and each respective Detachment/Site, and WHE is maintained, inspected, tested, and certified per this instruction and reference (a). WHE Certifying Officials/Alternates will consult and coordinate actions with the respective Site Director, Site Safety Branch Personnel, and the NSWCCD WHPM.

e. Trackage Certifying Official (TCO) will ensure that NSWCCD West Bethesda, Maryland and each respective Detachment/Site crane trackage is inspected, maintained, tested, and certified per this instruction and reference (c). The TCO will consult and coordinate actions for NSWCCD West Bethesda, Maryland, or each respective Detachment/Site, with the WHE Certifying Official/Alternate and Site Director, as necessary, and will designate the authorized track inspectors involved in the inspection and certification process in writing, per reference (c).

f. Licensing Program Official (LPO) will ensure that training, testing, and licensing of operators are completed per this instruction and reference (a). The LPO will consult and coordinate actions with the WHPM. The LPO will designate, in writing, the authorized license issuing officials, instructors, and performance examiners per reference (a). The LPO will ensure operator qualification cards for Non-Cab Operated Category 3 cranes are issued in lieu of an official license that demonstrate the knowledge and proficiency to operate these cranes although no formal license is required by reference (a).

g. The Safety Branch, Occupational Safety and Health (OSH) Office (Code1024) will provide safety oversight for the WHP, as required. The Safety Branch will be notified of all WHE accidents within 24 hours and will actively participate in any accident investigations.

h. Department Heads/Site Directors will ensure their respective possession and use of WHE is in compliance with reference (a) and this instruction.

i. Division Heads/Site Directors will ensure the use of WHE within their division/detachment complies with reference (a) and this instruction. Division Heads/Site Directors will ensure that WHE is available for inspection and certification when requested.

j. WHE Operators will operate WHE in a safe and proper manner and follow all provisions of reference (a) and this instruction. Per reference (a), WHE operators will also perform an inspection of the assigned WHE prior to operation. WHE operators will verify that all equipment is in good working order and is properly identified with current certification markings.

WHE operators who observe deficiencies will immediately secure the WHE from further operation and report the deficiency to their supervisor and the appropriate WHE Certifying Official/Alternate and Site Director. The Site Certifying Official/Alternate will report the deficiency to the WHPM and take appropriate corrective actions. Cranes or rigging gear showing any signs of damage will not be used and must be brought to the attention of the supervisor, the Site Certifying Official/Alternate, Site Director, and the WHPM. WHE operators will contact the Site Certifying Official/Alternate, Site Director, WHPM or someone within their department who is trained to operate the crane disconnect switch when activation of the crane disconnect switch is required.

6. WHP Policy and Procedures

a. General. All WHE maintenance, inspections, operations, licensing, testing, and certifications will be performed per the requirements of reference (a). In the event of a conflict between this instruction and reference (a), the requirements of reference (a) take precedence and will be followed. As required, supplemental lower-level WHP processes and standard operating procedures will be developed to address unique characteristics which are specific to NSWCCD West Bethesda, Maryland and each respective Detachment/Site.

b. Safety. Reference (a) and reference (d), Chapter 31, specify the minimum requirements and applicable standards for the safe use of all types of WHE. All personnel involved in WHE operations must use Personal Protective Equipment (PPE), such as hardhats, safety shoes, fall protection gear, and other PPE as appropriate for the work area.

c. WHE Operator Requirements

(1) Number of Operators. To reduce WHP costs and risk, the number of crane operators will be kept to the minimum necessary to perform the mission. This will be left to the discretion of the affected Department or Site Director, provided there are no concerns on the part of the WHPM. The determining factor will be to ensure a sufficient number of crane lifts are performed by all operators to maintain proficiency in crane operations. Lifts may be specifically mission-related to support ongoing operations or practice lifts assigned by the supervisor to ensure proficiency is maintained. Justification for new crane operator requests must be approved in writing by the potential operator’s supervisor, validated by the Division Head or Site Director and approved by the Department Head or the Department Head’s designee. Issuing a crane operator license is at the discretion of the LPO with concurrence from the WHPM. Prior to issuing a crane operator license, the WHPM will discuss any concerns with the various Department representatives or Site Director to ensure proficiency in crane operations can be maintained.

(2) Licensing. Only qualified crane operators with a valid crane license or operator qualification card are authorize to operate NSWCCD cranes. All NSWCCD crane operators must obtain a license, or qualification card, from the NSWCCD LPO before operating a crane.

In addition, all crane operators must have their crane license, or qualification card, on their person while operating cranes, unless prohibited by site specific conditions, in which case the Navy Crane Center (NCC) will grant approval.

(a) All Cranes. Per reference (a), all crane operators, before being issued a license or a qualification card, must meet applicable documentation and training requirements, physical examination requirements, and written and performance testing requirements. While there is no requirement for an official crane operator license per reference (a) for Non-Cab Operated Category 3 cranes, an operator qualification card is required to comply with this instruction.

(b) Non-Cab Operated Category 3 Cranes. Following the criteria in reference (a), prior to being issued their first qualification card, operators of Non-Cab Operated Category 3 Cranes must successfully complete Category 3 (Non-Cab operated) Crane Safety training and demonstrate competencies, must successfully complete Rigging Practices training, must successfully perform a minimum of five separate weight handling operations under the supervision of a licensed crane operator, and must properly document an Operator’s Daily Check List (ODCL). Although Rigging Practices training and documentation of an ODCL are one-time requirements for obtaining a qualification card, periodic Category 3 Crane Safety training is required, per reference (a).

(3) License Renewal. A crane operator’s license is valid for no longer than 2 years from the date of issue. Qualification cards to operate Non-Cab Operated Category 3 cranes are valid for 3 years from the date of issue. Per reference (a), renewal requirements, including those for operators of Non-Cab Operated Category 3 Cranes, must be met prior to renewal of a crane operator’s license or qualification card.

(4) The WHP LPO will issue and maintain record documentation for all NSWCCD crane operator licenses and qualification cards.

(5) Suspension of License. The operator’s supervisor, the WHP LPO, the Site Director, or the WHPM may suspend a crane operator’s license, or qualification card, for cause at any time.

(a) Reasons for suspension include, but are not limited to, unsafe or improper operation of a crane, side loading a crane, using unmarked, uncertified, or damaged rigging gear, using a crane for which the operator is not qualified to operate, using a crane that is out of certification, and not reporting an accident, near miss, or other unplanned occurrence to the supervisor or other designated WHP officials.

(b) Crane licenses, or qualification cards, will be automatically suspended when an operator is charged with a crane or rigging gear accident as defined by reference (a).

(c) The crane license, or qualification card, may be restored by mutual agreement between the WHE LPO, the WHPM and the supervisor upon completion of the crane license or qualification card renewal requirements described in reference (a) and this instruction, including any additional requirements deemed necessary by these management officials based on the circumstances. Any disagreements affecting restoring a crane license or qualification card will be discussed with the Site Director for possible resolution. If there is no agreement at the Site Director level, the CO will make a final determination on whether a crane license or qualification card should be restored.

(d) The WHE LPO will document the suspension, justification, and renewal actions in the operator’s licensing or qualification card record.

(6) Revocation of License. Reasons for revocation of a crane operator’s license or qualification card include, but are not limited to, repeated suspensions, flagrant unsafe operation, or obvious misuse of a crane or rigging gear. If a crane operator’s license or qualification card is revoked, the WHE LPO will notify the operator’s supervisor, and will also document the revocation, justification, and date in the operator’s licensing or qualification card records.

(7) Contractor Personnel who operate Navy-owned WHE will be certified as fully qualified by the contractor, at the contractor's expense and issued either an operator license or qualification card from their employer as stipulated in Section 6.c. At a minimum, operator qualifications will be equivalent to the requirements of reference (a). The contractor will provide documentation on all operators' qualifications to the NSWCCD Contracting Officer (KO) through the Contracting Officer Representative (COR) who will ensure that supplemental documentation is also transmitted to the respective WHP official at the affected site, and that all WHP requirements are implemented per this instruction and reference (a). The COR will consult and coordinate actions with the respective technical department representative for the contract, the Site Licensing Official, Site Director, Site Safety Office, and NSWCCD WHPM prior to any contractor operator engaging in any mode of WHE operation.

(8) Operator Checks

(a) Prior to first use of Category 1, 2, Cab-Operated 3 and 4 Cranes each day, crane operators must perform a complete check of the crane using the ODCL, per reference (a). The ODCL meets the requirements of reference (a), and will be used as a guideline for conducting and documenting this inspection. In addition, the first operator in each subsequent shift on the same day will perform the operational checks of the ODCL. The WHE Certifying Official/Alternate at each respective location will retain the ODCLs, per reference (a).

(b) For Non-Cab Operated Category 3 Cranes, operators must complete a pre-use check of the crane as required by reference (a). For Non-Cab Operated Category 3 bridge, wall, and gantry cranes, a documented pre-use check will be performed and documented at least once per calendar month while the crane is in use, per reference (a). This monthly check or Operator’s Monthly Checklist (OMCL) will be documented and submitted to the WHE Certifying Official/Alternate at each respective location who will retain the OMCLs, per reference (a).

d. Crane Certification. All cranes will be certified per the requirements of reference (a). A crane will not be used without a valid certification.

(1) A crane certification is valid for 1 year from the date of signature by the WHE Certifying Official/Alternate.

(2) In addition, each crane will have a history file, as detailed in reference (a), section 5, which contains information on its certification, specifications, alterations, lubrication details, and shop orders. The history files will be maintained by the Certifying Official/Alternate at each respective location or by the organization responsible for crane maintenance, inspection, test, and certification in the event any cranes are certified by non-NSWCCD weight handling personnel.

http://www.ncc.navfac.navy.mil/crane/307jun03.pdf

e. Alterations and Modifications to the Equipment

(1) As defined in reference (a), any alteration to a load-bearing part, a load-controlling part, or an operational safety device will be documented at NSWCCD West Bethesda, Maryland or each respective Detachment/Site as the site-specific local authority on a Crane Alteration Request (CAR) form, and approved by the WHPM, WHE Certifying Official and the NCC prior to performing the alteration.

(2) Alterations to crane components or equipment not described above must also be documented at NSWCCD West Bethesda, Maryland or each respective Detachment/Site as the site-specific local authority on a CAR; however, these CARs can be locally approved by the WHPM and the WHE Certifying Official/Alternate prior to performing the alteration. Per reference (a), documentation of site-specific locally approved CARs must be submitted to the NCC for information purposes.

(3) A record of all alterations and modifications will be kept in the history file for each crane.

f. Rigging Gear. The provisions of this instruction apply and as defined in reference (a).

(1) Management and Costs. To minimize inventory and reduce costs, all purchases and leases of WHE rigging gear will be approved by the WHPM, or an alternate designee, for a rigging gear purchase or lease approval, as appropriate. The WHPM and alternate designees will be listed as Approvers when a rigging gear purchase or lease is processed for their approval prior to purchase.

(2) New Purchases. When required by reference (a) for each new rigging gear equipment purchase, the manufacturer or supplier is required to perform a proof test. Proof test certification is also required, stating the applied proof test load and the duration of the proof test, which will be used as the initial load test certification for the respective equipment.

(3) Required Markings. When required by reference (a), the WHPM and Certifying Official/Alternate at the specific location will ensure each piece of rigging gear is tagged, marked, or engraved in a manner that clearly identifies the rated load, the re-inspection due date, and a unique identifying number or serial number that can be traced back to its test and inspection documentation.

4) Visual Inspection and Proof Test. When required by reference (a), rigging gear must be given an initial visual inspection and proof test as well as periodic inspections and load tests.

(a) The original equipment manufacturer or supplier, or a person qualified as a rigging gear inspector and load test director can perform the initial load test per reference (a). A person qualified as a rigging gear inspector and load test director must perform the initial visual inspection and required periodic inspections and load tests per reference (a). The pre-use inspection of rigging gear by the crane operator or rigger may satisfy the periodic inspection requirements for rigging gear, as permitted by reference (a).

(b) The operator or rigger must perform a visual inspection of each piece of rigging gear before and after each use. No documentation of this inspection is required. Damaged or unsatisfactory rigging gear must be removed from service and returned to the Certifying Official/Alternate at the specific location or the WHPM for investigation and disposition per reference (a).

(5) Sling protection must be used where there is a possibility of the sling being cut or otherwise damaged by abrasion or bearing. See reference (a) for suitable sling protection or contact the WHPM.

(6) Any operation requiring advanced or complicated rigging or a rigging configuration beyond the comfort of the weight handling crew, should be directed to the Certifying Official/Alternate at the specific location or WHPM.

g. Rented or Leased Cranes

(1) All contractor-owned cranes and multi-purpose machines configured as cranes (as described in reference (a)), which are to be used in conjunction with an NSWCCD project, on NSWCCD property, or in support of an NSWCCD facility, must meet the applicable requirements of reference (a). As applicable, the Certifying Official/Alternate at the specific location or the WHPM will verify that:

(a) The crane and/or multi-purpose machine (when configured as a crane), operators, rigging gear, and required documentation all meet the requirements of reference (a);

(b) The KO or COR has verified that provisions for cranes and/or multi-purpose machine (when configured as a crane) meet the requirements of reference (a), and are included in any contract involving contractor crane operations; and

(c) Verification occurs prior to any crane operations being performed at the site with the crane or multi-purpose machine (when configured as a crane).

(2) Per reference (a), the KO or COR must oversee contractor crane operators. Personnel performing oversight must complete the Contractor Crane Awareness training course or the NAVFAC 40-hr Contract Hazard Awareness training Course. Oversight must be performed using the Contractor Crane or Rigging Operation Checklist from appendix P of reference (a).

h. WHE Accidents, Near Misses, and Other Unplanned Occurrences. Reference (a), section 12 defines crane and rigging gear accidents, near misses, and other unplanned occurrences. All WHE personnel involved in crane and rigging operations must know and understand these definitions. The definitions are broad in scope, capturing minor-level events, from which WHE personnel may learn valuable lessons to further improve the safety of the WHP.

(1) In the event of an accident, or having seen evidence of damage (suspected accident), the crane team (WHE operators, rigging gear users, etc.) will:

(a) Immediately cease all operations;

(b) Ensure the accident scene is safe, secure, and undisturbed, and if there is impending danger to the equipment or personnel, place the crane and load in a safe position as quickly as possible; and

(c) Notify the WHE operator’s supervisor.

(2) The supervisor will review the situation and take additional emergency actions as required. The supervisor must immediately notify the Certifying Official/Alternate at the specific location, the WHPM, and the Safety Branch (Code 1024) of the accident or potential accident. Per paragraph 1003a(1)(e) of reference (f), supervisor should also prepare a mishap report in Enterprise Safety Applications Management System (ESAMS) within 24 hours.

(3) The WHPM will report all crane and rigging gear accidents as soon as practical, but no later than 8 hours following the accident. The following must be notified:

(a) The Commanding Officer;

(b) The Technical Director/Deputy Technical Director;

(c) The Department Head, Corporate Operations Department;

(d) The Department Head with operational authority over the facility, crane, or personnel involved in the accident; and

(e) The Division Head, Infrastructure Division (Code 102).

(4) Per reference (a), the WHPM must provide initial notification to the NCC for accidents involving a fatality, inpatient hospitalization, an overturned crane, collapsed boom, or any other major damage to the crane, load, or adjacent property, making this notification as soon as practical but no later than 8 hours following the accident. Notification for all other accidents must be made as soon as practical but no later than 3 working days after the accident.

(5) Accident investigations will include personnel involved in the operation when the accident occurred, the Safety Branch (Code 1024), the WHPM, and others as appropriate.

Significant accidents (defined by reference (a)) will be investigated per reference (a) and using the NSWCCD Quality Management Procedure (QMP)-8.3.1 Critique Process which is part of reference (e).

(6) The WHPM will complete the Crane and Rigging Accident Report form specified in reference (a), and will submit the report to the NCC within the required timeframe. The WHPM will forward the accident report to the following:

(a) The Commanding Officer;

(b) The Technical Director/Deputy Technical Director;

(c) The Department Head, Corporate Operations Department;

(d) The Department Head with operational authority over the facility, crane, or personnel involved in the accident; and

(e) The Division Head, Infrastructure Division (Code 102).

(7) Near misses and other Unplanned Occurrences are defined in reference (a), and while undesirable, may provide an opportunity to learn lessons that can help avoid accidents in the future. Near misses and other unplanned occurrences must be reported to the immediate supervisor and the WHE PM. Per reference (a), the WHE PM will report the near miss or unplanned occurrence to the NCC. Near misses will be recorded in ESAMS per paragraph 1003f of reference (f).

i. Crane Trackage. Crane Trackage will be inspected, tested, maintained, and certified per reference (c).

j. Multi-Purpose Machines used as Cranes. When using a Navy-owned, multi-purpose machine, material handling equipment (forklifts), or construction equipment configured as a crane for lifting suspended loads, the requirements of reference (a), section 10.21 must be met.

k. Program Evaluations and Audits. WHP evaluations and audits will be performed periodically to verify the WHP is in compliance with references (a) and (b).

(1) The NCC performs WHP evaluations. The Naval Facilities Engineering Command performs trackage audits. Evaluations and audits occur at NSWCCD West Bethesda, Maryland and at each respective Detachments/Site that have WHE and Trackage, as applicable.

(2) The WHPM will provide ample notification of evaluation and audit in and out briefs to the CO and other personnel involved, as appropriate.

(3) The WHPM will be the weight handling lead for evaluations and audits that occur at NSWCCD West Bethesda, Maryland. The WHPM will support each respective Detachment/Site Certifying Official and Site Director for his or her evaluations and audits.

(4) The WHPM and the Site Director, as applicable, will jointly prepare evaluation and audit responses. The CO will sign the evaluation and audit responses.

(5) The WHPM will track corrective actions described in the evaluation or audit response.

The Command Quality Tracking System, as part of reference (e), may be used for tracking corrective actions.

7. Records Management

a. Records created as a result of this notice, regardless of media and format, must be maintained and dispositioned according to the records disposition schedules found on the Directives and Records Management Division (DRMD) portal page:

https://portal.secnav.navy.mil/orgs/DUSNM/DOINAA/DRM/SitePages/Home.aspx.

b. For questions concerning the management of records related to this instruction or the records disposition schedules, please contact the NSWCCD Command Records Manager.

8. Review and Effective Date. Per OPNAVINST 5215.17A, Code 102 will review this instruction annually around the anniversary of its issuance date to ensure applicability, currency, and consistency with Federal, Department of Defense, Secretary of the Navy, and Navy policy and statutory authority using OPNAV 5215/40 Review of Instruction. This instruction will be in effect for 10 years, unless revised or cancelled in the interim, and will be reissued by the 10-year anniversary date if it is still required, unless it meets one of the exceptions in OPNAV 5215.17A, paragraph 9. Otherwise, if the instruction is no longer required, it will be processed for cancellation as soon as the need for cancellation is known following the guidance in OPNAV Manual 5215.1 of May 2016.

9. Forms. The Crane and Rigging Accident Report Form and other WHP forms are available for completion in reference (a).

TODD E. HUTCHISON

Releasability and distribution:

This instruction is cleared for public release and is available electronically via the Division Intranet Directives Page, https://cuthill.aw3s.navy.mil/wcm/docs.php?doctype_id=1 https://portal.secnav.navy.mil/orgs/DUSNM/DOINAA/DRM/SitePages/Home.aspx https://cuthill.aw3s.navy.mil/wcm/docs.php?doctype_id=1