SOW_Appendix_B_SWI-8834-0001_Rev_5-3.pdf

SWI-8834-0001 Rev 5-3

March 2014

John C. Stennis Space Center

Lifting Devices and Equipment

Management Instructions

National Aeronautics and Space Administration

John C. Stennis Space Center Stennis Space Center, MS 39529-6000

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Stennis

Work

Instruction

SWI-8834-0001 5-3

Number Rev.

Effective Date: March 7, 2014

Review Date: March 7, 2017

Responsible Office: RA00/Center Operations Directorate

SUBJECT: Lifting Devices and Equipment Management Instructions

Lifting Devices and Equipment

Management Instructions

August 2010

Approved by

Signature on file

Marina L. Benigno, Director

Center Operations Directorate

Concurrence

Signature on file

Michael Smiles, Manager

Office of Safety and Mission Assurance

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Document History Log

Status/Change/

Revision

Change Date Originator/Phone Description

Basic 12/20/01 Rich Harris, X3790 Initial Release

Rev 1 7/9/02 Rich Harris, X3790 Revision incorporating NASA-

STD-8719.9

Rev 2 1/21/03 Rich Harris, X3790 All, Additional incorporation of

NASA-STD-8719.9

Rev 3 04/24/03 Rich Harris, X3790 Added Paras 1.5, 1.15, 1.16, 1.17, Section 12 in full

Rev 4 06/16/06 Rich Harris, X3790 Deleted old para 3.3

EXCEPTIONS, deleted

Inventory of Cranes, various minor changes. Reformatted to meet requirements of SPR

1400.1. Section

titles/paragraphs added or rearranged and renumbered.

Title amended from

Management Plan to

Management Instructions

Rev 5 03/20/07 Rich Harris,X8-3790 Added new requirement paragraph 1.5. Renumbered existing 1.5 to 1.6.

Rev 5-1 3/6/2014 Brennan Sanders, X8-3243

Administrative Changes. Added number 11 to section 3.3.a

Rev 5-2 9/3/2014 Brennan Sanders, X8-3243

Administrative changes.

Updated 10.5.1, Overhead

Crane & Hoist Operator Daily or Pre-Use Checklist.

Rev. 5-3 8/13/2015 Brennan Sanders, X8-3243

Administrative changes.

Updated 3.5 for clarity.

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Table of Contents

1.0 OVERVIEW

1.1 Purpose

1.2 Applicability

1.3 Applicable Equipment

1.4 Definitions and Requirements for LDE Operations

1.4.1 Critical Lifts

1.4.2 Engineered Lifts

1.4.3 Severe Service

1.5 Suspended Load Operations

1.6 References

2.0 ROLES AND RESPONSIBILITIES

2.1 LDE Manager (LDEM)

2.2 Facility Operating Services Contractor (FOSC)

2.3 Agencies

2.4 Employees

3.0 OPERATIONAL RESPONSIBILITIES AND REQUIREMENTS

3.1 Lifting Operation

3.2 Inspection Maintenance and Repair

3.3 Management of Critical Lifts for Suspended Loads

3.4 Management of Critical Lifts for Supported Loads

3.5 Record Keeping and Trend Analysis

3.6 Deviations and Variances

3.7 Audits and Self-Assessments

3.8 Critical LDE Identification

3.9 Incorporating Critical LDE

3.10 Removal of Lifting Devices from Critical Lift Operations Designation

3.11 Checklists for Critical Lift Device Request Verification

3.11.1 Mobile Crane and Derrick Critical Lift Requirements Checklist

3.11.2 Forklift Critical Lift Requirements Checklist

3.11.3 Overhead Crane Critical Lift Requirements Checklist

4.0 MAINTENANCE RESPONSIBILITIES AND REQUIREMENTS

4.1 General

4.2 Procedures

4.3 Repair/Replacement

4.4 Scheduling/Equipment Inventory

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5.0 EQUIPMENT CERTIFICATION RESPONSIBILITIES AND

REQUIREMENTS

5.1 General

5.2 Certification Requirements

5.3 Voiding Certifications

5.4 Condition Inspection

5.5 Load Testing

5.6 Test Weights

6.0 ALTERATIONS RESPONSIBILITIES AND REQUIREMENTS

6.1 General

6.2 Approval

6.3 Repairs

6.4 Records

7.0 EQUIPMENT HISTORY FILE

7.1 General

7.2 Contents

7.3 Central Engineering Files

8.0 PURCHASING/DESIGN REQUIREMENTS

8.1 General

8.2 Criteria

8.3 Design/Procurement Checklist for Lifting Devices and Equipment

9.0 OPERATOR CERTIFICATON REQUIREMENTS

9.1 General

9.2 Certification/License

9.3 Qualification and Testing

9.4 Procedures and Documentation

10.0 OPERATOR INSPECTION REQUIREMENTS

10.1 General

10.2 Inspections

10.3 Documentation

10.4 Discrepancies

10.5 Inspection Checklists

10.5.1 Overhead Crane & Hoist Operator Daily or Pre-Use Checklist

10.5.2 Overhead Crane & Hoist Pre-Operation Inspection Log

10.5.3 Overhead Crane & Hoist Problem Log

10.5.4 Mobile Crane Operator’s Daily Checklist

10.5.5 Mobile Crane & Hoist Pre-Operation Inspection Log

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10.5.6 Mobile Crane & Hoist Problem Log

11.0 OPERATIONS SAFETY

11.1 General

11.2 Hazard Analysis

11.3 Crew Responsibilities

11.4 Safety Devices

11.5 Procedures

11.6 Communications

11.7 Safety Zones

11.8 Weather

11.9 Emergency Procedures

12.0 ADDITIONAL REQUIREMENTS

12.1 General

12.2 Markings

12.3 Stability Factors

12.4 Lockout/Tagout

13.0 RIGGING AND MISCELLANEOUS EQUIPMENT

13.1 General

13.2 Markings

13.3 Load Test

13.4 Inspection of Wire Rope, Hook, Chain, and Link

13.5 Inspection of Synthetic Rope, Webbing, and Round Slings

13.6 Shop-Fabricated Gear

14.0 CRITICAL LIFT DETERMINATION REQUIREMENTS AND PROCESS

14.1 General

14.2 Approval Process

14.3 Additional Equipment Features

14.3.1 Hoists

14.3.2 Mobile Cranes and Derricks

14.3.3 Bridge and Gantry Cranes

14.3.4 Special Hoist Supported Personnel Lifting Devices

14.3.5 Mobile Aerial Platforms

14.3.6 Powered Industrial Trucks (Forklifts Only)

14.4 Critical Lift Operations Approval Process General Guidance

14.4.1 Critical Lift Designation Request

14.4.2 Critical Lift Designation Process Flow

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1.0 OVERVIEW

1.1 Purpose.

This Lifting Devices and Equipment Management Instruction provides requirements for maintenance, inspection, test, certification, repair, alteration, operation, and/or use of Stennis

Space Center (SSC) weight handling and rigging equipment (i.e., Lifting Devices and Equipment

– LDE). Criteria within this document are the minimum requirements for applicable equipment and meet or exceed OSHA requirements.

1.2 Applicability

a. This instruction is applicable to NASA/SSC and to NASA contractors and SSC Resident

Agencies to the extent specified in their respective contractual documents.

b. Compliance with this document is mandatory for all NASA owned lifting devices and equipment and contractor supplied lifting equipment used in NASA operations at SSC.

Individual contractors are responsible for implementation and enforcement. If lifting equipment is equipped with features or components not specifically covered by requirements of this document, the Facility Operation Services Contract (FOSC) shall inspect and test (where testing is practical) the equipment for proper condition and operation. This document covers two types of lifting operations, critical and non-critical (ref. Unofficial Inventory of Cranes, Monorails, and

Hoists for identification. The official inventory resides in the FOSC Computerized Maintenance

Management System).

c. Specific instructions in this document are intended to act as a procedural reference for LDE frequently used at SSC. NASA and Contractors/Operators of NASA LDE property and/or lifting operations at SSC utilizing NASA LDE property are required to be in compliance of NASA-

STD-8719.9 and SWI-8834-0001. At a minimum, contractors conducting lift operations utilizing contractor owned LDE at SSC are required to be in compliance with applicable OSHA standards.

d. While it is not the intent to supersede or replace the requirements of NASA-STD-8719.9, Standard for Lifting Devices and Equipment; in those instances where NASA-STD-8719.9 is not pertinent to the unique operational needs of Stennis Space Center, an alternate means that is more applicable to Stennis Space Center is provided in accordance with Section 3.3. In all other cases, the requirements of NASA-STD-8719.9 apply and shall be required.

1.3 Applicable Equipment

This document applies to Monorail Hoists, Mobile Cranes, Derricks, Jib Cranes, Bridge Cranes, Chain Hoists, Gantry Cranes, rigging gear (slings, shackles, eyebolts, swivel hoist rings, links, RELEASED - Printed documents may be obsolete; validate prior to use.RELEASED - Printed documents may be obsolete; validate prior to use.

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Review Date: March 7, 2017 rings, turnbuckles, etc.), forklifts, jacks, manlifts, winches, aerial buckets, boom supported work platforms, scissor lifts, hydra sets, and load measuring devices. The document does not include front-end loaders or elevators.

1.4 Definitions and Requirements for LDE Operations

1.4.1 Critical Lifts

“Critical Lift” shall refer to any lifting operation/device or equipment used to handle flight hardware or unique, one-of-a-kind NASA articles or major facility components whose loss would have serious programmatic impact. Critical lifts also include the lifting of personnel with a crane or derrick. Additionally, for programmatic lifts at Stennis Space Center, the respective

Program Manager will classify lifts involving program hardware as “Critical” or “Non-Critical.”

Program lifting operations identified as “Non-Critical” may be reclassified as “Critical” by the

SSC LDE (Lifting Devices and Equipment) Manager or the SSC NASA S&MA (Safety and

Mission Assurance) Office if the lift involves hazards that are not program specific but reflect safety or facility concerns beyond normal lifting operations.

Exception: Forklift and jacking operations for packaged program critical hardware is considered to be a warehouse/shipping operation and does not constitute a critical lift.

1.4.2 Engineered Lifts

Engineered lifts include lifts in which the weight is 75% or greater of the capacity of a crane in its current configuration, and lifts utilizing multiple lifting devices which present significant risks and require special consideration. Engineered lifts require a written lift plan approved by the

SSC LDE Manager or Deputy prior to commencement of the operation. Additionally, the cognizant NASA S&MA representative shall be notified of the operations prior to the lift.

1.4.3 Severe Service

The operating environment of a crane or hoist can have a distinctive impact on the maintenance, testing and inspection to assure that the crane or hoist is in a safe operating condition. Factors such as corrosive atmospheres or elevated oxygen environments that are associated with clean line operations and test facilities can introduce factors that will accelerate the deterioration of components and structural elements.

These conditions require that the crane or hoist receive preventive maintenance, testing and inspections on a more frequent basis than cranes that are subjected to normal operating environments. These cranes will be designated severe service cranes and must have a tailored maintenance, testing and inspection schedule based upon each crane or hoist’s unique operating environment

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1.5 Suspended Load Operations

Suspended Load Operations at SSC shall comply with Appendix A of NASA-STD-8719.9.

1.6 References

a. OSHA 29 CFR 1910/29 CFR 1926

b. ANSI/ASME B30 Series

c. ANSI/ASME B56.1

d. ANSI/SIA A92.2, A92.3, A92.5, A92.6

e. NASA-STD-8719.9, Standard for Lifting Devices and Equipment

f. NPR 8715.3, NASA Safety Manual

2.0 ROLES AND RESPONSIBILITIES

This section delineates responsibilities of personnel and organizations directly involved in lifting equipment activity at SSC.

2.1 LDE Manager (LDEM)

a. The NASA SSC LDE Manager (LDEM) shall have responsibility for establishment of the

Lifting Devices and Equipment Program, and for selection/appointment of a Lifting Systems

Committee. The manager shall act as chairman of the committee. The Lifting Systems

Committee shall meet annually to review program performance and initiate program revisions and corrective actions. The agenda for the meeting shall include:

1. Status of preventive maintenance, inspection and testing activities, and scheduling.

2. Review of mishaps, incidents, and close calls.

3. Review of Lessons Learned from other NASA centers/installations, government agencies and industry.

4. Consideration of special requests or recommendations from operations, maintenance, inspection and testing.

b. Special Committee meetings to discuss quick response requests that require full committee consideration shall be called as required by the NASA SSC LDE Manager or Deputy Manager.

c. The LDE Manager shall be responsible for interface of the FOSC with outside contractors when NASA SSC lifting operations are performed.

d. The SSC LDE Manager can be contacted at 228-688-3790 and the Deputy Manager at 228-

688-2219.

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e. Specific written procedures (lift plans) shall be approved by the LDE Manager, or his designee, for critical lifts. Field changes to lift plans shall be approved by the S&MA personnel present at the lift. The below listed minimum requirements may be appropriately amended by the

LDEM as required for certain lifting requirements (e.g., verification of weather conditions for indoor operations may not be required):

1. Identification of the LDE, including all rigging gear.

2. Verification of operator and equipment certifications.

3. Verification of appropriate weather conditions at the lift site.

4. Identification of object to be lifted including weight and center of gravity, or a reference.

to the applicable analysis, drawing, or specification documents.

5. Verification of pre-operational inspection of equipment.

6. Verification of area safety zone security.

7. Description of lifting process.

Note: Non-critical lifts typically involving routine, minimal hazard lifting operations do not require written instructions.

2.2 Facility Operating Services Contractor (FOSC)

The FOSC shall be responsible for preventive and repair maintenance, scheduling, testing and certification of lifting devices identified in the SSC System Operation and Maintenance

Responsibility Database (SOMRD) designated for FOSC. Additionally, the FOSC shall manage

Equipment and Operator Certification Programs (ref. Sections 5/9).

2.3 Agencies

a. SSC agencies/organizations and their respective contractors shall be responsible for complying with this document and the applicable requirements listed in NASA-STD-8719.9.

b. Supervisors of SSC agencies/organizations and their respective contractors shall be responsible for assuring that employees are informed and are adequately knowledgeable of hazards associated with using lifting equipment by certification of training and/or documented pre-lift meetings.

2.4 Employees

Employees shall be responsible for abiding by respective safety standards/procedures associated with lifting operations.

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3.0 OPERATIONAL RESPONSIBILITIES AND REQUIREMENTS

3.1 Lifting Operation

A supervisor or designee shall be assigned responsibility for each lifting operation and shall ensure the following:

1. Certified personnel operate lifting equipment.

2. Lifting equipment is operated safely.

3. Preplanned and approved written instructions are used for critical lifts.

4. Lifting equipment and rigging gear is certified properly.

5. The equipment custodian is notified of equipment problems.

6. Appropriate safety zones are established.

3.2 Inspection Maintenance and Repair

A supervisor or designee shall ensure the following:

1. Equipment is inspected, maintained, and repaired by qualified personnel.

2. Inspectors, maintenance, and repair personnel have the appropriate tools and training to safely accomplish their work.

3. Inspectors, maintenance, repair and test personnel have access to adequate information including operation/maintenance manuals, repair procedures, spare parts list, wiring diagrams, and inspection/maintenance/repair documented history.

3.3 Management of Critical Lifts for Suspended Loads

a. A suspended load lift is defined as a lift where the LDE is lifting the load from above such as a crane, hoist, chain fall, etc. The supervisor or designee assigned by management of the contractor, agency, or organization performing a critical lift shall be responsible for the safety of the operation and shall ensure that the following activities are completed:

1. A critical lift written procedure is prepared and properly approved by the SSC LDE

Manager.

2. A documented prelift meeting is held with all personnel involved with the lift.

3. A flagman is assigned and identified to the lifting equipment operator when required.

4. Involved personnel are qualified and certified, if required, and understand how the job will be accomplished.

5. Proper equipment and hardware are selected and verified in conformance with the applicable requirements.

6. Equipment is properly set up and positioned.

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7. The work area is inspected for hazardous/unsafe conditions and secured from unauthorized or non-essential personnel entry.

8. The lifting operation is directed per the lifting procedure.

9. Details of the lifting operation are documented, transmitted to the appropriate manager, and placed in a history file.

10. During critical lifts there shall be one person present that is designated as responsible for the safety of the operations. That person will be in the Safety and Mission Assurance

(S&MA) organization of the company performing the lift.

11. Suspended load operations where personnel are required to be under the load shall be completed in accordance with NASA Standard 8719.9 Appendix A Alternate Standard for Suspended Load Operations.

b. Assignment flexibility shall be allowed for special situations (remote crane operations, repetitive lifts) whereas a designee acts for the supervisor in accomplishing the intent of the critical lift procedure.

c. For all critical lifts, a NASA S&MA or designated individual shall be notified of the operations prior to the lift.

3.4 Management of Critical Lifts for Supported Loads

a. A supported load lift is defined as a lift where the LDE is beneath the load as a forklift, jack, scissor lift, etc. The supervisor or designee assigned by management of the contractor, agency, or organization performing a critical lift shall be responsible for the safety of the operation and shall ensure that the following activities are completed:

1. A spotter is assigned and identified to the lifting equipment operator.

2. Involved personnel are qualified and certified, if required, and understand how the job will be accomplished.

3. Proper equipment and hardware are selected and verified in conformance with the applicable requirements.

4. Equipment is properly set up and positioned.

5. The work area is inspected for hazardous/unsafe conditions and secured from unauthorized or non-essential personnel entry.

b. Assignment flexibility shall be allowed for special situations (remote forklift operations, repetitive lifts) whereas a designee acts for the supervisor in accomplishing the intent of the critical lift procedure.

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3.5 Record Keeping and Trend Analysis

Lifting systems history files shall be maintained that will support trend and data analysis, and will include equipment type, manufacturer, age, maintenance, operational problems, discrepancy and corrective actions, mishaps, safety notices, waivers, and proof/load test results.

SSC shall utilize the FOSC Computerized Maintenance Management System (CMMS) for data collection and file storage of data for maintenance and load tests performed by the FOSC or TOC

(Test Operations Contractor).

All other FOSC or TOC data shall be maintained in the Central Engineering Files (CEF).

SSC site contractors/residents shall maintain data collection and file storage of maintenance records, load tests, and device manuals as governed by NASA-STD-8719.9.

3.6 Deviations and Variances

If a mandatory requirement cannot be met, a deviation/variance package shall be documented on

SSC form SSC-517 and prepared in accordance with SSTD-8070-0007-CONFIG, Standard for

Variance & Alternate Standard Request. All lifting device and equipment deviations and variances shall be dispositioned by the LDEM, concurred with by the SSC Center Operations

Director and the SSC S&MA Manager and approved by the SSC Center Director.

Deviations/Waivers shall be maintained in the Central Engineering Files (CEF).

3.7 Audits and Self-Assessments

The FOSC shall perform a lifting device assessment during the annual Facility Condition

Assessment (FCA) and generate a performance/status report for review by the SSC LDE

3.8 Critical LDE Identification

The LDEM an S&MA are responsible for review and approval or disapproval of requests to designate a mobile crane, overhead crane, derrick or hoist for critical lift operations and communicating those determinations. Such determinations will be communicated to the requestor, operating, and maintenance/testing/inspection contractors on SSC NASA letterhead.

3.9 Incorporating Critical LDE

a. Mobile cranes, overhead cranes, derricks or hoists designated for critical lift operations shall meet the additional NASA requirements for Critical Lift designation in accordance with the appropriate requirements of NASA-STD-8719.9. The requestor shall be responsible for

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Review Date: March 7, 2017 providing adequate documentation, which attests that the device complies with these requirements at the time of the request. A copy of the completed (including all documentation) request package will be maintained in CEF. The requestor is also responsible for funding the establishment and maintenance of the proper maintenance, inspection, testing, and tagging program requirements for the device as a critical lift device (including maintenance of required records in a central location, funding of those activities and the required data entry into the SSC

MAXIMO tracking system). Checklists are attached in paragraph 3.11 to assist in verifying the requirements for critical LDE.

b. Assignment of the lifting device to critical status may be made after all special critical lift operational feature requirements (or appropriate approved waivers), inspection, testing, maintenance and re-tagging are in place.

3.10 Removal of Lifting Devices from Critical Lift Operations Designation

Mobile cranes, overhead cranes, hoists, and forklifts which are no longer funded or no longer require critical lift operations status shall be removed from the critical operations lists. It is the responsibility of the entity that has been funding the maintenance, inspection, testing and documentation requirements to notify the SSC LDEM of the change so the certification tags, testing intervals, maintenance intervals, inspection intervals and documentation tracking

(MAXIMO) requirements may be properly revised to reestablish the lifting device as an active non-critical lift device or placed in idle/standby status as required by OSHA, ANSI and NASA-

STD-8719.9.

3.11 Checklists for Critical Lift Device Request Verification

Checklist examples in the following paragraphs are provided to assist in verifying the requirements for critical LDE (reference paragraph 3.9). These checklists or other equivalent may be used.

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3.11.1 Mobile Crane and Derrick Critical Lift Requirements Checklist

Manufacturer

Model: Mfg. S/N

NEMS: SSC Lift Device

Number

Location

Bldg:

Room

Area

Mobile Crane and Derrick Critical Lift Requirements CHECK ONE

YES NO N/A

General

1.

Complies with applicable OSHA requirements. (29 CFR

1910.179, 1910.180, & 1926.550)

2.

Complies with applicable ANSI/ASME Series B30 requirements. (ANSI/ASME B30.5, & B30.6)

3.

Complies with applicable PCSA standards? (PCSA, Standards

No. 1, No. 2, No. 4, and No. 5)

4.

Complies with applicable NASA-STD- 8719.9 requirements for critical operations.

5.

Has a Hazard Analysis be prepared, reviewed and accepted by

SSC LDEM? (NASA-STD-8719.9 – 5.2.3)

6.

If used for hoisting personnel, has a FEMA been prepared, reviewed and approved by SSC LDEM?

Mechanical Design Requirements

7.

Are there two holding brakes provided, each capable of bringing a rated load to zero speed and holding it? (NASA-

STD-8719.9 – 5.2.6(g)

Electrical Design Requirements

8.

If the device is to handle explosives, solid propellants, flammables, or any other load that requires a non-electrical or static-free environment.

9.

If answer to “6” above is “YES”, are provisions for grounding the hook provided. See NASA-STD-8719.9 - 5.8 for handling explosives or Electro-Explosive Devices (EEDs). Reference

NASA-STD-8719.9 – 5.2.7(e).

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3.11.2 Forklift Critical Lift Requirements Checklist

Number

Location

Bldg:

Forklift Critical Lift

Requirements

CHECK ONE

1910.178, 1926.451(c), 1926.600, 1926.601, & 1926.602)

Complies with applicable ANSI/ASME Series B56 requirements. (ANSI/ASME B56.1, & B56.6)

Complies with applicable NASA-STD-8719.9 requirements for critical forklift operations.

SSC LDEM? (NASA-STD-8719.9 – 12.2.3)

Mechanical Design Requirements.

There are no special mechanical design requirements X

There are no special electrical design requirements X

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3.11.3 Overhead Crane Critical Lift Requirements Checklist

Number

Location

Bldg:

Overhead Crane Critical Lift Requirements CHECK ONE

1910.179, 1926.550, 1926.552, 1926.553, & 1926.554)

Complies with applicable ANSI/ASME Series B30 requirements. (ANSI/ASME B30.2, B30.4, B30.7, B30.10, B30.11, B30.16, & B30.17)

Complies with applicable CMAA standards? (CMAA 70, 74)

Complies with applicable NASA-STD-8719.9 requirements for critical ops.

5.

SSC LDEM? ( NASA-STD-8719.9 – 5.2.3)

Mechanical Design Requirements.

7.

Are there two holding brakes provided, each capable of bringing a rated load to zero speed and holding it? NASA-

STD-8719.9 – 5.2.6(g)

8. If the device is to handle explosives, solid propellants, flammables, or any other load that requires a non-electrical or static-free environment.

9. If answer to “6” above is “YES”, are provisions for grounding the hook provided. See NASA-STD-8719.9 - 5.8 for handling explosives or Electro-Explosive Devices (EEDs). Reference

NASA-STD-8719.9 – 5.2.7(e).

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4.0 MAINTENANCE RESPONSIBILITIES AND REQUIREMENTS

4.1 General

a. The FOSC shall be responsible for maintenance of designated SSC/FOSC lifting devices and equipment identified in the System Operation and Maintenance Responsibility Database

(SOMRD). Activity involving new or abandoned equipment shall be input into the FOSC

Equipment Numbering Database (Mechanical Systems), maintained by the FOSC Facilities

Systems Division (FSD). Changes to the SOMRD shall be made via the Impact Statement

Process (ISP) and require approval from the SSC LDE Manager or Deputy Manager.

b. The FOSC preventive maintenance program shall be Reliability-Centered Maintenance

(RCM) based (subject to compliance with the minimum acceptable requirements of OSHA and

NASA) with updates to maintenance tasks via the FSD RCM Process. The FOSC shall normally provide repair maintenance for SSC lifting devices and equipment and shall have oversight and/or interface with outside contractors performing repair maintenance.

4.2 Procedures

a. Maintenance Instructions shall be used to perform preventive maintenance and load testing of

SSC lifting devices and equipment. The FOSC shall perform preventive maintenance tasks and condition inspections described in the Maintenance Instructions (MI’s) shown in the Inventory of

Cranes, Monorails, and Hoists, and shall perform the tasks at the frequencies specified in the

MI’s. Repairs to items in the load path of Critical Lift equipment shall utilize Process Plans or

Work Orders and shall require notification of the SSC LDE Manager or Deputy Manager.

Maintenance Instructions shall be reviewed annually, by the FOSC, to ensure they are current.

b. The FOSC shall maintain Original Equipment Manufacturer (OEM) manuals for SSC lifting devices and equipment in CEF. The manuals shall be made available as required to engineers, technicians, contractors and others involved in lifting device operations, maintenance, and other relevant activity.

c. CMMS generated work orders shall be the means to initiate and record SSC lifting device and equipment maintenance activity. Deficiencies discovered during a preventive maintenance activity may be corrected during that activity or through corrective maintenance. Deficiencies shall be recorded on the CMMS work order and/or a FOSC Discrepancy and Correction Report

(D & CR). Process/Work Plan or D&CR numbers shall be referenced on the CMMS work order.

4.3 Repair/Replacement

Repair/Replacement of wire rope, hooks, and chains/links shall be performed per OEM

Instruction. Load bearing structural members or major components of critical equipment that are

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Work Order approved by the FOSC. All repairs and replacement items shall be documented on the Work Order and entered into the CMMS.

4.4 Scheduling/Equipment Inventory

CMMS generated work orders shall be the means to schedule maintenance activity. The FOSC

Equipment Numbering Database and Impact Statement Process shall be used to update the

SOMRD and to update the Inventory of Cranes, Monorails, and Hoists.

5.0 EQUIPMENT CERTIFICATION RESPONSIBILITIES AND REQUIREMENTS

5.1 General

The FOSC shall be responsible for inspection, testing, and certification of SSC lifting devices and equipment with the exception of below the hook rigging gear (see Section 13). Certification shall be based on proper repair maintenance, the condition inspection and load test prescribed herein. It is the purpose of the condition inspection to ensure that the overall structural, mechanical and electrical components of the equipment have been maintained in a safe and serviceable condition and are functioning properly. It is the purpose of the load test to ensure by controlled operation with prescribed test loads that the equipment is capable of safely lifting and moving the rated load through all design motions. Technically competent inspection and test personnel, under the direction of a knowledgeable supervisor or designee, shall perform these inspections and tests. Upon successful completion of the condition inspection and load test, the test supervisor/designee and inspection personnel shall sign the applicable work order.

5.2 Certification Requirements

a. SSC lifting devices and equipment shall be certified per the inspection and load test

Maintenance Instructions cited in the Inventory of Cranes, Monorails, and Hoists. Critical lifting devices shall be certified annually. Non-critical lifting devices shall be certified on a four-year cycle. A lifting device shall not be used without a valid certification tag. The certification tag shall clearly indicate if the lifting device is certified for critical lifts. Following the load test, the lifting device shall be given a permanently affixed tag identifying the equipment and stating the next required load test date or certification expiration date. The Inventory of Cranes, Monorails, and Hoists identifies critical/non-critical lifting devices and provides recertification dates.

Inadequacies found during the certification process shall be documented on the appropriate work order and/or Discrepancy and Correction Report, and, if determined to be a hazard, corrected prior to further use. The SSC LDE Manager shall be notified of the problem by copy of the work order.

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b. When the adjustment, repair, disassembly, or replacement of a load bearing part, load controlling part, or operational safety device requires a load test for verification of satisfactory work performed, recertification is required. If load components or safety are not compromised, recertification is not required. If the certifying official and test personnel cannot reach agreement whether components have been compromised, the SSC LDE Manager or designee shall have final determination.

5.3 Voiding Certifications

Certifications for critical and non-critical lifting devices shall be automatically void after one and four years, respectively. Certifications shall be voided by the LDE Manager or designee upon detection of a major deficiency; or after adjustment, repair, disassembly, replacement or alteration of a load bearing or load controlling part or operational safety device which requires a load test for verification of satisfactory work.

5.4 Condition Inspection

A condition inspection by the operator shall be performed before, during and after the load test.

The inspection shall, in general, be by sight, sound, and touch with the depth and detail limited to that necessary to verify the overall condition. It is not intended to be in the same detail as a preventive maintenance inspection. Personnel performing the inspection shall record the results on the work order applicable to the equipment item. Deficiencies found before or after the load test shall be documented on the work order and corrective action taken. A selective load test shall be performed to test the component(s) corrected if certification is in question (ref. section

5.2).

5.5 Load Testing

The load test shall be performed in accordance with the Maintenance Instructions set forth in the

Inventory of Cranes, Monorails, and Hoists. Three types of tests are required for lifting devices:

proof load, rated load, and operational. The proof load and operational tests shall be performed prior to first use for new lifting devices, lifting devices with repairs to items in the load path, or altered lifting devices. The proof load for mobile cranes and derricks shall consist of a load test of 110 percent (+0/-5%) of the manufacturers rated capacity. The proof load for all other cranes shall consist of a load test of 125 percent (+0/-5%). The rated load and operational tests shall be performed annually on critical lifting devices and every four years on non-critical lifting devices.

The rated load shall consist of a load test of 100 percent (+5/-0%) of the manufacturers rated capacity. Test personnel shall follow the guidelines for testing in NASA-STD-8719.9.

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5.6 Test Weights

Test weights shall be marked with a unique identification number and the weight in pounds. The weight marked shall be the actual weight taken from a scale or other measuring device with an accuracy of +/- 2 percent or better.

6.0 ALTERATIONS RESPONSIBILITIES AND REQUIREMENTS

6.1 General

The FOSC shall be responsible for alterations to SSC lifting devices and equipment and/or shall have oversight of outside contractors performing alterations. Alterations generally refer to activities that change original equipment manufacturer (OEM) specifications and may consist of repairs, replacement of components, changes to manufacturer’s rated capacity, or changes in operating conditions. Alterations to load bearing parts, load controlling parts or operational safety devices shall be approved by the LDE Manager. A new Hazard Analysis will be performed on all alterations of a critical lift device.

6.2 Approval

Alterations to lifting devices and equipment shall meet the approval requirements of

Repair/Replacement section 4.3.

6.3 Repairs

Restoring a crane component or assembly to its original or virtually original condition, dimension, or mechanical property by technically recognized and accepted procedures is a repair and not an alteration. Examples are welds, electroplating, refinishing electrical contacts, approved material changes, wire rope replacement, etc.

6.4 Records

Documentation of alterations shall be recorded on the applicable CMMS work order for the equipment item.

7.0 EQUIPMENT HISTORY FILE

7.1 General

The FOSC shall be responsible for maintenance of a SSC lifting systems history file (ref. Record

Keeping and Trend Analysis section 3.5) in the FOSC Computerized Maintenance Management

System (CMMS). CMMS generated work orders that identify each equipment item with a

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FOSC Equipment Numbering process shall be used to update CMMS equipment identification numbers. Equipment history shall be made available upon request.

7.2 Contents

Content of the history file shall include as a minimum equipment type, manufacturer, date of manufacture, date of installation, maintenance, operational problems, discrepancy and correction actions, mishaps, safety notices, waivers, load test results, certification data, and alterations.

7.3 Central Engineering Files

OEM manuals, hazard analyses, studies, design changes and other significant data shall be maintained in the FOSC Central Engineering Files.

8.0 PURCHASING/DESIGN REQUIREMENTS

8.1 General

Lifting devices and equipment purchased for SSC operations shall be high quality, original manufacturer type equipment for critical and non-critical applications and shall meet user requirements and the requirements of the SSC Lifting Device and Equipment Program.

8.2 Criteria

Mechanical and electrical design criteria for purchasing of lifting device equipment and components shall meet the requirements in NASA-STD-8719.9. Additionally, the original equipment manufacturer shall supply a hazard analysis with all new lifting devices and equipment per NASA-STD-8719.9. The Hazard Analysis shall be reviewed and approved by the

NASA S&MA Manager prior to delivery of the lifting device. The Design/Procurement

Checklist for Lifting Devices and Equipment (or equivalent) provided below shall be included in purchase packages for SSC lifting devices and equipment.

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8.3 Design/Procurement Checklist for Lifting Devices and Equipment

Location: ______________________________________________ Identification/Tracking No.: __________________________

Type of Lifting Device: (Check one)

Bridge Crane

Jib Crane

Monorail

Gantry Crane

Derrick

Mobile Crane

Fixed Point Hoist

Special Hoist Supported Personnel

Lift Device

Other

(Specify)

Critical Lift Device? ____ Yes ___ No (If Yes, attached Operations Lift Determination Statement and Approval)

NOTE: If Lifting Device is to be Designated as a CRITICAL LIFT DEVICE Complete Back Side Also)

GENERAL REQUIREMENTS

Requirement Yes No N/A Comments Certificate of Compliance with Requirements (Including

Test Reports of Proof Load and other required tests)

Electrical per NEC(NFPA 70)

Hazardous (Classified) Location (NFPA Article 500 series)

Applicable ANSI/ASME B30 series Standard (Specify

Specific Standard in Comments)

CMAA Spec.70 (Specifications for Electrical Overhead

Traveling Cranes)

CMAA Spec.74 (Specifications for Top Running and Under

Running Single Girder Electric Overhead Traveling Cranes)

ANSI MH27.1 (Specifications for Underhung Cranes and

Monorails)

ANSI A58.1 (Min. Design Loads for Buildings and Other

Structures)

ANSI A10.4 (Safety Requirements for Personnel Hoists)

ANSI A10.22 (Safety Requirements for Rope Guided and

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Nonguided Workman’s Hoists)

ANSI A10.28 (Safety Requirements for Work platforms

Suspended from Cranes and Derricks)

ANSI A39.1 (Safety Requirements for Window Cleaning)

ANSI/ASME HST-1M (Performance Standard for Electric

Chain Hoists)

ANSI/ASME HST-2M (Performance Standard for Hand

Chain Manually Operated Chain Hoists)

ANSI/ASME HST-3M (Performance Standard for Manually

Lever Operated Chain Hoists)

ANSI/ASME HST-4M (Performance Standard for Overhead

Electric Wire Rope Hoists)

ANSI/ASME HST-5M (Performance Standard for Air

Chain Hoists)

ANSI/ASME HST-6M (Performance Standard for Air Wire

Rope Hoists)

SAE J765 (Crane Load Stability Test Code)

AWS D1.1 (Structural Welding and Cutting Code)

AWS D14.1 (Specifications for Welding Industrial and Mill

Cranes)

AISC (Manual of Steel Construction)

PCSA Std No. 1, No. 2, No. 4 and No. 5 (Power Crane and

Shovel Association)

ADDITIONAL CRITICAL LIFT REQUIREMENTS

Requirement Yes No N/A Comments

Hazard Analysis

FMEA( Failure Mode and Effects Analysis) for Special

Hoist Supported Personnel Lift Devices)

Speed Reduction from motor to drum achieved by

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Dual braking system, each capable of bringing a rated load to zero speed and holding the load (with or without power).

Operational Test Procedure to demonstrate each Brake’s ability to stop and hold the rated load.

Initial and final Upper limit switches (limit control valves)

Lower Limit switches

Two-Blocking damage prevention feature

Assessment for operational needs for remote emergency stops independent from operator controlled emergency stop.

Lockout Device to Prevent Unauthorized Use

Other: (Specify)

General Comments: _______________________________________________________________________

Prepared By : ________________________________ Date : _____________

Reviewed By: (S&MA for critical lift only)________________________________________ Date: _____________

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9.0 OPERATOR CERTIFICATON REQUIREMENTS

9.1 General

The SSC Certification Board shall be responsible for developing and maintaining a comprehensive SSC lifting device operator training and certification program.

9.2 Certification/License

a. Only SSC certified/licensed operators shall operate SSC lifting devices. Outside contractor personnel operating SSC or their own lifting devices shall be certified at his/her expense and shall as a minimum meet the requirements placed on the FOSC and other site contractors by this document. If an outside contractor wishes to train and certify his/her personnel, the contractor shall submit a Training and Certification Program Plan to the SSC LDE Manager for review.

Contractor shall not proceed with lifting operations until the plan has been reviewed and all requirements verified by the FOSC.

b. Maintenance and inspection personnel who operate SSC lifting devices incidental to maintenance or inspection of the equipment shall be tested and certified in accordance with the requirements of this document with the following exceptions:

1. Training course material and the certification test may be modified to suit appropriate conditions that the maintenance and inspection personnel may experience.

2. Lifting of loads shall be restricted to dummy loads in the performance of maintenance and inspections.

3. The certification shall include the statement “Maintenance/Inspection activities only.”

9.3 Qualification and Testing

a. Training, an examination, and certification by an approved independent third party training contractor shall be required for any individual to operate a crane/derrick or forklift. Two levels of operator training and proficiency shall be established for these operators: critical lift and non-critical lift.

b. The Personal Training and Certification program for non-critical lifts shall include the following:

1. Classroom training with written examination in safety, general rigging, signal person responsibilities, operations inspection/maintenance, general performance procedures, requirements, and pre-operational checks; performance training (hands on) and an operational demonstration test using the specific type of lifting device.

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2. Annual Physical Examination (criteria to be determined by the cognizant medical official and comply with ASME B30.2).

3. Certification via the SSC Certification Board; a requirement that certifications shall be renewed periodically (not to exceed a 4-year interval); certifications/licenses shall indicate the type of crane the holder shall be qualified to operate (specific equipment/device/system required for Critical Lift Certifications).

4. Operators shall be trained in specific tasks prior to a specific/critical operation.

5. Mobile Crane operators shall be familiar with the proper use and care of fire extinguishers.

c. The Personal Training and Certification program for critical lifts shall include the following:

1. In addition to non-critical lift requirements (1-5 above), operators being certified to perform critical lifts shall be trained in the specific hazards and special procedures associated with those types of lifts. Additional training for Critical lifts shall be provided by the contractor with operational responsibility of the specific crane. Critical lift certification shall be limited to specific equipment and not general types or categories of lifting equipment. The critical lift certification shall include the make and model of the lifting/hoisting system or the unique SSC lifting system identification number. For example, a critical lift derrick certification shall be limited to the specific derrick. An individual certified on the “B” Test Stand Main Derrick shall not automatically be certified for the “B” Test Stand Auxiliary Derrick. Exception: For chain fall hoists, critical lift certification shall be designated for mechanically operated chain falls, electrically operated chain falls, and pneumatically operated chain falls and should not be equipment number specific.

2. The complexity of the lifting/hoisting system shall be considered in the certification requirements. All crane operators, signal persons, and riggers shall be trained and certified.

9.4 Procedures and Documentation

Compliance with all training and certification criteria shall be documented for each individual.

Documentation shall be maintained by the SSC Certification Board for review by the SSC LDE

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