OMAO Procedure 0606-01 - Shipboard Lifting Appliance Certification and Inspections.pdf

OFFICE OF MARINE AND AVIATION

OPERATIONS

PROCEDURE VERSION

0606-01 1.0

EFFECTIVE DATE REVIEW DATE

4/8/2019 4/8/2024

AUTHORIZED BY: ISM CODE REFERENCE

Section 10

RESPONSIBLE POSITION

Troy Frost, NOAA Director, Marine Operations

Chief, Marine Engineering

SHIPBOARD LIFTING APPLIANCE CERTIFICATION AND

INSPECTIONS

1. PURPOSE

1.1 This procedure establishes a base requirement for the certification, inspection, and maintenance of lifting appliances on all NOAA ships.

1.2 This procedure describes the full rated capacities and Working Load Limit (WLL)/Safe Working Load (SWL) limits of booms, cranes, davits, A & J frames, gantries, and winches on NOAA Ship.

1.3 This procedure does not take into consideration the effects of other loading forces (acceleration and moment, drag, and snags) which may increase the total weight being supported by an apparatus and associated components.

2. SCOPE

2.1 This policy applies to all NOAA ships regarding maintaining certified lifting appliance onboard to ensure the sustained safe operation of a NOAA ship, including ship’s crew, operational personnel, and deployed assets.

2.2 This policy certified inspection requirements does not apply to apparatuses which WLL/SWL is less than 200 pounds.

2.3 All ships having booms, cranes, davits, frames, gantries, and winches used for weight lift must comply with the requirements of this policy. Does not apply to demersal scientific wire or trawl wire.

3. RESPONSIBLE POSITIONS

3.1 The following positions or groups have action item responsibilities within this procedure:

• Chief, Safety and Environmental Compliance Division

• Director, Marine Operations

• Designated Person Ashore

• Chief, Marine Operations Engineering

• Product Line Managers

• Port Engineer

• Ship Commanding Officers

• Ship Chief Engineer

• Ship Chief Boatswain

Page 2 of 7 Procedure 0606-01

4. RESPONSIBILITIES AND PROCEDURES

4.1 Lifting Appliance Applicability

Conduct an operational risk assessment before use of all weight handling apparatuses per OMAO Policy 1701-14 - Operational Risk Management.

4.2 Boom, Crane, Davit, Frame, Gantry, and Winch Inspections

Conduct inspections and overhauls using guidance contained herein from 29 CFR 1919 unless more specific guidance is provided by the manufacturer or ABS Classing Rule requirements. The ship’s crew must conduct pre-mission inspection before each day of operational use. An OSHA accredited person as per 29 CFR 1919, or ABS Certified Inspector conducts annual Inspections. Quadrennial Inspections (4 years) only apply to weight handling equipment that are rated for a WLL/SWL greater than 200 pounds, and must be completed by an OSHA accredited person as per 29 CFR 1919.11, or ABS Certified Inspector.

4.2.1 Inspection Schedules

Inspection frequency is as follows Pre-mission Inspection, Annually, and Quadrennial (4 years) basis.

A grace period of 6 months is allowed for Quadrennials as per 29 CFR 1919.18.

A. Pre-mission Inspection

1. General. The intent of this inspection is to conduct a visual inspection of the apparatus, rigging, and other critical equipment parts that could result in loss of life or equipment damage if failure occurs before each operation involving an apparatus.

2. A visual inspect of a boom, crane, frame, or winch and all sheaves, swivels, blocks, block hangers, padeyes, connecting links, shackles, hooks, wire, ropes and associated pins for corrosion, wear, deformation, cracks and any other condition that may lead to failure.

3. Conduct a satisfactory operational and visual test of the apparatuses limit switches and safety devices.

4. After visual inspection, record in ships log to indicate inspection was completed. Any deficiencies or limitation to the equipment on board must be reported immediately to the ships Commanding Officer and recorded into SAMMS equipment history.

B. Annual Inspections and Test Requirements

1. General. The intent of this inspection is to ascertain the safety of the rigging and other critical equipment parts that could result in loss of life or equipment damage if failure occurs.

2. In general, the inspection includes all wire and manmade rope, fittings, block fittings, hooks, links, shackles and associated pins, swivels, boom and frame padeyes, hoist control linkages, brake springs and linkages, limit switches, and safety devices.

3. Any visible permanent set or deformation in the form of bent pins, elongated holes, bent or distorted staples and padeyes are clear indications of overload or improper rigging. Any defective equipment must be reported, and the rig must not be used until the cause is found and corrected. The operator should also be aware of recurring cracks in paint, particularly in areas of high stress corrosion. If signs of stress or damage are observed, paint in the immediate area will be removed to clean metal surface for further inspection.

Page 3 of 7 Procedure 0606-01

4. Inspection. The following requirements are generic in nature and included in inspections as applicable in 29 CFR 1919.11 & .12. Period between inspection of components below maybe increased as determined by ships force and operational tempo.

a. Cradle, or securely position the boom, crane, davit, or frame and remove all wire or manmade rope. Inspect the wire or manmade rope per 29 CFR 1919.24.

b. Visually inspect all sheaves, swivels, blocks, block hangers, padeyes, connecting links, shackles, hooks, winches and associated pins for corrosion, wear, deformation, cracks and any other condition that may lead to failure. Inspection of sheaves must include sheave gage wear measurement per 29 CFR 1919 Subpart E.

c. Do not disassemble blocks, topping lift, vang swivels or equivalent devices unless there is reason to suspect damage, wear, corrosion, or marginal condition when last overhauled.

Inspect hoist and rotating gear brake springs and linkage, where appropriate. Carefully check brake springs for permanent set and compression, and replace if necessary.

NOTE: (As applicable) Failure of brake springs in service can result in loss of control or release of load. Inspect hydraulic or pneumatic hoses for ballooning, cracking and corrosion. Inspect electrical wiring and connections for corrosion. Inspect brake solenoids and switches for corrosion and contact wear.

d. Inspect and lubricate all moving parts and wire rope per the manufacturer technical manual and SAMM System requirements.

e. If possible, open drains and check the boxes for condensation at the bottom of the tanks.

Check any magnetic plugs, if equipped, for particles. Draw oil samples from gearboxes for analysis as per manufacturer technical instructions. Self-contained reservoir gearboxes with less than five gallons of lube oil must have the gear lube level topped off as needed after sampling or until systematic oil content testing indicates need of replacement.

f. Visually inspect all deck and bulkhead padeyes, links, chocks, cleats, bits, and mounting bolts. Where inspection indicates possible fractures, deformation or corrosion, conduct a more detailed inspection.

C. Quadrennial Inspection

1. General. The intent is to accomplish the annual inspection above, and inspect all major components whose performance or mechanical condition may have deteriorated. Disassembly may also be required and included in the inspection of other components whose performance is not affected by normal wear but whose failure could result in damage, injury or loss of life.

Examples of these are reduction gears, goosenecks, topping fittings, and sheave pins.

Disassembly of such items only needs to be carried out to the extent required to conduct the inspection. For example, it is not necessary to totally disassemble a reduction gear equipped with inspection plates that permit measurement of backlash and observable wear patterns.

Outside appearance is not necessarily indicative of the mechanical condition of the equipment.

2. Inspection. The following requirements are generic in nature and may be required by an OSHA accredited person as per 29 CFR 1919.11(d) & 12 or ABS Certified Inspector. The attending accredited person will determine the extent of disassembly required. Specific guidance in the manufacturer’s technical manual takes precedence.

a. Remove the arm, boom, or frame, disassembling the connection, between the boom or frame and the vessel that allows slewing motion.

b. Disassemble and inspect topping lifts, vangs, swivels, all blocks, hoist brakes, locking pawls, slewing gear, and pinion gear shafts and bearings. Check all pin, bearings, gears

Page 4 of 7 Procedure 0606-01 and sheaves for compliance with dimensional tolerances shown on the original equipment drawings.

c. Replace wire rope, as required. Replace wire rope if the total number of visible broken wires exceeds 10 percent of the total number of wires, or if the rope shows excessive wear, corrosion, or defects. Maintain a wire rope certificate issued by the manufacturer or vendor onboard and readily available upon request.

d. Inspect brake linings and brake discs, if applicable.

e. Inspect backlash and gear pattern of gear boxes equipped with inspection plates per manufacturer’s instruction manuals.

f. Perform a static test (125% of WLL/SWL Limit) on all equipment or bulkhead mounted links and padeyes used in the boom and frame systems for 5 minutes.

g. Visually inspect cleats and bitts associated with boom and frame systems and non-destructively examined using dye penetrant or other method deemed suitable.

4.3 Overhaul of Lifting Appliances

Overhaul components based on equipment condition or evidence of problems.

4.3.1 Diagnostic Means. Inspection and testing may be waived if the system is evaluated by diagnostic means. Diagnostic means are conducted by the manufacturer in a controlled environment. A certificate of inspection and test results will be issued by the manufacturer.

4.3.2 General. This level is to accomplish the requirements of the quadrennial inspection after overhaul, plus if required, the requirements in the manufacturers technical manual.

4.3.3 Inspection. The following components listed below should also be inspected and tested during an overhaul:

1. Inspect and overhaul all pneumatic components as required.

2. Inspect and overhaul all hydraulic components to include pumps, motors, control valves, accumulators, rams, etc. as required.

3. Apparatus weight tested at 125% of the WLL/SWL. The static test includes rotation of the test load through a range of motion that the equipment is required to perform in service. The weight handling system must be able to stop, start and hold the test load at any position within the service area.

4.4 New or Altered Lifting Appliance Structures and Associated Equipment

4.4.1 General. Before installing any new boom, crane, davit, frame, or winch on board a NOAA ship, Marine Operations Engineering (MOE) conducts an engineering and architectural review and provides approved drawing from ABS, or a certified Naval Architect. Maintain, either electronically or hard copy, a copy of approved plans onboard the ship and a second set of copy with the Marine Office of Engineering branch. Include all documentation, drawings, etc. in SAMMS.

4.4.2 Test apparatus and components at 125% of the intended use. Tests include rotation of the test load through a range of motion that the equipment is required to perform in service. The weight handling system must be able to stop, start and hold the test load at any position within the service area.

4.5 Rescue Boats, Davits or Cranes, and Releases

4.5.1 Inspect and weight test a rescue boat davit, crane, and their releases every 5 years, or

Page 5 of 7 Procedure 0606-01 immediately after any one of the components has been modified, overhauled, or replaced per 46 CFR §199.190. The test must be witnessed by ABS or OSHA accredited person. Rescue boats must be loaded to 1.1 times the Condition B-weight during the operational weighted test.

4.5.2 Servicing of a rescue boats quick release mechanism is as per the intervals specified by manufacturer’s instruction by an authorized facility. Records received from servicing must be retained by the ship.

4.5.3 Replace falls every 4 years, or if applicable, end for end at 30 months and not to exceed a total of 5 years from date of installation. If a visual inspection indicates falls is deteriorating, or has been damaged, replace immediately. Maintain a wire rope certificate issued by the manufacturer or vendor onboard and be readily available upon request.

Note: Inspect, test, and overhaul rescue boats used for occasional operational missions beyond actual emergencies and emergency training at the intervals listed within this procedure.

4.6 Safety

4.6.1 Stability Documentation

A. Ships with booms, cranes, davits, frames, gantries or winches must have these apparatuses included in a ship stability documentation (Stability and Loading Data Booklet), that addresses the stability of the vessel with the weight handling equipment in use.

B. Where the stability of the ship limits the operational capability of the weight handling equipment, prominently display a graphic safety placard at the equipment operator’s station to describe the limitation, and graphically show the safe working zone and working load limit.

C. When considering a ship’s stability characteristics during testing procedures, maintain specified test loads within limits that can be handled safely. If any of the test loads result in an excessive list, reduce the load accordingly to stay within those limits.

4.6.2 Label Plates

Install engraved or stenciled label plates on the booms, cranes, davits, gantries, and frames to document the WLL/SWL, test weights, inspection, and date of certification of the load test. Stencile WLL/SWL in large letters clearly visible on the apparatus.

4.6.3 Safety Precautions

The following safety precautions must be observed when conducting weight handling equipment tests:

A. To prevent excessive damage in the event of equipment failure during tests, place dunnage under test loads and keep each load as close to the deck as possible.

B. Wire ropes, slings, straps, chains, rings, shackles, and other loose gear must be tested, or stamped with weight-tested limits by the manufacturer as per 29 CFR 1919. 31. Retain all certificates issued by a manufacturer or vendor onboard and be readily available upon request.

C. To prevent loads from moving off center in the event of a casualty, rig preventer lines or cables athwartships from the test load. At minimum, the breaking strength of the preventers must be greater than or equal to the test load.

4.6.4 Documentation

A. At the completion of an annual or quadrennial inspection by an ABS certified inspector or an

OSHA Accredited Person, the inspector issues documentation as to what was inspected, Page 6 of 7 Procedure 0606-01 references inspected to, and final WLL/SWL and any deficiencies noted.

B. For each apparatus onboard, the ship must maintain one of the following:

1. ABS Lifting Appliance Registration/Certificate, or

2. Form OSHA-71, or

3. Certificate of Fitness issued by an OSHA Accredited Person’s company.

Note: A Certificate of Fitness (CF) is issued if a Form OSHA-71 is not. The CF is required to meet all elements listed within a Form OSHA-71 inspection and is considered a validation of compliance.

OMAO Fleet Inspection will accept a valid CF as full compliance with this procedure.

C. Enter the results of the inspections and tests prescribed in the ship’s SAMMS under Hull History record or logs.

5. RECORDS AND REPORTS

List documents – or – “No records or reports are created by this document.”

6. REFERENCES

NOAA Administrative Order 209-1A

46 CFR §189.35

46 CFR §199.190

29 CFR §1960, Basic Program Elements for Federal Agencies 29 CFR §1919.1, Gear Certification – Purpose and Scope 29 CFR §1919 Subpart C, Duties of Persons Accredited\ 29 CFR §1919 Subpart D, Certification of Vessels Cargo Gear 29 CFR §1919 Subpart E, Tests and Proof loads American Bureau of Shipping (ABS) Guidance for Certification of Lifting Appliances ABS American Society of Mechanical Engineers (AMSE) B30 OMAO Procedure 1701-14 – Marine Operational Risk Management

7. DEFINITIONS

Booms and Frames A structural member used for lifting, transferring or supporting heavy weights. The lower part of the boom or frame is supported by a bracket or step, which allows the boom or frame to pivot while transferring loads to structure. Rigging mounted on ships structure supports booms and frames.

Condition B Weight Weight of the complete small boat: includes all required equipment, fuel, and the weight of the persons at 185 lbs. per person for which it was designed to carry.

Crane and Davit A machinery arrangement or self-contained structure, with associated reeving suitable for lifting loads through several dimensions of motion.

Gantry A structural member used for lifting, transferring, or supporting heavy loads. The gantry is supported and suspends from the overhead of a ships compartment and can transverse continuously through multiple compartments within a ship or to an outside deck. Rigging or a hoisting apparatus is mounted to

Page 7 of 7 Procedure 0606-01 the gantry to suspend a load.

Winch A stationary motor-driven or hand-powered machine used for hoisting or hauling, having a drum around which is wound a manmade rope, wire rope, or chain attached to the load being moved.

Working Load Limit (WLL)/ Safe Working Load (SWL) This is the maximum weight which can be handled safely by an apparatus and all associated components used in conjunction with an apparatus, with the maximum authorized number of parts in the main purchase. An apparatus’s WLL/SWL may be limited by the maximum rating of a component used in conjunction with an apparatus.

Static Load Test A load test conducted on newly installed, structurally repaired

(e.g., by welding) or structurally overhauled (e.g., replacement of major structural sections) systems where a test weight equivalent to 125% of WLL/SWL is applied as a force by external means and held for not less than 5 minutes, to demonstrate structural adequacy of the equipment and foundation. No part of the equipment, fittings, and structure must take a permanent set, nor must degradation of any operating or control function occur as a result of the test.

OSHA Accredited Inspector An individual qualified to perform gear certification under the provision of 29 CFR 1919. Individual must be current in certification for Full Function (FF) vessels. A listing of OSHA accredited agencies can be found at https://www.osha.gov/dts/maritime/maritime_update.html.

8. NOTES

Effect on Other Documents: None

DOCUMENT HISTORY

Version Description of Change Effective Date

1.0 Initial Document.

https://www.osha.gov/dts/maritime/maritime_update.html