SSN_Enclosure 3.pdf

NOTUINST 11262.1B, CH 1

20 APR 2021

CRANE PROGRAM MANUAL

Published by

NAVAL ORDNANCE TEST UNIT

CAPE CANAVERAL, FL

DEPARTMENT OF THE NAVY

POST OFFICE BOX 1623

CAPE CANAVERAL FLORIDA 32920-1623

NOTU-M 11262.1B

SPP12

20 Apr 21

NOTU INSTRUCTION 11262.1B, CHANGE TRANSMITTAL 1

Subj: CRANE PROGRAM MANUAL

Encl: (1) Change No. 1 package for subject manual.

1. Purpose. To promulgate Change 1 to subject manual.

2. Action. Remove and replace the following sections of NOTU INSTRUCTION 11262.1B with the enclosed sections. Annotate on the Change Page; change number, date, date entered, and initials.

3. Change Summary. Chapter 6, Lockout/Tagout, was renamed to “Lockout/Tagout and Equipment Tagging” and content updated to better reflect the requirements of reference (a) paragraph 2.8.2 with respect to equipment tagging procedures.

B.A. SHUPP

Releasability and distribution:

This instruction is cleared for public release and is available electronically only via NOTU Directives Web site

SHUPP.BENJAMIN.

ANDERS.11360805

Digitally signed by

SHUPP.BENJAMIN.ANDERS.11

36080527 Date: 2021.04.20 12:05:42 -04'00'

DEPARTMENT OF THE NAVY

POST OFFICE BOX 1623

CAPE CANAVERAL FLORIDA 32920-1623

NOTUINST 11262.1B

SPP12

4 Feb 2020

NOTU INSTRUCTION 11262.1B

From: Commander, Naval Ordnance Test Unit

Subj: CRANE PROGRAM MANUAL

Ref: (a) NAVFAC P-307 Naval Facilities Engineering Command Management of Weight Handling Equipment

(b) OD 56780A Operational Directive Strategic Systems Programs Technical Program Management Requirements

(c) NAVSUP 538 Management of Materials Handling Equipment (MHE) and Shipboard Mobile Support Equipment (SMSE)

(d) NAVSEA OP-5 Ammunitions and Explosive Safety Ashore

(e) SECNAVINST 11260.2B Department of the Navy Weight Handling Program for

Shore Activities

(f) OSHA 29 Occupational Safety and Health Administration CFR 1910 Code of Federal

Regulation – General Industry

(g) NFPA 70E National Fire Protection Association

(h) NAVORDTESTUINST 5100.1H Safety Manual

(i) SSPINST 11452.1 Strategic Systems Programs Weight Test Policy

(j) CLOIS-C-STD-06 Cape Launch Operations and Infrastructure Support, Hazardous

Energy Control Program (Lockout/Tagout)

(k) SSPINST 3440.6D Strategic System Program Root Cause Analysis and Correction

Action Guidance

(l) SSPINST 8822.7F Policies and Procedures for Strategic System Program (SSP)

Coordination Document (m)SSPINST 8023.1E Strategic System Program Personnel Qualification Program

(n) NAVFACINST 11230.1F Inspection, Certification and Audit of Crane and Rail Road

Trackage

1. Purpose. To establish and maintain crane maintenance, inspection, and certification program for Naval Ordnance Test Unit (NOTU) using the guidance of references (a) through (n).

2. Cancellation. Cancel NAVORDTESTUINST 11262.1A dated 20 Feb 2014

3. Applicability. This instruction applies to NOTU Weight Handling Equipment(WHE) and their trackage systems. Crane, rigging gear and miscellaneous equipment maintenance, testing, inspection and certification are performed by the Base Contractor per reference (a).

NOTUINST 11262.1B

4 Feb 2020 i

TABLE OF CONTENTS

Chapter 1 GENERAL OVERVIEW AND PROGRAM MANAGEMENT

1. Responsibilities 1-1

2. Self-Assessment 1-6

3. Internal Program Audit 1-6

4. Monitor Program 1-7

5. Crane Replacement and Modernization Plan 1-7

Chapter 2 MAINTENANCE, INSPECTION AND CERTIFICATION

1. Preventative Maintenance Procedures 2-1

2. Preventative Maintenance Special Previsions 2-1

3. Preventative Maintenance Documents 2-1

4. Crane Safety Advisory (CSA) and Equipment Deficiency Memorandum 2-2

5. NOTU Crane Program Manager (PM) Responsibilities 2-2

6. Base Contractor PM Responsibilities 2-3

7. Procurement Inspection 2-3

8. Crane Certification 2-4

Chapter 3 TRAINING, QUALIFICATION, CERTIFICATION, AND OPERATOR

LICENSING

1. Applicability 3-1

2. Responsibilities 3-1

3. Requirements 3-1

4. Production Tasks Requiring Qualification in accordance to reference (a) 3-2

Chapter 4 CRANE ALTERATION AND ENGINEERING

1. General 4-1

2. Policy 4-1

3. NCC Initiated Alterations Include 4-1

4. Crane Alteration Accomplishment 4-2

Chapter 5 OPERATOR CHECKS

1. Operator Daily Checklist (ODCL) Process 5-1

2. Deficiencies 5-1 ii

TABLE OF CONTENTS (CONT)

3. Responsibilities 5-1

Chapter 6 LOCKOUT/TAGOUT

1. Applicability 6-1

2. Tags 6-1

3. Requirements 6-1

4. Procedures 6-2

5. Inactive or Deactivated Crane Tag 6-2

Chapter 7 ACCIDENTS, NEAR MISSES AND UNPLANNED OCCURRENCES

1. Crane and Rigging Operating Conditions 7-1

2. Trend Analysis 7-1

3. Informational Updates 7-1

4. Crane Incident Response 7-1

5. Incident Classifications 7-1

6. Crane Accident Reporting Procedures 7-2

Chapter 8 ADVERSE WEATHER PLAN PROCEDURES

1. General 8-1

2. Responsibilities 8-1

3. General Lightning Safety 8-1

4. Wind Policies 8-2

Chapter 9 CONTRACTOR CRANE POLICY AND PROCEDURES

1. Purpose 9-1

2. Applicability 9-1

3. Responsibility 9-1

4. Crane Approval Requirements 9-2

5. Crane Survey Procedure Requirements 9-2

6. Crane Operation Safety Requirements 9-2

7. Critical Lift 9-3

8. Complex Lift 9-3 iii

Chapter 10 CRANE GROUND AND ELEVATED TRACKAGE SYSTEM

1. Purpose 10-1

2. Applicability 10-1

3. Inspection Requirements 10-1

4. Responsibilities 10-2

5. Track Certification Approval Requirements 10-3

6. Track Inspection and Certification Procedure Requirements 10-4

7. Track Documentation and Record 10-4

8. Inspections 10-5

APPENDIX A

A-1 Sample NOTU Crane Replacement Upgrade Plan A-1-1 A-2 NOTU Sample Job Plan for Crane and Hoist, Category 2 and 3 A-2-1 A-3 NOTU Crane Tie Down Procedure A-3-1

SAMPLES

S-1 Certifying Official Designation Sample Letter S-1 S-2 Crane Load Test Director Designation Sample Letter S-2 S-3 Crane Mechanical or Electrical Inspector Designation Sample Letter S-3 S-4 Extension of Annual Certification Sample Memorandum S-4 S-5 NOTU Crane Trouble Failure Inspection Rejection Report S-5-1 S-6 NOTU WHE Program – Crane Alteration Request S-6-1 S-7 Operator Daily Check List S-7 S-8 Sample Critical Lift Plan S-8-1

FORMS

SPP11262.1/2 NOTU Corrective Action Requests SPP11262.1/3 Crane and Rigging Surveillance Worksheet SPP11262.1/4 Crane and Rigging Accident Checklist SPP11262.1/5 Crane Processing Completion Report SPP11262.1/6 Crane Activation Checklist SPP11262.1/7 Certificate of Compliance SPP11262.1/8 Contractor Crane or Rigging Operation Checklist

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CHAPTER 1

GENERAL OVERVIEW AND PROGRAM MANAGEMENT

1. Responsibilities

a. NOTU Commanding Officer (CO). The Commanding Officer is responsible for ensuring the safe operation of WHE within NOTU as delineated in reference (a), section 2. He/she shall designate in writing, the certifying official(s) and alternate certifying official(s), in accordance with reference (a), section 4.2. Refer to sample letter S-1.

b. Support Services/Planning Division Head (SPP10). The Support Services/Planning Division Head (SPP10) has overall division responsibility and supervisory responsibility for the Facilities Management Branch Head (SPP12), Facilities Management Section Head (SPP121), NOTU Crane Program Manager (SPP124) and operation of the command’s cranes.

c. Facility Management Branch Head (SPP12). The Facility Management Branch Head has overall departmental responsibility and supervisory responsibility for the Facility Management Section Head (SPP121), NOTU Crane Program Manager (SPP124) and operation of the command's cranes IAW reference (a).

d. Facilities Management Section Head (SPP121). The Facilities Management Section Head is responsible for the supervision of the NOTU Crane Program Manager (SPP124) and general oversight of the WHE program.

e. NOTU Crane Program Manager (SPP124). The NOTU Crane Program Manager has direct responsibility of the WHE program in accordance with reference (a), section 2.2. Specific responsibilities include:

(1) Receive and track Crane Safety Advisory (CSA) and the Equipment Deficiency Memorandum (EDM). Ensure corrective action, tests, inspections and measurements are performed as required and reporting back to the Navy Crane Center (NCC) in accordance with reference (a), section 2.9.

(2) Conduct Evaluations and Self-Assessments in accordance with reference (a), section 2.4.

(3) Oversite of the monitor program in accordance with reference (a), section 2.6.

(4) Review and approve new and revised preventative maintenance (PM) procedures.

(5) Coordinate PM and weight test schedules with the base contractor, facility manager and if applicable the NOTU Port Operations Division.

(6) Perform a utilization analysis of each crane during the annual maintenance to determine if the crane is still required for planned operations in accordance with reference (a), section 2.1.

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(7) Maintain all current designation letters.

(8) Maintain the crane replacement and modernization plans in accordance with reference (a), section 2.7.

(9) Maintain a quality data system in accordance to reference (b).

f. Certifying Official (BOS Contractor and/or NOTU). The Certifying Official(s) is/are designated in writing by NOTU’s Commanding Officer, and is responsible for ensuring NOTU's cranes are certified and safe to use for their intended purpose in accordance with reference (a), section 4. Refer to sample letter S-1. The Certifying Official shall, in turn, designate in writing the authorized test directors and condition inspectors involved in the certification, inspection, and testing process in accordance with reference (a), section 4.2. Refer to sample letters S-2 and S-3.

g. Base Contractor. The base contractor shall perform the maintenance and operation of NOTU cranes in accordance with reference (a). Responsibilities include but are not limited to:

(1) Perform crane maintenance and inspection in accordance with reference (a), section 3.

(2) Ensure personnel are properly trained to perform maintenance, inspection and repair of cranes, and rigging equipment in accordance with reference (a), section 7.

(3) Control and maintain PM procedures and incorporate approved changes into applicable procedures in accordance with reference (a), section 3.

(4) Coordinate PM and weight test schedules with the NOTU Crane Program Manager.

(5) Provide annual crane status report and schedule of maintenance and certification.

(6) Control and maintain crane history files.

(7) Prepare and submit alteration packages to NCC in accordance with reference (a), section 6.

(8) Ensure all crane certification documentation is posted on or in the vicinity of each crane.

h. Load Test Director. The Load Test Director shall be designated in writing by the Certifying Official and shall perform duties in accordance with reference (a), Appendix N, section 1.3. Refer to sample letter S-2. Responsibilities include but are not limited to:

(1) Complete required training and qualification courses.

(2) Demonstrate knowledge of the certification requirements of reference (a), section 4, and reference (a) appendices C, D, E and N.

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(3) Demonstrate knowledge in the use and care of precision instruments and recording of measurements.

(4) Demonstrate knowledge of Lockout/Tag-out procedures.

(5) Perform calculations of weight for load tests.

(6) Demonstrate general knowledge of the operational characteristics of the WHE and components being tested.

(7) Ability to interpret Operation Equipment Manual (OEM) load charts.

(8) Identify the limits of stability for the WHE being tested.

(9) Demonstrate proper crane communications (i.e. hand signals, radio communications, etc).

i. Electrical Shop Personnel (Electricians and Inspectors). Electricians and electrical inspectors shall be qualified and trained in accordance with reference (a) appendix N section 2.3.

Additionally the electrical inspectors shall be designated in writing by the Certifying Official and shall perform duties in accordance with reference (a). Refer to sample letter S-3.

Responsibilities include but are not limited to:

(1) Complete training requirements in accordance with reference (a), section 7.

(2) Perform maintenance and inspection of cranes in accordance with reference (a).

(3) Demonstrate knowledge of the crane maintenance, certification, and equipment history file requirements in accordance with reference (a), sections 2, 3, and 5, and reference (a) appendices C, D, and E.

(4) Demonstrate knowledge of National Electrical Code (NEC) electrical inspector’s requirements, as well as inspection requirements for electrical motors, motor control circuits, and other electrical components integral to the operation of WHE.

(5) Demonstrate knowledge for the proper use and care of precision instruments and recording of measurements.

(6) Demonstrate knowledge on Lockout/Tag-out procedures.

j. Mechanical Shop Personnel (Mechanics and Inspectors). Mechanics and mechanical inspectors shall be qualified and trained in accordance with reference (a), appendix N section

2.3. Additionally the mechanical inspectors shall be designated in writing by the Certifying Official and shall perform duties in accordance with reference (a). Refer to sample letter S-3.

Responsibilities include but are not limited to:

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(1) Complete training requirements in accordance with reference (a), section 7.

(2) Perform maintenance and inspection of NOTU cranes in accordance with reference (a).

(3) Demonstrate knowledge of the requirements of reference (a), sections 2, 3, and 5, and reference (a) appendices C, D, and E.

(4) Demonstrate knowledge of inspection requirements for the crane structure, brakes, clutches, drive trains, wire rope, and other mechanical components integral to the operation of

WHE.

(5) Demonstrate knowledge for proper use and care of precision instruments and recording of measurements.

(6) Demonstrate knowledge of Lockout/Tag-out procedures.

k. Crane Operator and Rigging Shop. Crane operators shall be certified by the base contractor as fully qualified and licensed to operate NOTU cranes. Operators and riggers shall be qualified and trained in accordance with reference (a). Responsibilities include but are not limited to:

(1) Complete training requirements in accordance with reference (a), section 7.

(2) Demonstrate knowledge of equipment operation.

(3) Determine the weight of crane loads.

(4) Determine the center of gravity of crane loads.

(5) Plan the loaded crane’s movement path, and check for clearances.

(6) Select and properly use appropriate rigging equipment.

(7) Use of basic knots, bends, and hitches.

(8) Perform necessary calculations to determine the allowable capacity of crane load rigging configurations.

(9) Select appropriate attachment points on crane loads to be lifted.

(10) Perform visual inspections of rigging equipment prior to their use.

(11) Prior to use, perform inspection and operation of WHE being operated, and complete the Operators Daily Checklist (ODCL).

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(12) Direct other personnel assisting in the rigging evolution.

(13) Be knowledgeable in accident and equipment deficiency problem recognition and reporting procedures.

(14) Demonstrate proper crane communications (i.e. hand signals and radio communications, etc).

(15) Provide the Crane Program Manager with ODCL copies at the beginning of each month.

(16) Perform Crane-Rigging Monitor as directed by the Crane Program Manager and provide copies to the Crane Program Manager at the beginning of each month.

l. Lockheed Martin Space System Company (LMSSC)

(1) Resident Director is responsible for ensuring the Strategic Weapons System (SWS) fixtures and lifting devices used at NOTU are maintained, inspected, and tested in accordance with reference (i). This includes LMSSC contractors who operate cranes in NOTU facilities.

(2) LMSSC crane engineering is responsible to:

(a) Provide controlled documentation to accomplish SWS equipment and fixture maintenance, inspection and testing in accordance with reference (a) and reference (i).

(b) Provide documentation procedures for testing and lifting SWS equipment and fixtures or utilize required documentation as provided by FBM contractors.

m. Fleet Ballistic Missile (FBM) Contractors

(1) FBM Contractors; Lockheed Martin Space System Company (LMSSC), Charles Stark Draper Laboratory (CSDL), Trident Research, and General Dynamics Marine Systems (GDMS) crane operators, shall be certified as fully qualified and licensed to operate NOTU cranes.

Operators and riggers shall be qualified and trained in accordance with reference (a).

Responsibilities include but are not limited to:

(a) Complete training in accordance with reference (a), Section 7.

(b) Demonstrate knowledge of equipment operation.

(c) Determine the weight of crane loads.

(d) Determine the center of gravity of crane loads.

(e) Plan the loaded crane’s movement path, and check for clearances.

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(f) Select and properly use appropriate rigging equipment.

(g) Use of basic knots, bends, and hitches.

(h) Perform calculations necessary to determine the allowable capacity of rigging configurations.

(i) Select appropriate attachment points on loads to be lifted.

(j) Perform prior-to-use visual inspections of rigging equipment.

(k) Prior to use, perform inspection and operation of WHE being operated, and complete the ODCL.

(l) Direct other personnel assisting in the rigging evolution.

(m) Be knowledgeable in accident and equipment deficiency problem recognition and reporting procedures.

(n) Demonstrate proper crane communications (i.e. hand signals and radio communications, etc).

(o) Provide the Crane Program Manager with ODCL copies at the beginning of each month.

(p) Perform Crane-Rigging Monitor as directed by the Crane Program Manager and provide copies to the Crane Program Manager at the beginning of each month.

2. Self-Assessment

a. The Self-Assessment Team consists of:

(1) NOTU Crane Program Manager (SPP124)

(2) NOTU Facilities Management Branch Head (SPP12)

(3) NOTU Facilities Management Section Head (SPP121)

(4) NOTU Oversight and Assessment (SPPOA)

(5) Base Contractor

(6) LMSSC Crane Program Personnel

(7) Trident Research

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(8) CSDL

(9) GDMS

b. Responsibilities. The self-assessment team shall identify major areas of concern within the WHE program and develop a plan for corrective action, risk management and root cause analysis. The self-assessment shall be conducted in accordance with reference (a), section 2.4, prior to the NCC annual audit and reference (e).

3. Internal Program Audit

a. NOTU Crane Program Manager Audit Responsibilities. The NOTU Crane Program Manager shall evaluate and conduct technical audits of the contractor’s compliance in accordance with reference (a), in the areas of maintenance, inspection, load testing, and certification of cranes. More specifically, audits shall be conducted on crane history files, training requirements, inspection and maintenance procedures, and load tests for NOTU cranes.

b. Contractor Monitoring. Technical audits shall include:

(1) A minimum of one (1) crane file shall be audited per month.

(2) The Base Contractor’s crane and hoist files are subject to review at any time to ensure documentation is up to date and all discrepancies have been corrected.

(3) Discuss anomalies identified in the reports with the Base Contractor certifying agent to ensure necessary corrective action has been performed.

(4) Findings and discrepancies shall be submitted to the contractor using the NOTU Corrective Action Request (NCAR) form. Refer to sample NCAR form SPP11262 1/2.

4. Monitor Program

a. The monitor program is a method of reporting deficiencies in lifting and handling equipment, processes and operations. Monitor documents shall provide feedback from issues and incidents, and ensure corrective actions are effective and identify areas of tangibles deficiencies that still require improvement.

b. Trends indicated by these monitor shall be used to identify opportunities to improve overall performance such as specifically targeted training and safety briefs associated with preventing Crane and Rigging Gear incidents. Refer to WHE Crane/Rigging Monitor form

SPP11262 1/3.

5. Crane Replacement and Modernization Plan. The NOTU Crane Program Manager shall develop and maintain a Crane Replacement and Modernization Plan to reflect issues and concerns identified during the self-assessment program. The plan of action shall include a

1-8 budget and time frame for execution. Refer to Crane Replacement and Modernization Plan Example appendix A-1.

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CHAPTER 2

MAINTENANCE, INSPECTION AND CERTIFICATION

1. Preventive Maintenance (PM) Procedures. The PM procedures shall contain all information and direction necessary to accomplish the preventive maintenance of a specific item. These shall include requirements, instructions, accomplishing activity frequency, tools and materials required. Equipment with an expired certification shall not be used until a PM is performed or a deviation extending the maintenance period is approved by the NOTU Commanding Officer.

2. Preventative Maintenance (PM) Special Provisions

a. Requests for extension of a PM time cycle must be approved by the NOTU Crane Program Manager unless the periodicity of the annual certification will be exceeded. NOTU Commanding Officer approval will be required for an extension of the annual certification. See reference (a) for requirements on extension of annual certification.

b. Accomplishment of a PM may uncover discrepancies that require corrective maintenance. Such corrective maintenance shall be accomplished in accordance with the Maintenance, Inspection and Specification Record (MISR) disposition. Corrective maintenance may be accomplished as an integral part of PM.

3. Preventive Maintenance (PM) Documents. Controlled PM documents are issued to the Base Contractor using a Work Order Number (WON). The Base Contractor generates the controlled documents through their data base system. The documents shall specify proper maintenance requirements and maintenance interval required for each crane.

a. Crane Job Plan. The Crane Job Plan is provided by the Base Contractor to the NOTU Crane Program Manager and they shall provide a copy to the associated contractors. Appendix A-2 is an example of a CAT2 and CAT3 Job Plan. A Job Plan contains the following documents:

(1) Maintenance, Inspection, and Specification Record (MISR) (appendix C and D of reference (a)).

(2) Load Test Procedures (appendix E of reference (a)).

(3) Crane Condition Inspection Record (CCIR) (reference (a), section 4, figure 4-3).

(4) Certification of Load Test and Condition Inspection record (CLTCIR) (reference (a), section 4, figure 4-1).

b. Maintenance, Inspection, and Specification Record (MISR).

(1) A MISR is a list of applicable inspection requirements and shall be used to record conditions at each inspection and filed in the equipment history file.

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(2) All inspections shall be performed by the Base Contractor in accordance with the

MISR.

c. Load Test Procedure. Load test procedures are used to verify that the crane and trackage are acceptable for certification. Inspection, load test, and PM procedures are scheduled together annually for efficiency. Not all PMs, inspections or load test procedures are required annually, only those identified as due or having exceeded their periodicity are required to be performed.

Load test procedure shall be similar to reference (a) appendix E.

d. Crane Condition Inspection Record (CCIR). A CCIR lists all inspection criteria that shall be performed before, during, and after the load test. A CCIR shall be similar to reference (a), section 4, figure 4-3.

e. Certification of Load Test and Condition Inspection Record (CLTCIR). A CLTCIR certifies the required inspections and tests have been conducted in accordance with reference (a), and the crane is satisfactory to lift its certified capacity. A copy of the CLTCIR is posted on the crane cab or close to the crane disconnect switch in accordance with reference (a), section 4, figure 4-1.

f. Crane Processing and Completion Report. The Base Contractor shall issue a Crane Processing Completion Report (CPCR) with applicable documents following the completion of crane certification. Open work orders for the subject certified crane shall be forwarded to the NOTU Crane Program Manager for review at this time. Refer to Crane Processing Completion Report (CPCR) Form SPP 11262.1/5.

4. Crane Safety Advisory (CSA) and Equipment Deficiency Memorandum (EDM). NCC receives reports of equipment deficiencies, component failures, crane and rigging gear accidents and other potentially unsafe conditions and practices throughout the fleet. When applicable, the NCC will issue a CSA or an EDM as a Naval Message.

a. A CSA is a directive and often requires feedback from the activities receiving the advisory.

b. An EDM is provided for information and can include deficiencies to non-load bearing/load controlling parts.

c. Upon receipt of a CSA or EDM, the NOTU Program Manager will update the CSA or EDM database and request the Base Contractor to investigate and prepare a Crane Trouble Failure Inspection/Rejection Report (CTFIRR) to initiate action as appropriate. See document in Appendix S-5 for reference.

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5. NOTU Crane Program Manager (PM) Responsibilities

a. Review and approve new and revised PM procedures.

b. Receive and track CSAs and EDMs, and ensure corrective action, tests, inspections, measurements etc., are performed as required, reporting back to the NCC as directed.

c. Coordinate the PM and weight test schedules with the Base Contractor and FBM contractor’s building manager.

d. Oversee the Base Contractor develop a CAR, as required, in response to applicable CSAs and EDMs, when applicable to NOTU Cranes.

e. Ensure new or reactivated cranes meet the requirement of previously issued CSAs and EDMs.

f. Monitor and maintain a status report of crane maintenance documents.

g. Conducts audits as necessary and review and approve corrective actions.

6. Base Contractor PM Responsibilities

a. Perform crane maintenance as required.

b. Control and maintain PM procedures, and incorporate approved changes into the procedures.

c. Coordinate PM and weight test schedules with the NOTU Crane Program Manager and the FBM contractor’s building managers.

d. Provide a six month schedule to the NOTU Crane Program Manager and changes as they occur.

7. Procurement Inspection. A procurement inspection is performed for crane materials (or parts) by the NOTU Crane Program Manager and the Base Contractor. Inspections are performed upon receipt of material to the specifications stated in the procurement documents and may include visual or dimensional inspection, chemical analysis, material certification or NDT.

a. NOTU Crane Program Manager Procurement Inspection Responsibilities

(1) Perform procurement inspection of all crane replacement parts.

(2) Perform in-process inspection of maintenance, repair, testing and other operations as required by approved documentation.

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(3) Perform certification of load test and condition inspections as required for annual certification and/or interim recertification.

8. Crane Certification

a. Certification Process

(1) The certification of cranes shall be in accordance with reference (a).

(2) Prior to using a new crane, the crane must be certified and all applicable documentation reviewed/approved by the NOTU Crane Program Manager.

(3) The Base Contractor shall provide a crane certification package to the NOTU Crane Program Manager for review and approval. The certification package shall include:

(a) Maintenance, Inspection, Specification Record (MISR)

(b) Crane Condition Inspection Record (CCIR)

(c) Certification of Load Test and Condition Inspection (CLTCI)

(4) The signature of the Certifying Official on the Certification of Load Test and Condition Inspection (CLTCI) form indicates the crane is certified and is ready for service.

(5) The Base contractor shall fill out a new certification form, and replace the previous form with the one bearing the current certification information.

(6) The Certifying Official shall withdraw certification whenever deemed appropriate.

(7) Failure of any crane to successfully pass a prescribed test shall be reported immediately to the NOTU Crane Program Manager. A CTFIRR shall be written to document the problem and appropriate action to resolve the problem in accordance with reference (a).

b. Interim Recertification

(1) Interim recertification shall be performed when adjustment, replacement, alteration, repair or disassembly of load-bearing or load-controlling parts or operational safety devices have been affected as defined in reference (a).

(2) Interim recertification testing requirements shall be provided by a Crane Processing Completion Report (CPCR).

(3) CPCR is completed by Base Contractor and forwarded to the NOTU Crane Program Manager for review and then forwarded to the Certifying Official for certification.

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c. Extension of Annual Certification

(1) When an emergent or other contingent condition exists precluding the timely certification of a crane, a memorandum detailing the situation and recovery plan will be sent to the Commanding Officer for approval. The requesting organization shall explain the reason for the extension and the number of days requested, not to exceed 60 calendar days from the certification expiration date. Refer to Memorandum S-4 for a template.

(2) Before the certification can be extended a CCIR (Crane Condition and Inspection Record) including functional testing must be performed in accordance with reference (a).

(3) A CCIR is completed by Base Contractor and forwarded to the NOTU Crane Program Manager for review and then forwarded to the Certifying Official for certification.

(4) After approval of the extension letter, the letter and the CCIR shall be retained in the crane history file.

(5) If the CCIR cannot be accomplished before the crane certification expires, the crane certification can still be extended by performing the CCIR after certification expiration. If the crane is to be used between the expiration date and the extension is approved, a request for clarification, deviation or revision (RCDR) must be submitted to NCC for approval to use the crane until the CCIR can be accomplished and the certification extended.

d. Withdrawal and Reinstatement of Certification

(1) If determined by the Certifying Official that certification should be withdrawn for any reason, the Base Contractor shall lock-out the crane and notify the facility manager. Refer to Chapter 6 Lockout/Tag-Out.

(2) After completion of remedial action and approval by the certifying official, the Base Contractor will inform the facility manager of their intention to remove the lock.

(3) After all requirements have been completed a new certification shall be performed.

e. Deactivated Cranes

(1) A request to deactivate a crane can be made by LMSSC, CSDL, Trident Research, L3Harris or GDMS Senior Management. The request for deactivation shall be submitted in writing or e-mail to the NOTU Support Services/Planning Division Head, SPP10.

(2) When deactivating a NOTU crane, the NOTU Crane Program Manager will evaluate contractual impacts, and will direct the Base Contractor to perform a CCIR. Neither hook NDT, nor weight test is required to be performed. Discrepancies shall be identified on a CTFIRR and disposition on a case-by-case basis. The crane shall be placed in a position providing the least amount of interference and Lock-Out/Tag-Out.

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f. Reactivate

(1) A request to reactivate a crane can be made by a LMSSC, CSDL, Trident Research, L3Harris or GDMS senior manager. The request for reactivation shall be submitted in writing or e-mail to the Support Services/Planning Division Head, SPP10.

(2) When reactivating a crane at NOTU, the NOTU Crane Program Manager will evaluate contractual impacts, and notify the Base Contractor to issue a WON to accomplish the PM and certification. In addition, the NOTU Crane Program Manager shall verify that there are no outstanding issues on the crane by completing an activation check sheet (reference to Crane Activation Checklist Form SPP 11262.1/6). The Base Contractor will notify the NOTU Crane Program Manager of any outstanding issues, as well as forwarding a copy of the activation check sheet, prior to certification, when all issues have been resolved.

g. NOTU Crane Program Manager Certification Responsibilities

(1) Review crane certification packages for accuracy and completeness.

(2) Ensure cranes are inspected and tested in accordance with reference (a).

(3) Verify all CTFIRRs are closed or do not affect certification, complete required entries, review for accuracy, and submit documents to the Certifying Official for crane certification.

h. Base Contractor Certification Responsibilities

(1) Certify NOTU cranes in accordance with reference (a).

(2) Review crane certification packages for accuracy and completeness.

(3) Complete PMs and submit documentation to NOTU Crane Program Manager.

(4) Maintain crane history file for each crane, in accordance with reference (a).

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CHAPTER 3

TRAINING, QUALIFICATION, CERTIFICATION, AND OPERATOR LICENSING

1. Applicability. Only trained and qualified/certified personnel will perform NOTU crane maintenance, inspection, and rigging functions. Only qualified and licensed, if required (see below), personnel will perform NOTU crane operations except while performing on-the-job training (OJT). Personnel shall be qualified/certificated for specific tasks and skills prior to accomplishing tasks involving those functions. Training paths for achieving qualification/ certification shall be established and documented for each task or skill requiring qualification/ certification in accordance to reference (a). For clarification, CAT III non-cab operated cranes do not require a license.

2. Responsibilities. Qualification/certification and licensing of personnel are the responsibility of the Base Contractor and NOTU Crane Program Manager. Training paths shall be established by the respective organization and documented for each skill requiring qualification/certification.

3. Requirements

a. NOTU Crane Program Manager

(1) Review the onsite contractor’s licensing program documents as they relate to the skills performed on NOTU cranes.

(2) Verify Base Contractor personnel performing maintenance on NOTU cranes have current qualification/certification and are on the Base Contractor’s list of qualified personnel.

b. Base and FBM Contractors

(1) Establish and maintain a crane operator qualification/certification and license program, and issue crane operator licenses to Contractor’s personnel in accordance with reference (a).

(2) Once personnel have met the training requirements submit a memorandum to the NOTU Crane Program Manager containing personnel name, position and date of completion.

(3) Train, qualify and license personnel. Ensure only qualified and licensed contractor personnel are assigned to tasks associated with NOTU cranes.

(4) Submit a current list of all qualified crane maintenance personnel to the NOTU Crane Program Manager each time the list is updated. The list shall include name, position, courses/requirements and qualification dates according to reference (a).

(5) Ensure a current list of all qualified crane operators, who operate cranes at NOTU, is available for inspection.

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4. Production Tasks Requiring Qualification in accordance with Reference (a)

a. Rigger

b. Crane Mechanic

c. Crane Electrician

d. Load Test Director

e. Crane Inspector

f. Crane Track Inspector

g. Crane Operator

h. Mechanic and Electrician (No-Load License)

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CHAPTER 4

CRANE ALTERATION AND ENGINEERING

1. General

a. Crane alteration occurs when any work causes a modification to the crane or when mandated by NCC Crane safety Advisory/Equipment Deficiency Memorandum (CSA/EDM).

b. Alterations will be promulgated by the Base Contractor, who will then provide it to the NOTU Crane Program Manager for technical review. Once NOTU and the Base contractor have completed a technical review, Base Contractor will prepare implementing documents using a Crane Trouble Failure Inspection/Rejection Report (CTFIRR) or a Crane Alteration Report (CAR). Refer to CTFIRR Sample S-5 and CAR Sample S-6.

2. Policy

a. Alterations are initiated using a CTFIRR, and shall be requested and documented using a Crane Alteration Request (CAR). Refer to Sample S-6.

b. Alterations shall be performed in a timely manner and properly documented in drawings and the crane history file.

c. Alterations shall be performed in accordance with section 6 of reference (a).

d. Locally approved alterations shall be reviewed by the NOTU Crane Program Manager.

Additionally, alterations to load bearing parts, load controlling parts or operational safety devices will be reviewed and approved by Navy Crane Center (NCC).

e. After an alteration is accomplished, the followings documents will be updated, as applicable to address the change:

(1) Controlled drawings – Specifications and OEM

(2) SSP Coordination Drawings

(3) Approved Crane Navy Change Requests (CNCR)

(4) Crane Operation Equipment Manual (OEM).

3. NCC Initiated Alterations Include:

a. Mandatory Crane Alterations

b. Standing Crane Alterations

c. Crane Safety Advisory (CSA)

d. Equipment Deficiency Memorandum (EDM)

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e. Alteration to load bearing, load controlling, or operational safety devises

4. Crane Alteration Accomplishment

a. The Base Contractor shall perform alterations in accordance with an approved CAR or

CTFIRR.

b. Upon completion of an alteration, NOTU Crane Program Manager shall forward the original CAR or closed CTFIRR to the Base Contractor. The Base Contractor shall scan the document and provide NOTU Crane Program Manager an electronic copy for retention and file the original in the crane history file as required by reference (a).

c. When an alteration is performed by an outside contractor, copies of “as built” drawings shall be forwarded to the Base Contractor.

d. The Certifying Official will recertify cranes after completion of alterations as required by reference (a).

e. All affected documents shall be updated.

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CHAPTER 5

OPERATOR CHECKS

1. Operator Daily Checklist (ODCL) Process

a. The Operator’s Daily Checklist (ODCL) is a checklist used for the operator’s pre-use crane inspections. ODCLs are customized for each crane.

b. A completed copy of the ODCL shall be forwarded by the supervisor to the NOTU Crane Program Manager for review within seven days. All ODCL(s) shall be retained in accordance with reference (a). Refer to ODCL Sample S-7.

c. For cranes idle for more than six months, a Crane Condition Inspection Record (CCIR) is required prior to use the crane. The CCIR will be performed by the Base Contractor in accordance with reference (a).

2. Deficiencies. For any deficiency noted on the ODCL, the item shall be marked as unsatisfactory and the operator shall describe the deficiency in the remarks block. The operator’s supervisor shall inform the NOTU Crane Program Manager.

3. Responsibilities

a. NOTU Crane Program Manager.

(1) Review ODCL and report any delinquent submissions to the cognizant organization.

(2) Use the ODCL data to build metrics on crane reliability and availability.

b. Base and FBM contractors

(1) Complete ODCLs per reference (a).

(2) Review ODCLs for technical and administrative content and initiate corrective action for all operator detected deficiencies. Report all deficiencies to the NOTU Crane Program Manager.

(3) Maintain a file of completed ODCLs.

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CHAPTER 6

LOCKOUT/TAGOUT AND EQUIPMENT TAGGING

1. Applicability. This chapter describes specific procedures for performing Lockout/Tag-Out (LO/TO) on NOTU facility cranes, and supplements the requirements and responsibilities for (LO/TO) in reference (h). These procedures apply to personnel required to perform LO/TO of NOTU facility cranes when unexpected energized, start up, or release of stored energy could cause injury to employees operating, servicing, or maintaining the crane. This chapter also describes equipment tagging unique from LO/TO requirements for equipment with known deficiencies or out of certification.

2. Tags

a. DANGER/Do Not Operate Tag. Referred to as a “Red Tag” or “Personal Tag”. A danger tag is used to ensure that the equipment is isolated from all potentially hazardous energy, and locked out or tagged out before employees perform any servicing or maintenance activities where the unexpected energization, start-up or release of stored energy could cause injury

(1) The Base Operating Support Contractor (BOSC) is responsible for maintenance on all NOTU cranes and is the organization charged implementing LO/TO. If the crane is turned over to a third party contractor by the BOSC, that contractor may apply LO/TO according to their procedures.

(2) The Base Contractor performing the maintenance, inspection and repair on NOTU cranes, shall comply with their established LO/TO procedures. This tag shall identify the item locked out, employees name, shop, contact phone number and date.

(2) NOTU Crane Program Manager shall direct the Base Contractor to perform LO/TO when it is required to isolate a function, system, or the entire piece of equipment.

b. Equipment Deficiency Tag. This tag may be a “Caution” tag or “Do Not Use” tag as identified by the organization procedures applicable to the facility associated with the crane.

This tag will be different from LO/TO tags as well as a different color. The equipment deficiency tag may be applied by any personnel within the facility in accordance with their organizational practices.

(1) An equipment deficiency tag does not necessarily mean the equipment is not safe for use, rather the equipment is not certified for operation. This could be due to an issue identified during performance of the Operator’s Daily Checklist (ODCL) or the crane is out of certification.

Note “Caution” tags may be used to identify other issues that do not affect operations or certification of the crane; the purpose for the Caution tag must be clearly denoted on the tag.

(2) The equipment deficiency tag is normally placed on the equipment floor level disconnect, pendant, or on the cab operated controls.

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(3) When an equipment deficiency tag is installed, the equipment can only be operated under the direction of maintenance personnel for repairs, adjustments and tests.

(4) Equipment deficiency tags may be removed by the Facility Manager, personnel designated by the Facility Manager, or in accordance with local organizational practices upon determination the tag is no longer required. Equipment deficiency tags may be removed at the request of BOSC personnel to facilitate maintenance or tests.

(5) The Facility Manager or organization crane representative shall notify the NOTU Crane Program Manager when an equipment deficiency tag is placed and removed.

3. Requirements. The Base Operating Support Contractor shall comply with their established procedures. Summary of BOSC requirements per their procedures follows.

a. Authorized personnel shall be trained in LO/TO procedures per the OSHA 29 CFR 1910 and the NFPA 70: National Electric Code.

b. Authorized personnel shall use contractor issued, red color-coded locks and tags in accordance with LO/TO procedures. No more than two keys shall exist for any lock. The person using the lock shall maintain one key and the supervisor, or person acting shall maintain the other key readily accessible in case of an emergency.

c. Locks used shall be marked and identified with the responsible person’s name and shop.

This may be written on the lock or the lockout tag. Indelible ink shall be used.

d. Locks shall be removed by the personnel applying the lock. Locks are not transferable between personnel.

e. All personnel potentially exposed to the stored hazardous energy shall install a separate lock at each energy isolation point.

f. If the person that applied the lock is not available to remove it, the person’s direct supervisor shall personally verify that the unavailable employee is no longer in the area or working on the equipment which required the LO/TO. This verification shall be in the form of communication with the unavailable employee, or by inspecting the area. After this verification is completed, the supervisor may remove the lock with the second key.

4. Procedures. Authorized employees shall perform LO/TO in accordance with the following procedures:

a. Authorized employees shall follow normal shutdown procedures in accordance with Chapter 12.6 of Reference (h).

b. Temporary Removal of Tags. If LO/TO devices must be temporarily removed and equipment energized to test, the authorized employee shall:

(1) Clear the machine of unnecessary equipment, tools, and materials.

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(2) Notify Facility Manager to ensure all personnel are clear.

(3) Remove LO/TO devices.

(4) Energize and test the equipment.

(5) De-energize and reapply LO/TO devices in accordance with paragraph 4.a.

c. Completed Maintenance. When maintenance is complete, the authorized employee shall restore the machine to the normal configuration in accordance with Chapter 12.6 of Reference (h).

5. Inactive or Deactivated Crane Tag. A yellow tag with out of service warning shall be installed on all inactive or deactivated cranes.

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CHAPTER 7

ACCIDENTS, NEAR MISSES AND UNPLANNED OCCURRENCES

1. Crane and Rigging Operating Conditions

a. Normal Operation. Normal operation status, adhering to standard practices and processes routinely performed to maintain safe crane operations.

b. Management Oversight. Crane Program Manager and/or Commanding Officer will consider management oversight as a short term operating condition, lasting no more than two weeks, whenever one or more of the following conditions exist:

(1) If there are two accidents (crane and/or rigging) within any seven day period.

(2) Whenever trends indicate a specific problem area.

(3) Whenever the risk of an accident is high.

c. Shut-down. Crane operations should be stopped immediately by the crane operator or crane crew personnel, when if allowed to continue, could result in an accident or damage to the crane or the crane load. The operator will stop the operation, shut-down the crane, and inform the supervisor and the supervisor shall inform the NOTU Crane Program Manager. A course of action must be developed prior to resuming crane operations including a crane condition inspection and repair or a site clearance. Only the NOTU Commanding Officer can authorize operations to resume after a shut-down has been ordered and only after the proper action(s) are taken to preclude recurrence of the condition that initiated the shut-down.

2. Trend Analysis. The NOTU Crane Program Manager shall document the annual use of the crane and compare annual usage to the number of incidents occurring per year.

3. Informational Updates

a. NCC Crane Corner. NCC publishes a quarterly newsletter that will be forwarded by NOTU Crane Program Manager to all organizations involved in crane operations at NOTU.

b. Industry Information Updates. The NOTU Crane Program Manager will forward all relevant Crane and Rigging Gear information received to all organizations involved in crane operations at NOTU.

4. Crane Incident Response. Crane and rigging gear incidents at NOTU must be handled and reported properly. The incident scene shall be preserved to allow the personnel investigating the incident to recreate the events that transpired as accurately as possible.

5. Incident Classifications. All crane incidents at NOTU shall be classified as either accidents (crane or rigging gear), near miss or unplanned occurrence as outlined in section 12 of reference (a).

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6. Crane Accident Reporting Procedure. Upon Discovery of an Incident:

a. Immediately stop operation when an incident occurs and notify the immediate supervisor.

b. Call CCAFS emergency services at (321)853-0911 if necessary.

c. The supervisor shall assess the situation and take any further emergency action, including stopping production work or other operations that could disturb the scene or aggravate the situation.

d. Do not move the crane unless there is impending danger to equipment or personnel.

Leave the crane with the load suspended and the operator remaining at the controls unless damage has occurred that makes the condition unsafe.

e. If impending danger to equipment or personnel, place the crane and load in a safe position prior to notifying the immediate supervisor.

f. Do not move or disturb anything at the site associated with the weight handling operation until permission is received from the NOTU Crane Program Manager investigating the accident.

g. The supervisor shall notify their chain of command, the NOTU Crane Program Manager, the NOTU Safety Manager, Cape Support, Contractor Safety (if applicable) and the Commanding Officer via the Command Duty Officer (CDO).

h. NOTU Crane Program Manager shall instruct the Base Contractor to tag the crane out of service.

i. The Base Contractor shall generate a Crane Trouble Failure Inspection Rejection Report

(CTFIRR).

j. The supervisor of the weight handling equipment (WHE) shall take any emergency action and ensure the scene is secured and undisturbed.

k. The supervisor of the operation when the incident occurred will coordinate with the appropriate safety departments and the NOTU Crane Program Manager. An investigation of the incident shall be performed by the Base Contractor and/or associated contractors.

l. The NOTU Crane Program Manager shall fill out a Crane and Rigging Accident Checklist. Refer to form SPP 11262 1/4.

m. The Base Contractor shall administratively suspend the operator’s license. The operator’s license will be reinstated if the investigation determines that the operator was not at fault for the incident.

n. The Commanding Officer will determine if an incident is an accident or a near miss.

o. NOTU’s Chief Engineer shall setup a critique time and location and invite at a minimum the following personnel: Executive Officer (XO), Chief Engineer, Safety Personnel, NOTU Crane Program Manager, Crane Certifying Official, NOTU Oversight and Assessment

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p. A critique is not required for a near miss with the Chief Engineer’s concurrence.

q. A safety representative from the organization in control of the operation when the incident occurred (if applicable) shall provide a written report to the NOTU Crane Program…