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ESH Manual Page: 10000: Material Handing and Transportation

1. CHAPTER

The Sanford Underground Research Facility (SURF), manages the use of Below-the-Hook (BTH) equipment to ensure the safety of the personnel and prevention of property damage.

This chapter outlines the requirements for designing, fabricating, operating, testing, inspecting and documenting of Below-the-Hook lifting devices fabricated in-house or purchased for a specific specialty use. 

2. SCOPE

This chapter applies to all personnel and activities using BTH devices and rigging equipment at SURF.

Rigging Equipment examples:

  • Slings
  • Clevises / Shackles

BTH Devices examples:

  • Spreader bars
  • Customized lifting devices (specialized to a specific equipment)

3. DEFINITIONS

Additional definitions and terminology are contained in the standards and/or manuals listed below:

Below-the-Hook (BTH) Lifting Devices:  That equipment (other than slings or rigging equipment) utilized between the hook and the load. May be used to support, position and bear the weight of a specific load.

Certified Inspector:   A person who has successfully passed a commercially recognized training course providing certification, e.g. KoneCrane Course 819-820.

Clevis: A U-shaped or forked metal connector within which another part can be fastened by means of a bolt or pin passing through the ends of the connectors. A Clevis is a three-piece connection device.

Competent Person: A person capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them. Ability to demonstrate proficiency for assigned tasks.

Critical Lift – Any load requiring exceptional care in handling. For example:

  • Safety concerns
  • Size or shape
  • Weight which exceeds 75% of the rated load
  • Close-tolerance installation
  • High susceptibility to damage
  • High value or potential impact of a high value item
  • Impact to operations (budget, schedule)
  • Load out of view of the crane operator
  • Potential release of hazardous material into the environment
  • Single lift involving multiple cranes, or other unusual factors.

Customized lifting devices: Custom fabricated lifting devices utilized between the hook and the load to handle unique or complicated lifting and rigging applications. May be commercially manufactured, designed and fabricated externally or in-house. Design, testing, certification and rated capacity/load shall be aligned with the requirements of this document.

Engineering Notes: Documentation of the professional evaluation performed on structural design specifications.

Qualified Person - a person who, by possession of a recognized degree or certificate of professional standing, or who, by extensive knowledge, training and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work.

Rated Capacity: Maximum working load (100%) permitted by the manufacturer under specified working conditions. This is indicated on the tag or on the lifting equipment.

Rated Load / Marking. The rated load marking of the BTH device shall be plainly identified on the lifting device and shall not exceed 80% of the rated load test or specification, whichever is less.

Rated Load Test – A formal process utilizing a known weight to evaluate both the hoisting device and supporting structure capability to safely establish the Rated Load.

Rigging Qualified Person – A person, who by possession of a recognized degree or certificate of professional standing in applicable field, or who by extensive knowledge, rigging training and experience has successfully demonstrated the ability to solve or resolve problems related to rigging and associated rigging work.

Shackle: A U-shaped or forked metal connector within which another part can be fastened by means of a bolt or pin passing through the ends of the connectors. A shackle is a two-piece connection device.

Slings: An assembly to be used for lifting when connected to a lifting mechanism. The upper portion of the sling is connected to the lifting mechanism and the lower portion supports the load. Types of slings:

  • Synthetic
  • Steel / Wire rope
  • Chain

Spreader-Bars: A type of device used to distribute the weight of load across more than one point. Provides for increased stability and positioning control.

4. RESPONSIBILITIES

The Facility Infrastructure Director is responsible for:

  • Maintaining an inventory and inspection program for slings, rigging hardware, and BTH rigging device, including documentation. Appoints and utilizes supervisors and foreman to administer this program.
  • Appointing a qualified person(s), a rigging qualified person(s) and a “Subject Matter Expert” with respect to hoisting and rigging.
  • Maintaining a hoisting and rigging training program and establishing training requirements for SURF personnel involved in BTH use.  This training program will include the incorporation of Lessons Learned from incidents.
  • Conducting a yearly audit of the slings, rigging, and BTH rigging device records.
  • In conjunction with the ESH Department, conducting a biennial review of the Hoisting and Rigging Program, including a review of this chapter to ensure it still meets SURF needs.
  • Maintaining manuals and manufacturer information and records related to testing, lifting capacity, inspection, and repair of all BTH devices.  
  • Selection of a qualified contractor to perform annual inspection, testing, maintenance and repair of BTH as needed.
  • Conduct an annual review of this chapter. (Document-73406).
  • For ensuring that all BTH equipment shall be inspected prior to critical lift by a qualified person.

The ESH Director is responsible for:

  • Verifying compliance with the requirements of this chapter on an annual basis. 
  • Deviations from the requirements of this chapter require ESH Director approval.
  • Assist Facility Infrastructure Department with development and implementation of training needs. 
  • Maintaining training records
  • Coordinating and scheduling training
  • Providing consultation services regarding safety of operations.
  • In conjunction with the Facility Infrastructure Department, conducting a biennial review of the Hoisting and Rigging Program, including a review of this chapter to ensure it still meets SURF needs.

The Engineering Director is responsible for:

  • Appointing a qualified engineer(s) to assist Facility Infrastructure, who provides engineering support with respect to the certification and load rating of all customized BTH lifting devices.
  • Creation and recordkeeping of all engineering notes. (See Section 5.1)

Project Managers are responsible for:

  • Communicating to Contractors/Users under their cognizance the requirements of this chapter. 
  • Ensuring that Contractors/Users under their cognizance, involved in hoisting and rigging activities are properly trained.

Supervisor/Foreman is responsible for:

  • Assist the Facility Infrastructure Director in the administration of inspections and documentation activities for slings, rigging hardware, and BTH lifting devices located in the area under their supervision.
  • Ensuring that only properly trained individuals are allowed to actively participate in work tasks involving hoisting and rigging activities.

LIFTING DEVICES PROGRAM ELEMENTS

Engineering Note Procedure for Customized BTH Devices

Customized BTH Lifting devices shall only be used after an engineering analysis has been performed on the modified BTH and this analysis documented with an Engineering Note.

A. Engineering Notes:  Shall be prepared by a qualified engineer for;

  • All customized BTH lifting devices owned by SURF or;
  • Research collaborators’ equipment used at SURF whether purchased or fabricated at SURF or a collaborating institution.
    • All subsequent changes in BTH usage that could affect the safety of personnel or the capability of performance shall require an amendment to the original engineering note. 
  • Modifications to BTH Lifting Devices or custom devices shall be documented, prior to use.
  • Similar Lifting Devices:  Lifting devices that are manufactured or fabricated to meet previously engineered, fabricated and reviewed lifting devices need not have the full engineering analysis repeated.  Documentation shall be provided by reference to an existing approved Engineering Note and the detailing of all differences.                           

B. Contractors may utilize an equivalent documented process such as a commercial source engaged in the manufacturing of lifting devices.

 An Engineering Note equivalency may include:

  • Commercial BTH devices
    • Manufacturer’s Certificate of Test
    • Copies of the Operator’s Manual and Inspections (if applicable)
  • Non-Commercial BTH devices:
    • Device designed by a Professional Engineer

C. Content

All Engineering Notes shall include all safety precautions, operating, and maintenance procedures, service or duty cycle rating (if applicable), recommend inspection frequency, and complete nameplate data required for the lifting device.

  • Where any fixture lifts a load at a point below the center of gravity, the engineering note must explicitly address the issue of the stability of the load and fixture combination.
  • Load tests results (See below Load test requirements).
  • Initial Inspection results (See below Inspection requirements).

D. Review of Engineering Notes:  All lifting device Engineering Notes shall be reviewed by a qualified person for compliance with the requirements of this chapter and approved by the Engineering Director.

Manufacturer

Non-Commercial

  • BTH lifting devices shall be manufactured to comply with this chapter and ASME B30.20.
  • Identification shall be a part of the manufacturing process.  Each device in service at SURF shall be permanently labeled with a SURF lifting device number and other nameplate data. 

Commercial

  • The manufacturer of purchased devices shall affix its nameplate data and label the device. SURF personnel will affix a SURF specific device number.  (All documentation shall reference the SURF device number.)
     

Commissioning Process

A. Initial Inspection - An initial inspection by a Certified Inspector of all new, modified, or repaired devices is required for commissioning to verify that:

  • Device is assigned a SURF identification number and affixed to the device
  • Unit is built and operates to specifications 
  • SURF identification number documented in ManagerPlusTM
  • Rated Load / Marking shall be affixed to the device
  • Information documented in the Engineering Notes for customized devices.

Load Testing

  1. The test must be performed when a BTH lifting device is newly installed, modified or repaired.
  2. The load test shall not exceed the specifications of the device.
  3. The load test results shall be documented and maintained within the ManagerPlusTM work order/asset system.
  4. Manufacture Certificate of Test may be equivalent if available.

Rated Load / Marking

Commercial BTH Devices:  Rated Capacity equals Rated Load.

Customized Lifting Devices require a load test used in the determination the rated load.

  1. The rated load shall not be more than 75% of the confirmed load test or specifications, whichever is less.
  2. Example: BTH device specification is 2 tons. The load test was done to 90% of the specification. (3600 lbs) The rated load would be 75% X 3600 lbs = 2700 lbs. 2700 lbs would be the value on the marking. The rated load shall be plainly identified on the BTH device
  3. The rated load shall be documented and maintained within the ManagerPlusTM work order/asset system.

Pre-Use Inspection

 All devices shall be visually inspected by the competent person prior to each use.  This is not a documented inspection but will cover the following:

  1. Verification of nameplate, load rating, and validation date of previous annual inspection.  The device shall not be used if the nameplate is missing, rated load is insufficient for the lift, or annual inspection is older than one year.
  2. Structural members for deformation, cracks or excessive wear on any part of the lifter
  3. Loose or missing guards, fasteners, covers, or stops
  4. All functional operating mechanisms and automatic hold-and-release mechanisms for maladjustments interfering with operation.
  5.  All lifting devices requiring repair shall be:
    • tagged out of service
    • reported to the supervisor
    • documented as per its SURF identification number
    • repair activities entered into ManagerPlus™

Annual Inspection

An annual inspection performed by a Certified Inspector must be completed for all BTH devices. The inspection must be documented and records entered into ManagerPlus™ and available for review by operators and others requiring access to inspection data and information.  The annual inspection date shall be affixed on the lifting devices.  At a minimum, the following shall be considered:

  1. Verification of nameplate and load rating
  2. Structural members for deformation, cracks or excessive wear on any part of the lifter
  3. Loose or missing guards, fasteners, covers, or stops
  4. All functional operating mechanisms and automatic hold-and-release mechanisms for maladjustments interfering with operation
  5. Missing hardware
  6. Excessive abrasion, nicks or discoloration
  7. Unauthorized modifications
  8. All lifting devices requiring repair shall be:
    • tagged out of service
    • reported to the supervisor
    • documented as per its SURF identification number
    • repair activities entered into ManagerPlus™

SLINGS AND RIGGING EQUIPMENT PROGRAM ELEMENTS

The slings/equipment shall be marked in such a fashion as to provide the information for the pre-use inspection to determine whether hardware can sustain the expected load.

See table below for specifics.

Information

Slings

 

Rigging Equipment

(Non-BTH devices)

Chains

 

Wire

Synthetic

 

 

Rated Capacity

X

X

X

X

Hitch Type

X

X

 

 

Manufacturer

X

X

X

X

Diameter (size)

X

X

 

X

Angle

X

X

 

 

Legs (if more than 1)

X

X

 

 

Type of Material

 

X

 

 

Grade

 

 

 

X

Use

  1. All slings and rigging hardware shall be used in accordance with the manufacturer’s recommendations, OSHA and SURF requirements.
  2. Damaged slings and rigging equipment are to be destroyed and discarded.
  3. Environmental conditions are to be considered in the use, e.g. UV damage on synthetic, fumes, acids, corrosives on steel. 

Storage

Specific facilities are to be utilized to organize and store equipment when not in use. Storage facilities shall consider the following:

  • Clean, dry and free of chemicals
  • Sufficient room to hang and organize
  • Good illumination for inspections
  • Controlled access
  • Strategic location to support work

REFERENCE AND RELATED DOCUMENTS

Related Documents

  • Cranes and Hoists
  • Engineering Note  
  • Slings, Rigging Hardware and Below-the-Hook Devices Inspection Form

References

  • OSHA 1910
  • OSHA 1926
  • ASME B30.20