6.2 Safety and Design Aspects. Generally, off-the-shelf, OEM type equipment is acceptable for critical and noncritical lifts if it is designed, maintained, inspected, and operated according to this standard
6.2.1 Design criteria that should be emphasized during hoist design are contained in the documents listed in Section 2
6.2.2 Labeling/Tagging of Hoists and Winches
a. The hoist’s or winch’s rated capacity shall be marked on it or its load block. This marking shall be clearly legible from the ground floor
b. Hoists and winches that have the specified design features, maintenance/inspection, and test intervals to lift critical loads shall be marked conspicuously so that the operator and assurance personnel can distinguish that the hoist or winch is qualified for critical lifts
c. A standard system of labeling shall be established and used throughout the installation
d. A standard lockout/tagout system shall be established and used throughout the installation to indicate equipment that is not to be used due to inspection discrepancies, ongoing maintenance operations, or other reason
e. Certification/recertification tags are required as described in paragraph 6.3.4
6.2.3 Safety Analysis and Documentation for Hoists and Winches used for Critical Lifts. A recognized safety hazard analysis such as fault tree analysis, FMEA, O&SHA shall be performed on all hoists and winches used for critical lifts. The analysis shall, as a minimum, determine potential sources of danger, identify failure modes, and recommend resolutions and a system of risk acceptance for those conditions found in the hardware-facility-environment- human relationship that could cause loss of life, personal injury, and loss of or damage to the hoist, winch, facility, or load. The analysis shall be done as part of the initial evaluation process for critical lift compliance and prior to use in a critical lift, included in the hoist or winch documentation, and updated as required to reflect any changes in operation and/or configuration. 53 6.2.4 Performance. Duty cycle, load capability, and the desired control characteristics with which the hoist or winch handles the load shall be addressed for all designs. Duty cycle requirements shall be based on the worst expected duty the unit will encounter. Operational requirements shall be considered in the design phase to ensure load and function are adequately defined and critical hoist design features are incorporated on the delivered units. Environmental conditions must also be considered
6.2.5 Structural. Structural design shall be in accordance with industry standards for material selection, welding, allowable stresses, design limitations, framing, wheels, and other structural elements. Refer to CMAA standards for specific design details
6.2.6 Mechanical. a. The use of high quality, off-the-shelf, OEM type equipment is acceptable for critical and noncritical lift applications if it meets all user requirements and the requirements of this document. This high quality commercial equipment employs a modular type construction of the hoist or winch unit with standard frame sizes and interchangeable gear boxes, drums, motors, brakes, and controls to achieve a wide range of capacities, lifts, operating speeds, reeving arrangements, and controls. These interchangeable parts are standardized for each manufacturer’s product line and the hoists and winches are built to order. b. The mechanical design requirements for hoist and winch components are as follows: (1) They meet all applicable requirements of OSHA, ASME, and CMAA
(2) Electric and air operated hoists and winches should be provided with at least two means of braking: a holding brake and a control brake. The torque rating, physical characteristics, and capabilities shall be in accordance with CMAA specifications
(3) For powered (electric and air) hoists and winches used for critical lifts, two holding brakes shall be provided, each capable of bringing a rated load to zero speed and holding it. Holding brakes shall be applied automatically when power to the brake is removed. If the control brake and holding brake are designed to operate as a system and cannot independently stop and hold a rated load, then another means of braking is required (e.g., emergency brake). The brakes shall be designed so that they can be tested as required in paragraph 6.3.3.e. The brake design shall provide for emergency load lowering
(4) For critical lift application, speed reduction from the motor to the drum on the hoist should be achieved by enclosure in a gear case. If open gears are required, they shall be guarded with a provision for lubrication and inspection
(5) All wire rope hoists and winches shall have not less than two wraps of hoisting rope on the drum when the hook is in its extreme low position. Drum grooves, when provided, shall be as recommended by54 CMAA. The rope ends shall be anchored securely by a clamp or a swaged terminal in a keyhole slot, provided a keeper is used to prohibit the swage from moving out of the narrow slot. Other methods recommended by the hoist or wire rope manufacturer are acceptable if the rope termination anchor together with two wraps of rope on the drum will give an anchor system equal to or greater than the breaking strength of the wire rope. (6) Safe and adequate access to hoist and winch components to inspect, service, repair, or replace equipment shall be provided for during design. The design shall provide for visual and physical accessibility. (7) Manually operated (nonpowered), off-the-shelf OEM type hoists and winches are acceptable for critical and noncritical lift applications. They shall comply with applicable ASME requirements. These hoists shall be equipped with at least one self-setting brake, referred to as a holding brake, applied directly to the motor shaft or some part of the gear train. No limit switches are required if proper over-travel restraint is provided
(8) Air operated chain hoists and winches can be equipped with over- travel protection devices instead of the hoist travel limit switches
(9) Initial and final upper limit switches (limit control valves) shall be provided and tested for air-operated hoists and winches as described in paragraph 6.2.7.i. The final upper limit switch (limit control valve) shall exhaust air from the hoist or winch, set the brakes, and require reset at the upper limit switch (limit control valve) level. (10) Worm gears shall not be used as a holding brake unless the lead angle is sufficient to prevent back driving. Worm gears used as a brake for air and electric powered hoists may be considered as a second holding brake. The braking properties of a worm gear tend to degrade with use; the design engineer shall consider this when purchasing new equipment or in existing installations where the hoist is subject to heavy use
(11) In the procurement of new lifting equipment, the use of cast iron components in the hoist or winch load path shall be approved, as a minimum, by the LDEM and the responsible design engineering organization. The material properties of cast iron allow catastrophic failure and should not be considered as reliable as steel or cast steel. The engineer shall consider this when selecting equipment and avoid the use of load bearing cast iron materials where possible
(12) Gearing shall be designed and manufactured to comply with the latest AGMA gear standards
(13) Each load-bearing component shall be specified or detailed to lift the maximum imposed loads resulting from zero to rated hook load with appropriate design factors.55 c. When the use of high quality, off-the-shelf, OEM type equipment is not possible due to unique design and operation requirements, then built-up type equipment must be used. These built-up hoists/winches generally use many commercially available or made-to-order motors, brakes, couplings, gear reducers, etc. These components are then custom engineered together as an assembly mounted on custom designed and built equipment frames. In many cases, gear reducers, drums, and drive shafts are custom designed and built. Structural and mechanical parts, such as sheave pins, hook-block components, bridge girders, and bridge and trolley drives are also custom designed and built as components or assemblies. The built-up type crane should only be used where commercial equipment is not available to meet the user/operational requirements described in this paragraph. Due to the nature of its one of a kind design and construction, this type of equipment is generally more prone to break down and should be considered as less reliable than commercial equipment. These units shall meet the mechanical design requirements provided in paragraph 6.2.6.b
6.2.7 Electrical. Electrical design requirements are as follows: a. The use of high quality, off-the-shelf, OEM type equipment is acceptable for critical and noncritical lift applications if it meets all user requirements and the requirements of this document
b. When the use of high quality, off-the-shelf, OEM type equipment is not possible due to unique design and operation requirements, then built-up type equipment must be used. This built-up equipment generally uses many commercially available or made-to-order components which are then custom engineered together as an assembly. Built-up equipment should only be used where commercial equipment is not available to meet the user/operational requirements. Due to the nature of its one of a kind design and construction, this type of equipment is generally more prone to break down and should be considered less reliable than commercial equipment
c. Wiring and safety devices shall be in accordance with the NFPA National Electrical Code
d. Electrical enclosures shall provide protection for the contained equipment against environmental conditions as required by NEMA
e. In addition to overload protection required by the National Electrical Code, undervoltage and phase reversal should be considered
f. For powered hoists and winches used for critical lifts, an assessment shall be performed to determine the operational needs for remote emergency stops independent from the operator controlled emergency stop. Not all hoists and winches used for critical lifts require a remote emergency stop. Remote emergency stops are required for hoists and winches used for critical lifts where the operator’s view is restricted/obstructed. When provided, this independent remote emergency stop should be located such that the independent remote emergency stop operator(s) can clearly see the critical lift area(s). The remote56 emergency stop circuit shall be separate from and take precedence over the operator control circuit. The control, when activated, shall cause all drives to stop and the brakes to set. Hand-held remote emergency stop pendants should be standardized and should include power and circuit continuity indication. For those hoists and winches required to make critical lifts that have not been modified to provide a remote emergency stop, handling procedures shall be developed and implemented to minimize the risk
g. Electrical control stations shall operate on 150 volts DC, 120 volts AC, or less. Positive detent pushbuttons or a control lever shall be used for speed control. Controls shall return to the off position when the operator relieves pressure. A red, emergency stop pushbutton shall be provided to operate the mainline contactor, main circuit breaker, or pneumatic source (main breaker preferred). A dump valve is acceptable for the emergency stop for a pneumatic hoist
h. The electrical system shall be designed fail-safe to ensure that a failure of any component will not cause the hoist or winch to operate in a speed range faster than commanded. A failure that causes a speed different from that selected is acceptable provided no hazards are introduced. Failure modes that cause the hoist or winch to slow down or come to a safe stop are acceptable; those that could cause unplanned directional shifts, and/or loss of control are unacceptable. i. For hoists and winches used for critical lifts (except manual), dual upper limit switches are required. For electric hoists and winches, the limit switches shall meet the following requirements: (1) Initial upper limit switch electrical contacts shall be a set of normally closed contacts in the “raise” contactor circuit such that movement in the raise direction shall be precluded after the limit switch is encountered. Movement in the “lower” direction will not be inhibited. (2) Final upper limit switch electrical contacts shall be a set of normally closed electrical contacts wired into the mainline circuit, hoist or winch power circuit, main contactor control circuit, or hoist/winch power contactor control circuit such that all hoist or winch motion shall be precluded after the limit switch is encountered. These normally closed contacts may be located in the low voltage circuitry
(3) After a final upper limit switch has been activated, movement of the load will require action (resetting) at the final upper limit switch level. An inspection shall be made to determine the cause of failure of the initial upper limit switch. Stopping hoist motion by the above design configuration may result in a hazardous suspended load condition. The hoist design should include a means of detecting limit switch failure and allow for safe inspection and repair. For example, a system may be equipped with two different colored annunciator lights, one for each limit switch. A reset button may be included so that when a final upper limit switch is tripped, the load can be lowered immediately. The reset button should be secured to prevent unauthorized use.57 (4) The initial upper limit switch shall be adjusted sufficiently low to preclude inadvertent actuation of the final upper limit switch if the hoist actuates the initial switch at full speed with no load. Similarly, the final upper limit shall be adjusted sufficiently low to ensure that the hoist or winch will not two-block (or otherwise damage wire rope) if the hoist or winch actuates the final switch at full speed with no load. Both limits shall be tested from slow speed to full speed to verify correct operation. It should be noted that this requirement effectively lowers the usable hook height of the hoist. The limit switch arrangement needs to be considered during new equipment design
j. Provisions for grounding the hook are required for handling explosives, solid propellants, flammables, or any other load that requires a nonelectrical or static-free environment. See paragraph 6.8 for handling explosives or EED’s
k. For hoists and winches used for critical lifts, lower limit switches to prevent reverse winding of the wire rope shall be provided
l. Electrical hoists and winches shall have the capability to be locked out at the main breaker to prevent unauthorized use
m. Hoists and winches shall be designed fail-safe in the event of a power outage
6.3 Testing. Three types of tests are required on hoists: proof load tests, periodic load tests, and operational tests. The proof load tests and operational tests shall be performed prior to first use for new, extensively repaired, or altered hoists and winches. The periodic load and operational tests shall be performed at least every 4 years. For hoists and winches used for critical lifts, these tests shall be based on frequency of usage. Hoists and winches used frequently for critical lifts shall be load tested annually. Hoists and winches used infrequently for critical lifts shall be load tested before each critical lift if it has been more than one year since the last test. If a hoist or winch is upgraded, a proof load test and an operational test shall be performed based on the upgraded rating. All load and operational tests shall be performed by qualified personnel according to written (specific or general) technical operating procedures. An inspection shall be performed after each load test and prior to the hoist being released for service to ensure there is no damage. Surface or volumetric NDT shall be used to validate the existence or absence of cracks or other load test effects indicated by this inspection
6.3.1 Proof Load Test. Before first use and after installation, all new, extensively repaired, modified, or altered hoists and winches shall undergo a proof load test with a dummy load as close as possible to, but not exceeding 125 percent of the rated load. The acceptable tolerance for proof load test accuracy is -5/+0 percent
6.3.2 Periodic Load Test. All hoists and winches shall be tested at least once every 4 years with a dummy load equal to the hoist’s/winch’s rated capacity. Platform hoists shall be tested using the attached platform only. Hoists and winches used for critical lifts shall be load tested at least once per year. Hoists and winches used infrequently for critical lifts shall be load tested before each critical lift if it has been over one year since the last test. The acceptable58 tolerance for periodic load test accuracy is + 5/-0 percent. The periodic load test can be fulfilled by a concurrently performed proof load test. 6.3.3 Operational Test. Together with proof load and periodic load tests, the following shall be performed with a dummy rated load unless otherwise specified (platform hoists shall be operationally tested using the attached platform only): a. Perform all hoist functions in an unloaded condition
b. Test operation of brakes and limit, locking, and safety devices
c. Determine trip setting of limit switches and limiting devices by tests under no load conditions. Conduct tests first by hand, if practical, and then under the slowest speed obtainable. Test with increasing speeds up to the maximum speed. Locate actuating mechanisms so that they will trip the switches or limiting devices in time to stop motion without damaging the hoist or winch
d. After testing in the unloaded state, apply the test load to the hoist or winch to check the proper load control. Test load hoisting, lowering at various speeds (maximum safe movement up and down as determined by the LDEM and the responsible safety, engineering, operations, and maintenance organizations), and braking/holding mechanisms. Holding brakes shall be tested to verify stopping capabilities and demonstrate the ability to hold a rated load (see paragraph 6.3.3.e). The load should be held long enough to allow any dynamics to dampen out. e. Powered hoists and winches used for critical lifts are required to be equipped with two holding brakes, each capable of bringing a rated load to zero speed and holding it (see paragraph 6.2.6.b(3)). If a worm gear is used as a holding brake, it shall be tested to ensure it is able to hold a static load and stop a dynamic load. The operational test must demonstrate each brake’s ability to stop and hold a rated load. This can be done in one of the following ways: (1) Each brake’s ability to hold shall be statically tested (under no load) with 150 percent of the rated load hoisting torque at the point of brake application
(2) Alternately, each brake shall be tested for its ability to stop and hold a rated load in both the raising and lowering modes. (CAUTION: It must be possible to quickly reenergize the out of circuit brake or provide other safety measures to perform this test safely.) (3) Other methods may be used as approved by the LDEM with concurrence from the responsible safety, engineering, operations, and maintenance organizations. f. The operational test for a modified hoist or winch can be tailored to test only those portions of the equipment that were modified, only if the periodic load and operational test interval has not expired
59 6.3.4 Test Reports and Periodic Recertification Tags. After each test, designated personnel shall prepare written, dated, and signed test reports, including procedure reference. Inadequacies shall be documented and, if determined to be a hazard, corrected prior to further use. These reports shall be filed and shall be made readily available by the organization responsible for testing the hoist. Following the periodic load test, all hoists and winches shall be given a permanently affixed tag, posted on the hoist or winch or an appropriate location, identifying the equipment and stating the next required periodic load test date or load test expiration date. 6.4 Inspection
6.4.1 Inspections, as described below, shall be performed on all hoists and winches in regular service. Inspections shall be performed according to this section, the manufacturers’ recommendations, and the applicable ASME standard. Inadequacies discovered during an inspection shall be documented and, if determined to be a hazard, tagged out and corrected prior to further use. Inspections shall be performed by qualified personnel according to approved technical operating procedures
6.4.2 All new, extensively repaired, or modified hoists and winches shall be inspected to the requirements of both daily and periodic inspections prior to first use. For component repair on hoists and winches, only the inspections that apply to the repaired portion need to be performed prior to first use unless a periodic inspection interval expires during the downtime (see paragraph 6.4.5). 6.4.3 Hoists and winches in regular service (used at least once per month) shall be inspected as required in paragraphs 6.4.4 and 6.4.5. Idle and standby hoists/winches shall be inspected according to paragraph 6.4.6
6.4.4 Daily Inspections. These inspections shall be performed each day the hoist or winch is used and shall include the following: a. Check operating and control mechanisms for proper function
b. Without disassembling, visually inspect all functional operating and control mechanisms, including brakes where visible, for excessive wear and contamination by excessive lubricants or foreign matter
c. Inspect load chain for wear, twists, damage links, or foreign matter
d. Visually inspect hooks for deformation, chemical damage, or cracks (see Section 7)
e. Inspect load bearing components for damage
f. Inspect running rope or chain for discrepancies
6.4.5 Formal Periodic Inspections. These inspections shall be performed at varying intervals, depending on activity, severity of service, environment, and criticality
a. Monthly Inspections (Frequent Inspections). At least once per month: 60 (1) Perform daily inspection requirements described in paragraph 6.4.4
(2) Inspect wire rope monthly (except those on platform systems that shall be inspected at least twice a year), paying particular attention to the following signs of deterioration and damage: (a) In running rope for a base mounted drum hoist, six randomly distributed broken wires in one rope lay or three broken wires in one strand in one lay or one valley break. In standing rope for a base mounted drum hoist, three randomly distributed broken wires in one rope lay or two broken wires at an end connection. In running rope for an overhead hoist, twelve randomly distributed broken wires in one rope lay or four broken wires in one strand in one lay or one valley break
(b) Individual wires with 1/3 wear of original outside diameter
(c) Kinking, crushing, bird caging, or any other damage resulting in distortion
(d) Evidence of heat damage
(e) End connectors that are cracked, deformed, or with evidence of rope pullout
(f) Corrosion (internal or external) that results in reduction of rope diameter, or at end connectors
(g) Reductions of nominal diameter (measured with a caliper or go/no-go gage) of more than: (i) 1/64 inch (0.4 mm) for diameters of rope up to 5/16 inch (8.0 mm)
(ii) 1/32 inch (0.8 mm) for diameters 3/8 inch (9.5 mm) to 1/2 inch (13.0 mm)
(iii) 3/64 inch (1.2 mm) for diameters 9/16 inch (14.5 mm) through 3/4 inch (19.0 mm)
(iv) 1/16 inch (1.6 mm) for diameters 7/8 inch (22.0 mm) through 1-1/8 inches (29.0 mm)
(v) 3/32 inch (2.4 mm) for rope diameters greater than 1-1/8 inches (29.0 mm)
(3) Inspect welded-link chain monthly by performing the following checks: 61 (a) Raise and lower hoist while loaded. The chain should feed smoothly into and away from the sprockets
(b) If chain binds, jumps, or is noisy, see that it is clean and lubricated. Inspect chain and mating parts for wear and distortion
(c) Clean chain and visually examine for gouges, weld splatter, corrosion, and distorted links. Slacken chain and move adjacent links to one side; look for wear at contact points. If wear is observed, measure chain according to hoist manufacturer’s instructions. If instructions are not available, select an unworn, unstretched portion of chain. Suspend chain vertically under tension and measure approximately 14 inches (35.5 cm) of links with a caliper gauge. Measure the same length in a work section and calculate the percentage of increase in length. If chain exceeds the hoist manufacturer’s recommended length or is 1.5 percent longer than the unused chain, replace it. (4) Inspect roller link chain monthly by performing steps a, b, and c in paragraph 6.4.5.a(3). In addition, perform the following checks: (a) With hoist or winch suspended in normal position, apply a load to eliminate slack in the chain. Check chain for elongation. In the absence of specific instructions from hoist manufacturer, check chain by determining nominal pitch and measuring a 12- inch (30.5 cm) section that usually travels over chain sprocket. Using a Vernier caliper, check dimension from the edge of one chain pin to the same edge of another pin; determine number of pitches per foot. If elongation exceeds 1/4-inch (6.3 mm) in 12 inches (30.5 cm), replace chain
(b) Check chain for twist. Replace it if twist exceeds 15 degrees in any 5-foot (1.5 m) section
(c) Check for camber. Replace chain that has a side bow exceeding 1/4 inch (6.3 mm) in a 5-foot (1.5 m) section
(d) Clean chain annually in an acid-free solvent. Check for pins turned from their original position, rollers that do not turn freely with light finger pressure, joints that cannot be flexed easily by hand, open link plates, corrosion, gouges, and weld splatter. Remove chain from hoist if required for proper cleaning and inspection
(5) Inspect hooks monthly, except those on platform systems, for deformation or cracks (see Section 7)
b. Annual Inspections (Periodic Inspections). At least once per year: (1) Perform monthly inspection (frequent inspection) requirements described in paragraph 6.4.5.a.62 (2) Check for loose bolts and rivets and cracked or worn drums and sheaves. Various methods of NDT such as ultrasonics, radiography, magnetic particle, and liquid penetrant shall be used as needed
(3) Check for worn, corroded, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers, and locking and clamping devices. Surface or volumetric NDT shall be used to validate the existence or absence of cracks or other load test effects indicated by this inspection
(4) Inspect for wear in brake and clutch system parts, linings, pawls, and ratchets that are readily accessible without major disassembly beyond an acceptable limit. Major teardown to inspect such parts should be based on a frequency consistent with gearbox lubrication analysis and other manufacturers’ recommended maintenance programs for these components
(5) Inspect electrical apparatus for pitting or other signs of deterioration. Visually inspect for signs of overheating
(6) Inspect hook-retaining nuts or collars, pins, welds, or rivets used to secure retaining members for deformations, cracks, or excessive corrosion. Surface or volumetric NDT shall be used to validate the existence or absence of cracks or other load test effects indicated by this inspection
(7) Ensure that supporting structure is not deformed or cracked
(8) Check that warning labels are legible
6.4.6 Idle and Standby Hoists/Winches. Idle and standby hoists/winches shall be inspected prior to first use according to the requirements of paragraphs 6.4.4 and 6.4.5 unless these daily and formal periodic inspections were performed at required intervals and recorded during the idle/standby period. 6.4.7 Inspection Reports. After each formal periodic inspection, qualified, authorized personnel shall prepare written, dated, and signed inspection reports. These reports shall include procedure reference and adequacy of the hoist/hoist components. Inadequacies shall be documented and, if determined to be a hazard, corrected prior to further use. These reports shall be filed and be made readily available by the organizational element responsible for hoist and winch inspection
6.5 Maintenance. A maintenance program based on manufacturers’ recommendations, integrating proactive, reactive, preventive, and predictive maintenance shall be established to increase the probability the hoist or winch will function in the required manner over its design life cycle with a minimum of maintenance. The program shall include procedures and a scheduling system for normal periodic maintenance items, adjustments, replacements, and repairs. The program shall also ensure that records are kept and unsafe test and inspection discrepancies are documented and corrected. Any hoist or winch found in an unsafe operating condition shall be tagged out and removed from service until repaired. All repairs shall be made by qualified personnel in accordance with the manufacturers’ instructions. 63 6.5.1 Maintenance Procedures. Before maintenance, adjustments, repairs, and replacements are initiated, the following safety precautions shall be taken: a. Move hoist or winch to designated maintenance area
b. Turn off all controls and main energy feed system and lockout unless task requires them to be on
c. If power has to be on, “Warning,” “Out-of-Order,” or a like sign shall be placed in a conspicuous location or an operator shall remain at the pendant
d. Hoists and winches shall not be operated until all safety devices have been activated and tested/adjusted if involved in the maintenance action. 6.5.2 Adjustments. Based upon the manufacturer’s documentation and/or experience, adjustments shall be made to ensure that all hoist components function properly, paying particular attention to: a. Brakes. Appropriate precautions shall be taken by inspectors, repair personnel, and others who may be potentially exposed to airborne dust fibers from any asbestos friction materials present in braking mechanisms
b. Control system
c. Limit switches
(1) The hoist initial upper limit switch shall be verified by running the empty hook at full speed into the limit switch. It is recommended that the switch be verified at slow speed prior to adjustment
(2) For hoists and winches used for critical lifts, the final upper limit switch shall be independently verified and adjusted as described above at installation and after modifications that could affect switch operation. The switch can be tested periodically by manually tripping it and verifying that all hoist motion is precluded
d. Power plants
e. Critical operating mechanisms and safety devices
6.5.3 Repairs and Replacements. Repairs or replacements shall be provided for safe operation. Special attention shall be given to: a. Worn or damaged braking components such as friction discs, ratchets, pawls, and pawl springs
b. Load-supporting components that are cracked, bent, or worn
c. Missing or illegible warning labels
64 d. For repair/replacement requirements for hoist and winch hooks with deformation or cracks, see Section 7. If repaired, hoist and winch hooks shall be proof load tested using the associated hoist or winch proof load value
e. The need to replace wire rope shall be determined by a certified or otherwise qualified person based on an evaluation of inspection results. Any of the signs of deterioration and damage outlined in paragraph 6.4.5.a are sufficient reasons for questioning continued use of the rope (see Wire Rope Users Manual for additional information on wire rope inspections)
f. Replacement rope or chain shall be at least equal to the same size, grade, and construction as original furnished by the hoist or winch manufacturer. When replaced, perform a proof load test using the associated hoist or winch proof load value
6.6 Personnel Certification
6.6.1 Program. Only certified (licensed) and trained operators shall be authorized to use/operate powered hoists and winches except for platform hoists where procedural controls can be provided in a technical operating procedure. A training, examination, and licensing program shall be established or made available. For those NASA installations that do not have a training program, all hoist and winch operators shall be trained and certified by a recognized hoist certification organization that normally performs this function. The operator certification program will be reviewed at least annually to assure that the contents, training material, testing, and examination elements are up-to-date with current methods and techniques; and that any “lessons-learned” are adequately addressed. Riggers (see Section 10) and personnel performing NDT (see paragraph 1.9) shall be certified in their discipline. Training shall be provided to observers and flagmen. All participants in the lifting operation shall have clearly defined roles and responsibilities. 6.6.2 Levels. Two levels of operator training and proficiency will be established. Operations where critical lifts are involved will require a more rigid operator certification program than those operations that involve more routine lifts that do not involve critical hardware or unique hazards. a. Noncritical Lifts. The certification program for noncritical lift operators shall include the following: (1) Training (a) Classroom training in safety, lifting equipment emergency procedures, general performance standards, requirements, pre- operational checks, and safety-related defects and symptoms (for initial certification and as needed)
(b) Hands-on training (for initial certification and as needed)
(c) An annual review of the items in paragraph 6.6.2.a(1) above. (This may be conducted informally by local supervisory personnel.) 65 (2) Examination (a) Physical examination (criteria to be determined by the cognizant medical official)
(b) Written examination
(c) Operational demonstration (for initial certification only)
(d) Proficiency examination for recertification
(3) Licensing/Operator Certification (a) An organizational element shall be designated to issue operator licenses/operator certification. Provisions shall be made to revoke licenses for negligence, violations of safety requirements, or failure to meet medical standards. Provisions shall be made for periodic checks of operators to verify they have licenses in their possession. The licenses shall indicate the type of hoist the holder is qualified to operate. Alternately, the organizational element may elect to maintain a master list of licensed operators instead of issuing individual licenses, providing copies of the list are readily available to assurance and supervisory personnel at the work site. (b) Renewal of all licenses shall require demonstration of proficiency or approval of supervision that proficiency is adequate and current. Licenses or certifications shall expire at least every 4 years. Renewal procedures will be established by each licensing organization, but as a minimum, will include items in paragraphs 6.6.2.a(1) and 6.6.2.a(2). b. Critical Lifts. Besides the training, examination, licensing, and renewal requirements for noncritical lifts, operators that are being certified to perform critical lifts must be trained in the specific hazards and special procedures associated with the lift. Operators must also demonstrate proficiency and operating finesse with the hoist using a test load as appropriate for the initial certification or alternately be immediately supervised by a certified operator during the first initial lifting period. The licenses will indicate specific hoists for which the operator is certified
6.7 Operations. Hoists and winches shall be operated according to this section, the manufacturers’ recommendations, and the applicable ASME standard. The following practices shall be followed for hoist and winch operations: a. Operators will adhere to all tags placed on the hoist or winch controls
b. Before starting a hoist or winch, the operator shall be certain that all personnel are clear of the area. Operators shall not engage in practices that will divert their attention while operating a hoist
66 c. The operator shall test all controls before beginning an operation. If the controls do not operate properly, adjustments or repairs shall be made before operations begin
d. Hoists and winches shall not be loaded beyond rated load except during authorized tests. Platform systems shall not be loaded beyond maximum load as designated on the platform hoist system
e. Hoists and winches shall not be used for handling personnel unless specifically designed for such purpose (see Section 9)
f. Personnel shall not be located under suspended or moving loads unless the operation adheres to the OSHA-approved NASA Alternate Standard for Suspended Load Operations (see Appendix A)
g. An operator shall be at the hoist or winch controls at all times while a load is suspended. Due to the length of some NASA operations, an operator change may be required while a load is suspended. This shall be accomplished via a procedure designed for the specific hoist and operation, ensuring that the hoist or winch controls are manned at all times
h. Before each lift or series of lifts, the operator shall functionally test proper operation of the upper limit switch with no load on the hook. Upper limit switches shall not be used as operating controls
i. Hoists and winches shall not be used to load test items such as slings, platforms, or lifting fixtures unless specifically identified to do so based on a specified percentage of rated load and a safety analysis approved by the LDEM and the responsible safety, engineering, operations, and maintenance organizations. Test procedures shall be approved by the responsible safety, engineering, operations, and maintenance organizations. This is to ensure that the hoist or winch is not damaged due to sudden unloading should the test article fail. Appendix D, crane/hoist requirements to load test other lifting equipment, shall be followed
j. Installed or fixed air or electric powered hoists and winches, excluding platform systems, shall be operated by designated personnel only. k. The operator shall ensure that the hoist or winch is within inspection and periodic recertification intervals by examination of its tag(s) and/or appropriate documentation
l. Outdoor hoisting operations should not commence if winds are above 20 knots (23 mph, 37 km/hr) steady state or if gusts exceed 35 knots (40 mph, 65 km/hr). Consideration shall also be given to sail area and weather conditions such as lightning or snow before commencing operations
m. Hoists and winches shall not be used for side pulls unless specifically designed to do so
67 n. If radio communications are to be used, operators and/or lift supervisors shall test the communication system prior to each operation. Operations shall stop immediately upon communication loss and shall not continue until communication is restored
o. If hand signals are required, only standard signals shall be used according to Appendix B. Hand signals shall be posted in a conspicuous location. p. The operator shall know the weight of the working load. When raising loads that approach 75% of the rated capacity of the hoist or winch, the operator shall test the holding brakes. The brakes shall be tested by raising the load minimally above the surface and holding the load with the brake. The load should be held long enough to allow any dynamics to dampen out
q. Wire rope should be used in accordance with the Wire Rope Users Manual
6.8 Special Criteria
6.8.1 Handling Explosives or Electro-Explosive Devices (EED’s). Special precautions shall be taken while handling explosives or EED’s
a. DOT-packaged explosives shall be handled in accordance with approved hazardous operating procedures. Barricades and warning signs shall be erected to control access
b. Explosives and EED’s that are not within DOT-approved containers shall be handled in accordance with approved hazardous operations procedures. In addition to system configuration controls, these procedures shall ensure the following requirements are met: (1) Voltage checks on crane hooks that will handle explosives or EED’s shall be performed prior to the start of operations; all crane motions shall be checked
(2) For static sensitive systems, the crane hook shall be connected to facility ground before connecting to explosives or EED’s. Electrical grounding of the hook and load shall be accomplished prior to lifting operations. If a ground connection must be disconnected to facilitate operations, an alternate ground should be connected prior to disconnecting the existing ground. The final attachment/detachment must be at least 10 feet (3 m) from exposed propellant grain, explosives, or EED’s. (3) The danger potential for radio transmissions near explosives shall be evaluated prior to the operation. (4) Personnel limits, protective clothing, warning signs and barricades shall be used as required. 68 (5) Safety surveillance requirements shall be followed
6.8.2 Policy shall be developed and enforced for hoist operation during electrical storms. Operations are generally permitted without restriction within enclosed metal or framed buildings that are properly grounded. Restrictions are necessary for outside operations or for those that cannot tolerate power failure/loss
7. HOOKS 7.1 General. This section establishes minimum standards for the design, testing, inspection, maintenance, and operation of hooks used with lifting equipment
7.2 Safety and Design Criteria. Hooks shall meet the manufacturer’s recommendations, and shall not be overloaded. Swiveling hooks should rotate 360 degrees on antifriction bearings with means for lubrication. If grease is a contamination concern, drip funnels (cups), nonlubricated bearings, or permanently lubricated sealed bearings should be provided. A latch or mousing shall be provided to bridge the throat opening of the hook to retain slings, chains, or other similar parts under slack conditions. Hooks on cranes used for lifting people shall be a lockable type as required by ASME B30.23
7.3 Testing. Hooks shall be required to pass the tests of the equipment of which they are a part. Written, dated, and signed test reports shall be prepared together with the test reports for the equipment of which the hooks are a part. Inadequacies shall be documented and, if determined to be a hazard, corrected prior to further use
7.4 Inspection
7.4.1 Hooks shall be inspected during the daily and periodic inspections of the equipment of which they are a part. 7.4.2 Daily Inspections. These inspections shall be performed each day the lifting equipment is used. Inspect for: a. Distortion, such as bending, twisting, or increased throat opening
b. Latches that are inoperative or fail to fully close the throat opening because of wear or deformation
c. Wear, deformation, cracks, nicks, and gouges (see paragraph 7.5.2)
d. Hook attachment and securing means
7.4.3 Periodic Inspections. These inspections shall be performed at varying intervals depending on activity, severity of service, environment, and criticality. The following inspections shall be performed at least once per year. Inspect for: a. Requirements for daily inspections as described in paragraph 7.4.2
b. Wear exceeding 10 percent (or as recommended by the manufacturer) of the original sectional dimension
69 c. A bend or twist exceeding 10 degrees from the plane of the unbent hook
d. An increase in throat opening exceeding 15 percent (or as recommended by the manufacturer)
7.4.4 Visual inspection of painted hooks requires consideration of the coating. Surface variations may indicate heavy or severe service. Such instances may call for stripping the paint to allow for more detailed analysis
7.4.5 NDT. Hooks shall be given a surface NDT (see paragraphs 3.1.35 and 3.1.57) immediately after all periodic load and proof load tests and prior to further use of the hook. Cracks are not acceptable. Linear indications greater than 1/8 inch long whose length is equal to or greater than three times its width are not acceptable. A visual inspection of hooks used for noncritical lifts (if not attached to a crane) and sling hooks of 5 tons or less is acceptable. All new crane hooks shall undergo a volumetric NDT (if determined necessary by the LDEM and the responsible design engineering organization) followed by a proof load test in accordance with ASME B30.10 followed by a surface NDT. Personnel performing NDT shall be qualified and certified in accordance with paragraph 1.9
7.4.6 Written, dated, and signed inspections reports shall be prepared in conjunction with inspection reports for the equipment of which the hooks are a part. Inadequacies shall be documented and, if determined to be a hazard, corrected prior to further use
7.5 Maintenance
7.5.1 Hooks with deficiencies as noted in paragraph 7.4 shall be removed from service and replaced or repaired. Replacement shall be with original equipment or equal. Repair shall require approval by certified or otherwise qualified personnel. Minor grinding of cracks is not considered a repair providing an approved procedure is used. 7.5.2 Cracks, nicks, and gouges shall be repaired by grinding longitudinally, following the contour of the hook, provided that no dimension is reduced more than 10 percent (or as recommended by the manufacturer) of its original value. 7.5.3 If repaired, hooks shall be proof load tested using the associated lifting device/equipment proof load value
7.5.4 A system shall be established for tracking/documenting the maintenance and repair history of hooks. 7.6 Operations. The following practices shall be followed when using hooks: a. Loads shall be centered in the base (bowl saddle) of the hook, to avoid point loading
b. Hooks shall not be side or back loaded. c. Duplex sister hooks shall be equally loaded on both sides, and the pin hole shall not be point loaded or loaded beyond the rated load of the hook except for testing
70 8. HYDRA-SETS AND LOAD MEASURING DEVICES 8.1 General. This section establishes minimum standards for the design, testing, inspection, maintenance, and operation of Hydra-sets and load measuring devices
8.2 Safety and Design Aspects
8.2.1 Design Criteria. Hydra-sets used for critical lifts shall have a 5 to 1 design factor based on ultimate strength for load bearing elements
8.2.2 Labeling/Tagging of Hydra-Sets and Load Measuring Devices
a. The rated load shall be plainly marked on each Hydra-set and load measuring device (unless permanent part of lifting device)
b. Hydra-sets and load measuring devices that have the necessary design features, maintenance/inspection, and test intervals to lift critical loads will be marked conspicuously so that the operator and assurance personnel can distinguish that the Hydra-set and load measuring device (unless permanent part of lifting device) are qualified for critical lifts
c. A standard system of labeling shall be established and used throughout the installation
d. A standard lockout/tagout system shall be established and used throughout the installation to indicate equipment that is not to be used due to inspection discrepancies, ongoing maintenance operations, or other reason. e. Certification/recertification tags are required as described in paragraph 8.3.5
8.2.3 Safety Analysis and Documentation of Hydra-Sets Used for Critical Lifts. A recognized safety hazard analysis such as fault tree analysis, FMEA, O&SHA shall be performed on all Hydra-sets used for critical lifts. The analysis shall, as a minimum, determine potential sources of danger, identify failure modes, and recommend resolutions and a system of risk acceptance for those conditions found in the hardware-facility-environment-human relationship that could cause loss of life, personal injury, and loss of or damage to the Hydra- set, facility, or load. The analysis shall be done as part of the initial evaluation process for critical lift compliance and prior to use in a critical lift, included in the Hydra-set documentation, and updated as required to reflect any changes in operation and/or configuration. 8.3 Testing. Three types of tests are required: proof load tests, periodic load tests, and operational tests. The acceptable tolerance for load test accuracy is +5/-0 percent. An inspection shall be performed after each load test and prior to release for service to ensure there is no damage. If cracks are suspected, suitable NDT techniques should be used to determine their extent. Tests shall be performed by qualified personnel according to written (specific or general) technical procedures
8.3.1 Hydra-set Proof Load Test. Before first use, all new, extensively repaired, modified, or altered Hydra-sets shall undergo a proof load at 200 percent of rated load. Proof71 load tests shall be performed with piston rod fully extended to prevent instrument and seal damage
8.3.2 Hydra-set Periodic Load Test. Load tests shall be performed with the piston rod fully extended to prevent instrument and seal damage. All Hydra-sets shall be tested at 100 percent of rated load at least every 4 years. Tests of Hydra-sets used for critical lifts shall be based on frequency of usage. Hydra-sets used infrequently for critical lifts shall be load tested before each critical lift if it has been more than one year since the last test. Hydra-sets used frequently for critical lifts shall be load tested at least once per year. 8.3.3 Hydra-set Operational Test. The following shall be performed in conjunction with proof load tests and periodic load tests and at least once per year: a. With a test load, at least equal to 50 percent of the Hydra-set’s rated capacity but not to exceed 100 percent, operate the unit to approximately the midstroke position. Using a dial indicator or equivalent, verify that the load does not move up or down more than .005 inches in 5 minutes. b. Inspect unit for hydraulic leaks and initiate repairs when required
c. Inspect for structural damage and corrosion of the piston rod
8.3.4 Load Measuring Device Periodic Load Test. Before first use, all new, extensively repaired, modified, or altered load measuring devices shall undergo a load test at rated capacity. All load measuring devices shall be tested at rated capacity at least once every 4 years. Load measuring devices used for critical lifts shall be load tested at least once per year. Load measuring devices used infrequently for critical lifts shall be load tested before each critical lift if it has been more than one year since the last test. Calibration of load measuring devices satisfies the load test requirement
8.3.5 Test Reports and Periodic Recertification Tags. After each load test and/or inspection, written, dated, and signed reports shall be prepared. Inadequacies shall be documented and, if determined to be a hazard, corrected prior to further use. These reports shall be kept on file by the responsible owner organization for a minimum of two test cycles and shall be made readily available. Following the periodic load test, all Hydra-sets and load measuring devices (unless permanent part of lifting device) shall have a permanently affixed tag or label, identifying the equipment and stating the next required periodic load test date or the load test expiration date
8.4 Inspection
8.4.1 Inspections, as described below, shall be performed on all Hydra-sets. Inspections shall be performed according to this section and the manufacturers’ recommendations. Inadequacies discovered during an inspection shall be documented and, if determined to be a hazard, tagged out and corrected prior to further use. Inspections shall be performed by qualified personnel according to approved technical operating procedures
8.4.2 All new, extensively repaired, or modified Hydra-sets shall be given a daily and a periodic inspection prior to first use. For component repair on Hydra-sets, only the inspections that apply to the repaired portion need to be performed prior to first use unless a periodic inspection interval expires during the downtime (see paragraph 8.4.5).72 8.4.3 Hydra-sets in regular service (used at least once a month) shall be inspected as required in paragraphs 8.4.4 and 8.4.5. Idle and standby Hydra-sets shall be inspected according to paragraph 8.4.6
8.4.4 Daily Inspections. These inspections shall be performed by the certified operator prior to first use each day the Hydra-set is used, and shall include the following: a. Check operating and control mechanisms for proper function
b. Without disassembling, visually inspect all functional operating and control mechanisms for excessive wear and contamination by excessive lubricants or foreign matter
c. Visually inspect for corrosion, damage, cracks, and deformities
d. Inspect hydraulic system for deterioration and leakage
e. Check for loose hardware
8.4.5 Periodic Inspections. Periodic inspections are the same as paragraph 8.4.4. Periodic inspections shall be performed at least once per year or more frequently if required by the manufacturer. Periodic inspections consist of visual inspection by an appointed person and require dated documented records
8.4.6 Idle and Standby Hydra-sets. Idle and standby Hydra-sets shall be inspected prior to first use according to the requirements of paragraphs 8.4.4 and 8.4.5 unless these daily and periodic inspections were performed at required intervals and recorded during the idle/standby period
8.5 Maintenance. A maintenance program based on manufacturers’ recommendations, integrating proactive, reactive, preventive, and predictive maintenance shall be established to increase the probability the Hydra-set or load measuring device will function in the required manner over its design life cycle with a minimum of maintenance. The program shall include procedures and a scheduling system for normal periodic maintenance items, adjustments, replacements, and repairs. The program also shall ensure that records are kept and unsafe test and inspection discrepancies are documented and corrected. Any Hydra-set or load measuring device found in an unsafe operating condition shall be tagged out and removed from service until repaired. All repairs shall be made by qualified personnel in accordance with the manufacturers’ instructions
8.6 Personnel Certification
8.6.1 A training and operator certification program that specifically addresses the properties of Hydra-sets and operational procedures needed to retain positive control of the same during close mating operations shall be implemented. Elements of the initial training and certification program will include a review of the above procedures, hands-on training, and an operational demonstration. 73 8.6.2 Licensing/operator certification will be issued every 4 years. Renewal shall require demonstration of proficiency or approval of supervision that proficiency is adequate and current
8.7 Operations. The following shall be followed for Hydra-set operations: a. When Hydra-set seals are replaced, an operational test and inspection shall be performed
b. Hydra-sets shall be stored in their appropriate handling containers when not in use
c. Hydra-sets and load measuring devices (unless permanent part of lifting device) shall be clearly and permanently marked with rated load value
d. Prior to use, the operator shall ensure the Hydra-set and load measuring device (unless permanent part of lifting device) are within the inspection and periodic recertification intervals by examination of the load test tag(s), load test label(s), and/or documentation. The operator shall adhere to all tags on the controls
e. Hydraulically controlled Hydra-sets are preferred over pneumatically controlled Hydra-sets where close mating operations or accurate control of distances is required. Pneumatically controlled Hydra-sets shall not be used for these operations unless the following items are incorporated: (1) Installation of a fail-safe check valve in the Hydra-set. This is installed on the Hydra-set pneumatic feedline and “locks up” the Hydra-set in the event of a drop or loss of pneumatic control system pressure. A procedure shall be developed and implemented to ensure that the valve is set to an appropriate sensitivity. Normally, the valve is set at the mid-point of its range, which is satisfactory for most operations. However, depending on the specifics of the lift, it may be necessary to reset the valve using a dummy load as outlined in the manufacturer’s recommended procedures
(2) Installation of a fast acting safety shutoff valve downstream of the load regulator that is used to provide positive control of the Hydra-set when no motion is desired. (3) Installation of electronic remote position indicators that warn operators of small movements of the hung load. However, these should only be installed if they will not adversely affect the operation or contamination control features of existing Hydra-sets. (4) Implementation of a training and operator certification program that specifically addresses the unique properties of pneumatically controlled Hydra-sets and operational procedures needed to retain positive control of the same during critical lift operations
