PNNL Hoisting and Rigging Manual

1 PNNL-18129. Prepared for the Department of Energy under Contract DE-AC05-76RL01830. PNNL Hoisting and Rigging Manual PNNL Worker safety & Health Division December 2008. DISCLAIMER. This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor Battelle Memorial Institute, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights.

2 Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof, or Battelle Memorial Institute. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. PACIFIC NORTHWEST NATIONAL LABORATORY. operated by BATTELLE. for the UNITED STATES DEPARTMENT OF ENERGY.

3 Under Contract DE-AC05-76RL01830. PNNL Hoisting and Rigging Manual PNNL Worker safety & Health Division December 2008. Prepared for the Department of Energy under Contract DE-AC05-76RL01830. Pacific Northwest National Laboratory Richland, Washington 99352. Acknowledgments The content of the PNNL Hoisting and Rigging Manual was derived from the Hanford Site Hoisting and Rigging Manual (DOE-RL-92-36). Permission was given to the Hanford Site Hoisting and Rigging Committee to use and reproduce portions of standards and information from the following sources: American Society of Mechanical Engineers Committee of Wire Rope Producers of the American Iron and Steel Institute Construction safety Association of Ontario The Crosby Group, Inc.

4 I Acronyms and Abbreviations ANSI American National Standards Institute. AWS American Welding Society ASME American Society of Mechanical Engineers ASTM American Society of Testing and Materials DL Designated Leader FM Factory Mutual OSHA Occupational safety and Health Act of 1970. NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association NDE Nondestructive Examination NDT Nondestructive Test SME Subject Matter Expert SWL Safe Working Load UL Underwriters Laboratories ii Contents Introduction.

5 1. 1. 1. Background .. 1. Manual Organization .. 1. Mandatory and Advisory Rules .. 2. Responsibilities .. 3. 3. Personnel Responsibilities .. 3. 3. Supervisor or Manager, Hoisting and Rigging Operations .. 3. Supervisor or Manager, Inspection, Maintenance, and Repair .. 4. Designated Leader for Critical Lifts .. 4. Designated Leader .. 5. Operator .. 5. Rigger .. 6. Equipment Custodian .. 6. Critical Lifts .. 7. 7. Critical Lift Determination .. 7. Guidelines and Rules for Critical Lifts .. 7. Guidelines .. 7. Critical Lift Equipment and Hardware.

6 8. General .. 8. Rigging Hardware for Critical Lifts .. 8. Rigging Hardware Rated-Capacity Testing for Critical 9. Critical Lift Plan .. 10. Critical Lift Plan Approval .. 11. Critical Lift Plan Field Revisions .. 11. Prelift and Field Revision Review Meetings .. 12. Special Lifts Non-Critical Lifts That Require Special Precautions .. 12. 13. Hooks .. 14. 14. New Hooks .. 14. Performance Tests .. 14. iii Throat Latches .. 14. Inspection .. 14. Inspection 14. Frequent Inspection Interval .. 15. Periodic Inspection Interval.

7 15. Frequent Inspection .. 15. Monthly and Periodic Inspections (Records Required) .. 16. Inspection Records .. 16. Nondestructive Testing .. 17. New Hooks .. 17. Existing Hooks .. 17. 19. 19. Responsibilities .. 19. Forklift Requirements .. 19. Common Errors during Forklift Operation .. 20. Management at the Using Organization .. 21. Forklift Truck Custodian .. 22. Forklift Truck Operator .. 22. Industrial safety Representative .. 22. Nameplate(s) and Marking .. 23. Truck Marking by the Manufacturer .. 23. Fork Arm Stamping by the Manufacturer.

8 23. Attachment Marking .. 24. User's Obligation for Truck Marking .. 24. Maintain Tags .. 24. Attachments, Modifications, and Free Rigging from 24. Attachments .. 24. Modifications .. 25. Free Rigging from 25. Overhead Guards .. 25. Warning 26. Fire Hazard Areas .. 26. Work Atmosphere .. 26. Operator Care of the Truck .. 26. Frequent (Pre-use) Inspection .. 26. Key Steps in a Pre-use Inspection .. 27. Truck Unsafe or Needs Repair .. 27. No Repair by Operator .. 27. iv Refueling .. 28. Maintenance and Inspection .. 28. Inspection of New and Rented Equipment.

9 28. Modified or Extensively Repaired Equipment .. 28. Replacement Parts .. 28. Inspection of Forks .. 29. Fork Load Rating .. 29. Fork Repair .. 30. Fork Load Test .. 30. Forklift Truck Load 30. Verify Maintenance/Inspection is 30. Test Weight Accuracy .. 30. Load Test Report .. 30. Conduct of Operator .. 31. Lifting of Personnel .. 34. Special Provisions Prior to Lifting 34. Qualification of Trucks Used for Lifting Personnel .. 34. Standard Precautions Lifting Personnel with Forklift Truck .. 34. Standard Hand Signals.

10 35. Designated Leader .. 36. Critical Lifts .. 37. Maintenance Files .. 37. Contents of Maintenance Files .. 37. Equipment Qualification .. 38. Forklift Trucks in Hazardous (Explosive) Atmospheres .. 38. Hazardous Area Equipment .. 38. Truck Designation .. 38. Hazardous-Area Signs .. 38. Hazardous Area Classification .. 40. Non-Hazardous 41. Hazardous Areas .. 41. Shop Cranes .. 43. 43. Operator 44. Conduct of Operators .. 44. Equipment Requirements .. 45. Operating Controls .. 45. Hook-Throat Latches .. 45. Marking and Identification.