DOE-STD-1090-96, DOE Standard Hoisting and Rigging Manual ...

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DOE·STD-I090·96 (Rev-I)1. Hoist braking system for properoperation.2. Hoist rope or chain reeving forcompliance with hoist manufacturer'srecommendations.3. Lever for bends, cracks, and the like4. Observations during operation.c. Examine deficiencies and detennine whethera more detailed inspection is required.8.2.6Periodic Inspectiona. A qualified inspector shall perform acomplete inspection at the following intervals:1. Normal service-yearly.2. Heavy service-semiannually.3. Severe service-quarterly.b. The qualified inspector shall examinedeficiencies and determine whether they constitutea safety hazard and whether disassembly isrequired.c. Dated and signed inspection records shall bekept on file and shall be readily available.d. A sample load test and inspection form isincluded as Exhibit I, which appears at the end ofthis chapter. This form is intended to be a sampleonly and is not intended to be mandatory.8.2.6.1 Hoistsa. In addition to the requirements listed inSection 8.2.4, "Frequent Inspection," periodicinspections ofhoists shall include the following:1. Loose fasteners.2. Cracked or worn drums or sheaves.3. Worn, corroded, cracked, or distortedparts such as pins, bearings, shafts, gears, rollerslocking, and clamping devices.4. Excessive wear on motor or loadbrakes.5. Excessive wear ofchains, ropes,synthetic web strap, load sprockets, drums,sheaves, and chain stretch.6. Deterioration or damage ofendconnections and terminations ofwire rope, loadchains, and synthetic web.7. Hooks having more than 15 percent inexcess ofnormal throat opening, or more than 10degree twist from the plane ofthe unbent hook(see Chapter 13 for additional hook requirements).8. Hook-retaining nuts or collars andpins, welds, orriveting used to secure the retainingmembers. .9. Suitable crack-detecting inspectionsfor hooks, such as dye-penetrant ormagnetic-particle inspections (performed whenrequired by the inspector).10. Electrical apparatus for signs ofpittingor any deterioration ofcontroller contactors, limitswitches, and push-button switches.11. Supporting structures and trolleys, ifused, for continued ability to support the imposedloads.12. Warning labels for illegibility orabsence.8.2.6.2 Wire Ropea. A qualified inspector shall inspect runningrope at least annually. This inspection shallinclude examination ofthe entire length ofrope,without detaching it from the hoist drum. Morefrequent intervals shall be determined by aqualified person and shall bebased on suchfactors as expected rope life as determined byexperience on the particular installation or similarinstallations, severity ofenvironment, percentageofcapacity lifts, frequency rates ofoperation, andexposure to shock loads. The qualified inspectorshall carefully note any deterioration, such asdescribed below, resulting in appreciable loss oforiginal strength and determine whether furtheruse ofthe rope constitutes an acceptable risk.1. Reduction ofrope size below nominaldiameter, whether due to loss ofcore support,internal or external corrosion, or wear ofoutsidewires (see Table 8-1).8-9Chapter 8Hoists
DOE-STD-I090-96 (Rev-I)2. A number ofbroken outside wires andthe distribution or concentration ofsuch brokenwires.3. Worn outside wires.4. Sections ofrope that are normallyhidden during inspection or maintenanceprocedures, such as parts passing over sheaves(these are points most subject to deterioration).5. Corroded or broken wires at endconnections.6. Corroded, cracked, bent, worn, orimproperly applied end connections.Table 8-1. Maximum allowable ropereductions.Rope diameterup to 5/16 in.(8mm)Over 5/16 in. to1/2 in. (13 mm)Over 1/2 in. to3/4 in. (19 mm)Over 3/4 in. to1 1/8 in. (29mm)Over 1 1/8 in. to1 1/2 in. (38 mm)Maxim urn allowablereductionfrom nominal diameter1/64 in. (0.4 mm)1/32 in. (0.8 mm)3/64 in. (1.2 mm)1/16 in. (1.6 mm)3/32 in. (2.4 mm)7. Kinking, crushing, cutting, orunstranding.b. No precise rules can be given fordetermining the exact time to replace wire ropebecause many factors are involved. Safetydepends largely on the use ofgood judgment by an~ppointed person in evaluating remaining strengthm a used rope, after allowance for deteriorationdisclosed by inspection. Safety ofrope operationdepends on this remaining strength.c. Conditions such as the following shall bereason for questioning rope safety and consideringreplacement:1. Inhoist ropes, 12 randomly distributed .broken wires in one rope lay, or 4 broken wires inone strand in one rope lay.2. Wear ofone-third ofthe originaldiameter ofoutside individual wires.3. Kinking, crushing, birdcaging, or anyother damage resulting in distortion ofthe ropestructure.4. Evidence ofheat damage from anycause.5. Reductions from nominal diametergreater than those shown in Table 8-1.d. The qualified inspector shall give specialattention to end fastenings and shall examineropes frequently at socketed fittings; on thedevelopment oftwo broken wires adjacent to thispoint, resocket or replace the rope. Resocketingshall not be attempted ifthe resulting rope lengthwill be insufficient for proper operation. Thoseportions ofthe rope subjected to reverse bendsand operation over sma1l-diameter drums orsheaves shall be closely examined.e. Replacement rope and connections shallhave a strength rating at least as great as theoriginal rope and connections furnished by thehoist manufacturer. Any deviation from theoriginal size, grade, or construction shall bespecified bya rope manufacturer, the hoistmanufacturer, or a qualified person.f. Never use discarded rope for slings.8.2.6.3 Welded-Link Chaina. A qualified inspector shall do the followingduring periodic inspections:1. Operate the hoist under load in raisingand lowering directions, and observe the operationofthe chain and sprockets. The chain should feedsmoothly into and away from the sprockets.2. Make sure that, ifthe chain binds,jumps, or is noisy, frrst clean and properlylubricate it. Ifthe trouble persists, inspect thechain and mating parts for wear, distortion, orother damage.3. The chain should cleaned beforeinspection. Examine visually for cracks, gouges,nicks, weld spatter, corrosion, and distorted links.Chapter 8Hoists 8-10
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INCH-POUNDDOE STANDARDDOE-STD-1 090
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DISCLAIMERPortions of this document
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DOE-STD-I090-96 (Rev-I)7.5.6 Attach
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DOE-STD-I090-96 (Rev-I)9.2.6.3 Hydr
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DOE-STD-1090-96 (Rev-l)11.2.3.1 6 x
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DOE-STD-1090-96 (Rev-l)13.4.5 Disco
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DOE-STD-I090-96 (Rev-I)15.4.2 Mobil
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DOE-STD-I090-96 (Rev-I)History and
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DOE-STD-I090-96 (Rev-I)Acknowledgme
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DOE-STD-I090-96 (Rev-I)Introduction
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DOE-STD-I090-96 (Rev-I)CHAPTER 1TER
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DOE-STD-I090-96 (Rev-I)CLOSING LINE
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DOE-STD-I090-96 (Rev-I)END CONTROL:
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LIFT, PREENGINEERED PRODUCTION:Repe
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QUALIFIED ENGINEER/QUALIFIEDENGINEE
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DOE-STD-I090-96 (Rev-I)INTENTIONALL
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DOE-STD-I090-96 (Rev-I)2.2 CRITICAL
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DOE-STD-1090-96 (Rev-1)INTENTIONALL
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DOE-STD-I090-96 (Rev-I)3.2 OPERATIO
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DOE-STD-I090-96 (Rev-I)2. Perform a
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DOE-STD-I090-96 (Rev-I)3.4.4 Approv
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DOE-STD-I090-96 (Rev-I)3.6 TRAINING
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DOE-STD-I090-96 (Rev-I)that create
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4.3 OVERHEAD CRANESDOE-STD-I090-96
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DOE-STD-I090-96 (Rev-I)lNTENTIONAIL
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DOE-STD-I090-96 (Rev-I)1. Class I-l
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DOE-STD-I090-96 (Rev-I)CAUTIONONLY
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DOE-STD-1090-96 (Rev-l)20. To avoid
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DOE-STD-1090-96 (Rev-1)RAISE THE TI
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DOE-STD-I090-96 (Rev-I)EXHIBIT I (c
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DOE-STD-1090-96 (Rev-l)Table 11-1.
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DOE-STD-I090-96 (Rev-I)11.2 WIRE RO
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DOE-STD-I090-96 (Rev-I)11.3 SLINGS1
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DOE-STD-1090-96 (Rev-1)11.3.1.3 Des
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DOE-STD-I090-96 (Rev-I)Table 11-4.
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DOE-STD-1090-96 (Rev-l)Table 11-8.
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DOE-STD-I090-96 (Rev-I)Angle of cho
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DOE-STD-I090-96 (Rev-I)temperatures
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DOE-STD-I090-96 (Rev-!)7. Locate sl
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DOE·STD·I090·96 (Rev-I)q. Never
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DOE·STD·1090-96 (Rev-1)certificat
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DOE-STD-I090-96 (Rev-I)Exhibits I t
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DOE-STD-1090-96 (Rev-l)lNTENTIONALL
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DOE-STD-1090-96 (Rev-l)INTENTIONALL
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DOE-STD-I090-96 (Rev-I)Good and Bad
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12.2 RIGGING HOOKSDOE-STD-I090-96 (
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DOE-STD-I090-96 (Rev-I)2. Heavy ser
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DOE-STD-I090-96 (Rev-I)Typical shac
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DOE-STD-I090-96 (Rev-I)• Shoulder
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12.5 TURNBUCKLESDOE-STD-I090-96 (Re
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12.6 LINKS AND RINGSDOE-STD-I090-96
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DOE-STD-I090-96 (Rev-I)12.7 METAL-P
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DOE-STD-I090-96 (Rev-I)Exhibit I is
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DOE-STD-1090-96 (Rev-l)13.2 INSPECT
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DOE-STD-I090-96 (Rev-I)13.3 TESTING
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DOE-STD-1090-96 (Rev-l)13.4 NONDEST
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DOE-STD-1090-96 (Rev-1)14.4.4.3 Per
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DOE-STD-I090-96 (Rev-I)14.2 STRUCTU
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DOE-STD-I090-96 (Rev-I)14.2.7 Maint
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DOE-STD-I090-96 (Rev-!)Four-pad pow
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DOE-STD-I090-96 (Rev-I)14.3.5 Testi
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DOE-STD-I090-96 (Rev-I)14.4 MAGNETS
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DOE-STD-I090-96 (Rev-I)1. External
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DOE-STD-I090-96 (Rev-I)instructed b
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DOE-STD-I090-96 (Rev-I)6. Charging
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DOE-STD-!090-96 (Rev-!)EXHIBIT IPag
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DOE·STD·I090-96 (Rev-I)15.2 DEFIN
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General note for Figures 15-5 throu
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DOE-STD-I090-96 (Rev-I)LIFT, ORDINA
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DOE-STD-1090~96 (Rev-l)Consideratio
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DOE-STD-I090-96 (Rev-I)15.4.2.4 Fre
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DOE-STD-I090-96 (Rev-I)4. Corroded
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DOE-STD-I090-96 (Rev-I)b. Test load
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DOE-STD-!090-96 (Rev-!)regardless Q
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DOE-STD-1090-96 (Rev-1)EMERGENCY ST
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DOE-STD-I090-96 (Rev-I)so by an app
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DOE-STD-I090-96 (Rev-I)Figure 15-13
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DOE-STD-I090-96 (Rev-I)include the
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DOE-STD-I090-96 (Rev-I)h. Report an
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DOE-STD-I090-96 (Rev-I)h. Provide 4
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DOE-STD-1090-96 (Rev-l)ASME B56.7,
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