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

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DOE-STD-1090-96 (Rev-l)scrubbing on the outer surface ofa hose, rigidtube, or fitting (means shall be taken to eliminatethe interface ofelements in contact or otherwiseprotect the components).15.4.2.5.2 Hydraulic andPneumaticPumps. Inspect for:a. Loose bolts or fasteners.b. Leaks atjoints between sections.c. Shaft sea11eaks.dUnusual noises or vibration.e. Loss ofoperating speed.f. Excessive heating ofthe fluid.g..Loss ofpressure.15.4.2.5.3 Hydraulic and PneumaticValves. Inspect for:a. Cracks in valve housing.b. Improper return ofspool to neutral position.c. Leaks at spools orjoints.d. Sticking spools.e. Failure ofreliefvalves to attain correctpressure setting (relief valve pressures shall bechecked as specified by the manufacturer).15.4.2.5.4 Hydraulic and PneumaticCylinders. Inspect for:a. Drifting caused by fluid leaking across theposition.b. Rod seal leakage.c. Leaks at welded joints.d. Scored, nicked, or dented cylinder rods.e. Dented case (barrel).f. Loose or deformed rod eyes or connectingjoints.15.4.2.5.5 Hydraulic Filters.Inspect hydraulic filters for evidence ofrubberparticles on the filter element that may indicatehose, "0" ring, or other rubber-componentdeterioration. Metal chips or pieces on the filtermay denote failure in pumps, motors, or cylinders.Further checking will be necessary to determinethe origin ofthe problem before corrective actioncanbe taken.15.4.2.5.6 Wire Ropes.a. A qualified inspector shall inspect all wireropes at least annually. More frequent intervalsshall be as determined by a qualified person andshall be based on such factors as expected ropelife as determined by severity ofenvironment,percentage ofcapacity lifts, frequency rates ofoperation, and exposure to shock loads. Thequalified inspector shall carefully note anydeterioration, such as described below, that resultsin appreciable loss oforiginal strength anddetermine whether further use ofthe ropeconstitutes an acceptable risk. This inspectionshall include examination of the entire rope lengthwithout detaching it from the drum.1. Reduction ofrope size belownominal diameter, whether due to loss ofcoresupport, internal or external corrosion, or wear ofoutside wires (see Table 15-1).2. A number ofbroken outside wiresand the distribution or concentration of suchbroken wires.3.Worn outside wires.Table 15-1. Maximum allowablerope reductions.Maximum allowablereductionRope diameter from nominal diameterUp to 5/16 in. 1/64 in. (D.4 mm)(8 mm)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. (29 mm)Over 1 1/8 in. to1 1/2 in. (38 mm)1/32 in. (D.8 mm)3/64 in. (1.2 mm)1/16 in. (1.6 mm)3/32 in. (2.4 mm)15-11Chapter 15Construction Hoisting and RiggingEquipment Requirements
DOE-STD-I090-96 (Rev-I)4. Corroded or broken wires at endconnections.5. Corroded, cracked, bent, worn, orimproperly applied end connections.6. Kinking, crushing, cutting, orunstranding.b. The qualified inspector shall take care wheninspecting running rope where rapid deteriorationcould occur, such as in the following:1. Sections in contact with saddles,equalizer sheaves, or other sheaves where ropetravel is limited.2. Sections ofthe rope at or near terminalends where corroded or broken wires mayprotrude.c. The qualified inspector shall take care wheninspecting certain ropes such as the following:1. Rotation-resistant ropes, because oftheir higher susceptibility to damage. The internaldeterioration ofrotation-resistant ropes may notbe readily observable.2. Boomhoist ropes, because ofthedifficulty ofinspection and the important nature ofthese ropes.d· No precise rules can begiven fordetermining the exact time to replace wire ropebecause many variables are involved. Safety inthis respect depends largely on the use ofgoodjudgment by an appointed person in evaluatingremaining strength in a used rope, after allowancefor deterioration disclosed by inspection. Safetyofrope operation depends on this remainingstrength.e. Conditions such as the following shall besufficient reason for questioning rope safety andconsidering replacement:1. In running ropes, six randomlydistributed broken wires in one rope lay, or threebroken wires in one strand in one rope lay.2. In standing ropes, more than twobroken wires in one lay in sections beyond endconnections or more than one broken wire at anend connection.3. In rotation resistant ropes, tworandomly distributed broken wires in six ropediameters or four randomly distributed brokenwires in thirty rope diameters.4. One outer wire broken at the point ofcontact with the core ofthe rope that has workedits way out ofthe rope structure and protrudes orloops out from the rope structure; additionalinspection ofthis section is required.5. Wear ofone-third the original diameterofoutside individual wires.6. Kinking, crushing, birdcaging, or anyother damage resulting in distortion ofthe ropestructure.7. Evidence ofheat damage from anycause.8. Reduction from nominal diametergreater than those listed in Table 15-1.f. All rope thathas been idle for a month ormore due to shutdown or storage of a crane onwhich it is installed shall be inspected before it isplaced in service. This inspection shall be for alltypes of deterioration and shall be performed byan appointed person whose approval shall berequired before further use ofthe rope. A writtenand dated report ofthe rope condition shall befiled.g. To establish data as a basis for judging theproper time for replacement, maintain acontinuing inspection record covering the pointsofdeterioration listed above.h. Ensure that replacement rope is the samesize, grade, and construction as recommended bythe crane manufacturer, unless otherwiserecommended by a rope or crane manufacturer dueto actual working condition requirements.i. Never use discarded rope for slings.15.4.2.5.7 Load Hooks/Load Blocks.Load hookslload blocks that have beenchanged-out shall be inspected by a qualifiedinspector before the crane is returned to service.Inspection records shall be retained throughout theservice life ofthe hook or load block and shall bereadily available.Chapter 15Construction Hoisting and RiggingEquipment Requirements 15-12
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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)5.2 HOSTILE
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DOE-STD-1090-96 (Rev-l)EXHIBIT IHOS
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6.2 QUALIFICATIONDOE-STD-I090-96 (R
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6.2.5Operators of ForkliftTrucksa.
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DOE-STD-I090-96 (Rev-I)6.3 TRAINING
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DOE-STD-1090-96 (Rev-l)24. Records
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6.4 REQUALIFICATIONDOE-STD-I090-96
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DOE-STD-I090-96 (Rev-!)Gantry Crane
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DOE-STD-I090-96 (Rev-I)Crane bridge
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DOE-STD-I090-96 (Rev-I)7.2 INSPECTI
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DOE-STD-I090-96 (Rev-I)h. Chain-dri
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DOE-STD-I090-96 (Rev-I)trouble pers
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DOE-STD-I090-96 (Rev-I)7.4 MAINTENA
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DOE-STD-I090-96 (Rev-I)HOIST. With
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DOE-STD-I090-96 (Rev-I)g. Do not lo
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DOE-STD-1090-96 (Rev-l). IN1ENTIONA
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DOE-STD-1090-96 (Rev-l)EXHIBIT I (c
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DOE-STD-I090-96 (Rev-I)EXHIBIT I (c
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DOE-STD-I090-96 (Rev-I)8.3 TESTING
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DOE-STD-I090-96 (Rev-I)Figure 8-3.
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DOE-STD-I090-96 (Rev-I)8.1.1Operato
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DOE-STD-I090-96 (Rev-I)operating co
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DOE-STD-I090-96 (Rev-I)2. A number
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DOE-STD-!090-96 (Rev-!)iv.Inspect f
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DOE-STD-I090-96 (Rev-I)d. Do not op
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DOE-STD-I090-96 (Rev-I)Exhibit I is
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DOE-STD-I090-96 (Rev-I)9.5.29.5.39.
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DOE-STD-I090-96 (Rev-I)Table 9-1. S
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DOE-STD-1090-96 (Rev-1)r-1r.ilE3...
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DOE-STD-I090-96 (Rev-I)d. Evidence
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DOE-STD-I090-96 (Rev-I)before retur
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DOE-STD-I090-96 (Rev-!)t. Lock carr
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DOE-STD-I090-96 (Rev-I)Figure 9-2.
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DOE-STD-1090-96 (Rev-1)c. Durable s
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DOE-STD-I090-96 (Rev-I)1. Cranel10a
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DOE-STD-I090-96 (Rev-I)IIIIIIIIIIII
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DOE·STD·I090·96 (Rev-I)HOIST. Wi
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DOE-STD-I090-96 (Rev-I)RETRACT 800M
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DOE-STD-I090-96 (Rev-I)Exhibit I is
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DOE-STD-1090-96 (Rev-1)10.5.5 Movin
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DOE-STD-I090-96 (Rev-I)10.1.6 Modif
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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-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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