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

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DOE-STD-I090-96 (Rev-I)7.3 TESTING7.3.1Operational Testsa. Prior to initial use, all new, reinstalled,extensively repaired, or modified cranes shall betested by a designated person to ensurecompliance with this chapter, including thefollowing functions:1. Lifting and lowering.2. Trolley travel.3. Bridge travel.4. Locking, limiting, and indicatingdevices, ifprovided.5. Limit switches/devices.b. The trip setting ofhoist-limit devices shallbe determined by tests with an empty hooktraveling at increasing speeds up to the maximumspeed. The actuating mechanism oftheupper-limit device shall be located so that it willtrip the device under all conditions and insufficient time to prevent contact ofthe hook orload block with any part ofthe trolley or crane.7.3.2Rated Load Testa. Prior to initial use, all new, reinstalled,extensively repaired, or modified cranes shall betested by or under the direction of a qualifiedinspector. A designated or authorized person shalldetermine ifrepairs made to a crane are extensive,requiring a rated load test, or routine maintenancerequiring only operational testing. The 'replacement ofrope is excluded from this requirement.However, a functional test ofthe craneunder a normal operating load should be madeprior to putting the crane back in service. Awritten report shall be furnished by the inspectorconirrming the load rating ofthe crane. The loadrating should not be more than 80 percent ofthemaximum load sustained during the test Testloads shall not be more than 125 percent oftherated capacity, unless otherwise recommended bythe manufacturer. Test weights shall be accurateto within -5 percent, +0 percent ofstipulatedvalues.b. The rated load test for new cranes shallconsist ofthe following operations as minimumrequirements:1. Hoist the test load a sufficient distanceto ensure that the load is supported by the craneand held by the hoist brakes. Personnel shall bekept clear ofthe test load while it is suspended.2. Transport the test load by means ofthetrolley for the full length ofthe bridge.3. Transport the test load by means ofthebridge for the full length ofthe runway, in onedirection with the trolley as close to the extremeright-hand end ofthe crane as practical, and in theother direction with the trolley as close to theextreme left-hand end ofthe crane as practical.4. Lower the test load, stopping by thebrakes.c. Extensively repaired or modified cranesshall be tested in accordance withparagraph 7.3.2.b above insofar as interferingequipment/structures permit and in accordancewith recommendations from the manufacturer or aresponsible engineering organization. However,test loads should not be carried over criticalsystems or components.7-11Chapter 7Overhead and Gantry Cranes
DOE-STD-I090-96 (Rev-I)7.4 MAINTENANCE7.4.1 Operating Equipment point to observe the approach ofactive cranes andprohibit contact by the active cranes with the idlea. A preventive maintenance program shall beestablished and based on the recommendation ofthe crane manufacturer or a qualified person.Dated records should be kept where readilyavailable to appointed personnel.b. Replacement parts shall be at least equal tothe original manufacturer's specifications.c. All moving parts ofthe crane for whichlubrication is specified shall be regularlylubricated. Check lubricating systems for deliveryoflubricant Follow manufacturer'srecommendations as to points and frequency oflubrication, maintenance oflubricant levels, andtypes oflubricant to be used.crane, with persons performing maintenance, orwith the maintenance equipment.7. Install a guard or barrier betweenadjacent runways for the length ofthe establishedwork area to prevent contact between personsperforming maintenance and any crane on theadjacent runway.7.4.2 Wire-Rope MaintenancePersonnel using wire rope shall ensure proper careby doing the following:a. Store rope to prevent damage ordeterioration.d. Maintenance personnel shall take thefollowing precautions before performingmaintenance on a crane:1. Move the crane to a location where itwill cause the least interference with other cranesand operations.2. Place any attached loads on the groundor floor.3. Place all controllers in the OFFposition.4. Perform a lockoutltagout procedure.5. Use warning signs and barriers on thefloor beneath the crane where overhead maintenancework creates a hazard.6. Ifthe runway remains energized, placestops or signalers full-time at a visual vantageb. Unreel or uncoil rope as recommended bythe rope manufacturer and with care to avoidkinking or inducing a twist.c. Before cutting rope, use some method toprevent unlaying the strands. Flame-cutting wirerope is prohibited.d. During installation, avoid dragging the ropein dirt or around objects that will scrape, nick,crush, or induce sharp bends in it.e. Maintain rope in a well-lubricated conditionto reduce internal friction and prevent corrosion.Ensure that lubricant applied as part ofamaintenance program is compatible with theoriginal lubricant and is also a type that does nothinder visual inspection. Those sections ofropelocated over sheaves or otherwise hidden duringinspection and maintenance procedures requirespecial attention when the rope is being lubricated.Chapter]Overhead and Gantry Cranes 7-12
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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)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-I090-96 (Rev-I)EXHIBIT I (c
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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-I090-96 (Rev-I)j. Despite t
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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)attention to
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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-1090-96 (Rev-l)the platform
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DOE-STD-I090-96 (Rev-I)h. Report an
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DOE-STD-!090-96 (Rev-!)fRAISE THE T
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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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