Best Rigging Practices in Lifting Operations

1

“BEST RIGGING PRACTICESIN LIFTING OPERATIONS”

Presented by Ted Wang

Risk Management and Lifting Requirements at the Load Hook

Engineered Products and Design Requirements

The fundamentals of Proper Use

Inspection and Comprehensive Inspection Program

THE SPECIAL NATURE OF RIGGINGAND LIFTING OPERATIONS

(MOM-01)“BEST RIGGING PRACTICES

IN LIFTING OPERATIONS”

2

EVERYLIFT


#1

PLAN:

“RISK MANAGEMENT AND THE LIFTINGREQUIREMENTS AT THE LOAD HOOK”(MOM-01)

RISK MANAGEMENT AND THE LIFTING REQUIREMENTS AT THE LOAD HOOK

(MOM-01)

MY FOCUS TODAY IS ON THE “LOAD HOOK”RISK IS CREATED EACH TIME A LOAD IS MOVED BY LIFTINGRISK MANAGEMENT REQUIRES THAT THESE RISKS BE IDENTIFIED AND A PLAN OF ACTION CREATED AND FOLLOWED TO CONTROL, MINIMIZE OR ELIMINATETHESE RISKS

“RISK MANAGEMENT AND THE LIFTINGREQUIREMENTS AT THE LOAD HOOK”

3

RISK MANAGEMENT AND THE LIFTING REQUIREMENTS AT THE LOAD HOOK

(MOM-01)

DETERMINE THE RISKS BY PROPERANALYSIS OF RISKS:

1. PROBLEMS AT THE START

2. PROPLEMS AT THE HARDWARE

3. PROBLEMS WITH SLINGS


DETERMINE THE RISKS:COMMON PROBLEMS AT THE START

COMPETENT (TRAINED) RIGGERS NOT ASSIGNED

USE OF IMPROPER HAND SIGNALS

NOT INSPECTING GEAR “FREQUENTLY”

CAPACITY OF RIGGING GEAR NOT KNOWN

NOT KNOWING WHAT TO INSPECT FOR

SLINGS MISSING TAGS OR TAGS NOT LEGIBLE

IMPROPERLY MADE BELOW THE HOOK DEVICES

WIRE ROPE SLINGS FORMED WITH CLIPS

(MOM-01)“RISK MANAGEMENT AND THE LIFTINGREQUIREMENTS AT THE LOAD HOOK”

4

TOO SMALL HARDWARE CONNECTED TO SLING EYE

TOO LARGE HARDWARE CONNECTED TO SLING EYE

BUNCHING OR PINCHING OF SYNTHETIC SLINGS

PLACING TOO MANY SLINGS IN HOIST HOOK, SHACKLES OR OTHER HARDWARE

LOOSE SHACKLE PINS OR OTHER CONNECTIONS

MISSING LATCHES ON HOIST HOOKS

IMPROPER SIDE LOADING OR MISALIGNMENT OF HARDWARE

(MOM-01)

DETERMINE THE RISKS:COMMON PROBLEMS WITH HARDWARE


BEATING DOWN CHOKER HITCH

BASKET CAPACITY USED WHEN NOT VERTICAL

BASKET HITCH (WIRE ROPE)OVER SMALL DIAMETER

USE OF HORIZONTAL SLING ANGLES SMALLER THAN 30 DEGREES

CAPACITY OF BRIDLE NOT ADJUSTED FOR ANGLESLING LOADS NOT PROPERLY DISTRIBUTED

CHOKER AND BASKET HITCHES AT SLING ANGLE SMALLER THAN 60 DEGREES

(MOM-01)

DETERMINE THE RISKS:COMMON PROBLEMS WITH SLINGS


5

PRODUCTS THAT ARE ENGINEERED TO MEET REQUIREMENTS OF LIFTING


#2

USE:

“ENGINEERED PRODUCTS ANDDESIGN REQUIREMENTS”(MOM-01)

ENGINEERED PRODUCTS AND DESIGN REQUIREMENTS

(MOM-01)

ALL LIFTING EQUIPMENT MUST BE ENGINEERED, DESIGNED TO THAT ENGINEERING AND MANUFACTURED TO THAT DESIGN

LIFTING GEAR HAS SEVEREDEMANDS PLACED ON IT

“ENGINEERED PRODUCTS ANDDESIGN REQUIREMENTS”

6

OPERATING CONDITIONS FOR CRITICALLOAD CARRYING COMPONENTS INCLUDE:

DESIGN LOADUNUSUAL LOADINGSHOCK LOADSREPEATED CYCLE LOADSENVIRONMENTAL CONDITIONS, TEMPERATURE

OPERATING CONDITIONS IN LIFTING APPLICATIONS DEMAND PERFORMANCE

ENGINEERED PRODUCTS ANDDESIGN REQUIREMENTS


ENGINEERING PRODUCTS FOR LIFTING APPLICATIONSMUST HAVE ALL OF THE PROPERTIES:

STRENGTHDUCTILITYFATIGUE RESISTANCETOUGHNESSTRACEABILITY

OPERATING CONDITIONS IN LIFTING APPLICATIONS DEMAND PERFORMANCE

ENGINEERED PRODUCTS ANDDESIGN REQUIREMENTS


7

STRENGTH - THE ABILITY TO WITHSTAND THE LOAD APPLIED.

DESIRABLE CHARACTERISTICSWITHSTAND RATED LOAD AND PROOF LOAD WITHOUT DEFORMATIONAT LOAD BELOW ULTIMATE STRENGTH, DEFORM AND GIVE INDICATION OF IMPENDING FAILURE

MATERIAL STRENGTHSAME MATERIAL DESIGNATION CAN BEHAVE DIFFERENTLY DUE TO PROCESSINGMATERIAL HARDNESS AFFECTS STRENGTHHARDENABILITY IS DETERMINED BY CHEMICAL COMPOSITION, AND ALLOYING ELEMENTS


ACTUAL PRODUCT STRENGTH IS ATTAINED ONLYIF ALL STEPS TAKEN:

DESIGNMATERIAL SELECTION

• MEASURED BY HARDNESS OR TENSILE TESTING

PROCESSING• HEAT TREATMENT DEFINES

HARDNESS/STRENGTH ATTAINABLEASSURANCE BY VERIFICATION

• ISO 9001• DESIGN VERIFICATION AND PRODUCT

AUDITS

STRENGTH – THE PROPER LEVEL MUST BE ASSURED


8

DUCTILITY - THE ABILITY TO DEFORM IN AN OVERLOADED CONDITION

ADVANTAGES OF A DUCTILE MATERIAL

CATASTROPHIC BRITTLE FAILURE DOES NOT GIVE ANYINDICATION OF IMPENDING FAILURE

DEFORMATION IS A VISUAL INDICATION OF OVERLOAD, AND A SIGNAL THAT OTHER COMPONENTS WITHIN THE SYSTEM MAY NEED INSPECTIONDUCTILE MATERIALS ARE AFFECTED LESS BY GEOMETRIC IRREGULARITIES THAN BRITTLE MATERIALS


DUCTILITY - THE ABILITY TO DEFORM IN AN OVERLOADED CONDITION

TESTING TO DETERMINE DUCTILITYMATERIAL TENSILE TESTING PROVIDES ROA AND ELONGATIONTESTING OF SHOULD TYPICALLY YIELD 17-20% EL, AND 40-60% ROALOAD TESTING OF PRODUCT INDICATES AMOUNT OF DEFORMATION VISUALLYDUCTILITY IS EVIDENCED IN FRACTURE SURFACE

Ductile material and typical fracture appearanceBrittle material

and typical fracture

appearance“ENGINEERED PRODUCTS ANDDESIGN REQUIREMENTS”(MOM-01)

9

FATIGUE RESISTANCE- ABILITY OF PRODUCT TO WITHSTAND REPEATED

APPLICATIONS OF LOADADVANTAGES OF FATIGUE RESISTANT PRODUCT

APPLICATIONS THAT ARE UNKNOWINGLY EXPOSED TO OTHER THAN STATIC LOADINGRESISTANCE TO FATIGUE DAMAGE DUE TO CYCLIC LOADING

STANDARDIZED TESTING PROTOCOL FOR FITTINGS

ACCELERATED CYCLE TEST OF PRODUCTATTAIN 20,000 CYCLES WITHOUT LOSS OF LOAD, WHEN CYCLED AT 1.5 X WLL UPPER LIMIT AND A LOWER LIMIT


FATIGUE RESISTANCE REQUIRES MANY THINGS

PROPERTIES THAT AFFECT FATIGUE LIFE INCLUDECHEMISTRY AND DESIGN OF THE PRODUCT

• ADDITION OF ELEMENTS SUCH AS ALUMINIUM, VANADIUM OR NIOBIUM USED AS GRAIN REFINERS, CONTROL GRAIN SIZE, IMPROVE TOUGHNESS, AND RESIST CRACK INITIATION AND GROWTH

• GEOMETRIC DISCONTINUITIES• SURFACE FINISH• RESIDUAL STRESS• DESIGN FOR STRESSES BELOW FATIGUE

STRENGTH OF MATERIAL“ENGINEERED PRODUCTS ANDDESIGN REQUIREMENTS”(MOM-01)

10

TOUGHNESS - THE ABILITY OF THE PRODUCT TO RESIST FRACTURE

ADVANTAGE OF PRODUCTS THAT EXHIBITGOOD TOUGHNESS

TOUGH MATERIALS ARE SUPERIOR IF PRODUCTS ARE SUBJECTED TO ABUSE AND UNEXPECTED RAPID APPLICATION OF LOADSTOUGH MATERIALS ARE MORE LIKELY TO ABSORB INADVERTENT OVERLOADS WITHOUT FRACTURE

STANDARDIZED TESTING FOR NOTCH TOUGHNESS31 FT-LBS. (42 JOULES) ENERGY ABSORBED AT

TEST TEMPERATURE OF –4 DEGREE F (-20 DEGREE C)


TOUGHNESS REQUIRESMANY THINGS

METALLURGICAL CONDITIONS THAT IMPROVE TOUGHNESS

HEAT TREATING BY NORMALIZING, OR QUENCH AND TEMPERING (THE TEMPERED MARTENSITE MICROSTRUCTURE PRODUCED BY Q AND T GIVES GOOD TOUGHNESS)ADDITION OF ELEMENTS SUCH AS ALUMINUM, VANADIUM OR NIOBIUM USED AS GRAIN REFINERS, CONTROLS GRAIN SIZE, AND IMPROVE TOUGHNESSADDITIONS OF NICKEL AND CHROMIUMCLEANLINESS OF STEEL, CONTROL OF RESIDUAL ELEMENTS


11

ALL INDIVIDUALS WHO USE HARDWARE AND SLINGS


#3

TRAIN:

“THE FUNDAMENTALS OF PROPER USE”(MOM-01)

THE FUNDAMENTALS OF PROPER USE

USERS SHALL BE TRAINED IN THE SELECTION, INSPECTION, CAUTIONS TO PERSONNEL, EFFECTS OF ENVIRONMENT, AND RIGGING PRACTICES

IDENTIFICATION SHOULD BE MAINTAINED BY THE USER SO AS TO BE LEGIBLE THROUGHOUT THE LIFE, THEY SHALL BE REMOVED FROM SERVICE IF MISSING OR ILLEGIBLE IDENTIFICATION


12

DETERMINING IF THEWORKING LOAD LIMIT IS ADEQUATE

KNOW THE WEIGHT OF THE LOAD

THE WEIGHT MUST INCLUDE ALL THAT IS SUPPORTED

KNOW WHERE THE CENTER OF GRAVITY IS

DYNAMIC LOADING WILL INCREASE THE LOADING OF THE RIGGING GEAR

SHOCK LOADING WILL GREATLY INCREASE THE LOADS AND ADVERSELY AFFECT THE RIGGING GEAR


THE SLING SEES THE COMBINED EFFECTS OF LIFTING AND CRUSHING KNOWN AS THE RESULTANT LOAD

AS HORIZONTAL SLING ANGLE BECOMES SMALLER, THE CRUSHING LOAD INCREASES

THE LOAD MULTIPLIER

LIFT

ING

LIFT

ING

CRUSHING CRUSHING

SLING LOAD SLING LOAD


13

LOAD UNDER CONTROL?

SLINGS CAPTURE CENTEROF GRAVITY?

LOAD LIFT LEVEL?

LOAD STABLE?

TAG LINE REQUIRED?

ETYRTRUYTYUTYU

ETYRTRUYTYUTYU ETYRTRUYTYUTYU

BEAM CAPACITY


RIG TO THE CENTER OF GRAVITY

CENTER OF GRAVITY IS DIRECTLY BELOW THE LOAD HOOK

&CONNECTION TO LOAD IS ABOVE CENTER OF GRAVITY

ETYRTRUYTYUTYU


14

THREE AND FOUR LEG BRIDLEAND LOAD CONTROL

EXCELLENT LOAD CONTROLIS ACHIEVED

THE LOAD ON EACH LEG WILL BE EQUALONLY IF THE C.O.G. IS IN THE MIDDLE OF THE PICKPOINTS, THE LEGS EQUAL IN LENGTH AND THELOAD FLEXIBLE


MULTIPLE LEG SLINGSLOAD DISTRIBUTION

THE LOADS CAN BE PROPERLY DISTRIBUTED IF THESLING LENGTH CAN BE ADJUSTED.


15

THERE ARE VARIOUS METHODS OF USING LIFTING BEAMSBASIC BEAMS

SPREADER BEAM

STIFF BACK BEAM

DUAL LIFT BEAM


DO NOT OPEN SLING EYE GREATER THAN 50% OF

EYE LENGTH

THICKNESS OF HOOK MUST BE LESS THAN

1/2 L

L L

CONNECTION OF SLINGS TO HOOKS


16

HOOKSIMPROPER LOADING

DO NOTTIP LOAD, SIDE LOAD OR BACK LOAD

HOIST HOOKS


THE INCLUDED ANGLEHOIST HOOKS

INCLUDED ANGLE

THE SLINGS MUST SIT IN THEBASE OF THE HOOK AND CLEAR OF THE LATCH

THE WORKING LOAD LIMITIS VALID FOR A SINGLELEG OR MULTIPLE LEGSAS LONG AS INCLUDEDANGLE DOES NOTEXCEED 90 DEGREES

45° 45°

90° MAXIMUM


17

FOULING OF LATCH

CORRECT!SLING IN BASE OF HOOK

INCORRECT!SLING FOULED ON LATCH


SHACKLE AS ACOLLECTOR RING

USE ONLY SCREW PINAND BOLT-TYPESHACKLES AS COLLECTOR

ORIENTATE SHACKLESO PIN IS UP AND BOW IS DOWN

INCLUDEDANGLE

120° MAXIMUM


18

BOLT-TYPE SHACKLES

USE BOLT-TYPESHACKLES WHEN A PERMANENT OR LONG TERM CONNECTION

USE SCREW PIN SHACKLES WHEN IT WILL BE A TEMPORARY CONNECTION


CONNECTION OF SLINGSTO SHACKLES

SHACKLE MUST BE LARGE ENOUGH TO AVOID PINCHING OF SYNTHETIC SLINGS

DIAMETER OF SHACKLE MUST BE GREATER THAN WIRE ROPE DIAMETER IF NO THIMBLE IN EYE


19

POINT LOADING OF SHACKLESPOINT LOADING OF CROSBYSHACKLE BOWS AND PINS IS ACCEPTABLE AS LONG AS LOAD IS REASONABLY CENTERED

DO NOT LOAD SHACKLE PIN TO SHACKLE PIN“THE FUNDAMENTALS OF PROPER USE”(MOM-01)

SPECIAL SHACKLES

SYNTHETIC SLING SAVER

SHACKLES

WIDE BODY SHACKLES


20

A MASTER LINK WITH SUB-LINKS ARE RECOMMENDEDFOR THREE AND FOUR LEG

CHAIN SLINGS

SINGLE MASTER LINKIS REQUIRED FOR

SINGLE AND TWO LEG CHAIN SLINGS

HINGE POINTSCHAIN SLINGS


SUB-LINKS ARE BEST PRACTICE FOR ALL TYPES OF THREE AND FOUR LEGS SLINGS

IMPROVED PRACTICE OVER PLACING DIRECTLY IN HOOK

HINGE POINTSWIRE ROPE AND SYNTHETIC SLINGS

BEST PRACTICEWITH SUB-LINKS


21

HOIST RINGS

ENGINEERED

CHAIN

SIDE PULL

WEB SLING

FORGED BOLTED

STREET PLATE“THE FUNDAMENTALS OF PROPER USE”(MOM-01)

REGULAR INSPECTION PROGRAM


#4

ESTABLISH:

(MOM-01)“INSPECTION AND COMPREHESIVE INSPECION PROPGRAM”

22

INITIAL: PRIOR TO INITIAL USE

FREQUENT: EACH DAY BEFORE THE RIGGING HARDWARE IS USED, SEMI-PERMANENT AND INACCESSIBLE LOCATIONS WHERE FREQUENT INSPECTIONS ARE NOT FEASIBLE SHALL HAVE PERIODIC INSPECTIONS PERFORMED

THE PERIODIC INSPECTION :NORMAL SERVICE – YEARLYSEVERE SERVICE – MONTHLY TO QUARTERLYSPECIAL SERVICE – AS RECOMMENDED

BY A QUALIFIED PERSON

INSPECTION OF RIGGING SLINGS AND HARDWARE - FREQUENCY

“INSPECTION AND COMPREHESIVE INSPECION PROPGRAM”(MOM-01)

INSPECTION OF SHACKLESDEFORMATION

ANY SIGNIFICANT PERMANENTDEFORMATION, OR CHANGE IN SHAPE,INDICATES IT HAS BEEN OVERLOADED ANDMUST BE REMOVED FROM SERVICE


23

DEFORMATIONHOOKS

ANY VISIBLE APPARENT BEND OR TWIST FROM THE PLANE OF THE UNBENT HOOK

ANY DISTORTION CAUSING AN INCREASE IN THROAT OPENING OF 5% OR MORE, NOT TO EXCEED ¼” OR AS RECOMMENDED BY THE MANUFACTURER


INSPECTION OF HARDWAREWEAR

10% OR MORE REDUCTION IN OF ANY SECTIONAL DIMENSION INDICATES IT HAS EXCESSIVE WEAR, MEASURE BY COMPARING TO A SECTION OF FITTING THAT HAS NO WEAR, OR TO THE CATALOG DIMENSIONS

MAKE SURE IDENTIFICATION IS LEGIBLE“INSPECTION AND COMPREHESIVE INSPECION PROPGRAM”(MOM-01)

24

INSPECTION OF HARDWARECRACKS AND SHARP NICKS

ANY CRACK, SHARP NICK OR GOUGE INTHE SURFACE OF ANY FITTING CAN CAUSESTRESS CONCENTRATION AND IS CAUSEFOR REMOVAL FROM SERVICE


INSPECTION OF RIGGING HARDWARE REMOVAL CRITERIA FOR THREADS

EXCESSIVE THREAD DAMAGE OR WEAR OF SCREW PINS, SHANK HOOKS AND TURNBUCKLES:

REMOVE FROM SERVICE IF THREADS DAMAGED OR CORRODED FORMORE THAN 20% OF THE LENGTH ENGAGEDIN EAR OF SHACKLE OR NUT OF HOOKOR TURNBUCKLE

ENGAGED LENGTH


25

INSPECTION OF HARDWARE HEAT DAMAGE

HEAT DAMAGE CAUSED BY EXPOSURETO TEMPERATURES ABOVE 400°F

WELD SPLATTERS

ARC STRIKES

EXPOSURE TO EXCESSIVE TEMPERATURE WILL DAMAGE THE HEAT TREATMENT AND MATERIAL STRENGTH, SEVERE WELD SPLATTERS AND ARC STRIKES CAN CREATE STRESS CONCENTRATION AND ARE CAUSE FOR REMOVAL FROM SERVICE


INSPECTION OF HARDWAREPROPER FUNCTION

MISSING LATCHES WHEN REQUIRED

DAMAGED LATCHES WHEN PRESENT

SWIVEL BEARINGS THAT LACK THE ABILITY TO FREELY ROTATE WHEN NOT LOADED

LOOSE OR MISSING NUTS, BOLTS, COTTER PINS, SNAP RINGS, OR OTHER FASTENERS AND RETAINING DEVICES

MALFUNCTION OR MISSING LOCKING DEVICES IS CAUSE FOR REMOVAL FROM SERVICE


26

INSPECTION OF WIRE ROPE SLINGSREMOVAL CRITERIA

MISSING OR ILLEGIBLE SLING IDENTIFICATION

EXCESSIVE BROKEN WIRES

SEVERE LOCALIZED ABRASION OR SCRAPING

KINKING, CRUSHING, BIRDCAGING,OR ANY OTHER DAMAGE RESULTING IN DAMAGE TO THE ROPE STRUCTURE

EYE

BODY

MECHANICALSPLICE


INSPECTION OF WIRE ROPE SLINGSREMOVAL CRITERIA

EVIDENCE OF HEAT DAMAGE

END ATTACHMENTS THAT ARE CRACKED, DEFORMED, OR WORN

SEVERE CORROSION OF THE ROPE, END ATTACHMENTS, OR FITTINGS

OTHER CONDITIONS, INCLUDING VISIBLE DAMAGE, THAT CAUSE DOUBT AS TO THE CONTINUED USE OF THE SLING

EYE

BODY

MECHANICALSPLICE


27

INSPECTION OF CHAIN SLINGSREMOVAL CRITERIA


CRACKS OR BREAKS

EXCESSIVE WEAR, NICKS, OR GOUGES

STRETCHED CHAIN LINKS OR COMPONENTS

BENT, TWISTED, OR DEFORMED CHAIN LINKS OR COMPONENTS


INSPECTION OF CHAIN SLINGSREMOVAL CRITERIA

EVIDENCE OF HEAT DAMAGE

EXCESSIVE PITTING OR CORROSION

LACK OF ABILITY OF CHAIN OR COMPONENTSTO HINGE FREELY

WELD SPLATTER

OTHER CONDITIONS, INCLUDING VISIBLE DAMAGE, THAT CAUSE DOUBT AS TO THE CONTINUED USE OF THE SLING


28

INSPECTION OF WEB SLINGSCAUSE FOR REMOVAL


ACID OR CAUSTIC BURNS

MELTING OR CHARRING OF ANYPART OF THE SLING

HOLES, TEARS, CUTS, OR SNAGS

BROKEN OR WORN STITCHINGIN BEARING SPLICES

EXCESSIVE ABRASIVE WEAR“INSPECTION AND COMPREHESIVE INSPECION PROPGRAM”(MOM-01)

INSPECTION OF WEB SLINGSCAUSE FOR REMOVAL

KNOTS IN ANY PART OF SLING

DISCOLORATION AND BRITTLE OR STIFF AREAS ON ANY PART OF THE SLING, WHICH MAY MEAN CHEMICAL OR ULTRAVIOLET / SUNLIGHT DAMAGE

FITTINGS THAT ARE PITTED, CORRODED, CRACKED, BENT, TWISTED, GOUGED, OR BROKEN

OTHER CONDITIONS, INCLUDING VISIBLE DAMAGE, THAT CAUSE DOUBT AS TO THE CONTINUED USE OF THE SLINGS


Documents

Best Rigging Practices in Lifting Operations