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Revision Log

Light Sources Directorate Policies and Requirements Manual

Number: LS-ESH-PRM-1.6.0/1.6.1
Date: 09/24/2008
Revision: 4
Prepared by: Robert Kiss
Approved by: Andrew Ackerman (ESH/Q Manager)

1.0 Purpose
  All hoisting, rigging, and material handling must conform to BNL requirements as outlined in the SBMS.  The requirements below are specific to the NSLS Hoisting, Rigging and Material Handling program.
2.0 Scope

These requirements apply to the use, inspection, and maintenance of all material handling equipment used at the NSLS.  Equipment covered by this procedure includes forklifts, overhead cranes, chain falls/hoists, slings, engine lifts, material lifts, and pallet jacks.

3.0 Definitions/acronyms

-         BNL F&O:  Brookhaven National Laboratory Facilities and Operations Division 

-         HRMH POC:  Hoisting, Rigging and Material Handling Point of Contact.  The NSLS HRMH POC is the NSLS Building Manager. 

-         HEMO: Heavy Equipment Mechanical Operator 

-         SBMS:  Standards Based Management System 

-         Authorized Crane Operators:  NSLS Staff or Users that have been trained and qualified in the use of overhead cranes and basic rigging are considered to be authorized crane operators. 

-         Responsible Persons:  NSLS Staff or Users that have been designated and assigned to a NSLS Crane, responsible for the safe use and review of lifts with a particular crane.

4.0 Responsibilities


  4.1   Authorized crane operators

-         Maintain their training qualifications required for Authorized Crane Operators and Basic Rigging.  

-         Perform pre-operational daily inspections for each lift they perform.  Document those inspections with the NSLS Daily Lift Checklist (crane specific forms have been developed for each crane from a general template) and submit that form to the HRMH POC. 

-         Complete a lift plan/evaluation through use of the NSLS Lift Evaluation Form and submit that form to the crane Responsible Person for approval. 

-         Operate the equipment in a safe manner as defined in the lifting plan. 

-         Report any damaged or unsafe conditions of equipment, rigging or accessories to the NSLS HRMH POC.



  4.2 Responsible Persons

-         Have the same responsibility as that listed above for Authorized Crane Operators and must: 

o       Approve or reject all lifts for his/her equipment through review of the NSLS Lift Evaluation forms. 

o       Submit the NSLS Lift Evaluation forms to the NSLS HRMH POC at the completion of the lift. 




The NSLS HRMH POC shall 

-         Maintain records for all material handling equipment owned by the NSLS.  These records include: 

o       NSLS Lift Evaluation Forms 

o       NSLS Daily Lift Checklists 

o       NSLS Monthly Inspection forms (forms are held for one year and then submitted to the BNL Crane Inspector at the end of the calendar year). 

o       Annual inspection forms 

o       Annual preventive maintenance forms

o       System installation documentation 

o    Structural analysis documentation 

-         Perform monthly inspections of all cranes in service and document those inspections with NSLS Monthly Inspection forms. 

-         Coordinate annual inspection of all lifting equipment.  Annual inspections are tracked and scheduled by BNL F&O. 

-         Coordinate annual Preventive Maintenance of all lifting equipment.  Annual maintenance is tracked, scheduled, and performed by the BNL F&O HEMO shop. 

-     Arrange for needed repairs through use of a BNL F&O Work Order. 

-     Arrange for necessary Load Test and documentation for new or repaired equipment.  

-     Maintain a key control program to keep all cranes and powered Material Handling equipment locked to prevent use by un-authorized persons.  

-     Update the NSLS Crane Status Database

5.0 Program Information

Many NSLS cranes are locked out of service because of inadequate installation documentation.  Use of those devices is prohibited unless first evaluated as defined in NSLS Procedure, LS-ADM-003, "Overhead Crane Use Procedure for NSLS OOS Cranes" or brought back to service through a detailed structural analysis of the device installation.


  5.1 NSLS Crane Status Database

The NSLS Crane Status Database has been developed to track the status of all the cranes within the NSLS complex.  A record for each crane is included in that system that includes, the crane identification number, crane location, service status, and lists of authorized operators and responsible people.


  5.2 Key Control

All NSLS overhead cranes are key locked (except for the powered overhead cranes above the VUV floor).



Powered cranes

-   The lock is on the pendant controller.  The responsible person for each crane has a key.  A second key is kept in the Control Room lock box.  A third key is kept in a lock box controlled by the HRMH POC

-   The VUV powered, overhead cranes are operated by rf remote controllers.  Those controllers are kept in the NSLS Control Room and are issued only to Responsible Crane Persons for those cranes.

Manual cranes

The manual cranes are locked with padlocks.  There are three keys for each lock and one master key for all the locks.

-   For cranes that are in service:

  • Key #1 is kept in a lock box in the NSLS Control Room

  • Key #2 is kept in the NSLS Master Key lock box managed by the Administration Services Group Head.

  • Key #3 is kept by the crane Responsible Person

 -  For cranes that are not in service:

  • All three keys are kept in a lock box:

  • Key #2 is kept by the Administration Services Group Head.

  • Key #ís 1 and 3 are kept by the NSLS HRMH POC.

    The Master Key for the entire set of locks is kept in the lock box controlled by HRMH POC.
6.0 In Service Crane Lift Requirements

The following requirements apply to all ordinary lifts.  The personnel responsible for each item are listed above.

 -         The load must be ≤ 95% of the crane capacity

 -         A pre-operational daily inspection must be performed

 -         A lift plan must be developed

 -         The lift must be approved by the Responsible Person.

7.0 Attachments
  7.1 NSLS Daily Lift Checklist
  7.2 NSLS Lift Evaluation Form

PRM Table of Contents

Document Review Frequency 3 Years

Review signatures on file with master copy of controlled document

Document Number: LS-ESH-PRM-1.6.0/1.6.1

> See NSLS Quality Control Coordinator for original revision and review signatures <

Rev Description Date
2 Original Document 07/29/96
3 Updated Links 04/26/01
4 Complete re-write of procedure 09/24/08

For information regarding this document contact Lori Stiegler